Woodward EGCP-2 Operation Manual
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Woodward EGCP-2 Operation Manual

Engine generator control package
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Operation (End User) Manual
EGCP-2
Engine Generator Control Package
8406-115, 150–300 Vac PT Input, 9–32 Vdc
8406-116, 50–150 Vac PT Input, 9–32 Vdc
Manual 26086 (Revision E)

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  • Page 1 Operation (End User) Manual EGCP-2 Engine Generator Control Package 8406-115, 150–300 Vac PT Input, 9–32 Vdc 8406-116, 50–150 Vac PT Input, 9–32 Vdc Manual 26086 (Revision E)
  • Page 2 Revisions—Text changes are indicated by a black line alongside the text. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Manual 26086 EGCP-2 Engine Generator Control Package Contents ................. EGULATORY OMPLIANCE ..........LECTROSTATIC ISCHARGE WARENESS 1. G ............1 HAPTER ENERAL NFORMATION Introduction......................1 Control Electrical Ratings ..................1 2. C ............... 3 HAPTER ONTROL VERVIEW Introduction......................3 Operator Interface ....................5 3. S ............
  • Page 4 EGCP-2 Engine Generator Control Package Manual 26086 Contents 7. T .............107 HAPTER ROUBLESHOOTING Control Hardware and I/O.................. 107 Engine Control/Sensing Parameters ..............108 Synchronization ....................109 Breaker Close/Open Control ................110 Real Load Control....................111 Reactive Load Control ..................112 Sequencing......................
  • Page 5 Figure 3-28. Direct (Export) Process Action............51 Figure 3-29. Indirect (Import Power) Process Action ...........51 Figure 3-30. Direct (Import/Export) Process Action ..........52 Figure 3-31. EGCP-2 Control Dip Switch.............52 Figure 3-32. Measured vs. Monitored ..............59 Figure 3-33. Typical AVR with Aux Input (Newage SX-440)........60 Figure 3-34.
  • Page 6 EGCP-2 Engine Generator Control Package Manual 26086 Illustrations Figure 4-5. Loss of Mains Detection Active............82 Figure 4-6. Generator Off Line ................82 Figure 4-7. Mains Parallel Unit with Voltage/Frequency Detect......83 Figure 4-8. Mains Parallel Unit(s) with Load Surge Detect ........83 Figure 4-9. Typical Automatic Sequencing Routine ..........85 Figure 4-10.

  • Page 7: Regulatory Compliance

    Wiring must be in accordance with applicable electric codes with the authority having jurisdiction. • The EGCP-2 is suitable for use in non-hazardous locations only. • Wiring must be in accordance with applicable electrical codes and in accordance with the authority having jurisdiction.

  • Page 8: Electrostatic Discharge Awareness

    PCB from the control cabinet, place it in the antistatic protective bag. CAUTION—ELECTROSTATIC DISCHARGE 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. Woodward...

  • Page 9: Chapter 1. General Information

    Manual 26086 EGCP-2 Engine Generator Control Package Chapter 1. General Information Introduction This manual describes the Woodward EGCP-2 Engine Generator Control Package models 8406-115 and 8406-116 (9–32 Vdc maximum input voltage range). Control Electrical Ratings nominal supply voltage range 10–29 Vdc (12 or 14 volt systems) max.

  • Page 10: Figure 1-1. Egcp-2 Wiring Diagram

    EGCP-2 Engine Generator Control Package Manual 26086 Figure 1-1. EGCP-2 Wiring Diagram Woodward...

  • Page 11: Chapter 2. Control Overview

    EGCP-2 Engine Generator Control Package Chapter 2. Control Overview Introduction The EGCP-2 is a microprocessor based complete generator load control and engine management package designed for use with an Electronic engine speed control and a separate voltage regulator. The control's functions include: Engine Control •...
  • Page 12 • KVAR droop for manual VAR control 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...

