Page 1 Product Manual 26194 (Revision F) Original Instructions EGCP-3 Engine Generator Control Package LS (Load Sharing) Model 8406-113 Operation Manual...
Page 2: General Precautions
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 26194 EGCP-3 LS Operation Contents ................ ARNINGS AND OTICES .......... LECTROSTATIC ISCHARGE WARENESS 1. G ............1 HAPTER ENERAL NFORMATION Introduction ......................1 Application and Functions ..................2 2. F ........7 HAPTER RONT ANEL...
Page 4 EGCP-3 LS Operation Manual 26194 Contents 10 Status Alarms Menu ..................111 11 Status Metering Menu ...................111 5. S ........112 HAPTER TARTUP HECKOUT ROCEDURES Before Starting the Generator Set ..............112 Sequence Of Startup And Checking Parameters ..........113 ...
Page 5 OWNLOAD 26. S ............. 217 HAPTER ERVICE PTIONS Product Service Options ..................217 Woodward Factory Servicing Options ..............218 Returning Equipment for Repair ................. 218 Replacement Parts ..................... 219 Engineering Services ..................219 How to Contact Woodward ................. 220 ...
Page 6 EGCP-3 LS Operation Manual 26194 Illustrations and Tables Figure 2-1a. EGCP-3 Front Panel and Operator Interface ........7 Figure 2-1b. Keypad ....................8 Figure 2-2a. EGCP-3 Navigation (1) ..............12 Figure 2-2b. EGCP-3 Navigation (2) ..............13 ...
Page 7: 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 8: 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 9: Chapter 1. General Information
The details on installation, wiring, communication, Regulatory Notes and Warnings are in the EGCP-3 Installation Manual 26122. The EGCP-3 LS is intended for power generator applications where multiple control/generators will supply an isolated bus, or operate in parallel with a Mains (Utility) bus. The EGCP-3 can perform engine start/stop sequencing.
Page 10: Application And Functions
*—Modbus is a trademark of Schneider Automation Inc. HMI/Front Panel Display The EGCP-3 has a keypad and two 4-line display panels on the front cabinet mounted chassis. The display can be used to configure and set up the control for site specific requirements.
Page 11: Load Control
Load Share with other units also connected to the bus. The speed bias output will control the load of each engine by slight changes to the speed control’s speed reference. When the breaker is open, the EGCP-3 will be in droop operation. Another mode of Load control is BaseLoad; it begins at breaker closure when the load control function takes control of the EGCP-3 speed bias output directly from the synchronizer.
Page 12: Process Control
When unloading from the process control, an adjustable unload ramp provides time controlled unloading to the unload trip level. When load reaches the unload trip level, the EGCP-3 control automatically issues a breaker open command to remove the generator set from the system.
Page 13 Power Factor levels of each generator. ATS Control ATS functions are not included in the LS model of EGCP-3. A Master Control (MC) is used to control the mains circuit breakers and local bus circuit breakers to perform ATS functions.
Page 14 HMI, PLC, remote control and monitoring equipment. The remote monitoring and interface can be by Modbus tools or Woodward ServLink tools. Configuration of the EGCP-3 may be done from the front panel or through a serial port using Woodward Watch Window software. The Watch Window software allows easy configuration in a Windows environment.
Page 15: Chapter 2. Front Panel Operator Interface
This chapter is intended to show the operation of and features available though the EGCP-3 display. The function of the configurable items shown here are described in more detail in following chapter(s).
Page 16: Keypad
Status key is pressed both screens will display status menus. Alarm/Event, Status, and Configuration Keys: These three keys determine the type of menus being displayed by the EGCP-3. ALARM / EVENT The ALARM/EVENT KEY is used to access the alarm and event menu in the right hand display screen.
Page 17: Alarm Clear
Manual 26194 EGCP-3 LS Operation STATUS The STATUS KEY, when pressed, will put both left and right LCD into the monitor display mode. The status displays provide information about different items of engine, generator set and bus operation. See the STATUS MENU buttons, below for details on the various status keys.
Page 18 EGCP-3 LS Operation Manual 26194 The ESCAPE KEY is used to move upwards (out of) the configuration menu levels. It also is used when tuning a value to restore the previous value, if the new value is not entered into memory (see the enter key, below).
Page 19 Manual 26194 EGCP-3 LS Operation Press the I/O STATUS key to display the status of all the discrete inputs and outputs, as well as information on analog inputs and outputs. There are three I/O status screens. SYNC Press the SYNC STATUS key to display status information regarding the generator breaker and mains breaker synchronizer.
Page 20: Navigation Procedure
Navigation Procedure The following drawings detail a step-by-step procedure for navigating through the EGCP-3 software. Additionally, the typical display entries seen at each step are shown. The cursor position is shown with an Underline of the first letter in the active line.
Page 21: Figure 2-2B. Egcp-3 Navigation (2)
>AO 1 High Cal Value synchronizer status >AO 1 Low Cal Value >AO 2 Function >AO 1 Function >AO 1 High Cal Value synchronizer status SCROLL >AO 1 Low Cal Value >AO 2 Function Figure 2-2b. EGCP-3 Navigation (2) Woodward...
Page 22: Figure 2-2C. Egcp-3 Navigation (3)
CONFIGURATION MENUS >AO 1 Function >AO 1 High Cal Value synchronizer status >AO 1 Low Cal Value >AO 2 Function Digital Inputs Digital Outputs synchronizer status Analog Outputs Analog Inputs (*last item in list) Figure 2-2c. EGCP-3 Navigation (3) Woodward...
Page 23: Figure 2-2D. Egcp-3 Navigation (4)
GEN BKR FEEDBACK ERR 22-APR-01 16:12:33.3 GEN PHASE DIFF CURR 01-MAY-01 11:32:54.5 SCROLL engine status GEN BKR FEEDBACK ERR 22-APR-01 16:12:33.3 GEN BKR FEEDBACK ERR 22-APR-01 16:12:33.3 engine status SCROLL --------------------------------------------------- -------------------End of List---------------- Figure 2-2d. EGCP-3 Navigation (4) Woodward...
Page 24: Alarms And Events
Figure 2-2e. EGCP-3 Navigation (5) Alarms and Events The EGCP-3 contains two separate events lists. Both lists contain a combination of diagnostics, warnings, and alarms. One list contains only the current events. The other list is referred to as a history log. It contains all events that have occurred at any time in the past or present.
Page 25 Manual 26194 EGCP-3 LS Operation In case the ALARM/EVENT KEY is pressed and there are no active or logged alarms, the display will look like this: S T A T U S D I S P L A Y N o n e...
Page 26: History Log
History Log. Status Menus There are nine status menus in the EGCP-3. Use the status keys on the face of the EGCP-3 to access these status menus. The information in the status menus is dynamic, and updates about every 200 milliseconds (ms). The status menus are used to display all of the inputs and outputs of the control and the associated modes of operation for the control.
Page 27: System Status
EGCP-3 LS Operation System Status When the EGCP-3 is initially powered up, it will default to the System Status Screen 1. Below is an example of what the Screen may look like. The System Status Screen can be accessed while in any other status screen by pressing the SYSTEM key.
Page 28: Engine Status
This is what the System Status screen looks like for a generator set that was started on a Network start from another EGCP-3 and is load sharing with other units on the bus at 500 kW, 0.80 lagging PF, with one alarm.
Page 29 Manual 26194 EGCP-3 LS Operation Time of Day (24 hour clock format) HH:MM: Date with two digits for the day and three letters for the month. DD-MMM: Four digit year. YYYY: The state of the engine control function. This is a repeated Engine: element from System Status Screen #1.
Page 30 EGCP-3 LS Operation Manual 26194 Generator Status Screens Generator Status Screen #1 contains summary information for both the generator and bus sources. It displays totals and averages as appropriate. It is the first screen shown in the generator status section. Pressing the Scroll Down button will page down to Generator Status Screen #2.
Page 31 Manual 26194 EGCP-3 LS Operation Denotes this screen is for the generator bus. GEN: Three phase readings for the generator. A B C: Phase KVA reading. The display will put a blank, k, or M as the KVA: first letter so that the units appear as VA, kVA or MVA for the displayed value.
