G OVERNORS

DPG100/101-F
4. Fasten the DPG to the pump by tightening bolts in the locations shown below.
5 Wiring
Engine Sensor
SMARTVU ENGINE RESPONSE PARAMETERS

A MERICA Name Definition Range Default

C ORP.
R Digital Pump Governor ISO 9001
CERTIFIED

1.
SmartVU:
The DPG100 or 101 can be programmed using GACs SmartVU software. Instructions P Proportional (P) set point. [GAIN]
0 -100,
100 = Max 10
for SmartVU using the DPG101 can be found at http://www.governors-america.com/ Gain

1 Wiring
Engine Sensor
INTRODUCTION Downloads/SmartVU.
I Integral (I) set point. [STABILITY]
0 -100,
100 = Longest 35
Setup Connection Menu Time
The DPG is a microprocessor based digital governing system integrat-
2. 3. After the DPG has been properly selected from D Derivative (D) set point. [DEADTIME] 0 -100 25
ed with an electro-mechanical in a single pump-mountable housing and
the Setup Connection submenu ( found under UPDATE & PID
designed for BQ series inline fuel injection pump. The fixed speed DPG
the Configure pull-down menu ) and SmartVU
has two connectors: power and speed. To measure the engine speed, the recognizes the device, parameters can then be
Parameter Definition Range Default
DPG relies on a magnetic speed sensor. The sensor is positioned in close adjusted using the Main Menu. Changes the rate at which the
5. PID Loop Time 4 - 250 ms 4 ms
proximity to the engines ring gear. The governor then compares the actual 4. PID routine is called.(in ms)
speed with the desired speed. The digital electronics then adjusts the posi- P Scale If a PID Scale multiplier is 0 - 20 17
tion of the rack to command the proper amount of fuel. Changes in engine I Scale
changed (e.g. P Scale), the cor-
0 - 20 17
responding parameter (e.g. P)
speed are processed using the GACs highly developed EDGe PID algo- 6. 7. will be affected in two ways. See
rithm for closed loop speed control. D Scale below. 0 - 20 8
Main Menu
2
If the multiplier is decreased by 1 The corresponding parameter will double.
Wiring
Engine
NamingSensor
Convention
4
If the multiplier is increased by 1 The corresponding parameter will halve.
Wiring
Engine
WIRINGSensor
ENGINE RESPONSE PARAMETERS
PRODUCT NO. DEFINITION
NOTE There are two ways to control the DPG: Name Definition Range Default
DPG100 Basic unit
Adds a high-frequency, low am-
DPG101 Basic unit plus power LED & extended travel 1. Via GACs SmartVU software. The EAM211 must be purchased plitude signal to the actuator to 0 - 100% 0%
separately in order to interface the DPG with a USB DITHER
prevent the from sticking in harsh (no dither)
PRODUCT NO. DEFINITION connection on a computer.
2. Via the DPI100, a hand held unit with physical buttons also sold environment.
F Fixed Speed separately. The DPI100 comes with the proper serial connector. Maximum allowable actuator % the
FUEL LIMIT 0 - 100% 99%
R Right-Hand Rack system can command fuel
MAGNETIC SPEED POWER & SWITCHES Serial Connector
L Left-Hand Rack SPECIAL FUNCTIONS
PICKUP 3 Pin Connector to Computer or DPI100
12 12 Volt version 2 Pin Connector Parameter Definition Range Default

24 24 Volt version White Blue Red Black Green Slows down engine response
Soft Coupling and improves steady state per- Off, On Off
EXAMPLE formance.
DPG101-FR-12 Basic 12 volt unit with power LED, fixed speed, and right rack. A B A B C Rack Adjust Not Available - -
EAM211 is required for
Changes the cutoff frequency
computer hookup
3 Wiring
Engine Sensor
INSTALLATION Filter Samples
for soft coupling when soft cou-
pling is enabled. Lower numbers
1 - 63 40

Fuse 10A Max

filter out higher frequency noise.
Connecting DPG to the Pump:
Idle Sets the droop mode (On = Auto
1. Remove pin from DPG Droop Switch Off, On On
To Magnetic Speed Pickup offset, Off = Manual).
2. Install pin and nut on pump rack Lead Circuit in PID - response
Lead / Lag Off, On Off
increase.
To Battery To Battery EAM211
+ -
6
STARTING PARAMETERS
-or-
Name Definition Range Default
Wiring
Engine
DPI100Sensor
DPI100:
Crank termination is the RPM at which
CRANK
the DPG switches from starting to gov- 100 - 500 RPM 250 RPM
TERMINATION NOTE The parameters found in SmartVU can also be found on the DPI100.
erning.

