Woodward EGCP-2 Installation And Operation Manual
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Woodward EGCP-2 Installation And Operation Manual

Engine generator control package
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Product Manual 26174
(Revision B)
Original Instructions
EGCP-2
Engine Generator Control Package
8406-120, 150–300 Vac PT Input, 9–32 Vdc
8406-121, 50–150 Vac PT Input, 9–32 Vdc
Installation and Operation Manual

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  • Page 1 Product Manual 26174 (Revision B) Original Instructions EGCP-2 Engine Generator Control Package 8406-120, 150–300 Vac PT Input, 9–32 Vdc 8406-121, 50–150 Vac PT Input, 9–32 Vdc Installation and Operation Manual...
  • Page 2 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Manual 26174 EGCP-2 Engine Generator Control Package Contents ................  ARNINGS AND OTICES ..........  LECTROSTATIC ISCHARGE WARENESS VIII 1. G ............1  HAPTER ENERAL NFORMATION Introduction ......................1   Regulatory Compliance ..................1   Control Electrical Ratings ..................1  ...
  • Page 4 EGCP-2 Engine Generator Control Package Manual 26174 Contents 5. C ........117  HAPTER ONTROL EATURES AND UNCTIONS Engine Control ....................117   Engine Protection ....................117   Generator Voltage and Reactive Load Control ..........117   Generator Protection ..................117   Mains Sensing ....................118  ...
  • Page 5 Manual 26174 EGCP-2 Engine Generator Control Package Contents C. V ..........183  PPENDIX OLTAGE ONNECTIONS Basler AVC63-12 ....................183   Basler AEC63-7 ....................184   Basler APR63-5 ....................185   Basler APR63-5 with AMP200 ................186   Basler KR2F, 4F, or 7F ..................187  ...
  • Page 6 Figure 3-3. Wiring Diagram for EGCP-2 ............... 20   Figure 3-4. Dip Switch Locations ................21   Figure 3-5. Three Wire Delta PT Connections for EGCP-2 ......... 23   Figure 3-6. Four Wire Wye PT Connections ............23   Figure 3-7. Utility/Local Bus Single PT Wiring for Delta and Wye Configuration for Multiple or Single Engine Applications ..........
  • Page 7 Figure 4-27. Voltage Matching (1% set point) ............89   Figure 4-28. Maximum Phase Window = 10 Degrees .......... 90   Figure 4-29. EGCP-2 Control Dip Switch ............. 95   Figure 4-30. Direct (Export) Process Action ............96   Figure 4-31. Indirect (Import Power) Process Action ........... 96  ...
  • Page 8 EGCP-2 Engine Generator Control Package Manual 26174 Illustrations and Tables Figure 5-16. Changing the Priority of a Slave Unit ..........143   Figure 5-17. Changing the Priority of a Slave Unit ..........143   Figure 5-18. Changing the Priority of a Slave Unit ..........144  ...

  • Page 9: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 10: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.

  • Page 11: Chapter 1. General Information

    Manual 26174 EGCP-2 Engine Generator Control Package Chapter 1. General Information Introduction This manual describes how to Install and Operate the Woodward EGCP-2 Engine Generator Control Package, models 8406-120 and 8406-121. Associated publications:  26175—Application Manual  26181—Communications Manual ...

  • Page 12: Chapter 2. Control Overview

    400 to 3600 rpm. Designed for generator sets up to 30,000 kW, the EGCP-2 can be configured to operate stand-alone or utility paralleled. A network of EGCP-2 controls is capable of controlling up to eight un-manned generator sets for backup power, baseload, or peak shaving applications.
  • Page 13  Externally adjustable VAR or PF control reference levels. Automatic Generator Sequencing  Automatically starts additional EGCP-2 equipped generators when load exceeds a user specified percentage of the rated load of the operating machines.  Provides controlled unloads for engines when the load is low enough that the remaining engines will not exceed a user specified percentage of the rated load.

  • Page 14: Hardware

    EGCP-2. See Appendix A for mating connector information.  5417-551—Communication Cable for RS422. This cable will connect your PC to the EGCP-2 RS422 port. This is a point-to-point connection. It can be used with EGCP-2 software tools. Communication Manual 26181 contains the software tool information.

  • Page 15: Figure 2-1. Physical Outline With Dimensions Of Egcp-2

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 2-1. Physical Outline with Dimensions of EGCP-2 Woodward...

  • Page 16: Figure 2-2. Egcp-2 Interface Connections

    EGCP-2 Engine Generator Control Package Manual 26174 Figure 2-2. EGCP-2 Interface Connections Woodward...

  • Page 17: Operator Interface

    EGCP-2 Engine Generator Control Package Operator Interface The EGCP-2 Operator Interface is designed for simplicity and redundancy of function in all operating modes. Two backlit Liquid Crystal Display screens are used to display various operating and status information to the operator, as well as for tuning set points.
  • Page 18 EGCP-2 Engine Generator Control Package Manual 26174 There are a total of 19 keys on the keypad. Each key has the following function(s): ALARM/EVENT LOG KEYS: ALARM / EVENT The ALARM/EVENT key is used to access the Event log. When pressed, the current alarm events will be displayed on the right hand LCD screen.
  • Page 19 Manual 26174 EGCP-2 Engine Generator Control Package NAVIGATION and ADJUSTMENT KEYS: SCROLL The SCROLL KEY is used to move the cursor up, down, left and right. It also is used to increment and decrement values while in the configuration menus.
  • Page 20 EGCP-2 Engine Generator Control Package Manual 26174 CONFIG The CONFIG KEY, when pressed, will put the right hand LCD into the configuration mode. Configuration menu items will be displayed in the right hand screen. Status information will continue to be displayed in the left hand screen.
  • Page 21 KW LOAD The KW LOAD STATUS key, when pressed, shows the status information for the kW load control of the EGCP-2. PF / KVAR Press the PF/KVAR STATUS key to display VAR/PF Mode information, as well as three phase generator voltage and current.

  • Page 22: Navigation Procedure

    EGCP-2 Engine Generator Control Package Manual 26174 Navigation Procedure Figure 2-4(a-e) details a step-by-step procedure for navigating through the EGCP-2 Status screens and Configuration menus. The Keypad entries with the associated Display screens are shown. LEFT HAND LCD DISPLAY RIGHT HAND LCD DISPLAY...

  • Page 23: Figure 2-4B. Egcp-2 Navigation (2)

    Manual 26174 EGCP-2 Engine Generator Control Package From Previous Page SCROLL Configuration (*first item in list) Shutdowns and Alarms synchronizer status Engine Control Synchronizer Shutdowns and Alarms SCROLL Engine Control synchronizer status Synchronizer Real Load Control Process Control Transfer Switch...

  • Page 24: Figure 2-4C. Egcp-2 Navigation (3)

    EGCP-2 Engine Generator Control Package Manual 26174 ENTER From Previous Page NEXT GENSET DLY 30 Sec synchronizer status -------------------WOODWARD EGCP2------------- CONFIGURATION MENUS SCROLL NEXT GENSET DLY 29 Sec synchronizer status -------------------WOODWARD EGCP2------------- CONFIGURATION MENUS ENTER >AUTO SEQUENCING (*first item is list) >MAX GEN LOAD...

  • Page 25: Figure 2-4D. Egcp-2 Navigation (4)

    Manual 26174 EGCP-2 Engine Generator Control Package CONFIG from previous page Configuration Shutdowns and Alarms synchronizer status Engine Control Synchronizer Configuration Shutdowns and Alarms input/output status Engine Control Synchronizer STATUS input/output status input/output status ALARM / EVENT CRANK FAIL 12:00 1 - 1...

  • Page 26: Figure 2-4E. Egcp-2 Navigation (5)

    EGCP-2 Engine Generator Control Package Manual 26174 ENTER from previous page MAIN VOLT LOW ALM 12:00 1 - 1 engine status ---------------------------------------------------- -------------------End of List----------------- ENTER MAIN VOLT LOW ALM 12:00 1 - 1 engine status ---------------------------------------------------- ALARM CLEAR -------------------End of List-----------------...

  • Page 27: Chapter 3. Electrical Installation And Specifications

    Wiring Fixed Terminal Figure 3-1. CageClamp Termination Blocks (example photos) Most of the EGCP-2 control’s terminal blocks are designed to be removed by hand. After EGCP-2 input power is disconnected, the terminal blocks can be removed one at a time by pulling them straight out. Care should be taken not to pull the plug out at an angle as this will fracture the end terminal.

  • Page 28: Figure 3-2. Recommended Single Point Grounding Scheme

    (or 1 of 3 other like termination points without label) to reduce the risk of electric shock. The EGCP-2 ships with 2 thread forming screws (M4 x 6 mm, Woodward #1029-525) for this connection.
  • Page 29 All other shield terminations except at the EGCP-2 should be ac coupled to earth through a capacitor. A 1000 pF, 500 V capacitor is sufficient. The intent is to provide a low impedance path to earth for the shield at frequencies of 150 kHz and up.