Page 32 EGCP-3 LS Operation Manual 26194 Generator Screen #5 is the second Harmonics screen for both power sources: generator and bus. Pressing the Scroll Up button pages up to Generator Status Screen #4. Pressing the Scroll Down key pages down to Generator Status Screen #6.
Page 33 Manual 26194 EGCP-3 LS Operation Generator Screen #8 is the electric power overview for the generator three-phase power sensor. This is a repeat for Generator Status Screen #2 except that L-N values are used. Pressing the Scroll Up key pages up to Generator Status Screen #7.
Page 34 Com Port 3 port fault exists, NORMAL indicates the port does not have a fault. The status of LON communication between EGCP-3 or LON Status compatible controls. ALARM indicates a LON port error, NORMAL indicates the port does not have an error.
Page 35 Manual 26194 EGCP-3 LS Operation The slip frequency in Hz of the generator with relationship to the Slip: bus. The phase angle difference in degrees between the generator Phase: and the bus. The voltage differential in percent between the generator and the Volts: bus.
Page 36 Two or more EGCP-3s are tied to the same bus and are sharing load via LON LOAD SHARE information There is an EGCP-3 acting as a process master on this active bus. This unit is a PROC SLAVE slave to that master.
Page 37 The actual VAR/PF control mode. Mode: Displayed Mode Meaning VAR/PF control is off The EGCP-3 is adjusting the gen voltage to rated value. The unit is isolated, and VOLT TRIM is VAR/PF enabled. EGCP-3 is biasing to control PF. PF CONTROL The voltage bias is controlling to a specific PF that is broadcast over the LON.
Page 38 EGCP-3 LS Operation Manual 26194 Sequence Status Screens On the EGCP-3 Load Sharing (LS) units, this screen will always report as shown below. No other sequencing screens are available or applicable. U n i t : S t a t e : O F F...
Page 39: Security Access
ATS Status #1 Security Access The EGCP-3 has built-in security to protect against configuration changes and alarm log purges by unauthorized personnel. There are five levels of access to the configuration menus. They are listed in the table below. Each successive level has access to all of the levels above.
Page 40: Entering And Changing Values
EGCP-3 LS Operation Manual 26194 Level Type of Access Default Password View Status Screens, None Required Monitor View current events and event history log Silence-Acknowledge alarms View and Reset (clear) current Alarm/Event action View Status Screens, 9002 Operator View Configuration menus,...
Page 41 EGCP-3 operation. Only four lines may be viewed at a time but the complete list is shown below for simplicity. The Up and Down Scroll keys allow one to navigate to different menu items in the list.
Page 42: Figure 2-3. Navigation In Configure Mode
EGCP-3 LS Operation Manual 26194 After Security code is ENTER CONFIG ENTER First Time Startup Engine Protection COMPONENT Shutdowns and Alarms MENU Generator Protection Mains Protection Engine Protection >LANGUAGE >GEN CT RATIO >GEN PT RATIO >GEN SENSING TYPE >GEN HW RANGE ENTER >RATED GEN VAR...
Page 43: Chapter 3. Control Configuration
Chapter 3. Control Configuration Introduction The EGCP-3 must be configured before it can be used. All configuration points that are necessary for standard operation are available from the front panel display. These configuration points plus additional points are available when using Watch Window software through the ServLink communications serial link.
Page 44 Q ANALOG INPUTS Define Function and Scaling of Analog Inputs T REMOTE CONTROL Monitor ServLink Parameters U SEQUENCE STATES Use to Observe the State of the EGCP-3 engine Sequence V UNITS Displays the Units (KW, MW) of the System W LON MESSAGING...
Page 45: Parameter Descriptions
(_, K, or M). The variable units depend on the configured CT Ratio, PT Ratio, Sensing Type, and Hardware Range for the generator or mains input. The appropriate units calculated by the EGCP-3 are shown on the V UNITS sheet of Watch Window, or throughout the Status screens on the display.
Page 46: First Time Configure Menu
13,800:120, then the value to enter here is 115. (13800  120 = 115) The EGCP-3 will multiply the sensed voltage at the input by this value to determine the actual voltage on the generator for the given phase. The EGCP-3 will also need to know the next two parameters to fully define the voltage.
Page 47 True True=3 This value can be either 1 or 3 with a default of 3. If set to 1, the EGCP-3 will ignore any inputs on the B and C phase generator ac voltage inputs and current inputs, and set these phase values to zero. When 1Ø is selected the power measurements will be a per-phase value, and not the total.
Page 48 Even if no MPU is provided, this must be properly configured in order to pass the configuration check. The EGCP-3 assumes the MPU is located on a flywheel that spins at the same rate as the crankshaft and the generator. If this is...
Page 49 For example, the generator could be wired to the load as Wye but wired to EGCP-3 as Delta using Open Delta transformers. When the configuration is set for Zig Zag, the setting Gen Sensing type must also be set to False for single phase.
Page 50 This value can be either 1= Delta (Line-to-Line), 2= Wye (Star, Line-to-Neutral), or 3=Zig Zag. If set to Wye, it indicates that the wiring between the bus and the EGCP-3 is done in a L-N manner. It does NOT necessarily relate to the bus configuration.
Page 51 Compatible Mode MODE If the system consists ONLY of EGCP-3 connected to the LON bus, this is set to “EGCP-3”. If the system is required to interface with Woodward MSLC or DSLC controls, this is set for D/MSLC to allow communication between these controls and the EGCP-3.
Page 52: Digital Input Menu
Units LON Start LON START Both False True True=Enabled Sequencing SEQUENCING This will enable the EGCP-3 to initiate engine starts when a start is requested from the LON network. Item Display Name Panel / WW Default Units Engine Start START...
Page 53 Manual 26194 EGCP-3 LS Operation FIXED INPUTS Inputs Function Digital Input 1 Emergency Stop Digital Input 2 Auto Digital Input 3 Test Digital Input 4 Run with Load Digital Input 5 Generator Breaker (Auxiliary 52) Units Display Name Panel / WW...
Page 54: Digital Output Menu
(right) of the Quick Configure tabs. Items in the menu can be viewed but not edited until the EGCP-3 is in I/O Lock. Some items from this menu are also present on the front panel display in the CONFIG, Digital Outputs menu.
Page 55 Manual 26194 EGCP-3 LS Operation CONFIGURABLE OUTPUTS Item Display Name Panel / Default Units Digital Output 3 DIGITAL OUTPUT 3 Both 1=Not Used 2=Bus Breaker Digital Output 4 DIGITAL OUTPUT 4 Both Shunt Trip Command Digital Output 6 DIGITAL OUTPUT 6...
Page 56: Engine Protection Menu
EGCP-3 LS Operation Manual 26194 Value Command Display Notes Spark Ignition Ignition Enable Used to enable an external ignition Command controller Air Shutoff Solenoid Air Shutoff Solenoid Used to starve air from engine inputs. This output activated by an emergency stop or overspeed will engage for 5 seconds and is non-latching.
Page 57 Manual 26194 EGCP-3 LS Operation Coolant Temp. High Alarm Level should be set to a value higher than the Coolant Temperature High Pre-Alarm. Item Display Name Panel Default Units / WW Coolant Temp. High Pre- HIGH H20 TEMP PRE-ALM 1=Disabled Alarm Coolant Temp.
Page 58: Shutdowns And Alarms Menu
EGCP-3 LS Operation Manual 26194 Item Display Name Panel Default Units / WW Rated Oil Pressure Low LO RTD OIL PRES PRE- 1=Disabled Pre-Alarm Rated Oil Pressure Low LO RTD OIL PRES PALM 1000.0 40.0 psi/kPa Pre-Alarm Level This pre-alarm will operate if the oil pressure is below the set limit and engine speed goes above 90% of rated speed and the Idle/Rated output is set to rated.
