Woodward EGCP-2 to easYgen-3200XT User manual

Product Manual 35070
(Revision A, 08/9/17)
Original Instructions
EGCP-2 to easYgen-3200XT Conversion Kit
Instruction Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26455, Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
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. Manual 35070
Copyright © Woodward, Inc. 2017
All Rights Reserved

Manual 35070A EGCP-2 to easYgen-3200XT Conversion Kit
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Contents
WARNINGS AND NOTICES...........................................................................2
ELECTROSTATIC DISCHARGE AWARENESS .................................................3
CHAPTER 1. GENERAL INFORMATION..........................................................4
Scope of Manual ....................................................................................................4
EGCP-2 to easYgen-3200XT Conversion Kit Description.....................................4
EGCP-2 to easYgen-3200XT Conversion Kit Description.....................................4
CHAPTER 2. MOUNTING &WIRING..............................................................8
Mounting.................................................................................................................8
External Wiring.......................................................................................................8
Internal Wiring......................................................................................................11
CHAPTER 3. INSTALLATION AND SETUP ....................................................15
Communications ..................................................................................................15
CHAPTER 4. PRODUCT SUPPORT AND SERVICE OPTIONS ..........................17
Product Support Options......................................................................................17
Product Service Options ......................................................................................17
Returning Equipment for Repair ..........................................................................18
Replacement Parts...............................................................................................18
Engineering Services ...........................................................................................19
Contacting Woodward’s Support Organization ....................................................19
Technical Assistance ...........................................................................................20
Illustrations and Tables
Figure 1-1. Completed EGCP-2 to easYgen-3200XT Conversion Kit (front side).5
Figure 1-2. Completed EGCP-2 to easYgen-3200XT Conversion Kit (back side) 5
Figure 1-3. Sheet Metal Plate Dimensions ............................................................6
Figure 1-4. Bracket Sheet Metal Dimensions ........................................................7
Figure 2-1 Connecting EGCP-2 System to easYgen System................................8
Figure 2-2. Mounting Hole Pattern and Dimensions of the EGCP-2 .....................9
Figure 2-3. Original CT Input Connections ..........................................................10
Figure 2-4. New CT Input Connections................................................................10
Figure 2-5. Optional CT Input Connections .........................................................11
Figure 2-5. EGCP-2 to easYgen 3200 XT Wiring................................................14
Figure 3-1: One Line Diagram Example ..............................................................15
Figure 3-2. One Line Diagram with a Network Switch Example..........................16

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Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
IMPORTANT - Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Automotive
Applications
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
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property
damage.

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Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
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.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
External wiring connections for reverse-acting controls are identical
to those for direct-acting controls.

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Chapter 1.
General Information
Scope of Manual
This manual provides the information necessary to replace the EGCP-2 control with an easYgen XT 3200
control. Topics covered include mechanical installation and internal and external electrical wiring. The
following manuals will help in the set-up and commissioning of the easYgen XT 3200 control system.
26174 - EGCP-2 –Installation and Operation Manual
26175 - EGCP-2 –Application Manual
26181 - EGCP-2 –Communications Manual
37574 - easYgen-3200XT-P1
37442 –Load Share Gateway (LSG)
EGCP-2 to easYgen-3200XT Conversion Kit Description
The EGCP-2 to easYgen-3200XT Conversion Kit was designed at Woodward, but is not manufactured by
Woodward. It was designed to be manufactured by the Woodward Channel Partner’s. This manual can
help create this product.
The EGCP-2 to easYgen-3200XT-P1 conversion can be done in two different methods, depending on the
customer’s installation:
1. The first method is to evaluate the EGCP-2 wiring. If the wiring is such that you can re-wire or re-
route the wires to the easYgen, then all you need is a front panel.
2. The second method is the drop in replacement. This would include the front panel and the
brackets to un-plug the EGCP-2 and install the new easYgen, front panel and the wired brackets.
This would be the quicker of the two methods.
EGCP-2 to easYgen-3200XT Conversion Kit Description
The EGCP-2 to easYgen-3200XT Conversion Kit includes the following components:
Unpainted Sheet metal chassis with terminal blocks. Can be painted to match existing cabinets.
easYgen-3200XT-P1 pre-wired to the mounted terminal blocks
The two EGCP-2 part numbers that can be replaced are 8406-120 and 8406-121.
The connectors I used were ordered through On-Line Electronics and can be reached at
www.onlineelec.com
1. Qty. 6 –231-612/019-000
2. Qty. 2 –231-608/019-000

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Figure 1-1. Completed EGCP-2 to easYgen-3200XT Conversion Kit (front side)
Figure 1-2. Completed EGCP-2 to easYgen-3200XT Conversion Kit (back side)