  • Page 30: Figure 3-3. Wiring Diagram For Egcp-2

    EGCP-2 Engine Generator Control Package Manual 26174 Figure 3-3. Wiring Diagram for EGCP-2 Woodward...

  • Page 31: Input Power

    CLOSED position. Input Power The EGCP-2 accepts any input power source that supplies a voltage within the 9- 32 Vdc voltage range. It is expected that the installation of this equipment will include overcurrent protection between the power source and the EGCP-2. This...

  • Page 32: Potential Transformer (Pt) Inputs

    Potential Transformer (PT) Inputs Potential Transformers (PTs) are utilized with the EGCP-2 control to allow high voltages to be stepped down to a safe level for the EGCP-2 input circuitry. The EGCP-2 control senses generator output voltage through three Generator PTs, and utility and plant-bus voltages via one shared utility/plant-bus PT.

  • Page 33: Figure 3-5. Three Wire Delta Pt Connections For Egcp-2

    Figure 3-6. Four Wire Wye PT Connections Utility (Mains) and Plant Bus PT Input Wiring The EGCP-2 utilizes one PT input to sense both utility tie-line voltage and plant- bus voltage. This PT input must be the same configuration as the generator PT input.

  • Page 34: Figure 3-7. Utility/Local Bus Single Pt Wiring For Delta And Wye Configuration For

    When the Mains PT Disconnect changes state, the EGCP-2 has to measure less than 40 Vac on the Mains/Bus PT input (terminals 40 and 41). If the EGCP-2 measures greater than 40 Vac after the Mains PT Disconnect command was given, the EGCP-2 senses this as a fault and will not synchronize.

  • Page 35: Figure 3-8. Utility/Local Bus Single Pt Wiring For Delta And Wye Configuration For Multiple Or Single Engine Prime Power Applications

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 3-7 Notes: 1. For Multiple or Single Engine Applications a. Loss of Mains (LOM) b. Mains Parallel or No Parallel c. Prime Power 2. K1 and K2 relays a. Not supplied by Woodward b.

  • Page 36: Figure 3-9A. Pt Wiring Relationships For Generator, Bus, And Utility Inputs

    Required PT Wiring Relationships The EGCP-2 control uses its programmed PT-Ratio setting to calculate and compare all PT input voltages. Thus, the EGCP-2 control requires the following generator, utility, and plant-bus PT relationships. Figures 3-9(a & b) and 3-10 (a &...
  • Page 37 Voltage Input: Delta PT Ratio : 2:1 Voltage Ref: 480 Vac, L-L Figure 3-9b. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-120. 2. Follow Utility/Local Bus PT wiring. Woodward...

  • Page 38: Figure 3-10A. Pt Wiring Relationships For Generator, Bus, And Utility Inputs

    Voltage Input: Wye VIS-148B 02-5-29 PT Ratio : 4:1 Voltage Ref: 277 Vac, L-N Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-121. 2. Follow Utility/Local Bus PT wiring. Woodward...

  • Page 39: Figure 3-10B. Pt Wiring Relationships For Generator, Bus, And Utility Inputs

    Voltage Input: Wye VIS-148C PT Ratio : 1:1 02-5-29 Voltage Ref: 277 Vac, L-N Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-120. 2. Follow Utility/Local Bus PT wiring. Woodward...

  • Page 40: Current Transformer (Ct) Inputs

    Current Transformer (CT) Inputs Current Transformers (CTs) are utilized with the EGCP-2 control to allow high currents to be stepped down to a safe level for the EGCP-2 input circuitry. The EGCP-2 senses generator current via external current transformers. The “Amps per phase”...

  • Page 41: Mpu (Speed) Input

    The closer the MPU’s pole piece is to a gear’s teeth and the faster the gear turns the higher a passive MPU’s output amplitude will be. The EGCP-2 must sense an MPU voltage of 3.5 to 25 Vrms for proper operation.

  • Page 42: Process Import/Export Input

    Manual 26174 Process Import/Export Input The EGCP-2 control can be configured to control any process that is determined or affected by generator load. The Process Import/Export input is used by the EGCP-2 control to sense the process level being controlled. This input can be DIP switch, switch 4, configured to accept either a 4–20 mA or 1–5 Vdc signal.

  • Page 43: Coolant Temperature And Oil Pressure Inputs

    EGCP-2 Engine Generator Control Package Coolant Temperature and Oil Pressure Inputs The EGCP-2 has one analog input dedicated to sense engine coolant temperature and one analog input dedicated to sense engine oil pressure. These inputs can be utilized for monitoring, alarm, and shutdown. Configurable alarm set points are provided for both a high and low alarms.

  • Page 44: Figure 3-15. Wiring Diagram For Temperature Inputs

    EGCP-2 Engine Generator Control Package Manual 26174 +12 Vdc 537.5 SW2-1 Coolant Temperature SW2-3 SW2-4 SW 2-2 Sensor Input VIS-050b 01-01-31 Input 4-20mA 1-5 Volt 200 Ohm Sensor X - May be closed to insert shunt SW2-1 Open Open Closed...
  • Page 45 8. You need a temperature gauge on the engine to do the final calibration. 9. Start the engine and let stabilize at operating temperature. 10. Compare the Water Temperature reading on the EGCP-2 to the Temperature gauge on the engine.

  • Page 46: Speed Bias And Voltage Bias Outputs

    An example is the Basler SSR regulator, see connection diagram in Appendix C. The EGCP-2 only provides an analog, ± Vdc output and will not function with any regulator that accepts discrete inputs only. An example of this is the Marathon 2000 DVR.

  • Page 47: Figure 3-16. Wiring Diagram For Speed Bias And Voltage Bias Outputs

    Manual 26174 EGCP-2 Engine Generator Control Package Speed and Voltage Bias Output Ratings Number of Channels: Min Drive Impedance: 1000 Ω Configuration menu (Items Affected) 1. Speed Bias Type 2. Voltage Bias Type Calibration menu 1. Speed Bias Offset 2. Volts Bias Offset 500 Hz PWM .5 to 4.5 VDC...

  • Page 48: Discrete Inputs

    EGCP-2 control is in the VAR control mode (VAR control programmed, generator breaker closed, utility tie breaker closed), these contact inputs can be used to raise and lower unit VARs. If the EGCP-2 control is in the Power Factor control mode (Power Factor control programmed, generator breaker closed, utility tie breaker closed), these contact inputs can be used to raise and lower unit Power Factor.

  • Page 49: Relay Outputs

    Figure 3-17. Wiring Diagram for Typical Discrete I/O Connections Relay Outputs Twelve (Form C type) Relay Outputs are used by the EGCP-2 control to interface with system devices. Before installation verify that the EGCP-2’s relay contacts meet the power requirements of the circuit with which it is being interfaced.

  • Page 50: Figure 3-18. Example Of The Mains Breaker No Output Connected To Close The Mains (Utility) Breaker (Energize To Close)

    6, and Normally Closed (NC), terminals 6 and 7, contacts to select from. The “Mains (utility) Breaker Close” relay output is utilized by the EGCP-2 to command the Mains (utility) Breaker to close. This output is configured for use with a BREAKER or a CONTACTOR in the Configuration menu under “CKT...

  • Page 51: Figure 3-19. Example Using The Nc Output To Control The Mains (Utility) Contactor (Energize To Open)

    ENERGIZE (continuously) to open the Mains Contactor . This is reverse logic from the Generator Contactor Close, discrete output # 2. External logic will be needed to verify the contactors state when installing or replacing EGCP-2 controls and for multiple control systems.

  • Page 52: Figure 3-20. Example Of The Generator Breaker Close No Output Connected To Close The Generator Breaker (Energize To Close)

    Contactor. The “Generator Breaker Trip”, discrete output #10, is NOT used in the Contactor mode. The EGCP-2 will DE-ENERGIZE (continuously) to open the Generators Contactor and ENERGIZE (continuously) to close the Generators Contactor. This is reverse logic from the Mains Contactor Close, discrete output # 1.
  • Page 53 The “Engine Preglow” relay output utilizes a set of normally open (NO) contacts on terminals 11 and 12. The “Engine Preglow” relay output is utilized by the EGCP-2 to turn on a diesel engine’s glow plugs, if so equipped. This relay will energize for a programmed length of time, based on the “Preglow Time”...
  • Page 54 The “Local Bus PT Connect” relay utilizes a set of Normally Open (NO) contacts on terminals 21 and 22. The “Local Bus PT connect” relay output is utilized by the EGCP-2 to connect the Local Bus PT to the EGCP-2’s “Utility and Local Bus PT Input” on terminals 40 and 41.

  • Page 55: Figure 3-22. Example Using The No Contacts To Control The Mains Breaker Trip (Open) Coil (Energize To Open)

    With the relay de-energized, this output has Normally Open (NO), terminals 28 and 29, and Normally Closed (NC), terminals 29 and 30, contacts to select from. The “Generator Breaker Trip (open)” relay output is utilized by the EGCP-2 to command the Generator Breaker to open. The relay output will DE-ENERGIZE to open the Generator Breaker.