Page 59: Generator Protection Menu
Units Powersense Board POWERSENSE FAIL ALM 4=Audible Fail Alarm This alarm is continuously enabled. It operates when the main CPU board detects a problem with the Powersense board of the EGCP-3. Item Display Name Panel / WW Default Units Phase Rotation...
Page 60 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Generator Over GEN VOLT HI Both 6=Hard Voltage Alarm Shutdown Generator Over GEN VOLT HI Both 30000 *Volts Voltage Alarm Level This alarm will operate when the highest phase voltage is continuously greater than the limit setting for the time delay setting.
Page 61 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Generator Phase Over GEN CURRENT HI Both 6=Hard Current Alarm Shutdown Generator Phase Over GEN CURRENT HI Both 30000 1500 *Amps Current Alarm Level This alarm is continuously enabled. It first selects the generator phase with the highest current.
Page 62 Generator Over Power Pre-Alarm. The Generator Over Power Level should also be set higher than the Rated Power in the First Time Configuration menu. The EGCP-3 uses the lower of these two settings when calculating the System Load percentage for isolated load sharing.
Page 63 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Generator Reverse GEN REV-PWR Disabled Power Pre-Alarm PRE-ALM Generator Reverse GEN REV-PWR -30000 30000 *Watts Power Pre-Alarm Level PRE-ALM LVL This alarm is continuously enabled. It should be set to a value higher than the Generator Reverse Power Alarm but lower than Rated Generator Real Power.
Page 64 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Generator Reverse GEN REV-VAR Both 6=Hard VAR Alarm Shutdown Generator Reverse GEN REV-VAR Both -30000 30000 *VAR VAR Alarm Level This alarm is continuously enabled. It should be set to a value lower than the Generator Reverse VAR Pre-Alarm.
Page 65 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Generator Negative GEN NEG SEQ V HI Both 120.0 10.0 Seconds Phase Sequence Over ALM DL Voltage Alarm Delay This value determines the amount of time that the generator Negative Phase Sequence voltage must be above the Generator Negative Phase Sequence Over Voltage Alarm Level before declaring an alarm.
Page 66: Bus Protection Menu
EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Generator Phase GEN DIFF CURRENT Both 5=Soft Current Differential Shutdown Alarm Generator Phase GEN DIFF CURRENT Both 30000 *Amps Current Differential Alarm Level This alarm is continuously enabled in 3Ø installations. It should be set to a value higher than the Generator Phase Current Differential Pre-Alarm but lower than Rated Generator Current.
Page 67 Manual 26194 EGCP-3 LS Operation Refer to Table 3-2 for the list of alarm actions. It is used in many places within the Bus Protection Menu. Item Display Name Panel / WW Default Units Bus Over Voltage Alarm BUS VOLT HI ALM...
Page 68 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Bus Phase Over Current BUS CURRENT HI Both 30000 1500 *Amps Alarm Level ALM LVL This alarm is continuously enabled. It first selects the Bus phase with the highest current.
Page 69 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Bus Under Frequency BUS FREQ LO ALM Both 2=Warning Alarm Bus Under Frequency BUS FREQ LO ALM Both 40.0 70.0 40.0 Hertz Alarm Level This alarm is continuously enabled. It should be set to a value lower than the Bus Under Frequency Pre-Alarm.
Page 70 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Bus Import Power BUS IMP-PWR Both 2=Warning Alarm Bus Import Power BUS IMP-PWR Both -30000 30000 -100 *Watts Alarm Level This alarm is continuously enabled. It should be set to a value indicating the Bus import level is greater than a warning (pre-alarm) condition.
Page 71 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Bus Import VAR Alarm BUS IMP-VAR ALM Both 6=Hard Shutdown Bus Import VAR Alarm BUS IMP-VAR LVL Both -30000 30000 *VAR Level This alarm is continuously enabled. It should be set to a value indicating the Bus import VAR level is greater (more negative) than an alarm condition.
Page 72 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Bus Negative Phase BUS NEG SEQ V HI Both 120.0 10.0 Seconds Sequence Over Voltage Alarm Delay This value determines the amount of time that the Bus Negative Phase Sequence voltage must be above the Bus Negative Phase Sequence Over Voltage Alarm Level before declaring an alarm.
Page 73 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Bus Phase Current BUS DIFF 1=Disabled Differential Pre-Alarm CURRENT PRE- Bus Phase Current BUS DIFF CURR 30000 *Amps Differential High Pre- PRE-ALM LVL Alarm Level This alarm is continuously enabled. It should be set to a value lower than the Bus Phase Current Differential Alarm.
Page 74: Engine Control Menu
EGCP-3 LS Operation Manual 26194 Engine Control Menu The Engine Control Menu is included in both the front panel display and Watch Window. However, there are some items that only appear in Watch Window. Items in it can be viewed and edited with caution while the engine is running.
Page 75 This value indicates to the EGCP-3 what speed the external speed control will control at when Idle is selected. The EGCP-3 needs to know this speed so that it can determine when the engine has reached 90% of idle. This feature is only active when Start Sequencing is Enabled.
Page 76 This parameter will initialize the Engine Run Hour clock to the values that are programmed in the next 2 settings. There is one setting for thousands of hours and one for hundreds of hours. It is useful if the EGCP-3 is retrofitted to a new engine or newly rebuilt engine.
Page 77 4 settings. There is one setting for Hundreds of hours, one for Thousands of hours, one for Millions of hours, and one for Billions of hours. It is useful if the EGCP-3 is retrofitted to a new engine or newly rebuilt genset. Item...
Page 78: Synchronizer Menu
Billions place (GIGA) This parameter is used to program in a preset number of Bus gigawatt hours. For example, if the EGCP-3 were installed on an existing generator, it may be necessary to preset the GW to a certain value. Item...
Page 79 Watch Window menu, or Modbus HMI. The last mode selected by any of these interface methods will be the mode of operation used. Off mode, the EGCP-3 performs no synchronization functions, The running sequence would stop with the engine at rated speed, and an external function would be required to close the breaker and continue the sequence.
Page 80 The synch fail alarm (if enabled) will be activated and the synchronizer will enter the auto-off mode if the breaker fails to close in the specified number of tries. Woodward suggests setting Close Attempts to 2 or greater for any application.
Page 81 If the CB Aux contact opens during the reclose delay interval, it is considered a failed closed attempt. The EGCP-3 will remain in the selected operating mode (run, check, or permissive) during the Reclose Delay interval.
Page 82 This value specifies the time required for the circuit breaker contacts to engage after receiving a closure command. It is normally found in the circuit breaker manufacturer’s specifications. The EGCP-3 will automatically subtract this time from the calculated time to initiate breaker closure in order to maintain proper phase alignment when performing slip frequency synchronizing.
Page 83: Real Load Control Menu
Manual 26194 EGCP-3 LS Operation Real Load Control Menu The Real Load Control Menu is included in both the front panel display and Watch Window. Most items appear in both. Items in it can be viewed and edited with caution while the engine is running. Items in this menu are part of a Service block.
Page 84 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units BaseLoad Reference BASELOAD REFERENCE Both 30000 *Watts This value is the default BaseLoad set point. This setting must be greater than the Unload Trip set point. It is the generator load level when in BaseLoad mode.
Page 85 Manual 26194 EGCP-3 LS Operation The following Load Level switches are not intended to be Generator Protection Functions. Item Display Name Panel / WW Default Units High Load Level Alarm HIGH LOAD ALM Both 2=Warning This value defines the alarm action taken when the genset load exceeds the configured High Load Level.
Page 86 EGCP-3 which can be viewed on the I/O Display Screen. A setting of 1 means that the EGCP-3 will not give any pulses if the speed bias is between –1% and 1%. This setting is only applicable when the Speed Bias Type, in the First Time Config menu, is set for Raise/Lower.
Page 87: Reactive Load Control Menu
Remote control. Manual is only used if no automatic control is desired. Remote control is used if external equipment will control the VAR or PF through the EGCP-3. This may be useful in order to still have the ability for Raise/Lower switches and voltage matching during synchronizing. Power Factor or VAR control is used when in parallel with the mains.