  • Page 13: Operator Interface

    The backlight will turn off after five minutes of non-use and the engine is shut down. NOTE The EGCP-2 Operator Interface can only be used for unit configuration and monitoring. Unit start/stop, sync, or mode selection commands can not be given through the EGCP-2’s front panel.
  • Page 14 EGCP-2 Engine Generator Control Package Manual 26086 There are a total of 19 keys on the keypad. Each of the keys has the following function(s): ALARM/EVENT LOG KEYS: ALARM / EVENT The ALARM/EVENT key is used to access the Event log.
  • Page 15 Manual 26086 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 16 EGCP-2 Engine Generator Control Package Manual 26086 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 17 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 18: Figure 2-2. Egcp-2 Navigation

    EGCP-2 Engine Generator Control Package Manual 26086 Navigation Procedure The following drawings detail a step-by-step procedure for navigating through the EGCP-2 software. Additionally, the typical display entries seen at each step are shown. Figure 2-2. EGCP-2 Navigation (next five pages)
  • Page 19 Manual 26086 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 20 EGCP-2 Engine Generator Control Package Manual 26086 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 21 Manual 26086 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 22 EGCP-2 Engine Generator Control Package Manual 26086 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 ---------------------------------------------------- -------------------End of List-----------------...

  • Page 23: Chapter 3. Software Overview

    Status Screens There is a total of 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 24 • SPINDOWN • RETRY Operating State: Shows if the EGCP-2 is in AUTO or MAN(ual) 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 25: Figure 3-2. System Status Screen-Isochronous

    Manual 26086 EGCP-2 Engine Generator Control Package 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 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 26: Figure 3-4. Engine Overview

    EGCP-2 Engine Generator Control Package Manual 26086 The following is an overview of each of the status menu screens, starting with engine overview: Figure 3-4. Engine Overview HH:MM: 24 hour clock readout. MM-DD:Date (MM-DD). Engine: The state of the engine control function.

  • Page 27: Figure 3-5. Generator Status (Voltage Line To Line)

    Manual 26086 EGCP-2 Engine Generator Control Package Figure 3-5. Generator Status (Voltage Line to Line) 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 28: Figure 3-6. I/O Status

    EGCP-2 Engine Generator Control Package Manual 26086 Figure 3-6. I/O Status DI: Discrete Inputs 1 through 16. DO: Discrete Outputs 1 through 12. Volt Bias: % voltage bias output (±100% range). Speed Bias: % speed bias output (±100% range). Process In: Process Input in milliamps (mA).

  • Page 29: Figure 3-7. 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 30: Figure 3-8. Kw Load Status

    EGCP-2 Engine Generator Control Package Manual 26086 Figure 3-8. KW Load Status Generator KW: The sum of the three phase generator KW. 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 31: Figure 3-9. Pf /Kvar Status

    Manual 26086 EGCP-2 Engine Generator Control Package Figure 3-9. PF /KVAR Status VAR/PF MODE: The configured VAR/PF control mode. PF REFERENCE: The PF control reference value for the control. NOTE Power Factor (PF) reference changes to KVAR REF when in VAR control.

  • Page 32: Figure 3-10. Sequencing Menu

    EGCP-2 Engine Generator Control Package Manual 26086 Figure 3-10. 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 and on load. Network Priority of all units in auto on the network.

  • Page 33: Figure 3-11. Sequencing Menu (Multi-Unit)

    Manual 26086 EGCP-2 Engine Generator Control Package The example below is a typical sequencing screen for a 5 unit system. Figure 3-11. Sequencing Menu (Multi-Unit) As displayed on the sequencing screen: Units 1 3, and 5 are on load with their generator breakers closed.

  • Page 34: Figure 3-12. Ats (Automatic Transfer Switch) Status

    EGCP-2 Engine Generator Control Package Manual 26086 Figure 3-12. 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 (++) indicates mains are in spec and stable.

  • Page 35: Alarm / Event Log

    This log contains up to eight 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 36: Figure 3-14. Empty Event Log

    EGCP-2 Engine Generator Control Package Manual 26086 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 3-14. Empty Event Log The alarms displayed in the alarm / event log are arranged in a first in, last out (FILO) order.

  • Page 37: Configuration Menus

    EGCP-2 Engine Generator Control Package Configuration Menus If the Config key on the EGCP-2 keypad is pressed, the right had LCD screen will switch to the configuration menus. The first item in this menu is the Security Code. The Security Code value determines which configuration menus are accessed.