  • Page 56: Figure 3-23. Example Using The Nc Contacts To Control The Generator Breakers Open Coil (De-Energize To Open)

    EGCP-2 Engine Generator Control Package Manual 26174 Generator EGCP-2 Breaker Trip Generator Breaker Trip (Open) Coil Discrete Output #10 VIS-154e 01-06-01 Figure 3-23. Example Using the NC Contacts to Control the Generator Breakers Open Coil (DE-ENERGIZE TO OPEN) EGCP-2 External Wiring...
  • Page 57 LED on the face of the EGCP-2 to flash. All alarm indicators will remain active until the alarm condition is acknowledged. No control actions occur as a result of an audible alarm condition.

  • Page 58: Ac Inputs

    EGCP-2 Engine Generator Control Package Manual 26174 AC Inputs The EGCP-2 receives ac inputs from the generator, bus, mains and engine. They are as follows: Location Description Signal Burden Generator PT phase A + AC Voltage 200 kΩ Generator PT phase A –...

  • Page 59: Discrete Inputs

    Manual 26174 EGCP-2 Engine Generator Control Package Discrete Inputs Loc. Description Signal Input Auto Discrete Input (DI-1) – power supply (internal connection) Test Discrete Input (DI-2) – power supply (internal connection) Run/Ld Discrete Input (DI-3) – power supply (internal connection)

  • Page 60: Communication Ports: Rs-485 & Rs-422 (1 Each)

    Modbus /ServLink Communications The laptop or desktop computer, which will be used with the EGCP-2 RS-422 port, will have a 9-pin serial port. This port is configured by the computer hardware to use a serial communications protocol called RS-232. The details of...

  • Page 61: Figure 3-25. Rs-422 Communications

    Manual 26174 EGCP-2 Engine Generator Control Package In a system with multiple (8 maximum) EGCP-2 controls, each control is interconnected to the others on the 422 network in a multi-drop fashion. The computer is linked to the network at any control as if it were the next control on the network, as shown below.

  • Page 62: Inter-Control Communications (Rs-485 Network)

    1.0 mm² (16 AWG) wiring. Making this connection will force all communications transceivers to the same reference. As shown in Figure 3-26, the EGCP-2 uses Switch 4 (4-1, 4-2, and 4-3) to terminate the 485 network. Switches 4-1, 4-2, and 4-3 will be closed (pushed down toward the PC board, see Figure 3-4) for proper 485 network terminations.

  • Page 63: Alarms And Shutdowns

    The information on the RS-485 network is for communications between controls only and must not be interfaced in any way with external devices. There is an RS-422 port on the EGCP-2, which is used to monitor and control the units remotely.
  • Page 64 LED on the face of the EGCP-2 will stay on continuously. A unit, which has experienced a hard shutdown condition, will remove itself from any automatic sequencing displays.
  • Page 65 Manual 26174 EGCP-2 Engine Generator Control Package These 5 items, located in the Transfer Switch menu, can be configured for a Loss of Mains condition: Load Surge Senses a step kW load change (% of Rated Load Set Point per Second) on generator.

  • Page 66: Chapter 4. Software Overview

    Status Screens There are nine status menus in the EGCP-2. Use the status keys on the face of the EGCP-2 to access these status menus. The information in the status menus is dynamic and updates about every 200 milliseconds.
  • Page 67 SPINDOWN  RETRY Operating State: Shows if the EGCP-2 is in AUTO or MAN (manual) mode. Load Control State: Shows the state of the load control logic of the EGCP-2. The load control states are: Load Control States:  ...

  • Page 68: Figure 4-2. System Status Screen-Isochronous

    EGCP-2 Engine Generator Control Package Manual 26174 This is what the System Status screen would look like with the mains out of spec, the engine running, carrying 100 kW load isochronously, and the generator voltage and frequency is within specified limits. This would be a typical screen if the unit was set for loss of mains detection, and the mains had failed.

  • Page 69: Figure 4-4. Engine Status

    Manual 26174 EGCP-2 Engine Generator Control Package The following is an overview of each of the status menu screens, starting with Engine status: Figure 4-4. Engine Status HH:MM: 24 hour clock readout. MM-DD: Date (MM-DD). Engine: The state of the engine control function.

  • Page 70: Figure 4-5. Generator Status (Voltage Line To Neutral)

    EGCP-2 Engine Generator Control Package Manual 26174 Figure 4-5. Generator Status (Voltage Line to Neutral) A B C: Three phase readings for the generator. KVA: Three phase kVA readings. KW: Three phase kW readings. KVR: Three phase kVAR readings. V: Volts for each phase of the generator.

  • Page 71: Figure 4-6. I/O Status

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 4-6. I/O Status IN: Discrete Inputs 1 through 16. OUT: Discrete Outputs 1 through 12. Volt Bias: % voltage bias output (±100% range). Speed Bias: % speed bias output (±100% range). Process In: Process Input will be displayed in Engineering Units configured in the Process menu.

  • Page 72: Figure 4-7. Synchronizer Status

    Volts: The voltage differential in percent between the generator and the bus or mains it is paralleling to. Mains/Bus: The active PT input being monitored by the EGCP-2. Dead Bus: Indicates if the PT input (mains or bus) being measured is dead.

  • Page 73: Figure 4-8. Kw Load Status

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 4-8. kW Load Status Generator KW: The total, three phase kW the generator is producing. Load Reference: The load reference, in kW for the generator. System Load: The calculated system load for all units operating in isochronous load sharing mode.

  • Page 74: Figure 4-9. Pf /Kvar Status

    EGCP-2 Engine Generator Control Package Manual 26174 Figure 4-9. PF /kVAR Status VAR/PF MODE: The configured VAR/PF control mode. PF REFERENCE: The PF control reference value for the control. Power Factor (PF) reference changes to kVAR REF when in VAR control.

  • Page 75: Figure 4-10. Sequencing Menu

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 4-10. Sequencing Menu Unit: Network Address of all units in Auto on the network. Oper: Units in auto, and on the network with their breakers closed will have an X under their Address.

  • Page 76: Figure 4-11. Sequencing Menu (Multi-Unit)

    EGCP-2 Engine Generator Control Package Manual 26174 The example below is a typical sequencing screen for a 5-unit system. Figure 4-11. Sequencing Menu (Multi-Unit) As displayed on the sequencing screen: Units 1 3, and 5 are on load with their generator breakers closed.

  • Page 77: Figure 4-12. Ats (Automatic Transfer Switch) Status

    Manual 26174 EGCP-2 Engine Generator Control Package Figure 4-12. ATS (Automatic Transfer Switch) Status. Mains: A graphic display of the mains condition. Two minus symbols (--) indicates the mains are out of spec, one plus symbol indicates the mains are in spec, but not declared stable (+-) two plus symbols (++) indicate mains are in spec and stable.

  • Page 78: Security Access

    Factory Full access, includes the Engine Run Time and the Calibration menu. When the Config key on the EGCP-2 keypad is pressed, the right LCD screen will switch to the configuration menus. A Security Code prompt will be provided prior to access into the Configuration Menus. The Security Code value determines which configuration menus are accessible and if the Alarm / Event log can be cleared.

  • Page 79: Alarm / Event Log

    This log contains up to sixteen individual warning, alarm, or shutdown items. When the Alarm / Event button is pressed on the EGCP-2 keypad, the right hand LCD screen will switch to the Alarm/Event log. This log displays the following information.

  • Page 80: Figure 4-15. Empty Event Log

    EGCP-2 Engine Generator Control Package Manual 26174 In the event that the Alarm /Event Log key is pressed, and there are no active or logged alarms, the display will look like this: Figure 4-15. Empty Event Log The alarms displayed in the alarm / event log are arranged in a first in, last out (FILO) order.

  • Page 81: Configuration Menus

    When a valid security code is entered, the configuration menu list will be displayed. The configuration list allows the user to configure, calibrate, and adjust all relative items to the EGCP-2 operation. Figure 4-16a. Configuration Menu List (Screen 1) Figure 4-16b. Configuration Menu List (Screen 2)

  • Page 82: Figure 4-16C. Configuration Menu List (Screen 3)

    Sanity Checks In order to prevent improper configuration that may damage the generator set when started, the EGCP-2 runs through a series of “sanity checks”. The items involved, all in the Configuration menu, for these “sanity checks” are: 1. Numbers of Poles 2.

  • Page 83: Figure 4-17. Program Configuration Error

    Uncommitted items will have an asterisk (*) next to the item’s value on the display screen. Asterisks will appear whenever a Set Point file is downloaded to an EGCP-2. To commit an item you must press the ENTER key. Open the Configuration menu and open each item, then ENTER that item.
  • Page 84 Answer: Calculated kVA  (Voltage Ref * 3) * CT Ratio = Unit OK Rated kW  Rated kVA = Unit OK If the EGCP-2 is not providing an engine start signal:  Check for pound signs (#) signs and/or asterisks (*).
  • Page 85 Manual 26174 EGCP-2 Engine Generator Control Package Number of Poles  Range: 2—18  Determines Speed/Frequency Relationship.  Number of Poles = 120 * Hertz / rpm Number 60 Hertz 50 Hertz of Poles Generator Generator 3600 rpm 3000 rpm...