Page 88 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units VAR/PF Gain VAR/PF GAIN Both 0.01 20.00 0.20 This value is the proportional gain of the reactive load P-I-D controller for all modes of operation other than VAR/PF Sharing. This value determines how fast the VAR/PF control responds to an error between kVAR/PF and VAR or PF reference.
Page 89 VOLTAGE VOLTAGE This value is used as a trigger to command the EGCP-3 to use the Operating Voltage setting above. Normally this value would be False. The user would change the value to True to set the trigger and then back to False again.
Page 90: Process Control Menu
EGCP-3 Power Factor control when the KVA reading is below this level. For example, a setting of 2 % means that the EGCP-3 must measure at least 2% of its rated KVA setting before the Power Factor control is enabled on an isolated bus.
Page 91 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / Default Units Process Proportional PROCESS GAIN Both 0.001 20.00 0.50 Gain This value is the proportional gain of the Process P-I-D controller. It determines how fast the process control responds to an error between process variable and process reference.
Page 92: Transfer Switch Menu
EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Process High Limit PROCESS HIGH Both -30000 30000 User units This value is the highest process that should be carried by the genset. If the monitored process exceeds this level, a High Process Limit Alarm will be issued (if configured).
Page 93 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Default Units Start/Stop Sequencing RUN TIME MANAGER Both 5=Unit logic Number The sequence function is performed between LS units on the same active bus segment. It may also be initiated by a Master Controller (MC) but the negotiation between units is performed by the slaves themselves with the start and stop order determined by the run-time mode.
Page 94 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Minimum % Load to MIN LOAD LVL Both Trigger a Stop The desired lower load level for this genset, when demand is below this level a stop command will be given to the next scheduled unit...
Page 95 Synchronization SYNCH Needs to be enabled for the EGCP-3 to react to contact inputs from an external synchronizer to perform bus to bus synchronizing. The LS unit then broadcasts a sync bias level to all LS units on the same bus segment.
Page 96: Communications Menu
Both 1=RS232 This value is an enumerated list used to select the serial hardware interface for Serial Port 1. It may be RS232 =1, RS422 =2, or RS485 =3. See the EGCP-3 Installation Manual for details on each. Item Display Name...
Page 97 SERIAL 2 TYPE Both 1=RS232 This value is an enumerated list used to select the serial hardware interface for Serial Port 2. It may be RS232, RS422, or RS485. See the EGCP-3 Installation Manual for details on each. Item Display Name...
Page 98 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Serial 2 Parity SERIAL 2 PARITY 1=1 No Parity This value is an enumerated list used to select the parity for Serial Port 2. It may be 1 = No Parity or 2 = Odd or 3 = Even.
Page 99: Calibration Menu
This value selects the current day of the week. It is part of the date and time configuration. The EGCP-3 has a battery backed real time clock that, once properly configured, will keep the date, time, and day of week even if control power is removed.
Page 100 This value is the exact day in a calendar year. The Day, Month, and Year are independently configurable as separate fields. Use the navigation keys to select and change each field separately. The EGCP-3 has a battery backed real time clock that, once properly configured, will keep the date, time, and day of week even if control power is removed.
Page 101 FALSE TRIGGER Adjust the clock parameters above to the current time. The EGCP-3 clock will be set to these values when the trigger is set TRUE, the seconds will be set to 0.0. The trigger must then be returned to FALSE.
Page 102 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / WW Default Units Operator Password OPERATOR PASSWORD Both 9999 9002 This value is the password to use when logging in at the Operator Level. It can only be changed if logged in as a Technician.
Page 103: Remote Alarm Menu
The Remote Alarm 1 Delay value is the time to wait after activation of the input prior to announcing the alarm condition. The Remote Alarm 1 Level is used to configure how the EGCP-3 interprets the input state. If set to Active Low, the absence of an input at the Digital Input terminals will be considered an active alarm.
Page 104 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / Default Units Remote Alarm 2 REMOTE Both 1=Disabled ALARM 2 Remote Alarm 2 REMOTE Both 30.0 Seconds Delay ALARM 2 DLY Remote Alarm 2 REMOTE Both False True True=Active Level...
Page 105: Force Relay Menu
Manual 26194 EGCP-3 LS Operation Item Display Name Panel / Default Units Remote Alarm 6 REMOTE ALARM Both 1=Disabled Remote Alarm 6 Delay REMOTE ALARM Both 30.0 Seconds 6 DLY Remote Alarm 6 Level REMOTE ALARM Both False True True=Active...
Page 106: Analog Outputs Menu
EGCP-3 LS Operation Manual 26194 Analog Outputs Menu Item Display Name Panel / WW Min Default Units Analog output 1 ANOUT1 FUNCTION Both 2=Synchroscope Function Input Value at ANOUT1 HI CAL Both -30000 30000 Max output VALUE Input Value at...
Page 107: Analog Inputs Menu
Manual 26194 EGCP-3 LS Operation Item Display Name Panel / WW Min Default Units Voltage Bias Max Limit VOLT BIAS MAX LIMIT Voltage Bias Min Limit VOLT BIAS MIN LIMIT -100 -100 The Min and Max limits for the voltage bias signal can be used to clamp the output range.
Page 108 EGCP-3 LS Operation Manual 26194 Item Display Name Panel / Default Units Voltage or ANALOG INPUT Both 1=4–20 mA Current input 3 TYPE Selection User Defined ANALOG IN 3 ~~~~ ANALOG IN ASCII Label LABEL Sensor Value ANIN3 LOW CAL...
Page 109 Manual 26194 EGCP-3 LS Operation Item Display Name Panel / Default Units Voltage or ANALOG INPUT Both 1=4–20 mA Current input 4 TYPE Selection User Defined ANALOG IN 4 ~~~~ ANALOG IN ASCII Label LABEL Sensor Value ANIN4 LOW CAL...
Page 110: Remote Control Menu
EGCP-3 LS Operation Manual 26194 Remote Control Menu The Remote Control Menu contains items that can be tuned or configured from Watch Window, but would normally be set from an external device. They are included here as items that can be used during installation tests.
Page 111: Chapter 4. Monitoring By Watch Window
Sequence States Menu The EGCP-3 uses a state machine for determining its operating mode at any given time. The unit will step through these state from start to stop. Some states the control will skip or step through too quickly to see indication change.
Page 112: Lon Status Messaging Menu
EGCP-3 LS Operation Manual 26194 If a value of Kilovolt is observed, the related ac quantity is scaled by 1000. For example, if Bus Voltage Units is Kilovolt than a value of 4.160 in Bus Rated Voltage will be interpreted as 4160 volts. On the front panel display this can be observed as the units changing to kV.
Page 113: 01 Status System Menu
Manual 26194 EGCP-3 LS Operation Display Name IN/OUT Units STRT NODES Number of Gensets ready to start on this bus STOP NODES Number of Gensets ready to stop on this bus SYS_PF indicates the system power factor SYS LOAD System Load % SYNC BIAS Indicates the master sync bias command value.
Page 114: 02 Status Engine Menu
02 Status Engine Menu An overview of the Engine state and operating parameters. Display Name Item Units 01 DATE / TIME Current Date and Time of the EGCP-3 Clock Y/M/D H:M:S 02 ENGINE: The state of the engine control function 03 RPM:...
Page 115: 04 Status Bus Menu
Manual 26194 EGCP-3 LS Operation Display Name Item Units 36 GEN CURR, 11TH HARM Eleventh Current Harmonic 37 GEN CURR, 13TH HARM Thirteenth Current Harmonic 38 GEN VOLT, THD Total Harmonic Distortion of the Voltage 39 GEN VOLT, 3RD HARM...
Page 116: 05 Status I/O Menu
Amp* 49 BUS NEG-PHS-SEQ AMP Negative Phase Sequence Current Amp* 05 Status I/O Menu The monitor menu for all inputs to the EGCP-3 and its outputs to the system. Display Name Item Units 01 DI - IN 1 STATE Input 1 Open or Closed...