  • Page 38: Figure 3-16A. Configuration Menu List (Screen 1)

    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 3-16a. Configuration Menu List (Screen 1) Figure 3-16b. Configuration Menu List (Screen 2)

  • Page 39: Figure 3-16C. Configuration Menu List (Screen 3)

    Manual 26086 EGCP-2 Engine Generator Control Package Figure 3-16c. Configuration Menu List (Screen 3) NOTE See manual 26108 (included with the control) for security code and access level information. Various Security codes access different portions of the configuration screens, depending on the level of security code used. The up and down keys are used to move the blinking cursor to the tuning menu that the user wants to enter.
  • Page 40 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 41 Answer: Calculated KVA ≤ (Voltage Ref * 3) * CT Ratio = Unit OK Rated KW ≤ Rated KVA 10. Rated KVAR ≤ Rated KVA If the EGCP-2 is not providing an engine start signal: • Check for pound signs (#) signs and/or asterisks (*).

  • Page 42: Figure 3-17. Ac Power Triangle

    EGCP-2 Engine Generator Control Package Manual 26086 Rated KW (numeric) • Rated KW of Generator. Rated KVA (numeric) • Used to determine Rated Current (I) of Generator for minimum overcurrent level. • Equation used to determine Rated Current: Voltage input is DELTA I = KVA x 1000 Voltage Ref x 1.73...
  • Page 43 Manual 26086 EGCP-2 Engine Generator Control Package Voltage Input (Wye L-N, 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 setpoint menus.
  • Page 44 EGCP-2 Engine Generator Control Package Manual 26086 • Idle / Rated Switch Defines Discrete Output #12 as an Idle / Rated speed switch. This output is typically used to automatically send the engine speed control an idle/rated command upon start up.

  • Page 45: Figure 3-18. Breaker Logic And Contactor Logic

    Manual 26086 EGCP-2 Engine Generator Control Package EGCP-2 External Wiring Connections Gen Breaker Close Generator Breaker Close Coil Gen Breaker Trip Generator Breaker Gen Breaker Trip will energize when in "Auto" and "Gen Trip Coil Stable Delay" is met. Generator Breaker Configuration Based Logic.

  • Page 46: 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 47: Figure 3-20. Generator Over/Under Frequency

    Manual 26086 EGCP-2 Engine Generator Control Package Generator High/Low Volt Limit Alarm • Even if the Alarm Setpoints 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 Setpoint.
  • Page 48 EGCP-2 Engine Generator Control Package Manual 26086 Overcurrent Level (numeric) • Set for per Phase Overcurrent 3 Phase sensing, selects phase with highest current • Uses Inverse Time Function as basis for overcurrent detection This allows different levels of overcurrent based on time, AMP•SECONDS AMP•SECONDS are determined by:...

  • Page 49: Figure 3-21. Current Goes To 160 Amps, An Alarm Or Shutdown Will Be Received

    Manual 26086 EGCP-2 Engine Generator Control Package Amp•Seconds accumulate when current is equal to or greater than the Rated Current Amp•Seconds reset to 0 when current is less than Rated Current Example: Overcurrent Level = 160 160 Amps Rated Current...

  • Page 50: Figure 3-23. Current Goes To 152 Amps, An Alarm Or Shutdown Will Be Received

    EGCP-2 Engine Generator Control Package Manual 26086 Configuration Overcurrent Level = 160 Amps Rated Current = 144 Amps Overcurrent Delay = 10 Seconds Amp/Seconds = 160 Overcurrent Trip Zone Current (per phase) • 160 Amp Seconds Time (seconds) Figure 3-23. Current goes to 152 Amps, an Alarm or Shutdown will be received...

  • Page 51: Engine Control

    Engine rpm level where crank command is canceled. Crank Delay • Time between Engine Crank Attempts. Crank Repeats • Number of times EGCP-2 will attempt to re-start engine. Cranking attempts will equal the value of Crank Repeats +1. Crank Fail • Alarm Setpoint. •...
  • Page 52 Timer which sets the delay in seconds the EGCP-2 waits once the Idle/Rated Speed setpoint is exceeded. Once the Idle/Rated Time is passed, the EGCP-2 will energize the #12 Discrete Output (if the Relay #12 output is configured for the idle/rated function).