Throttle positions rate of change. From

THROTTLE RAMP The DPI100 is the user interface for configuring the either the DPG. All adjustments
the throttle begin point to 100%, during 0-100 2
TIME are made using the LCD and five buttons 3 COLUMN select buttons, 1 UP ARROW,
DPI100 the start/crank cycle.
1 DOWN ARROW.
THROTTLE Starting position of the actuator during
0-100% 100%
BEGIN POINT the start/crank cycle.
POWER BUNDLE
SETUP & SAFETY
MATING
3. Move DPG close to the pump. Connect the DPG link to the pin on the rack and secure FUNCTION PIN COLOR
CONNECTOR Name Definition Range Default
it with the second nut.
Battery + A Red RPM at which to automatically shut off
OVERSPEED 0 - 3800 RPM 2220 RPM
EC1523 the actuator.
(3 Pin) Battery - B Black
Number of teeth on the flywheel for
TEETH 50-250 108
Idle C Green engine speed calculation.
MAGNETIC SPEED PICKUP BUNDLE Allows for rapid engine speed re-
sponse with minimal overshoot during 0 - 9999
MATING RAMP 150 RPM/s
FUNCTION PIN COLOR engine start acceleration and deceler- RPM/s
CONNECTOR ation.
EC1360 Mag Pickup 1 A White FIXED SPEED PARAMETERS
(2 Pin) Mag Pickup 2 B Blue Name Definition Range Default
RECOMMENDATIONS SPEED Fixed speed setpoint for operating. 0 - 3800 RPM 1500 RPM

1. Shielded cable should be used for all external connections to the DPG control. DROOP Droop to apply under maximum load. 0 - 5% 0%