Page 117: 06 Status Synchronizer Menu
Percent of system loading 04 LOAD REFERENCE: The load reference for the generator 05 PROCESS ACTUAL IN %: The actual process level as seen by the EGCP-3 06 PROCESS REF %: The process reference for the process control 07 LOAD MODE:...
Page 118: 08 Status Pf/Kvar Menu
EGCP-3 LS Operation Manual 26194 08 Status PF/KVAR Menu An overview of the reactive Power control. Display Name Item Units 01 MODE: The actual control mode 02 VOLT CNTRL STATE: The state of the VAR/PF controller 03 PWR FACTR REF: The PF control reference value.
Page 119: 10 Status Alarms Menu
Manual 26194 EGCP-3 LS Operation 10 Status Alarms Menu A monitor of the alarm condition of the genset. Display Name Item Units 01 CURRENT DATE / TIME Current Date & Time of internal clock Y/M/D H:M:S 02 NUMBER OF ALARMS ACTIVE...
Page 120: Chapter 5. Startup Checkout Procedures
When this is confirmed, apply the power supply to the EGCP-3. When the EGCP-3 is given power, it will go through RAM test and self test. After a self check period it will display the System Status Menu. If the EGCP-3 fails to power up properly, remove the power supply input and double check the polarity and amplitude of the voltage feeding the EGCP-3.
Page 121: Sequence Of Startup And Checking Parameters
4. Set synchronizer mode to Off, in the Synchronizer menu. 5. Set load control mode to Isochronous, in the Real Load menu. 6. Manually start the engine using only the TEST switch of EGCP-3. 7. Check engine overview status screen for engine rpm readout. Confirm rpm is correct for unit.
Page 122: Loading The Generator Set
EGCP-3 LS Operation Manual 26194 Loading The Generator Set Operation of the engine/generator set with incorrect CT and PT phasing could cause serious injury or damage to equipment. If the load on the unit rises rapidly when the generator or mains breaker is closed, immediately open the breaker and shut the unit down.
Page 123 19. Return to BaseLoad control, by opening the Process input, and adjust VAR/PF Gain and Integral for stable reactive load control. 20. If other EGCP-3 LS or MC units are in this bus, observe I/O status and Sequence status to confirm that controls are communicating on LON Network.
Page 124 EGCP-3 LS Operation Manual 26194 22. Remove Run with Load input to unit.  Verify unload ramping.  Verify unload trip point.  Verify generator breaker opens.  Verify cooldown timer (if reached). 23. Set Crank Repeats, BaseLoad Reference, Process Reference, Load Ramp Times, and Load Control Mode as required for proper operation.
Page 125: Chapter 6. Application Overview
Manual 26194 EGCP-3 LS Operation Chapter 6. Application Overview In this chapter, block diagrams of the control functions are shown to give the basic signal flow and control methods. Control Block Diagram The basic overall control flow can be represented by the below flowchart. Each mode is further described in the next section.
Page 126: Figure 6-2. Alarm Logic Block Diagram
EGCP-3 LS Operation Manual 26194 The alarm and event logic within the EGCP-3 can be simplified to the below flowchart. The flowchart also indicates how events can be reset and cleared. Alarm History Log Any Alarm/Fault Remote Alarm 1 Silence...
Page 127: Load Controller
Manual 26194 EGCP-3 LS Operation Load Controller The load controller controls the speed bias output and therefore, it controls real load only. The synchronizer works through the load controller in order to get to the speed bias output so that they do not fight over control of the output. Process is considered a type of load control and will also work through the load controller.
Page 128: Process Controller
EGCP-3 LS Operation Manual 26194 Process Controller The process controller controls the real and reactive loads using the Real and Reactive Load Controllers. The output of the process controller is an input to the load controllers. Process Direct/Inverse Action Temp/Press...
Page 129: Reactive Load Controller
Manual 26194 EGCP-3 LS Operation Reactive Load Controller The reactive load controller controls the voltage bias output and therefore, it controls reactive load only. The synchronizer works through the reactive load controller in order to get to the voltage bias output so that they do not fight over control of the output.
Page 130: Synchronizer
EGCP-3 LS Operation Manual 26194 Synchronizer The synchronizer controls the voltage bias output and the speed bias output through the load controllers. It is only active when necessary. When it transitions from active to inactive, the load controllers will ramp out the synchronizer effect in a slow controlled ramp.
Page 131: Chapter 7. Calibration Procedures
EGCP-3. The current transformers will certainly be less accurate than the EGCP-3 across the full range. The EGCP-3 allows the user to correct for error on each phase independently. The correction factors may be found in the calibration menu.
Page 132: Analog Outputs
The MPU input itself needs no calibration. However, for the frequency detected at the input to be meaningful, the EGCP-3 must know the number of teeth on the gear being measured. With this single data point, the EGCP-3 can determine the speed of the gear.
Page 133: 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-3 Voltage Bias Offset applied to the regulator. Speed Bias Output The speed bias output is calibrated in three modes.
Page 134 Woodward Governor Company, an offset may be required for proper operation. When initially powered up, the EGCP-3 will always apply the value for the speed bias offset to the speed bias output. When calibrating, it is best to start from a known state where the speed control is already properly configured for rated speed when the EGCP-3 is not connected to it.
Page 135: Chapter 8. Alarm And Diagnostic Summary
Alarm Actions on the list. An action is available only when the listed actions are appropriate. Disabled The EGCP-3 will not look for the alarm condition. No alarm will be logged, sent over a communication link, or shown on the display. Warning When the EGCP-3 detects the event/alarm condition, the alarm will be added to the current event list and the alarm history log.
Page 136 Manual 26194 Hard Shutdown When the EGCP-3 detects the event/alarm condition, the alarm will be added to the current event list and the alarm history log. If a discrete output is configured to indicate a Herd Shutdown alarm condition, the output will be asserted. The communication links will indicate a hard shutdown alarm condition exists.
Page 137: Alarm List
Manual 26194 EGCP-3 LS Operation Alarm List The following table is a list of all alarms generated by the EGCP-3. The Modbus ID is the Boolean Read address where the status of the named alarm can be determined via Modbus.
Page 138 EGCP-3 LS Operation Manual 26194 Alm # Event Name Display Name Modbus ID Bus Export VAR Alarm BUS EXPORT VARs 10109 Bus Export VAR Pre-Alarm PRE BUS EXPORT VAR 10110 Bus Import VAR Alarm BUS IMPORT VARs 10107 Bus Import VAR Pre-Alarm...
Page 139 The EGCP-3 should not be used as the only means for detecting voltage or current disturbances, dead bus conditions, or overcurrent conditions. The generator should be equipped with a sync check relay,...
Page 140 Likewise, the lowest voltage of the 3 phase inputs is always used for the Under Voltage protective relay. Once an alarm is issued, it is latched until the EGCP-3 is reset. The generator Under Voltage relay is automatically disabled anytime the generator breaker is open. The Bus Under Voltage relay, Generator and Bus Over Voltage relays are not inhibited by breaker position.
Page 141: Figure 8-1. Over Voltage/Under Voltage Alarm
The Over and Under Frequency protective relay is definite time. It operates by comparing the actual frequency to the level set points for this relay. Once an alarm is issued, it is latched until the EGCP-3 is reset. The generator Under Frequency relay is automatically disabled anytime the generator breaker is open.
Page 142: Directional Power
Alarm or Pre-Alarm action is taken. The delay time is recalculated each time the power level changes. Once an alarm is issued, it is latched until the EGCP-3 is reset. The Directional Power relays are continuously enabled. The below graph shows how the Pre-Alarm and final Alarm settings relate to actual and rated power levels.
Page 143: Figure 8-3. Over Power/Reverse Power Time Delay
Manual 26194 EGCP-3 LS Operation The graph below shows how the inverse time curve is applied to the directional power protective relay. Note the same curve shift applies to both Over and Reverse Power. Likewise, for the Bus, the same curve shift would apply to both Import and Export Power but is different than the curve shift used for the generator directional power protective relay.