  • Page 86: Figure 4-18. Ac Power Triangle

    Voltage Input  Range: Wye L-N or Delta L-L  Set for sensing/transformer used between generator and EGCP-2.  Defines which calculations will be used for kW, kVA, kVAR, etc.  Defines the expected input type for voltage levels in the set point menus.
  • Page 87 Manual 26174 EGCP-2 Engine Generator Control Package Voltage Reference  Range: 1—30000  Operating Voltage of Generator per Generator Nameplate. Used for VAR/PF Sharing as the Reference that multiple generators share reactive load to. This maintains the voltage reference while in Power Factor Sharing or kVAR Control mode on an isolated bus.
  • Page 88 EGCP-2 Engine Generator Control Package Manual 26174 Speed Bias Type  Range: ±3 Vdc, 0.5–4.5 Vdc, or 500 Hz PWM  ±3 Vdc (WGC) Sets the speed bias output to ±3 Vdc range. 0 Vdc is zero output, –3 Vdc is –100% speed bias output, +3 Vdc is +100% speed bias output.

  • Page 89: Figure 4-19. Breaker Logic And Contactor Logic

    Manual 26174 EGCP-2 Engine Generator Control Package Number of Units  Range: Single or Multiple  Defines whether unit is part of a multiple unit system or not.  If single unit, there is no auto starting, auto sequencing, load or PF sharing with other units under any circumstances.

  • Page 90: Shutdowns And Alarms

    Hard Shutdown--Same as above, but immediately opens generator breaker and de-energizes the fuel solenoid. Voltage Range Alarm  Alarm/Shutdown point for an excess of voltage bias signal from the EGCP-2 to AVR.  Preset to trigger at ±100% voltage bias output.

  • Page 91: Figure 4-21. Generator Over/Under Frequency

    Manual 26174 EGCP-2 Engine Generator Control Package Generator High/Low Volt Limit Alarm  Even if the Alarm Set Points for the High/Low Limits are Disabled, the Voltage Bias will not allow adjustment beyond these limits.  The same is true for the synchronizer, which will not allow a gen breaker closure if the High or Low Voltage limits are met or exceeded for a period of time which exceeds the Gen Volt Timer Set Point.
  • Page 92 If Start Sequencing is Disabled and no MPU is present, then this alarm compares Generator Frequency to Generator Frequency, so the Speed/ Frequency Mismatch Alarm will never alarm. Woodward recommends that the Speed/Frequency Mismatch Alarm be set the same as the Overspeed Alarm to protect against the loss of the MPU signal.

  • Page 93: Figure 4-22. Delay Time Is 10 Seconds, Current Goes To 190 A, An Alarm Or Shutdown Will Be Received In 30 Seconds

    Manual 26174 EGCP-2 Engine Generator Control Package Overcurrent Delay  Range 0.1 – 20.0 seconds  Used with the Overcurrent Level and Rated Current to determine the amount of time (AMP  SECONDS) any current can be greater than the overcurrent level before an alarm or shutdown is received.

  • Page 94: Figure 4-24. Delay Time Is 10 Seconds, Current Goes To 220 A, An Alarm Or Shutdown Will Be Received In 7.5 Seconds

    EGCP-2 Engine Generator Control Package Manual 26174 Overcurrent Trip Zone Current (per phase) Overcurrent Level Rated Current 0 7.5 Time (seconds) Figure 4-24. Delay Time is 10 Seconds, Current goes to 220 A, an Alarm or Shutdown will be Received in 7.5 Seconds...

  • Page 95: Figure 4-25. Reverse Power

     Range: –.0 to –00  Set as a percentage of the Rated kVAR. If the EGCP-2 senses a kVAR load greater than this value the Reverse kVAR Delay begins. When the Delay times out, an alarm will trigger. ...

  • Page 96: Engine Control

    50 rpm. Cannot restart engine until this time has expired. Crank Repeats  Number of times EGCP-2 will repeat its attempt to start the engine. Cranking attempts will equal the value of Crank Repeats +1. Crank Fail ...
  • Page 97 When “Start Sequencing” is Disabled, the PT signal is used to calculate the overspeed signal. No MPU is needed in this condition. Woodward recommends that the Speed/Frequency Mismatch Alarm be set the same as the Overspeed Alarm to protect against the loss of the MPU signal.

  • Page 98: Synchronizer

    Normal operating mode.  Actively synchronizes and issues breaker closure command.  EGCP-2 control MUST be in RUN to operate as a dead bus closing device.  In multiple unit systems EGCP-2 control MUST have AUTO input active to enable breaker control.

  • Page 99: Figure 4-27. Voltage Matching (1% Set Point)

    Voltage Window  Overall percentage of error allowed between generator and bus, or generator and mains.  EGCP-2 control will not issue a breaker closure if error is greater than voltage window. Gen Voltage High Bus or Mains Voltage 484.8 VAC 480 VAC 475.2 VAC...

  • Page 100: Figure 4-28. Maximum Phase Window = 10 Degrees

     Maximum allowable phase angle deviation from phase matched condition.  EGCP-2 Control will not issue breaker closure if phase angle between generator and bus, or generator and mains exceeds this window. Must be within +/- 10 deg window for breaker closure Figure 4-28.

  • Page 101: Real Load Control

    Manual 26174 EGCP-2 Engine Generator Control Package Synchronizer Time Out  Sets time allowed for synchronization in seconds.  Begins timing when synchronizer activates.  Active for all gen and mains breaker open and close commands from EGCP-2 control. ...
  • Page 102  Must be set less than the Baseload Load Reference value. Load Droop  Percentage of kW droop used when EGCP-2 control is operating in a droop mode. Load Time  Time in seconds for generator to load from unload trip level to base load level.
  • Page 103 Unload Trip = 25 kW The difference is 175 kW The EGCP-2 will ramp 175 kW in 10 seconds This breaks down to 17.5 kW per second Remember, if the Base Load Ref or Unload Trip is changed, it will affect the ramping rate when unloading.

  • Page 104: Reactive Load Control

    EGCP-2 Engine Generator Control Package Manual 26174 KVA Switch High  Sets level, which when exceeded, will cause the kVA relay output to de- energize. Only applicable for units with the relay#12 function configured for kVA Load Switch. Summary of kVA load switch action:...

  • Page 105: Process Control

    Process Control Process Import/Export Hardware EGCP-2 Control can accept a 4–20 mA or 1–5 Vdc input signal from a kW transducer. Input signal conditioning is selected by a dip switch on the back of the EGCP-2 control, switch position 4, switch number 4. Closing this switch selects the 4–20 mA input hardware.

  • Page 106: Figure 4-30. Direct (Export) Process Action

    EGCP-2 Engine Generator Control Package Manual 26174 20 mA export power speed bias 4 mA Figure 4-30. Direct (Export) Process Action 20 mA imported power speed bias 4 mA Figure 4-31. Indirect (Import Power) Process Action 20mA speed bias ->...
  • Page 107 Manual 26174 EGCP-2 Engine Generator Control Package Process Gain  Sets system gain response while in process control.  Effective when active master unit only. Slaves rely on Load Control dynamic settings to control response to master load reference. ...
  • Page 108 EGCP-2 Engine Generator Control Package Manual 26174 Raise Rate  Rate, in %/s, at which the process reference will change when the EGCP-2 receives a Raise Load input (Discrete Input #6) or Modbus address AW40328 while operating in process control mode. Lower Rate ...
  • Page 109 Manual 26174 EGCP-2 Engine Generator Control Package  Engineering unit selections Displayed Units kVAR MVAR Deg C Deg F Process Low Value  The Process Input, when at 4 mA or 1.0 volt, will be displayed as. Example: Process Low Value = –1000 kW Process Input is 4 Ma ...

  • Page 110: Transfer Switch

    Alarms when Mains Voltage exceeds Alarm Set Point.  Alarm can be set for Loss of Mains.  If Mains Voltage is above High Limit, Mains are not considered stable, and the EGCP-2 control will not issue a mains breaker closure command. Woodward...
  • Page 111  If Mains Frequency is above High Limit, Mains are not considered stable, and the EGCP-2 control will not issue a mains breaker closure command. Main Freq High Alarm The Main Frequency High condition will cause a response defined by this set point.

  • Page 112: Sequencing And Comms (Communications)

    EGCP-2 Engine Generator Control Package Manual 26174 LOM Action Delay  Sets Time Delay for LOM Action to begin once Loss of Mains is detected.  Delay time From LOM detection to mains breaker open, and engine start command. ...
  • Page 113 Minimum Generator Load  % of system load at which the Master EGCP-2 begins the Reduced Load Delay to sequence units off line.  With only two engines operating, the Master unit will NOT sequence off the next unit if the System Load Percentage will increase above the Max Gen Load –10%.