  • Page 53: Synchroscope

    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 54: Figure 3-26. Voltage Matching (1% Setpoint)

    Voltage Window (numeric) • 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 55 Dwell Time (numeric) • The period of time that the generator must be within the Max. Phase Window for before the EGCP-2 control will issue a breaker closure. • Longer dwell times will give typically give better stability after the breaker closes.

  • Page 56: Real Load Control

    Load. Unload Trip • Load Level where Generator Breaker/Contactor open command will be issued when EGCP-2 control is off loading generator set. Load Droop • Percentage of KW droop used when EGCP-2 control is operating in a droop mode. Woodward...
  • Page 57 Manual 26086 EGCP-2 Engine Generator Control Package Load Time • Time in Seconds for generator to load from unload trip level to base load level. This rate is applied during any automatic loading function, including ramping to load sharing. Unload Time •...

  • Page 58: Reactive Load Control

    EGCP-2 Engine Generator Control Package Manual 26086 Summary of KVA load switch action: If the relay 12 output is configured for KVA Load Switch action: If the three phase sum of the generator KVA is greater than the KVA Switch Low setpoint, AND less than the KVA Switch High setpoint, the K12 relay output shall energize.

  • Page 59: Process Control

    Manual 26086 EGCP-2 Engine Generator Control Package PF Deadband • ± deadband around PF reference point. • Set in PF. • Active in PF and PF sharing modes. • Can be used to stabilize units at low loads if needed.

  • Page 60: Figure 3-30. Direct (Import/Export) Process Action

    Process Import/Export Hardware • EGCP-2 Control can take a 4–20 mA, or 1–5 Vdc input signal from a transducer. Input signal conditioning is selected by a dip switch on the back of the control, switch position 4, switch number 4. Closing this switch selects the 4–20 mA input hardware.
  • Page 61 Raise Rate • Rate, in mA/Sec., at which the process reference will change when the EGCP-2 receives a raise load contact input while operating in process control mode. Lower Rate • Rate, in mA/Sec., at which the process reference will change when the EGCP-2 receives a lower load contact input while operating in process control mode.

  • Page 62: Transfer Switch

    EGCP-2 Engine Generator Control Package Manual 26086 Process High Limit Alarm • Sets alarm mode when process High Limit is reached. Process Low Limit • Minimum allowable process reference level. Set in mA. • Effective on active master unit only.
  • Page 63 • 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 Alm The Main Frequency High condition will cause a response defined by this setpoint.

  • Page 64: Sequencing And Comms (Communications)

    EGCP-2 Engine Generator Control Package Manual 26086 Main Freq Low Alm The Main Frequency Low condition will cause a response defined by this setpoint. The available responses are: • Disabled • Warning • Loss of Mains • Loss of Mains with Alarms LOM Action Delay (numeric seconds) •...
  • Page 65 System Load Percentage must be 25% or less to sequence off the next unit. This provides a buffer so that when there is a System Load Percentage that is moving between 29 and 31%, the EGCP-2 will not sequence the unit off and then sequence it back on.

  • Page 66: 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 67: Figure 3-32. Measured Vs. Monitored

    Speed Bias Offset • Factory calibrated for 0 Vdc offset on ±3 Vdc range. • All Woodward Speed controls operate with this bias output, so no calibration should be required. • Calibration may be required for other manufacturer’s speed controls.

  • Page 68: Figure 3-33. Typical Avr With Aux Input (Newage Sx-440)

    Volts such as Leroy Summers AVRs, an external trim pot must be used to limit the range of the voltage bias input from the EGCP-2 control. Figure 3-34. Typical AVR with External Voltage Adjust Potentiometer AVR DROOP • It is highly recommended to fit the AVR with a Droop CT input, and utilize a medium droop level on the AVR.
  • Page 69 Same as above, but for B and C phases of Gen. CT Phase A , B and C Offset • Calibrates CT Phase A , B , Or C input sensing of EGCP-2 at zero current. • Measure actual gen. currents with clamp on ammeter, or panel ammeter.