Page 144: Negative Phase Sequence Over Current
This Negative Phase Sequence Over Current protective relay is a definite time relay. The negative phase sequence over current is derived the same as the voltage above. Once an alarm is issued, it is latched until the EGCP-3 is reset. The Negative Phase Sequence Over Current relays are continuously enabled.
Page 145: Voltage Restrained Phase Over Current
Alarm or Pre-Alarm action is taken. The delay time is always being recalculated for the present current level input. Once an alarm is issued, it is latched until the EGCP-3 is reset. The Phase Over Current protective relay is continuously enabled.
Page 146 Alarm or Pre-Alarm action is taken. The delay time is always being recalculated for the present current imbalance level input. Once an alarm is issued, it is latched until the EGCP-3 is reset. The Phase Current Differential protective relay is continuously enabled.
Page 147: Figure 8-5. Phase Current Imbalance
IEEE definition is only valid above 1 per unit. Nevertheless, the configuration values for the Alarm and Pre-Alarm Level are to be entered as the actual allowed difference. The EGCP-3 will automatically add Rated Current to the configured value.
Page 148: Sync Check
One configurable high and one configurable low level trigger are provided. The low level alarm is disabled while the engine is cranking since the EGCP-3 may be powered from the same set of batteries and would see a “normal” low voltage during this time. Otherwise, this protection is always enabled.
Page 149: Figure 8-7. Coolant Level Alarm
If no oil pressure sensor is provided, this protection is disabled. Once an alarm is issued, it is latched until the EGCP-3 is reset. Speeds are determined from the MPU. If no MPU is provided, the Idle Oil Pressure protection will not be able to operate.
Page 150: Figure 8-8. Oil Pressure Engine Protection
EGCP-3 LS Operation Manual 26194 The diagram in below shows when the Idle Oil Pressure Alarms are enabled. During the ramp from Idle to Rated speed, the Low Idle Oil Pressure Alarm remains enabled. Rated Oil Pressure Alarm The Rated Oil Pressure Pre-Alarm and Alarms are definite time delay with a fixed timeout period of 2 seconds.
Page 151: Remote Alarms
The EGCP-3 takes the ratio of the input being used (phase current, power, etc.) to the rated value of that unit. The inverse time curve always uses a ratio of rated for its data element.
Page 152 Also shown below is a figure with the Inverse Time Curve converted to linear axis scale. The values used in the EGCP-3 extend above 25 second delay between 1.0 and 1.35, and also extend to the right beyond the ratio of 5.0.
Page 153: Figure 8-9. Inverse Curve Time Delay, Level Shift
Manual 26194 EGCP-3 LS Operation The curve shift value of 0.24 is required to meet the desired level and delay requirement. Inverse Time Log Plot 1000.0 Curve Level shifted by 5.0 100.0 Default Curve 10.0 Curve Level shifted by 0.1 10.00...
Page 154: Diagnostics
Manual 26194 Diagnostics The following table is a concise list of all diagnostics generated by the EGCP-3. The Modbus ID is the Boolean Read address where the status of the named diagnostic can be determined via Modbus. Diagnostic actions are not configurable.
Page 155 Fail to Synchronize This Fail to Synchronize Diagnostic will occur if the EGCP-3 was not able to bring the generator and bus into synchronization long enough to close the breaker prior to the Synchronizer Timeout expiring. If the EGCP-3 attempts to close the breaker but cannot due to other reasons, this diagnostic would not apply.
Page 156 This indicates that the breaker auxiliary contact circuit is open or failed. When this condition occurs, the EGCP-3 automatically begins performing the actions associated with the relevant breaker closure as if the auxiliary contact indicated the breaker was closed.
Page 157: Configuration Check
This board is located in the middle of the stack. If this diagnostic occurs, the EGCP-3 will automatically perform an I/O Lock, which will shutdown the genset, and open the generator breaker.
Page 158 EGCP-3 LS Operation Manual 26194 The PowerSense board also has LEDs for the LON status; these are located next to the CPU status LED. The center LON Status LED will flash green to indicate the LON communication is operational. The rate of flashing indicates the amount of “traffic”...
Page 159: Chapter 9. Engine Start Sequencing
Disable setting of Start Sequencing. When a stop request occurs, the first check is also to see if Start Sequencing is disabled. An external device is expected to handle all elements of start and stop excluding cooldown that the EGCP-3 can still provide (but doesn’t have to).
Page 160: Figure 9-1. Engine Starting Flow Chart
EGCP-3 LS Operation Manual 26194 Start Speed>0? Set Crank Denied Alarm Flag Initialize Timers & Counters Set Idle/Rated=Idle Crank Attempt Counter > Crank Attempt Setpoint? Speed => Speed > 0 Set Crank Fail Crank Cutout 3sec yet? RPM? Alarm Flag...
Page 161: Stopping Procedure
The initial step in all shutdown routines is to remove load and open the generator breaker. If Cooldown at Idle is selected during configuration, the EGCP-3 will switch the idle/rated output to idle during cooldown. If a discrete output is configured for Engine Running, it will be de- energized when the engine comes to rest.
Page 162: External Starting Procedure
When a START signal is received, this routine assumes and external device will perform the necessary sequence to start the engine. Although repeated checks are not shown in the flowchart for E-stop, the EGCP-3 does continuously look for an E-stop request during the start sequence and will respond accordingly.
Page 163: External Stopping Procedure
EGCP-3 LS Operation External Stopping Procedure When the EGCP-3 is configured for Engine Start Sequence disabled, a STOP signal will perform the same sequence to stop the engine as when internal logic is enabled. The engine will unload, open breaker(s) and cooldown. The discrete output for Engine Running will be de-energized simultaneous with the Fuel Solenoid (Run Relay) Output.
Page 164: Chapter 10. Mode Control Switch
EGCP-3 LS Operation Manual 26194 Chapter 10. Mode Control Switch Introduction The mode control switch is defined as the three (3) switch inputs labeled, Test, Run w/ Load, and Auto. The Process Enable and BaseLoad Enable switch inputs affects the final mode but does not affect starting conditions. As long as the physical Auto switch is closed (asserted), the mode switch “inputs”...
Page 165: Auto Mode
When the Process Enable input is closed, the Process mode is active if the unit is operating in parallel with the mains. When in parallel with other EGCP-3 LS units, the Process Mode of the Process Master will control the load of the other LS units as Process Slaves.
Page 166: Chapter 11. Unit Sequencing Configuration
When the Run-Time Manager is set for Disabled operation, no individual sequencing is performed, but all starts initiated by an EGCP-3 MC will still occur. This feature allows an operator to keep single units or all units online all of the time.
Page 167: Figure 11-2. Staggered Run Time Sequencing
Manual 26194 EGCP-3 LS Operation Disabled is the only sequencing algorithm that can be configured with another algorithm. For example, all units must be on Staggered Run Time or Disabled. The controls cannot have Staggered and Unit number. If the controls are configured incorrectly, a LON ERROR 261 will be present in: ...
Page 168: Figure 11-3. Equal Run Time Sequencing
EGCP-3 LS Operation Manual 26194 Equal Run Time Equal Run Time sequencing applies the Service Interval in its sequencing mechanism. The Service Interval is configured in the Sequencing menu and is set up so that alarms can be configured when this time expires. When a genset is running, the service hours decrement.
Page 169: Figure 11-5. Smallest Unit First Sequencing
Manual 26194 EGCP-3 LS Operation Smallest Unit First The Smallest Unit First sequencing algorithm starts the smallest real load capacity unit upon a start request and stops the largest real load capacity unit upon a stop request. The stopping order will always be exactly the opposite of the starting order.
Page 170: Sequencing Mechanism
EGCP-3 LS Operation Manual 26194 Sequencing Mechanism The operator has several configurations to work with in the sequencing menu.  Run-Time Manager Type of sequencing performed by LS units  Max Load Delay Time above the Max Gen Load Level before the next unit is started ...
Page 171: Sequencing Configuration
Manual 26194 EGCP-3 LS Operation Sequencing Configuration In order to avoid overloading, and also to increase efficiency of operation, the sequencing configurables Max Gen Load Level and Min Gen Load Level need to be analyzed for different sized units and also for different sequencing types. The...