  • Page 114: Calibration Menu

    The Calibration Menu allows calibration of all the analog inputs to the EGCP-2, as well as the speed bias and voltage bias outputs. All calibration points in the EGCP-2 are used to make the actual value of an input, such as generator voltage, read out on the respective display screen of the EGCP-2 the proper value of the signal being monitored.

  • Page 115: Figure 4-33. Process In Scale

    Measured vs Monitored 480.0 VAC Measured A -B phase Line to Line Measured vs. Monitored 480.0 Monitored Voltage EGCP-2 configured for Line to Line (3 wire) PT input. Woodward ALARMS: 1 UNIT: 1 A PHASE PT SCALE Mains: -- Gen: ++ 1.00...
  • Page 116 EGCP-2 Engine Generator Control Package Manual 26174 Speed Bias Offset  Range: 50% to –50% of selected Speed Bias Type  Factory calibrated for: Speed Bias Type Voltage at Terminals Speed Bias Offset 73(+) – 74(-) ±3 Vdc 0.00 Vdc 0.0%...

  • Page 117: Figure 4-35. Typical Avr With Aux Input (Newage Sx-440)

     Press the Enter key to save the final Volts Bias Setting  The EGCP-2 control will always reset to the saved Volts Bias Offset value when the generator breaker is opened.  Whenever the Generator set is started or taken offline, it will control at the rated voltage when calibrated correctly.

  • Page 118: Figure 4-37. Avr Droop

    AVR. This adds stability to the AVR for VAR/PF sharing at low loads.  Cross current compensation must be disabled in the AVR Droop CT circuit. +/- 1 VDC output from EGCP-2 trim Volts Droop Figure 4-37.
  • Page 119 Manual 26174 EGCP-2 Engine Generator Control Package CT Phase A, B and C Offset  Calibrates CT Phase A, B, or C input sensing of EGCP-2 at zero current.  Only calibrate when generator is operating with no load. ...
  • Page 120 Bus PT calibration Measure the Bus voltage. If the BUS is dead no calibration can be done. To get the EGCP-2 to switch from monitoring the Mains to monitoring the Bus, the generator must be started.  Configure Synchronizer Mode for CHECK ...
  • Page 121 Resistive sensors are commonly a direct relationship.  Adjust the Oil Pressure Gain, the Calibration menu will provide a monitored reading that will be compared to a measured reading.  Adjust gain until EGCP-2 monitored reading matches actual reading. Example of a Direct type sensor Woodward...

  • Page 122: Figure 4-38. Oil Pressure Sensor Curve

    (1)shut down and (2)running at rated speed.  Record the pressure and resistance.  Then connect a potentiometer or decade box to the EGCP-2 oil pressure input, terminals 68 and 69.  Set the resistance for the running value. ...
  • Page 123 To adjust the Water Temperature Gain, the Calibration menu will provide a monitored value that will be compared to a measured reading.  Adjust gain until EGCP-2 monitored reading matches actual reading.  If it is not possible to reach the high or low temperature, it may be necessary to add one or more of the shunt resistors by closing the DIP switch 2, switch 2, 3, or 4, on the EGCP-2.
  • Page 124 EGCP-2. In these situations it will be necessary to calibrate the EGCP-2 for the two most important readings, such as the high and low alarm points. In between these points there might be a slight error in reading as shown in Figure 4-39, but the reading will be correct at the two critical points.

  • Page 125: Figure 4-39. Water Temperature Curves

    Water Temperature Resistive Sensor (Ohms) Figure 4-39. Water Temperature Curves No shunt resistors SW 2-2 clsd 249 Ohm SW 2-3 clsd 100 Ohm Water SW 2-3&4 clsd 50 Ohm Temperature EGCP-2 Curve Characteristic Figure 4-40. EGCP-2 Water Temperature Characteristics Woodward...
  • Page 126 Excess numbers of NetComm Dropouts on network due to faulty wiring, improper shielding, or improper setup will result in the unit experiencing the dropouts to flash intermittently in the Sequencing Menu of the EGCP-2. Typically set at 5 to 10 dropouts.

  • Page 127: Chapter 5. Control Features And Functions

    Manual 26174 EGCP-2 Engine Generator Control Package Chapter 5. Control Features and Functions Engine Control  Programmable Auto Start on Loss of Mains  All units in Auto Mode with Loss of Mains detection enabled start and assume load. ...

  • Page 128: Mains Sensing

    EGCP-2 Engine Generator Control Package Manual 26174 Mains Sensing  Over/Under Voltage  Over/Under Frequency  Load Surge  Programmable for Alarm/Loss of Mains Detect  Loss of Mains Action Timer  Stable Mains determined by being within Voltage and Frequency Limits for a...

  • Page 129: Engine Cranking

    If for some reason the engine does not reach the crank cutout rpm level, the EGCP-2 will crank the engine for the Crank Time. If the engine fails to rise above the crank cutout level in this time, the EGCP-2 will remove the Crank output signal, wait for the Crank Delay, and if allowed by the number of Crank Repeats, will crank the engine again (RETRY).

  • Page 130: Idle/Rated Relay Output

    Reactive Load Control tuning menu, at the Voltage Ramp Time set point. The voltage ramp time is the amount of time it will take for the EGCP-2 to send a 0 to 100%, or 0 to –100% voltage bias signal to the AVR.

  • Page 131: Generator Load Control

    The percent level of the voltage bias output can be monitored in the I/O status screen of the EGCP-2. This is a useful point to monitor during initial start of the unit. By issuing Voltage Raise and Lower inputs to the control while operating in the Test Mode, confirmation of proper generator voltage levels at various voltage bias points can easily be made.

  • Page 132: Figure 5-1. Droop Mode

    The EGCP-2 can be operated in Droop if the Real Load Control menu item “Load Control Mode” is configured for kW Droop or if the unit is operated with the Generator CB Aux input open while connected to a load, or to the mains.

  • Page 133: Figure 5-2. Isochronous Mode

    Manual 26174 EGCP-2 Engine Generator Control Package Isochronous Isochronous means repeating at a single rate or having a fixed frequency or period. A generating set operating in the isochronous mode will operate at the same set frequency regardless of the load it is supplying up to the full load capability of the generator set, as illustrated in Figure 5-2.

  • Page 134: Figure 5-3. Droop/Isochronous Load Sharing

    Load Control Mode in either Normal or Soft Transfer. Isochronous load sharing operates all generator sets in a system in the isochronous mode. Load sharing is accomplished by using the load sensor of the EGCP-2 to bias the speed reference of the isochronous governor. The EGCP-2 load sensors are connected by inter-control RS-485 network.

  • Page 135: Automatic Generator Loading Functions

    Process menu of the EGCP-2. This set point uses milliamps for units, so that it is easily related to the 4–20 mA or 1–5 Vdc input signal. The EGCP-2 then adjusts the generator load to maintain the desired value. The EGCP-2 will only operate in a process control mode if it is configured to be a Mains Parallel unit, and receives an Auto, Run With Load, and Process discrete inputs.
  • Page 136 (Auto, Run w/Load, and Process) as the Master. 1. Pass the Master by changing the priority of the slave to 1. The EGCP-2 will pass the Master to the slave, and if the new Master has the same process reference setting there will be no noticeable change.
  • Page 137 Voltage Trim Control The EGCP-2 control will perform a Voltage Trim function when configured for Single unit or if it’s the only Multiple unit operating on an isolated bus. The Voltage Trim function will control the generator set at the Voltage Reference setting (Configuration menu) when on an isolated bus.

  • Page 138: Synchronizer Description

    PF to move in an increasing Leading PF angle. Power Factor Sharing When either VAR or Power Factor Control is selected, and the EGCP-2 control is operating in isochronous load sharing mode, power factor sharing is automatically selected.
  • Page 139 Mains PT input by switching to DO8 (Mains Disconnect) whenever generator synchronization is complete. Switching to the Mains PT allows the EGCP-2 to monitor for a loss of mains condition when operating on a generator that is not synchronizing across its generator breaker.
  • Page 140 EGCP-2 Engine Generator Control Package Manual 26174 When an EGCP-2 control receives a lock request, it does the following actions: 1. If a dead bus permission request is not also currently being made, a dead bus condition is indicated, and the GENERATOR AUX CONTACT discrete input is inactive (the EGCP-2 control returns a reply message to the requesting unit).
  • Page 141 Dwell Time allows the synchronizer to be configured for a wide range of synchronizing conditions. The Max Phase Window and Dwell Time set points are found in the Synchroscope tuning menu of the EGCP-2. A larger Max Phase Window, and Shorter Dwell time would typically be used on emergency standby sets, where rapid synchronization is needed.

  • Page 142: Figure 5-4. Synchronizer Time Line-Standard Sequence

    Figure 5-4. Synchronizer Time Line—Standard Sequence Loss Of Mains Detection and Action The EGCP-2 can be configured to detect a loss of mains condition, and respond to that condition by isolating the mains from the load, and transferring the supply of power to the load from the mains to on site engine generator sets.