  • Page 70: Figure 3-36. Direct Proportional Input To Water Temp Or Oil Pressure Input

    (depending on synchronizing operation) and A phase generator inputs. • With synchronizer in “check” mode, and a live bus, monitor the synchroscope menu of the EGCP-2 for “phase angle”. • Monitor Voltage across open gen contactor/breaker or panel synchroscope for phase angle error between generator and bus.

  • Page 71: Figure 3-39. Battery Vco

    Sets level, or offset of oil pressure input to VCO frequency. • Set to read 0 psi in Engine Overview menu of EGCP-2 with engine off. • Gain and Offset DO affect each other, so it is necessary to check adjustments at both ends of the scale (0 psi to operating psi) if an adjustment is made to either gain or offset.

  • Page 72: Figure 3-41. Water Temperature Vco

    Inverse, Non-Linear 0–200 Ω engine mounted sensor shown. • If using a non linear resistive style input, utilize Shunt resistor dip switches on back of EGCP-2 (SW-2, 3 and 4 ON). These resistors help to linearize the sensor input. •...
  • Page 73 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 74: Chapter 4. Control Features And Functions

    EGCP-2 Engine Generator Control Package Manual 26086 Chapter 4. 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 75: Mains Sensing

    Manual 26086 EGCP-2 Engine Generator Control Package 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 76: 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 77: Idle/Rated Relay Output

    Reactive Load Control tuning menu, at the Voltage Ramp Time setpoint. 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 78: Generator Load Control

    The percent level of the voltage bias output can be monitored in the I/O Display 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 79: Figure 4-1. Droop Mode

    Droop Droop Load Control in the EGCP-2 uses the sensed KW on the generator to provide negative feedback to the speed reference of the speed control governor through the speed bias output. This will result in a decrease in generator frequency as the load is increased while operating as a single unit on an isolated bus.

  • Page 80: Figure 4-2. Isochronous Mode

    EGCP-2 Engine Generator Control Package Manual 26086 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 4-2.

  • Page 81: Figure 4-3. 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 82: Automatic Generator Loading Functions

    EGCP-2 then adjusts the generator load to maintain the desired set point. 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 input.
  • Page 83 Manual 26086 EGCP-2 Engine Generator Control Package When the process function is initially selected, the reference is set equal to the internal or remote process reference. If the process input and process reference are not equal, the control ramps the load reference in the appropriate direction to reduce the difference error.
  • Page 84 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 85: Synchronizer Description

    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 86 This security is required to prevent two or more units from closing their breakers at the same time. To provide this security, a network message requesting the lock is made to all other EGCP-2 controls currently active on the network.
  • Page 87 When enabled, voltage matching will occur in both the Check and Run modes and is verified only by the sync-check function in Permissive mode. When enabled at an EGCP-2 control which is monitoring and controlling the mains breaker, the voltage matching will occur across both the generator and mains breaker prior to the synchronizer issuing a breaker close command when paralleling the generator(s) to the mains.
  • Page 88 Dwell Time allows the synchronizer to be configured for a wide range of synchronizing conditions. The Max Phase Window and Dwell Time setpoints 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 89: Figure 4-4. Synchronizer Time Line-Standard Sequence

    Figure 4-4. 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 90: Figure 4-5. Loss Of Mains Detection Active

    EGCP-2 Engine Generator Control Package Manual 26086 Standard Sequence: Single No Parallel Unit in Auto with Loss Of Mains Detection Enabled. Fast Transfer Mains Stable Fast Transfer Mains In Spec and Delay Delay Delay On Load Gen Stable Delay Genset On Load Mains in Spec.

  • Page 91: Figure 4-7. Mains Parallel Unit With Voltage/Frequency Detect

    Manual 26086 EGCP-2 Engine Generator Control Package 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 92: 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 93: Figure 4-9. Typical Automatic Sequencing Routine

    Manual 26086 EGCP-2 Engine Generator Control Package 100% SYSTEM LOAD TIME VIS-114 00-04-27 Figure 4-9. Typical Automatic Sequencing Routine 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 which brings the system load to approximately 70%.
  • Page 94 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 95: Figure 4-10. Original System Configuration

    Manual 26086 EGCP-2 Engine Generator Control Package Assuming a New Master—All Units Off Load When a unit’s priority is changed in such a manner as to make it the new master on the system, the response of the system to the change of masters depends on the operating state of the system at the time the change is made.