Page 172 EGCP-3 LS Operation Manual 26194 Largest to Smallest The largest to smallest stop sequence will be Gen1 – Gen 2 – Gen 3. This can occur for any sequencing type except Smallest Unit First. Number of Units Online: 3 (System Capacity = 1200 kW)
Page 173: Summary
Avoiding sequencing configuration errors is critical to obtaining optimum performance from the EGCP-3. With an understanding of the process of sequencing, operators should be able to custom fit the EGCP-3 network to their system. By running through the above calculations with your system, problems can be eliminated and performance improved.
Page 174: Chapter 12. Ls Isolated Application
In a Multiple Unit Prime Power Application, the EGCP-3 controls will operate an isolated load bus (A) that never operates in parallel with the mains bus. Breakers 1,2, --- (up to 16), are Generator breakers controlled by the EGCP-3. The Local Breakers are not controlled by the EGCP-3s.
Page 175 Manual 26194 EGCP-3 LS Operation Start/Stop To initiate the first start, manually give the control a run input. If Auto and Run inputs are given the control will start the engine ramp to rated, and close the breaker onto a dead bus. Once the unit (LS1) is running the run input can be taken away.
Page 176: Chapter 13. Ls Mains Parallel Application
SPM-D Load In a Multiple Unit Prime Power Application, the EGCP-3 controls will operate into an isolated load bus (A) that can also operates in parallel with the mains bus. Breakers 1,2, --- (up to 16), are Generator breakers controlled by the EGCP-3.
Page 177 Manual 26194 EGCP-3 LS Operation  The local display and HMI will: Provide V, A, W, KVA, KVAR, PF information for single or three phase configuration. Provide Engine Speed, Oil Pressure, Coolant Temp, Battery (supply) voltage, kW-hours, accumulated engine run time (hours), and Service hours information.
Page 178: Ls Isolated, Split Bus Application
SPM-D. The EGCP-3 controls and SPM-D will perform the following functions:  Start the genset, and place the generator on load (dead bus closing or active synchronization) upon receipt of the appropriate input commands.
Page 179 Manual 26194 EGCP-3 LS Operation  The local display and HMI will: Provide V, A, W, KVA, KVAR, PF information for single or three phase configuration. Provide Engine Speed, Oil Pressure, Coolant Temp, Battery (supply) voltage, kW-hours, accumulated engine run time (hours), and Service hours information.
Page 180: Chapter 15. Ls-Mc Mains Parallel Application
Local Breakers Load In a Multiple Unit Mains Parallel Application, a EGCP-3 MC is will sequence gensets, synchronize the Mains (breaker 16) to the local bus (A) and control import/export of power with the mains by controlling genset/bus power through the LS units.
Page 181 Number of units on load Next unit start sequence Next unit stop sequence The EGCP-3 LS slave control shall perform the following functions:  Start the genset(s), and placing the generator on load (dead bus closing or active synchronization) upon receipt of the appropriate input commands.
Page 182: Chapter 16. Ls-Mc Mains Parallel Ats Application
Breakers Load In a Multiple Unit Mains Parallel Application, a EGCP-3 MC is required to sequence, synchronize and control import/export of power with the mains (breaker 16). With the addition of the bus tie breaker (w) the MC control is capable of ATS operation.
Page 183 Number of units on load Next unit start sequence Next unit stop sequence The EGCP-3 slave control shall be capable of:  Start the genset(s), and placing the generator on load (dead bus closing or active synchronization) upon receipt of the appropriate input commands.
Page 184: Chapter 17. Ls-Mc Mains Parallel, Split Bus Application
Load Load A Multiple Unit, Mains Parallel, Split bus Application would use EGCP-3 LS, and MC control with a SPM-D synchronizer. Each bus is capable of isolated or mains parallel operation. Both local buses can also be tied together. In this and all applications with split buses, and multiple feeds, location of the mains and bus PT/CT sensors is important for the proper measurements.
Page 185 Number of units on load Next unit start sequence Next unit stop sequence The EGCP-3 slave control shall be capable of:  Start the genset(s), and placing the generator on load (dead bus closing or active synchronization) upon receipt of the appropriate input commands.
Page 186: Chapter 18. Synchronizer Description
Functional Description The Synchronizer is the functional section in software and hardware of the EGCP-3 that synchronizes the generator(s) to the bus and closes the breaker. To accomplish this the synchronizer has three outputs, a speed bias output, a voltage bias output, and a breaker/contactor command. Working with the outputs are the four “modes”...
Page 187: Operating Modes
Raise/Lower Speed panel switches. This mode is typically used with breaker closure wiring in series with a manual closure command such that the EGCP-3 is not actually closing the breaker but allowing it to close.
Page 188: Dynamic Adjustments
Match Window before a breaker close command output will be issued. The synchronizer automatically controls the generator at the specified slip frequency. The EGCP-3 outputs an error signal to the auxiliary or summing point of an electronic speed control to provide the correction. Gain and Stability...
Page 189 The voltage matching function of the EGCP-3 uses generator A phase and mains A phase signals. True RMS measurements are compared and matched. The...
Page 190 When the Permissive or Check modes are selected, the synchronizer timeout is considered infinite. If a Synchronizer Time Out occurs, the EGCP-3 will initiate a Synchronizer Time Out Alarm based on the Synchronizer Time Out Alarm Action.
Page 191: Figure 18-1. Synchronizer Action Time-Line
Either one or both may be configured as breakers or contactors. Open and Close logic for each type is indicated below. In Breaker operation the EGCP-3 control has a pulsed output to the breaker closing circuit, and a separate pulsed output to give an open command the breaker shunt trip circuit.
Page 192: Shunt Trip
However, when the EGCP-3 is put into a test start (only the test input is asserted), the generator breaker shunt trip output will NOT be energized. This will prevent manual breaker closure.
Page 193 Manual 26194 EGCP-3 LS Operation The user also has the ability to configure breaker or contactor logic for breaker closure. This configuration may be set for each breaker (generator and bus) independently. When configured as a breaker the output is held on until an auxiliary contact feedback is received or for the Breaker Hold Time configuration –...
Page 194: Chapter 19. Real Load Control Description
Real Load Control Description Introduction The Real Load Controller is the software functional section of the EGCP-3 that controls the generator load. Load control begins at breaker closure when the load control function takes control of the EGCP-3 speed bias output directly from the synchronizer.
Page 195: Power Sensor Operation
Power Sensor Operation The digital signal processing (DSP) power measurement technique used by the EGCP-3 control involves sampling of the voltage and current over a number of waveform periods. The microprocessor computes the product of the voltage and current samples, then sums and averages the products to give a computation of power.
Page 196: Figure 19-1. Droop Mode
EGCP-3 LS Operation Manual 26194 Figure 19-1. Droop Mode The Droop load control operation is internal to the EGCP-3. The primary speed control receiving the speed bias signal must be configured to operate in Isochronous. In the Droop mode the load control droops the speed by an amount equal to the Droop setting.
Page 197: Figure 19-2. Isochronous Mode
Figure 19-2. Isochronous Mode Isochronous Load Sharing The LS Model of EGCP-3 is capable of controlling the load distribution between multiple gensets in Isochronous mode. The feedback signal is provided from load information supplied by the LON Network. Because of feedback, the speed can remain constant over the load range of the genset.
Page 198: Optional Load Functions
EGCP-3 LS Operation Manual 26194 Internal BaseLoad When Internal BaseLoad is active at the time of breaker closure to the utility, the load control will ramp the load reference to the BaseLoad configuration setting using the Load or Unload Time, whichever applies. In addition the user also has the ability to stop the ramp with the activation of the Load Raise/Lower switches or the Pause switch.
Page 199 Manual 26194 EGCP-3 LS Operation Ramp Pause When the Ramp Pause panel switch is closed the load reference ramp will pause and hold the current load until the switch is opened again. The ramp pause allows for temperature, oil pressure, etc., to reach the desired operating point while hold the load at a safe level.