  • Page 143: Figure 5-5. Loss Of Mains Detection Active

    Manual 26174 EGCP-2 Engine Generator Control Package Standard Sequence: Single No Parallel Unit in Auto with Loss Of Mains Detection Enabled. Fast Transfer Mains Stable Fast Transfer Mains In Spec and Gen Stable Delay Delay Genset On Load Delay Delay On Load Mains in Spec.

  • Page 144: Figure 5-7. Mains Parallel Unit With Voltage/Frequency Detect

    EGCP-2 Engine Generator Control Package Manual 26174 Standard Sequence: Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains Detection Enabled. Generator Mains Stable Mains In Spec and Unload Ramp Genset On Load Delay On Load Mains in Spec.

  • Page 145: Generator Sequencing

    When configured for automatic sequencing, as described above, the Sequencing status screen of the EGCP-2 will show all of the active units on the network in order of their Network Address, and the priority of those units in the sequencing scheme.

  • Page 146: Figure 5-9. Typical Automatic Sequencing Scenario

    EGCP-2 Engine Generator Control Package Manual 26174 100% SYSTEM LOAD TIME VIS-114 00-04-27 Figure 5-9. Typical Automatic Sequencing Scenario Point A Master Generator carrying load isochronously on an isolated bus. System load steps from approximately 10% to 30%. Point B Master Generator responds to a step load that brings the system load to approximately 70%.
  • Page 147 Sequencing and Comms menu. The Master unit in any multiple unit EGCP-2 system is always the unit with the lowest Network Priority setting. All slave units are then sequenced on line in ascending order of their Network Priority settings, and sequenced off line in descending order of their Network Priority Settings.
  • Page 148 Network Priority In order to give the end user of the EGCP-2 the ability to control engine run time levels in a multiple unit system, any EGCP-2 in the system can be used to change the network priority of any of the EGCP-2 units actively on the same network.

  • Page 149: Figure 5-10. Original System Configuration

    Manual 26174 EGCP-2 Engine Generator Control Package Shortly after this occurs, the new Master’s Sequencing Status screen will re- order the Next On and Next Off slave units to fit the new system priority configuration. No units will start or go on load under these conditions as a result of the assumption of the new master.

  • Page 150: Figure 5-12. Original System Configuration

    EGCP-2 Engine Generator Control Package Manual 26174 The master unit will have a Min Gen Load setting of 25%, and a Max Gen Load setting of 65%. These values will be used throughout the remaining examples. MAINS MAINS FAILURE DETECTED...
  • Page 151 Manual 26174 EGCP-2 Engine Generator Control Package Remember: The new Master needs a reason to start. If the original Master was started with a Run w/Load input and you switch the Master to another unit that only has the AUTO input closed, the new Master will NOT start. This example shows that the new Master will start due to a LOMs condition.

  • Page 152: Figure 5-14. Changing The Priority Of A Slave Unit

    EGCP-2 Engine Generator Control Package Manual 26174 Changing the Priority of a Slave Unit—No Slaves On Load MAINS NO MAINS FAILURE DETECTED MASTER SEQUENCING SCREEN ADDRESS: 1 OPER. PRIORITY 1 SYSTEM LOAD = 0% MASTER NEXT ON ALL NEXT OFF...

  • Page 153: Figure 5-16. Changing The Priority Of A Slave Unit

    Manual 26174 EGCP-2 Engine Generator Control Package Master running on load against the isolated bus (Figure 5-15). System load level is at 40%, so no slave units are sequenced on line. MAINS MAINS FAILURE DETECTED OR RUN WITH LOAD AT MASTER...

  • Page 154: Figure 5-18. Changing The Priority Of A Slave Unit

    EGCP-2 Engine Generator Control Package Manual 26174 Above figure represents system on load on an isolated bus in load sharing. The master unit has sequenced on the priority 2 slave unit. System load is at 50%. MAINS MAINS FAILURE DETECTED...
  • Page 155 The above examples are typical sequencing functions of the EGCP-2. Isolated bus applications were shown for clarity. The EGCP-2 is capable of automatic sequencing while in parallel with the mains in the process control, or process control soft transfer operating modes.

  • Page 156: Chapter 6. Calibration Of Control Inputs And Outputs

    EGCP-2 must be properly calibrated in order to perform its role as a controlling device accurately. This chapter discusses the calibration of these various inputs and outputs of the EGCP-2, and the effects of the calibration on the metering and control functions of the EGCP-2.

  • Page 157: Calibration Of Generator Pts And Cts

    The sensed generator voltage on the A phase is used in Power Factor/VAR sharing mode when the EGCP-2 is in parallel with other units on an isolated bus. The EGCP-2 uses the Voltage Reference as found in the Configuration tuning menu as a generator voltage reference point when balancing the reactive load on the bus between generators.
  • Page 158 Alarms Affected The generator current on A phase is monitored and used as an input for the Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing overcurrent conditions, and selects the phase with the highest current at any given moment.
  • Page 159 Alarms Affected The generator current on A phase is monitored and used as an input for the Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing overcurrent conditions, and selects the phase with the highest current at any given moment.
  • Page 160 Alarms Affected The generator current on B phase is monitored and used as an input for the Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing overcurrent conditions, and selects the phase with the highest current at any given moment.

  • Page 161: Calibration Of The Bus Pt

    Calibration of the Bus PT The bus PT input to the EGCP-2 plays a “dual role” in that it is used to sense both the bus, and the mains PT voltage sensing. The EGCP-2 automatically switches between the Bus and the Mains PT input when performing mains monitoring, synchronizing and dead bus closing actions.

  • Page 162: Speed Bias Output

    The Speed Bias Offset calibration point sets an offset on the speed bias output of the EGCP-2. This output is fed into the speed control governor to bias the governing speed for synchronization and load control functions. This offset is the starting point from which the EGCP-2 begins all of its speed biasing operations.

  • Page 163: Figure 6-1. Relationship Between Voltage Bias And Generator Voltage

    It is recommended that the voltage adjustment of the automatic voltage regulator be set for the desired rated voltage of the generator with the EGCP-2 not connected. Woodward...

  • Page 164: Chapter 7. General Start-Up Instructions

    When this is confirmed, apply the power supply to the EGCP-2. With the EGCP-2 powered up, the unit will go through a RAM test, and after a self check period, will display the System Status Screen. If the control fails to power up properly, remove the power supply input and re-check the polarity and amplitude of the voltage feeding the EGCP-2 Control.

  • Page 165: Sequence Of Start-Up And Checking Parameters

    Set crank repeats to 0. Set synchronizer mode to check. Set load control mode to normal. Start engine using test switch (discrete input 2) of EGCP-2. Check Engine Status screen for engine rpm readout confirm rpm is correct for unit.
  • Page 166 EGCP-2 Engine Generator Control Package Manual 26174 Monitor synchroscope status menu. Verify action of synchronizer. If using Process 4–20 mA input, set Process Reference to proper level. 10. After generator breaker closes to the mains, monitor Generator Status screen. Monitor kW load on unit.
  • Page 167 Manual 26174 EGCP-2 Engine Generator Control Package 14. Start another unit and allow it to parallel to the live bus. Confirm phase match and synchronizer action. Verify generator breaker closure. 15. Load Control Verify load sharing. Verify VAR/PF sharing. 16. Start additional units and parallel to the bus in the same manner as previous units.

  • Page 168: Chapter 8. Troubleshooting

    EGCP-2 Engine Generator Control Package Manual 26174 Chapter 8. Troubleshooting Control Hardware and I/O Problem Probable Cause Corrective Action Unit does not power up No input power supply Check input power supply on terminals 1 and 2. This input must be 9 to 32 Vdc.

  • Page 169: Engine Control/Sensing Parameters

    Manual 26174 EGCP-2 Engine Generator Control Package Engine Control/Sensing Parameters Problem Probable Cause Corrective Action Start command(i.e. test or Configuration menu has not Enter the configuration set run with load) does not start been accepted or entered points in the Configuration...

  • Page 170: Synchronization

    EGCP-2 Engine Generator Control Package Manual 26174 Synchronization Problem Probable Cause Corrective Action Unit never adequately Synchronizer Mode set Set synchronizer Mode to matches phase point in synchroscope menu appropriate setting. See set to PERMISSIVE description of set points. Synchronizer dynamics in...

  • Page 171: Breaker Close/Open Control

    Manual 26174 EGCP-2 Engine Generator Control Package Breaker Close/Open Control Problem Probable Cause Corrective Action When generator set is in Synchronizer set to CHECK Set synchronizer Mode to synchronization, the appropriate setting. See breaker never closes description of set points.

  • Page 172: Real Load Control

    EGCP-2 Engine Generator Control Package Manual 26174 Real Load Control Problem Probable Cause Corrective Action kW for a phase(s) reads Current transformer(CT) Verify/reverse polarity of negative. has reversed polarity current transformer for effected channel(s) Engine generator set must be off to safely open circuit a current transformer.