DPG100/101-F Digital Pump Governor
2014 Copyright All Rights Reserved
One end of each shield, including the speed sensor shield, should be grounded Idle speed setting. Must be lower than
IDLE SPEED 0 - 3800 RPM 850 RPM
2. to a single point on the DPG case. operating speed. There are 3 configuration menus: Main, Special, and Advanced
Main display conists of most frequently adjusted parameters
There are 5 rows with 3 parameters in each row
If the DPG100 or 101 detects no input from the magnetic pickup, the
DPG will set the actuator to 0V and set the speed to 0 RPM. After the
WARNING
DPG has detected loss of magnetic pickup, the system must be reset.
7.14 PIB 4168 A To reset the DPG, DC power must be cycled.
 8
Special Menu: Instability
MAIN MENU CONTROLS
The Special Menu is used to view and change lesser used parameters. Wiring
Engine Sensor
ADJUSTING FOR STABILITY
ACTION BUTTONS
SPECIAL MENU PARAMETERS nce the engine is running at operating speed and at no load, the following governor
O PROBABLE CAUSE OF
Press and hold both Parameter Adjust Up and Parameter Ad-
INSTABILITY SYMPTOM
Lock the Display performance adjustment can be made to increase engine stability. ABNORMAL READING
just Down buttons for 2 seconds. Parameter Definition Range Default
MAIN MENU Slow Periodic An irregularity 1. Verify the SOFT COUPLING Gover-
Press and hold both Parameter Adjust Up and Parameter Ad- Soft Coupling - dampening of system of speed below nor Advanced Setting parameter is
Unlock the Display SOFT Off, On Off
just Down buttons for 2 seconds. (slow down response). PARAMETER ADJUSTMENT PROCEDURE 3Hz. (Sometimes disabled.
severe) 2.
Tap Parameter Adjust Up or Down buttons. The display will LEAD Lead Circuit - response increase. Off, On Off P 1. Increase this parameter until instability develops. Decrease the update rate of the
Change Display Mode toggle between showing engine RPM, duty cycle, and actuator (GAIN) controller by decreasing the UPDATE
current. RADG Rack adjust not used. Off, On Off 2. Then, gradually decrease this parameter until stability returns. Advanced parameter. (Each time
Change Parameter Row Press any Column button. Sets the droop mode (On=Auto Offset, UPDATE is changed, P, I, and D must
D SW Off, On On 3. Finally, decrease this parameter one increment further to insure be re-adjusted.
Off = Manual Offset) stable performance.
View Parameter Press and hold Column button under desired parameter.
Dither - adds white noise to actuator to 4. If instability persists, adjust the next parameter.
3. Check fuel system linkage during
Press and hold Column button under desired parameter DITH 0 - 10 0 engine operation for:
while tapping the Paramter Adjust Up button or Parameter
prevent sticking in the fuel rack. (%)
Change Parameter Value I 1. Follow the same adjustment procedure as the P parameter. a. binding
Adjust Down button ( holding the Adjust buttons will scroll the System current to the actuator that b. high friction
DRNG 0.0 - 10.0 3.9 (STABILITY)
values). represents full load. Units in (A). c. poor linkage
2. If instability persists, adjust the next parameter.
SPECIAL MENU CONTROLS DSPD Droop offset when D SW is set to Off (RPM) 0 - 9999 1500 D 1. Follow the same adjustment procedure as the P parameter. 4. Add a small amount of droop.
ACTION BUTTONS (DEADTIME)
Non-Periodic Erratic Engine 1. Increasing the P parameter should re-
Hold all 3 Column buttons until AUX appears in the display Advanced Menu: NOTE P, I, & D parameter adjustments may require minor changes after engine load is Behavior duce the instability but not totally cor-
Special Menu applied. Normally, adjustments made at no load achieve satisfactory perfor-
(approximately 2 seconds). The Advanced Configuration Menu is used to manipulate the operating characteristics rect it.
mance. If further performance improvements are required, refer to Advanced
Next Parameter Press Column button 3. of the PID control. These parameters include PID update rate, Filter, Gain, Stability, and Menu Parameters in Section (6) and SYSTEM TROUBLESHOOTING in Section If this is the case, there is most likely a
Deadtime Compensation scale adjustments. (10).
Previous Parameter Press Column button 1. problem with the engine itself.
Check for:
Change Parameter Value Tap or hold down the Parameter Adjust Up or Down button. Modifying the advanced parameters without thorough knowledge of a. engine misfirings
Return to Main Menu Press and hold all 3 Column buttons for 2 seconds.
WARNING
their use can damage the engine or cause injury. 9 Wiring
Engine
OTHER Sensor
FEATURES b. an erratic fuel system
c. load changes on the generator set
ADVANCED MENU CONTROLS voltage regulator.
ADVANCED MENU PARAMETERS OVERSPEED If the DPG101 detects the engine speed has reached the value speci-
ACTION BUTTONS fied by OVERSPEED parameter ( Main Menu ), the DPG101 will com- 2. Excessively high deadtime/derivative
Parameter Definition Range Default mand the engine speed to 0 RPM and the actuator ouput to 0V. term.
Press and hold all 3 Collumn buttons until RATE appears in
Advanced Menu
the display (approximately 10 seconds). RATE The time (mS) between calls to the PID control loop. 4 - 250 mS 8 After the DPG has detected an overspeed, the system must
Next Parameter Press Column button 3. Number of speed samples in frequency calculation.
NOTE
be reset. To reset the DPG, DC power must be cycled. Unsatisfactory Performance
1 - 62
FLTR Filter is active when soft coupling (SOFT) is set to 10
Previous Parameter Press Column button 1. ON. Lower numbers filter high frequency noise. samples
SPEED DROOP Droop replicates a mechanical governors response to a load change. PROBABLE CAUSE OF
OPERATION
SYMPTOM NORMAL READING