  • Page 96: Figure 4-11. After A Change Of Priority-Units Not Operating

    EGCP-2 Engine Generator Control Package Manual 26086 MAINS NO MAINS FAILURE DETECTED MASTER SEQUENCING SCREEN ADDRESS: 1 OPER. PRIORITY 2 SYSTEM LOAD = 0% MASTER NEXT ON ALL NEXT OFF ALL GENERATORS OFF LOAD VIS-116 00-04-27 NETWORK ADDRESS #1 NETWORK ADDRESS #2...

  • Page 97: Figure 4-13. A New Master Takes Over-Single Unit Operating On The Isolated Bus

    Manual 26086 EGCP-2 Engine Generator Control Package Within a 5 minute period the sequencing screen on any unit will reflect the change of master from unit one to unit two. The system load is at a level somewhere between 25 and 65 percent, at which no slave units are sequenced on or off line.

  • Page 98: Figure 4-14. Changing The Priority Of A Slave Unit

    EGCP-2 Engine Generator Control Package Manual 26086 Also, for a transfer of master to occur, the units have to be in an auto sequencing mode of operation. This implies either a load sharing, or process mode of load control. Without being in these operating modes, a transfer of master cannot occur because the New Master cannot sequence the Previous master off line.

  • Page 99: Figure 4-15. Changing The Priority Of A Slave Unit

    Manual 26086 EGCP-2 Engine Generator Control Package MAINS MAINS FAILURE DETECTED OR RUN WITH LOAD AT MASTER MASTER SEQUENCING SCREEN ADDRESS: 1 OPER. PRIORITY 1 SYSTEM LOAD = 50% MASTER NEXT ON NEXT OFF VIS-120 00-04-27 NETWORK ADDRESS #1 NETWORK ADDRESS #2...

  • Page 100: Figure 4-17. Changing The Priority Of A Slave Unit

    EGCP-2 Engine Generator Control Package Manual 26086 Changing the Priority of a Slave Unit—Slave On Load Case 2 will occur if the slave unit is not running, and no Loss of Mains detection has occurred, and the slave’s priority is increased (taken to a lower numerical value) to a level which replaces another slave which is operating on load.

  • Page 101: Inter-Control Communications (Rs-485 Network)

    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 102: Remote Control/Monitoring (Rs-422)

    Manual 26086 Remote Control/Monitoring (RS-422) To facilitate the use of external computer connections, the EGCP-2 has an RS- 422 port which allows direct access to the various operating and monitoring functions within the control. The RS-422 network is a multi-drop line which allows connection of an external device at any point on the network.

  • Page 103: Chapter 5. Calibration Of Control Inputs And Outputs

    For example, assume there is a 480 volt line-to-line generator set operating in a system which uses 4:1 voltage transformers to feed the EGCP-2. The input AC line to line voltage at the EGCP-2 is 118 volts due to primary to secondary losses across the voltage transformers. The EGCP-2 Generator Status menu will display a generator voltage of 472 Vac L-L for each phase, which is not truly what the generator is producing.

  • Page 104: 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 105 Manual 26086 EGCP-2 Engine Generator Control Package PT Phase B Scale Calibrates the B phase generator PT input. Menus Affected Changes in the calibration setpoint will change the generator B phase voltage as read in the Generator Status menu. Changing this value will also have an effect on generator KW and KVAR levels.
  • Page 106 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 107 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 108: 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 109: 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 110: Voltage Bias Output

    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 Voltage Bias Offset applied to the regulator. Woodward...

  • Page 111: Chapter 6. General Startup 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 Control Overview Menu. 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 112: Sequence Of Startup And Checking Parameters

    EGCP-2. If this range cannot be achieved, shut down the generator set, and select the next highest voltage bias output level on dip switch SW-2 located on the back of the EGCP-2. Repeat steps 9 through 11 until satisfactory results are achieved.
  • Page 113 Manual 26086 EGCP-2 Engine Generator Control Package Set load/unload ramp times to at least 60 seconds. Set base load level to 30% of rated load. Shut down the unit by removing the Auto and Run with Load Inputs. Set synchronizer to run mode.
  • Page 114 EGCP-2 Engine Generator Control Package Manual 26086 10. Tune individual synchronizer dynamics. Calibrate synchronizer if needed. 11. Once satisfied with each synchronizers operation, shut down these units by removing the auto input. 12. Change synch mode settings to run on all units.