  • Page 173: Reactive Load Control

    Manual 26174 EGCP-2 Engine Generator Control Package Reactive Load Control Problem Probable Cause Corrective Action Phase power factors do not CT’s are connected to Verify CT’s are connected agree. Two of the three incorrect phase inputs to the appropriate input phases are extremely far terminals.

  • Page 174: Sequencing

    EGCP-2 Engine Generator Control Package Manual 26174 Sequencing Problem Probable Cause Corrective Action Unit number(s) does not switch in manual position Switch unit(s) to the Auto show up in the sequencing switch active position. See order in the sequencing dc inputs/outputs.

  • Page 175: Mains/Bus Sensing

    Manual 26174 EGCP-2 Engine Generator Control Package Mains/Bus Sensing Problem Probable Cause Corrective Action Unit(s) do not respond to Shutdown/alarm set points Appropriately set mains loss of mains for mains sensing not set high/low frequency and for LOSS OF MAINS high/low voltage set points in shutdown/alarm menu.

  • Page 176: Chapter 9. Definition Of Terms

    The action taken by the EGCP-2 when it senses a mains failure can be programmed for either an alarm action, or a standby power action where all generators start and tie to the load after the failed mains have been isolated from that load.
  • Page 177 AC generator in such a way as to maintain a specific voltage level over the operating load range of the generator. The EGCP-2 control biases the voltage setting of the AVR to voltage match during synchronization and to control reactive load during load share and mains parallel operation.
  • Page 178 A shutdown condition used by the EGCP-2 for various Hard Shutdown alarm settings that will cause the unit to immediately open its generator breaker if on load, and shut down when reaching or exceeding the alarm parameters.
  • Page 179 VAR/PF sharing, sequencing, synchronization to the mains, mains breaker closure/opening, and multiple unit starting. A switch input to the EGCP-2 that puts the control in a Manual manual operating mode. When in manual, the EGCP-2 does not communicate with other units on the network, and if in a multiple unit system, will not issue a dead bus closing command.
  • Page 180 An operating mode of the EGCP-2 that will not allow the No Parallel generators to operate in parallel with the mains under any circumstances.
  • Page 181 A variable used in the load control program of the System Load EGCP-2, which is the ratio of total load demand to total generating capacity that is supplying the load. System Load = kW Load/kW Capacity. A discrete input to the EGCP-2, which is used to start Test the engine for test and initial start check out.

  • Page 182: Chapter 10. Service Options

    Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. You can locate your nearest Woodward distributor, AISF, RER, or RTR on our website at: www.woodward.com/directory...

  • Page 183: Woodward Factory Servicing Options

    Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in “like- new” condition and carry with it the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is applicable to mechanical products only.

  • Page 184: Replacement Parts

    Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website.  Technical Support ...

  • Page 185: How To Contact Woodward

    EGCP-2 Engine Generator Control Package How to Contact Woodward For assistance, call one of the following Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service.

  • Page 186: Appendix A. Connector Information

    Appendix A. Connector Information Wago pluggable style terminal blocks are used on the EGCP-2 to connect the field wiring to the control. THESE CONNECTORS ARE NOT INCLUDED WITH THE EGCP-2. Woodward carries the EGCP-2 connector kit, which contains all of the terminal blocks used on the EGCP-2 as part number 8928-301.
  • Page 187 Manual 26174 EGCP-2 Engine Generator Control Package Recommended Wire Types: Size Insulation Type 0.3 mm²/ Multiple conductor, Discrete I/O 600V 22 AWG unshielded PT inputs Speed Bias, Voltage 0.3 mm²/ 300V Two conductor, shielded Bias, MPU, Oil and 22 AWG Water Sensors 1.0 mm²/...

  • Page 188: Appendix B. Speed Bias Connections

    EGCP-2 Engine Generator Control Package Manual 26174 Appendix B. Speed Bias Connections EGCP-2 SPEED Speed Bias Output CONTROL EGCP-2 To EPG Speed Control Wiring and Configuration Settings VIS-125a Speed Bias Output Type = +/- 3VDC 00-06-20 EGCP-2 2301A Speed Bias Output...
  • Page 189 Manual 26174 EGCP-2 Engine Generator Control Package EGCP-2 FLO-TECH Speed Bias Output Speed Control EGCP-2 To FLO-TECH Speed Control Wiring and Configuration Settings VIS-127a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common FLO-TECH Speed Control Part Numbers:...
  • Page 190 EGCP-2 Engine Generator Control Package Manual 26174 EGCP-2 Speed Bias Output Speed Control EGCP-2 To CSC Speed Control Wiring and Configuration Settings VIS-129a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC EGCP-2 2301A LSSC...
  • Page 191 EGCP-2 Engine Generator Control Package 701 or 701A EGCP-2 Speed Speed Bias Output Control EGCP-2 To 701 and 701A Wiring and Configuration Settings VIS-131a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common 701 and 701A Speed Control Part Numbers:...
  • Page 192 Manual 26174 723 or 723 Plus EGCP-2 Speed Speed Bias Output Control EGCP-2 To 723 or 723 Plus Wiring and Configuration Settings VIS-133a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common 723 or 723 Plus Speed Control Part Numbers:...

  • Page 193: Appendix C. Voltage Bias Connections

    VAR/ PF Stability: move the generator voltage in the PF Deadband: 0.005 increase direction. 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive * - These are only the generator voltage in the decrease suggested values direction.

  • Page 194: Basler Aec63-7

    Adjust the potentiometers on the AEC63 for rated voltage and stability. Voltage Trim Potentiometer: 2. Connect the EGCP-2 to the voltage regulator 1000 ohm, 10 Turn, 2 Watt as shown. Set to Mid-range 3.

  • Page 195: Basler Apr63-5

    Adjustment Procedure Voltage Regulator settings: Start with the generator at rated voltage (EGCP-2 Not Connected). Have the Pot set at Droop - set for 2 to 5 % In a multiple generator system, set droop the same mid-range and adjust the potentiometers on the APR 63 for rated voltage and stability.

  • Page 196: Basler Apr63-5 With Amp200

    Adjustment Procedure Voltage Regulator settings: Start with the generator at rated voltage (EGCP-2 Not Connected). Have the Pot set at Droop - set for 2 to 5 % In a multiple generator system, set droop the same mid-range and adjust the potentiometers on the APR 63 for rated voltage and stability.

  • Page 197: Basler Kr2F, 4F, Or 7F

    VAR/ PF Stability: now calibrated and should not be PF Deadband: 0.005 adjusted anymore. 4. Close the Voltage Raise discrete input (4) and verify the EGCP-2 can * - These are only move the generator voltage in the suggested values increase direction.

  • Page 198: Basler Decs 15

    Gen Volt Lo Lmt: * 10% below Adjustment Procedure rated 1. Start the generator with the EGCP-2 NOT connected. Set DECS for rated voltage Reactive Load Control Menu 2. Connect the EGCP-2 as shown VAR/ PF Gain: 1.0 3. Start Generator Volts Ramp Time: 4.

  • Page 199: Basler Decs 100

    Shutdown & Alarms Menu Adjustment Procedure Gen Volt Hi Lmt: * 10% above rated 1. Start the generator with the EGCP-2 NOT Gen Volt Lo Lmt: * 10% below connected. Set DECS for rated voltage rated 2. Connect the EGCP-2 as shown 3.

  • Page 200: Basler Decs 200

    Gen Volt Lo Lmt: * 10% below Adjustment Procedure rated 1. Start the generator with the EGCP-2 NOT connected. Set DECS for rated voltage Reactive Load Control Menu 2. Connect the EGCP-2 as shown VAR/ PF Gain: 1.0 3. Start Generator Volts Ramp Time: 4.

  • Page 201: Basler Sr4A Or Sr8A

    * - These are only 4. Close the Voltage Raise discrete suggested values input (4) and verify the EGCP-2 can move the generator voltage in the increase direction. 5. Close the Voltage Lower discrete input (5) and verify the EGCP-2 can move the generator voltage in the decrease direction.

  • Page 202: Basler Ssr

    VAR/ PF Stability: increase direction. PF Deadband: 0.005 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease * - These are only direction. suggested values 8.

  • Page 203: Caterpillar Cdvr

    * - These are only increase direction. suggested values 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease direction. 8. The Reactive Load Control Menu items may need adjusted for stable Power Factor control.

  • Page 204: Caterpillar Digital Voltage Regulator

    EGCP-2 Engine Generator Control Package Manual 26174 Caterpillar Digital Voltage Regulator Resistor sizes: Caterpillar EGCP-2 0.250 Watts Digital 1.62K Voltage Regulator Voltage Regulator settings: EGCP-2 Settings: Droop - set for 2 to 5 % Configuration Menu In a multiple generator system, set...