Change Parameter Value Tap or hold down the Parameter Adjust Up or Down button. If the GAIN parameter is at maximum and more In Droop Operation, the engine speed will decrease as engine load ABNORMAL READING
GAIN is required, increase GMUL. GAIN will be increases. DROOP (Main Screen: Fixed Speed Parameters & Variable
Return to Main Menu Press and hold Column button 1 and Collumn button 3. GMUL 1 - 20 16 Engine 1. Do Not Crank. Ap- 1. After the actuator goes to full fuel,
more responsive. If small changes in the GAIN Speed Parameters) is based on the Droop Function System Range
parameter are over responsive, decrease GMUL. found in the Governor Advanced Settings. Over- ply DC power to the disconnect the speed sensor at the
speeds governor system. Mag Pickup Bundle Blue wire. If the
If the STABILITY parameter is at maximum and more actuator is still at full fuel-speed then
10
ADJUSTABLE MAIN MENU PARAMETERS
SMUL
STABILITY is required, increase SMUL. STABILITY
will be more responsive. If small changes in STABIL-
1 - 20 16 Wiring
Engine
SYSTEMSensor
TROUBLESHOOTING the control unit is defective.
OVERSPEED #TEETH CRANK ITY parameter are over responsive, decrease SMUL. 2. If the actuator is at minimum fuel po-
RPM to automatically shutoff Number of teeth on RPM which DPG switches If DEADTIME value is at maximum and more DEAD- System Inoperative sition and there exists an
the actuator. flywheel. from starting to governing. TIME is required, increase DMUL. DEADTIME will be erroneous speed signal, then check
DMUL 1 - 20 10 If the engine governing system does not function, the fault may be determined by per- speed sensor
more responsive. If small changes in DEADTIME pa-
Range: 500 - 9999 RPM Range: 50 - 255 Range: 0 - 9999 RPM forming the voltage tests described in Steps 1 through 3. Positive (+) and negative (-)
rameter are over responsive, decrease DMUL.
Default: 2200 RPM Default: 108 Default: 250 RPM refer to meter polarity. Should normal values be indicated during troubleshooting steps, 2. Check #TEETH 1. Incorrect tooth count entered.
Multiplier Changes can make drastic changes. Changing a multiplier then the fault may be with the actuator or the wiring to the actuator. Tests are performed parameter.
SPEED RAMP V.SPEED LOCKED CAUTION
(e.g. GMUL) will affect the corresponding Main Menu parameter (e.g. with battery power on and the engine off, except where noted. See actuator publication
for testing procedure on the actuator. Overspeed 1. Examine the 1. SPEED parameter set too high.
Rate at which speed GAIN) in two ways: shuts down SPEED and OVER-
NOTE: Not available with this Indicates if DPI will lock after
changes from idle to speed 1. If the multiplier is decreased by 1, corresponding P,I, or D value engine af- SPEED operating 2. OVERSPEED set too close to
model. 5 minutes of non-use.
and back. will double. PROBABLE CAUSE OF ter running parameters for the SPEED.
STEP WIRES NORMAL READING
2. If the multiplier is increased by 1, corresponding P,I, or D value ABNORMAL READING speed is engine
Range: 0 - 9999 Range: NA Range: OFF, ON
will halve. reached 3. GAIN set to low.
Default: 150 RPM/sec Default: NA Default: OFF 1 Power Battery Supply 1. DC battery power not
Bundle Voltage connected. Check for blown fuse 4. Actuator or linkage binding.
START FUEL DROOP% FUEL RAMP The engine will maintain current operation while adjusting parameters. Wires (12 or 24V DC)
NOTE
( i.e. NO CHANGES ) Since the scaling will be made to the Gain, Stabil- Red & Black 2. Low battery voltage
Percent of fuel to apply to
Droop to apply under
Percent per second to ity, and Derivitive parameters automatically, go back and readjust these 5. Speed Control unit defective.
maximum load (based on parameters to the diesired levels.
actuator first upon cranking.
current of actuator).
apply fuel as engine starts. 3. Wiring error Overspeed 1. Check impedance 1. OVERSPEED set too low
shuts down between the Mag
Range: 0 - 100% Range: 0 - 25.0% Range: 0 - 100% 4. LED on? (DPG101 only) engine Pickup Bundle 2. If the speed sensor signal is
Default: 100% Default: 0.0% Default: 2%
7 Wiring
Engine Sensor
Pre-Start SETUP 2 Mag Pickup
Bundle Blue
1.0 - 2.0 VAC RMS
min. while cranking
1. Gap between speed sensor and
gear teeth too great
before run-
ning speed
Blue wire & the
Mag Pickup Bundle
erroneous, then check the wiring.
SPEED IDLE FUEL LIM is reached Black wire (Ground).
The following parameters must be set before starting the engine: Wire Should be 30 to
Speed of engine when IDLE Maximum actuator 2. Check Gap 1200 ohms. See
Operating speed of engine. &
input is closed. percentage allowed. Setup & Safety Parameters Starting Parameters specific Magnetic
3. Improper or defective wiring to Pick-up data for
Range: 0 - 9999 RPM Range: 0 - 9999 RPM Range: 0 - 100% OVERSPEED TEETH CRANK TERMINATION THROTTLE RAMP TIME Mag Pickup the speed sensor resistance.
Default: 1500 RPM Default: 850 RPM Default: 100% Bundle
RAMP THROTTLE BEGIN POINT Black wire 4. Resistance between the Mag Actuator 1. Measure the voltage 1. If the voltage is less than:
GAIN STABILITY DEADTIME (Ground) Pickup Bundle Blue wire and the does not at the battery while a. 10V for a 12V system, or
Fixed Speed Parameters Mag Pickup Bundle Black wire
Proportional (P) set point of Integral (I) set point of the Derivative (D) set point of the energize cranking. b. 20V for a 24V system, Then:
the PID control. PID control. PID control. SPEED IDLE SPEED (Ground) should be 30 to 1200 fully Check or replace battery.
ohms. See specific Mag Pickup
Range: 0 - 100, Range: 0 - 100, data for resistance. Defective Engine 1. 1. Idle set above operating speed
Range: 0 - 100 speed sensor. does not
100 = Max Gain 100 = fastest response
Default: 25 get to cor- 2. Fixed speed set above overspeed
Default: 10 Default: 35
rect speed
3. Set crank cutoff speed above idle or
fixed speed