  • Page 115: Chapter 7. Troubleshooting

    Manual 26086 EGCP-2 Engine Generator Control Package Chapter 7. 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 116: Engine Control/Sensing Parameters

    EGCP-2 Engine Generator Control Package Manual 26086 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 117: Synchronization

    Manual 26086 EGCP-2 Engine Generator Control Package 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 118: Breaker Close/Open Control

    EGCP-2 Engine Generator Control Package Manual 26086 Breaker Close/Open Control Problem Probable Cause Corrective Action When generator set is in Synchronizer set to CHECK Set synchronizer Mode to synchronization, the breaker appropriate setting. See never closes description of set points.

  • Page 119: Real Load Control

    Manual 26086 EGCP-2 Engine Generator Control Package 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) NOTE: engine generator set must be off to safely open circuit a current transformer.

  • Page 120: Reactive Load Control

    EGCP-2 Engine Generator Control Package Manual 26086 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 121: Sequencing

    Manual 26086 EGCP-2 Engine Generator Control Package 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 122: Mains/Bus Sensing

    EGCP-2 Engine Generator Control Package Manual 26086 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 123: Chapter 8. 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 124 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 125 A shutdown condition used by the EGCP-2 for various Hard Shutdown alarm settings which will cause the unit to immediately open its generator breaker if on load, and shut down when reaching or exceeding the alarm parameters.
  • Page 126 VAR/PF sharing, sequencing, synchronization to the mains, mains breaker closure/opening, and multiple unit starting. A switch input to the EGCP-2 which 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 127 The EGCP-2 uses an internal reference level for the process input, and compares this reference to the transducer input. The EGCP-2 then raises or lowers the amount of load on the generator to maintain the process transducer input to the referenced value.
  • Page 128 A discrete input to the EGCP-2 which signals the unit to Run With Load operate the generator on load. The way that the control...
  • Page 129 Manual 26086 EGCP-2 Engine Generator Control Package A discrete input to the EGCP-2 which is used to start the Test engine for test and initial start check out. The test input is also used with the run with load or process inputs, and a software setpoint, to put the EGCP-2 into a soft transfer mode.

  • Page 130: Chapter 9. Service Options

    Product Service Options The following factory options are available for servicing Woodward equipment, based on the standard Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is purchased from Woodward or the service is performed: •...

  • Page 131: Returning Equipment For Repair

    Returning Equipment for Repair If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact Woodward in advance to obtain a Return Authorization Number. When shipping the item(s), attach a tag with the following information: •...

  • Page 132: Replacement Parts

    To expedite the repair process, contact Woodward in advance to obtain a Return Authorization Number, and arrange for issue of a purchase order for the item(s) to be repaired. No work can be started until a purchase order is received.

  • Page 133: Engineering Services

    EGCP-2 Engine Generator Control Package Engineering Services Woodward Industrial Controls Engineering Services offers the following after- sales support for Woodward products. For these services, you can contact us by telephone, by email, or through the Woodward website. • Technical Support •...

  • Page 134: Technical Assistance

    Type of Fuel (gas, gaseous, steam, etc) Rating Application Control/Governor Information Please list all Woodward governors, actuators, and electronic controls in your system: Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter...

  • Page 135: Egcp-2 Setpoint Worksheet

    Manual 26086 EGCP-2 Engine Generator Control Package Appendix A. EGCP-2 Setpoint Worksheet Configuration Menu Item: Range: Default: As Set Value: Note: SECURITY Min: 0 **** See Password CODE Max: 9999 section NETWORK Min: 1 Only accessible if ADDRESS Max: 8...

  • Page 136: Shutdown And Alarms Menu

    EGCP-2 Engine Generator Control Package Manual 26086 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 137 Manual 26086 EGCP-2 Engine Generator Control Package Item: Range: Default: As Set Value: Note: REVERSE PWR Disabled Soft Shutdown Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown LOSS OF EXCITE Min: -100.0 -50.0 % Max: -5.0 LOE ALARM Disabled...