Page 200: Chapter 20. Reactive Load Control Description
EGCP-3 LS Operation Manual 26194 Chapter 20. Reactive Load Control Description Introduction The VAR/PF (Volt Amp Reactive or Power Factor) controller adjusts the reactive power component of the generator in parallel systems. In an infinite bus system, the controller compares either the reactive power on the generator with an reactive power setpoint, and makes corrections to the voltage regulator until the desired reactive power is obtained.
Page 201: Mode Description
Mode Description Off / Droop Control The manual control mode keeps the EGCP-3 from regulating PF or VAR levels. The Voltage Raise/Lower switches will allow a user to change the voltage of the generator. An analog input cannot be used to control PF or VAR levels in this mode.
Page 202: Optional Load Functions
When this mode is selected, the PF or VAR reference level is determined by an analog input. The EGCP-3 is still controlling PF or VAR but the reference is set by an analog input or from Modbus. The range / calibration of how to use the signal is achieved using the calibration for the input.
Page 203 Manual 26194 EGCP-3 LS Operation Ramp Pause When the Ramp Pause panel switch is closed the reactive load reference ramp will pause and hold the current reactive load until the switch is opened again. When the switch is opened again, the load ramp will continue where it left off.
Page 204: Chapter 21. Process Control Description
CB Aux, Bus CB Aux and mains CB Aux switch inputs are closed. To control a process the EGCP-3 LS has to vary the genset and bus power output level. Increasing or decreasing power will increase or decrease a measured parameter (temperature, pressure, KW, etc).
Page 205: Mode Description
Mode Description Master Process Control When an EGCP-3 LS is connected to a bus system and the Process Enable input, Generator CB Aux, Bus CB Aux and Mains CB Aux switch inputs are closed, the first (or only) genset on the bus becomes the Master Process Control.
Page 206: Droop Control
EGCP-3 LS Operation Manual 26194 Reset Load When the Reset Load switch is closed and then opened, the process control will ramp the process reference to the original internal reference (configuration setting) at the Load or Unload Rate. This function will not work with a Remote Reference.
Page 207 Manual 26194 EGCP-3 LS Operation Filter The process being controlled will react to load changes quickly or slowly. The process controller includes an adjustable filter to adjust the process control rate of response. The filter is a low pass filter where the frequency is adjustable.
Page 208: Chapter 22. Pid Tuning Description
EGCP-3 LS Operation Manual 26194 Chapter 22. PID Tuning Description Overview The Real load, reactive load, and process control all utilize PID controllers. The response of each control loop can be adjusted for optimum response, however it is important to understand what a PID controller is and the effect of each controller adjustment has on the controller response.
Page 209: Proportional Response
Manual 26194 EGCP-3 LS Operation Proportional Response The amount of proportional response is directly related to the process change and the Proportional gain stetting on the controller; Controller output change is proportional to the process change. If there is no process change, there is no change in output from the controller ( or valve change) regardless of the deviation.
Page 210: Integral Response
Manual 26194 Integral Response Integral gain as stated in the Woodward controls is repeats per minute (or Reset Rate). Therefore, a high amount of Integral gain (high number) would result in a large amount of reset action. Conversely, a low integral gain (low number) would result in a slower reset action.
Page 211: Proportional And Integral Response (Closed Loop)
Manual 26194 EGCP-3 LS Operation Proportional and Integral Response (closed loop) The figure below shows the closed loop effects of integral action. The bottom curve displays the load change. The next curve up shows the setpoint and the measured variable, temperature. With the load change the temperature droops or deviates from the setpoint.
Page 212: Derivative Response
Proportional action to reduce stabilization time in returning the process to the setpoint after an upset. Derivative will not remove offset. Woodward Derivative is split into two working domains, Input dominant and Feedback dominant. The allowed values for DR range from 0.01 to 100. The most common derivative is Feedback dominant, it is automatically selected with an Derivative Ratio (DR) from 1 to 100.
Page 213: Proportional + Derivative (Closed Loop)
Manual 26194 EGCP-3 LS Operation Input dominant derivative applies the DR term before the integrator term of the PID equation. When the DR is less than 1, the derivative is input dominant and reacts very quickly to process upsets. This function is very adapted for PIDs that control the load parameter, such as load shaft turbine speed.
Page 214: Derivative (Effects Of Settings)
EGCP-3 LS Operation Manual 26194 Derivative (Effects Of Settings) Figure 22-6. Derivative Setting Effects The figure above shows the effect of different derivative settings. The curves are relative since it depends on what type of control is desired in order to properly adjust derivative time.
Page 215: Adding Derivative
Manual 26194 EGCP-3 LS Operation Figure 22-7. Closed Loop Proportional, Integral and Derivative Action In summary, Derivative provides a temporary over-correction to compensate for long transfer lags and reduce stabilization time on process upsets (momentary disturbances). Do not use if high frequency noise is normally in the measured variable or the main lag is dead time.
Page 216: General Guidelines Field Tuning
EGCP-3 LS Operation Manual 26194 An input dominant controller is more sensitive to the change-of-rate of its input (i.e. Speed, Cascade in or Auxiliary in), and can therefore prevent overshoot of the setpoint better than a feedback dominant controller. Although this response is desirable during a startup or full load rejections, it can cause excessive control motions in some systems where a smooth transition response is desired.
Page 217 Manual 26194 EGCP-3 LS Operation Tuning Example If the system is unstable, make sure the governor is the cause. This can be checked by closing the valve limiter until it has control of the actuator output. If the governor is causing the oscillation, time the oscillation cycle time. A rule-of- thumb is, if the system’s oscillation cycle time is less than 1 second reduce the...
Page 218: Chapter 23. Lon (Local Network) Description
LON is a software and hardware configuration. See also the chapter on Unit Sequencing. Functional Description The EGCP-3 LON is capable of working with multiple bus segments all connected on the same LON link. In the EGCP-3 implementation, the LON segments are always joined and the messaging indicates which genset is in which segment and which tie breakers are closed.
Page 219: Figure 23-2. Lon Bus Configuration, With Mains Tie(S)
Manual 26194 EGCP-3 LS Operation If the system also has mains connections, it may be modified as below. The masters (MC units) on the LON still have a node number within the range of 1–16. Figure 23-2. LON bus configuration, with Mains Tie(s)
Page 220 EGCP-3 LS Operation Manual 26194 Real Load Sharing This function is performed between LS controls on the same active bus segment only. The LON block will determine which nodes are part of the active bus segment and perform all calculations necessary to provide the application with the average load value.
Page 221 Networked Start/Stop The EGCP-3 LS can determine when there is a need to start and stop gensets on a bus. It communicates this over the LON network, The decision to start/stop units will be due to generator load, buss failure (trip tie function), mains failure, MC time scheduled start, MC demand start, or manual request from MC.
Page 222 Manual 26194 Compatibility There is a software configurable parameter to allow the EGCP-3 to use LON messaging and application consistent with the DSLC and MSLC products. This mode will be used when a DSLC and/or MSLC are present on the same LON network with one or more EGCP-3 controls.
Page 223: Chapter 24. Acronyms
Central Processing Unit. Distributed Generation (Connected to mains and operated by utility) Discrete Input (Contact Input) Discrete Output (Relay Driver Output) Distributed Resource EGCP-3 (May be connected to mains) DSLC Digital Synchronizer and Load Controller Digital Signal Processing EGCP Engine Generator Control Panel Emergency Power System Engineering Unit (psi, KW, ºC, etc.)
Page 224: Chapter 25. Application Download
The following will guide the user through the boot up and application-loading procedure used for the EGCP-3. 1. Apply power to the EGCP-3. At this point the control will begin to boot and perform diagnostic tests on the hardware. NOTE: This will take slightly less than 1 minute to complete.
Page 225: Chapter 26. 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 226: 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 227: Packing A Control
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 228: How To Contact Woodward
EGCP-3 LS Operation Manual 26194 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 229: Egcp-3 Ls Control Specifications
EGCP-3 LS Control Specifications Please refer to the EGCP-3 Installation Manual 26122 for all control specifications.
Page 230 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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