DPG100/101-F Digital Pump Governor 7.14 PIB 4168 A

2014 Copyright All Rights Reserved
11 Wiring
Engine Sensor
SPECIFICATIONS 12 Wiring
Engine Sensor
OUTLINE DRAWING & DIMENSIONS
Performance

Isochronous Operation 0.25%

Dimension Units 2.992

Speed Range / Governor 400 - 10 KHz
[X.XX] [mm]
Droop Range 1 - 5% regulation X.XX in
PHYSICAL
Dimension See Section 12
Weight 3.1 lbs (1.41 kg)
INPUT / OUTPUT
Supply 12-24 VDC Battery Systems (7.0 to 33 VDC)
Polarity Negative Ground (Case Isolated)
Power Consumption (12VDC) 40mA MAX (no load)
6A MAX (full load)
2.7 - 3.3A Typical Range
2.0 - 4.0A Operating Range
Power Consumption (24VDC) 40mA MAX (no load)
121.0
3A MAX(full load)
1.3 - 1.7A Typical Range
1.0 - 2.0A Operating Range
Speed Sensor Signal 1.0 - 120VRMS
Mechanical Shutdown Lever Force Required 20 lb-in (2.3 N-m)
Mechanical Max Fuel Rack Stop Adj Screw 12mm
Range

RELIABILITY
Vibration 4G, 20-500 Hz DIGITAL PUMP
GOVERNOR
Shock 20G Peak
DPG101-FR-12

Testing 100% Functional Testing 39.9

.342
Environmental
Ambient Temperature -40 to 85C (-40 to 180F)

Relative Humidity up to 95%

60.2
3.346
All Surface Finishes Fungus Proof and Corrosion Resistant 2.369

COMPLIANCE / STANDARDS 94.0

Agency CE and RoHS Requirements 6.00

Communications RS-232-C, IEEEE J1939

DPG100/101-F Digital Pump Governor 7.14 PIB 4168 A

2014 Copyright All Rights Reserved