  • Page 205: Caterpillar Vr3

    Manual 26174 EGCP-2 Engine Generator Control Package Caterpillar VR3 Caterpillar Voltage Trim EGCP-2 Potentiometer 10 K ohm Voltage Regulator Voltage Regulator settings: EGCP-2 Settings: Droop - set for 2 to 5 % Configuration Menu Voltage Bias Type: +/- 1 VDC...

  • Page 206: Caterpillar Vr6

    VAR/ PF Stability: move the generator voltage in the PF Deadband: 0.005 increase direction. 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive * - These are only the generator voltage in the decrease suggested values direction.

  • Page 207: Kato Kcr360 Or 760

    Manual 26174 EGCP-2 Engine Generator Control Package KATO KCR360 or 760 Kato KCR EGCP-2 Voltage Trim 360, 760 Potentiometer 250 ohm Voltage Clockwise Regulator Counter Clockwise EGCP-2 settings: Voltage Regulator settings: Configuration Menu Droop - set for 2 to 5 %...

  • Page 208: Kato K65-12B Or K125-10B

    VAR/ PF Stability: move the generator voltage in the PF Deadband: 0.005 increase direction. 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive * - These are only the generator voltage in the decrease suggested values direction.

  • Page 209: Leroy Somer R438, R448, Or R449

    VAR/ PF Stability: move the generator voltage in the PF Deadband: 0.005 increase direction. 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive * - These are only the generator voltage in the decrease suggested values direction.

  • Page 210: Leroy Somer R600

    * - These are only adjusted anymore. suggested values 4. Close the Voltage Raise discrete input (4) and verify the EGCP-2 can move the generator voltage in the increase direction. 5. Close the Voltage Lower discrete input (5) and verify the EGCP-2 can move the generator voltage in the decrease direction.

  • Page 211: Leroy Somer R610

    * - These are only adjusted anymore. suggested values 4. Close the Voltage Raise discrete input (4) and verify the EGCP-2 can move the generator voltage in the increase direction. 5. Close the Voltage Lower discrete input (5) and verify the EGCP-2 can move the generator voltage in the decrease direction.

  • Page 212: Marathon Pm 100/200

    EGCP-2 Engine Generator Control Package Manual 26174 Marathon PM 100/200 Marathon Voltage Trim EGCP-2 Potentiometer 10 K ohm PM100 / Voltage Regulator Voltage Regulator settings: EGCP-2 Settings: Droop - set for 2 to 5 % Configuration Menu Voltage Bias Type:...

  • Page 213: Marathon 2000E

    6. Close the Voltage Raise discrete input (4) and verify the EGCP2 can move the generator voltage in the increase direction. 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease direction. Woodward...

  • Page 214: Mecc Alte Uvr

    EGCP-2 Engine Generator Control Package Manual 26174 Mecc Alte UVR Mecc Alte Voltage Trim EGCP-2 Potentiometer 100 K ohm Voltage Regulator Connect together only for 60 Hertz operation Voltage Regulator settings: EGCP-2 Settings: The Mecc-Alte UVR has no terminal Configuration Menu...

  • Page 215: Newage Ma325

    VAR/ PF Stability: increase direction. PF Deadband: 0.005 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease * - These are only direction. suggested values...

  • Page 216: Newage Ma327

    VAR/ PF Stability: increase direction. PF Deadband: 0.005 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease * - These are only direction. suggested values...

  • Page 217: Newage Mx321/341

    VAR/ PF Stability: increase direction. PF Deadband: 0.005 7. Close the Voltage Lower discrete input (5) to verify the EGCP-2 can drive the generator voltage in the decrease * - These are only direction. suggested values...

  • Page 218: Appendix D. Egcp-2 Set Point Worksheet

    EGCP-2 Engine Generator Control Package Manual 26174 Appendix D. EGCP-2 Set Point Worksheet Configuration Menu Item: Range: Default: As Set Value: Note: SECURITY CODE Min: 0 **** See Security Access Max: 9999 NETWORK Min: 1 Only accessible if ADDRESS Max: 8...

  • Page 219: Shutdown And Alarms Menu

    Manual 26174 EGCP-2 Engine Generator Control Package Shutdown and Alarms Menu Item: Range: Default: As Set Value: Note: VOLTAGE RNG Audible Alarm Warning Visual Alarm Warning Disabled GEN VOLT HI Min: 50 250.0 Volts Max: 30000 GEN VOLT HI Disabled...
  • Page 220 EGCP-2 Engine Generator Control Package Manual 26174 Item: Range: Default: As Set Value: Note: REVERSE PWR Disabled Soft Shutdown Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown REVERSE kVAR Min: –100.0 -50.0% LIMIT Max: –5.0 REVERSE kVAR Min: 0.1 5.0 s...
  • Page 221 Manual 26174 EGCP-2 Engine Generator Control Package Item: Range: Default: As Set Value: Note: REMOTE FAULT6 Disabled Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown FAULT6 TIMER Min: 0.0 0.0 s Max: 30.0 Woodward...

  • Page 222: Engine Control Menu

    EGCP-2 Engine Generator Control Package Manual 26174 Engine Control Menu Item: Range: Default: As Set Value: Note: PREGLOW TIME Min: 0 Max: 1200 CRANK TIME Min: 0 10 s Max: 240 CRANK CUTOUT Min: 5 550 rpm Max: 10000 CRANK DELAY...
  • Page 223 Manual 26174 EGCP-2 Engine Generator Control Package Item: Range: Default: As Set Value: Note: LO OIL PRESS Min: 0.0. 2.0 Bar or PSI PRE-LMT Max: 120.0 LO OIL PRESS Disabled Disabled PRE-ALM Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown LO OIL PRESS Min: 0.0...

  • Page 224: Synchronizer Menu

    EGCP-2 Engine Generator Control Package Manual 26174 Synchronizer Menu Item: Range: Default: As Set Value: Note: SYNC MODE Check Check Permissive SYNC GAIN Min: 0.01 0.10 Max: 100.00 SYNC STABILITY Min: 0.00 1.00 Max: 20.00 VOLTAGE Disabled Enabled MATCHING Enabled VOLTAGE Min: 0.1...

  • Page 225: Real Load Control Menu

    Manual 26174 EGCP-2 Engine Generator Control Package Real Load Control Menu Item: Range: Default: As Set Value: Note: LOAD CONTROL Normal Normal MODE Soft Transfer Droop LOAD CTRL GAIN Min: 0.001 0.01 Max: 100.0 LOADSHARE Min: 0.1 0.72 GAIN Max: 2.0 LOAD STABILITY Min: 0.0...

  • Page 226: Reactive Load Control Menu

    EGCP-2 Engine Generator Control Package Manual 26174 Reactive Load Control Menu Item: Range: Default: As Set Value: Note: VAR/PF MODE Disabled PF Control PF Control VAR Control VAR/PF GAIN Min: 0.01 1.00 Max: 20.0 VOLTS RAMP Min: 0 60.0 s...

  • Page 227: Process Control Menu

    Manual 26174 EGCP-2 Engine Generator Control Package Process Control Menu Item: Range: Default: As Set Value: Note: PROCESS Direct Indirect ACTION Indirect PROCESS GAIN Min: 0.001 0.10 Max: 100.0 PROCESS Min: 0.0 1.0 s STABILITY Max: 20.0 PROCESS Min: 0.0 0.1 s...

  • Page 228: Transfer Switch Menu

    EGCP-2 Engine Generator Control Package Manual 26174 Transfer Switch Menu Item: Range: Default: As Set Value: Note: CHECK MAINS Disabled Enabled BREAKER Enabled FAST XFER Min: 0.1 1.0 s DELAY Max: 30.0 MAINS STABLE Min: 1 60 s Max: 30000...

  • Page 229: Sequencing And Comms Menu

    Manual 26174 EGCP-2 Engine Generator Control Package Sequencing and Comms Menu Item: Range: Default: As Set Value: Note: AUTO Disabled Disabled SEQUENCING Enabled AUTO Min: 1 120 s SEQUENCE Max: 1200 DELAY MAX GEN LOAD Min: 1 Max: 100 NEXT GENSET...

  • Page 230: Calibration Menu

    EGCP-2 Engine Generator Control Package Manual 26174 Calibration Menu Item: Range: As Set Value: Note: Process In scale Min: 0.5 Max: 2.0 Speed Bias offset Min: –50.0 Max: 50.0 Volts Bias offset Min: –50.0 Max: 50.0 PT Phase A scale Min: 0.5...
  • Page 231 Manual 26174 EGCP-2 Engine Generator Control Package Woodward...

  • Page 232: Declarations

    Declarations...

  • Page 233: Egcp-2 Control Specifications

    249 W (1/3 hp), 125 Vac (7.2 A, 0.4–0.5 PF) 10 A, 30 Vdc Resistive Communication Ports RS-485, RS-422 Ambient Operating Temperature –20 to +70 °C (–4 to +158 °F)(around outside of EGCP-2 chassis) Storage Temperature –40 to +105 °C (–40 to +221 °F) Humidity 95% at 20 to 55 °C (68 to 131 °F)
  • Page 234 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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