  • Page 138: Engine Control Menu

    EGCP-2 Engine Generator Control Package Manual 26086 Engine Control Menu Item: Range: Default: As Set Value: Note: PREGLOW TIME Min: 0 5 sec Max: 1200 CRANK TIME Min: 0 10 sec Max: 240 CRANK CUTOUT Min: 5 550 RPM Max: 10000...
  • Page 139 Manual 26086 EGCP-2 Engine Generator Control Package Item: Range: Default: As Set Value: Note: LO OIL PRESS Min: 0.0 15 Bar or PSI Max: 120.0 LO OIL PRESS Disabled Soft Shutdown Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown HI H20 TEMP Min:75.0...

  • Page 140: Synchronizer Menu

    EGCP-2 Engine Generator Control Package Manual 26086 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 141: Real Load Control Menu

    Manual 26086 EGCP-2 Engine Generator Control Package Real Load Control Menu Item: Range: Default: As Set Value: Note: LOAD CONTROL Droop Normal MODE Normal Soft Transfer LOAD CTRL GAIN Min: 0.001 0.01 Max: 100.0 LOADSHARE Min: 0.1 0.72 GAIN Max2.0 LOAD STABILITY Min: 0.0...

  • Page 142: Reactive Load Control Menu

    EGCP-2 Engine Generator Control Package Manual 26086 Reactive Load Control Menu Item: Range: Default: As Set Value: Note: VAR/PF MODE Disabled PF control PF control VAR/PF GAIN Min: .01 1.00 Max: 20.0 VOLTS RAMP Min: 0 60 sec TIME Max: 1000 VAR/PF Min: .01...

  • Page 143: Transfer Switch Menu

    Manual 26086 EGCP-2 Engine Generator Control Package Transfer Switch Menu Item: Range: Default: As Set Value: Note: CHECK MAINS Disabled Enabled BREAKER Enabled FAST XFER Min: 0.1 1.0 sec DELAY Max: 30.0 MAINS STABLE Min: 1 60 second Max: 30000...

  • Page 144: Sequencing And Comms Menu

    EGCP-2 Engine Generator Control Package Manual 26086 Sequencing and Comms Menu Item: Range: Default: As Set Value: Note: AUTO Disabled Disabled SEQUENCING Enabled MAX GEN LOAD Min: 1 60 % Max: 100 NEXT GENSET Min: 1 30 sec Max: 1200...

  • Page 145: Calibration Menu

    Manual 26086 EGCP-2 Engine Generator Control Package Calibration Menu Item: Range: As Set Value: Note: Process In scale Min: 0.5 Max: 2.0 Speed Bias offset Min: -10.0 Max: 10.0 Volts Bias offset Min: -25.0 Max: 25.0 PT Phase A scale Min: 0.5...

  • Page 146: Appendix B. Download Instructions

    DOWNLOAD is a DOS-based freeware program that can upload and download configuration files through the EGCP-2's RS-422 serial port. This program is available through the Internet at the following location: Go to www.woodward.com/software In the box, select EGCP-2 Tools for all EGCP-2 related software available at present time. Requirements •...
  • Page 147 The following examples assume that COM1 is the available serial port on the PC, and the download.exe program has been saved to the directory, c:\EGCP2. On the EGCP-2, under the SEQUENCING AND COMMS menu, step to the “422 Protocol” item. Select "Upload Setpoints" and press the Enter key.
  • Page 148 When the power is restored to the control the download will begin. A scroll bar will appear on the computer screen showing the progress of the download (see below). On the EGCP-2 screen the text “SETPOINTS” will be displayed. Woodward...
  • Page 149 It is highly recommended that Uploading and Downloading of setpoints only be done between units with the same code revision level. The EGCP-2 will display a warning message and reboot after the self-tests if the setpoints and labels are not compatible with the internal code revision number.
  • Page 150 EGCP-2 Engine Generator Control Package Manual 26086 Woodward...

  • Page 151: Egcp-2 Control Specifications

    1/3 HP, 125 Vac (7.2 Amp, 0.4-0.5 P.F.) 10 Amp, 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 152 Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058 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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