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Figure 1-3. Sheet Metal Plate Dimensions

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Figure 1-4. Bracket Sheet Metal Dimensions

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Chapter 2.
Mounting & Wiring
This chapter provides general information on replacing the EGCP-2 with the easYgen-3200XT
conversion kit and the associated wiring.
Mounting
The EGCP-2 to easYgen-3200XT conversion kit will mount approximately 3.3” tall. The original EGCP-2 is
2.1” tall. Verify that the conversion kit will mount properly with no obstructions. See Figure 2-2 dimensions.
External Wiring
The replacement kit will mount directly in the same mounting holes as the original EGCP-2. The wire
locations are closely matched and should be close when completing the external wiring. The exception is
the CT –Current Transformer connections. These need to be extended by about 9 inches (see Figures 2-3
and 2-4).
Steps for installing the easYgen-3200XT conversion kit.
1. Verify that you have the original EGCP-2 settings written down. This will help in the set-up of the
easYgen-3200XT.
2. Verify that the existing wires are labeled so that when installing the easYgen-3200XT, wiring
errors are eliminated.
3. Verify that no AC or DC power is applied to the EGCP-2!
4. There are two ways of communicating between devices.
a. The existing RS-485 communications in the EGCP-2 can connect up to an LSG –Load
Share Gateway. See Figure 2.2.
b. Inter-control communications can be done over Ethernet communications on Ethernet
Network A.
5. Remove the six mounting screws holding the EGCP-2 in place.
6. Install the easYgen-3200XT kit in its place.
7. Re-install the six mounting screws to hold the easYgen-3200XT in place.
8. Connect the original terminal blocks to the easYgen-3200XT terminal blocks.
Figure 2-1 Connecting EGCP-2 System to easYgen System

Manual 35070A EGCP-2 to easYgen-3200XT Conversion Kit
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Figure 2-2. Mounting Hole Pattern and Dimensions of the EGCP-2

Manual 35070A EGCP-2 to easYgen-3200XT Conversion Kit
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Figure 2-3. Original CT Input Connections
Figure 2-4. New CT Input Connections

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Figure 2-5. Optional CT Input Connections
Figure 2-5 shows an optional Terminal block that could be mounted underneath the bracket for the
terminal blocks to wire in the CT’s.
Internal Wiring
Figure 2-5 below shows the wiring configuration of the EGCP-2 to easYgen-3200XT conversion kit. The
wiring shown is from the EGCP-2 terminal blocks to the easYgen-3200XT terminal blocks.
When performing the internal wiring, proper wiring considerations
must be practiced. Using proper wire gauges and wire types for the
high voltage potential transformer and current transformer wires,
using twisted shielded pairs with the shield wire properly grounded,
Isolating the high voltage wires from the low voltage.

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Manual 35070A EGCP-2 to easYgen-3200XT Conversion Kit
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Wiring Configuration of EGCP-2 to easYgen-3200XT Conversion Kit (cont’d.)

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Wiring Configuration of EGCP-2 to easYgen-3200XT Conversion Kit (cont’d.)
Figure 2-5. EGCP-2 to easYgen 3200 XT Wiring

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Chapter 3.
Installation and Setup
Communications
The original EGCP-2 system utilized serial RS-485 communications for the inter-control communications.
The easYgen-3200XT utilizes Ethernet technology or CAN bus for load sharing and all of the
communications between devices or it can also utilize CAN bus protocol. Therefore, for ease of
installation, it is recommended to create the Ethernet or CAN bus network first.
The network addressing of the easYgen-3200XT allows up to 32 easYgens in an application.
Figure 3-1: One Line Diagram Example

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Figure 3-2. One Line Diagram with a Network Switch Example

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Chapter 4.
Product Support and Service Options
Product Support Options
If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email ([e-mail]) with
detailed information on the product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone or return email.
5. If the issue cannot be resolved, you can select a further course of action to pursue based on the
available services listed in this chapter.
OEM or Packager Support: ManyWoodward controls and control devices are installed into the equipment
system and programmed by an Original Equipment Manufacturer (OEM) or Equipment Packager at their
factory. In some cases, the programming is password-protected by the OEM or packager, and they are the
best source for product service and support. Warrantyservicefor Woodward products shipped with an
equipment system should also be handled through the OEM or Packager. Please review your equipment
system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:
A Full-Service Distributor has the primary responsibility for sales, service, system integration
solutions, technical desk support, and aftermarket marketing of standard Woodward products within
a specific geographic area and market segment.
An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs,
repair parts, and warranty service onWoodward's behalf. Service (not newunit sales) is an AISF's
primarymission.
A Recognized Engine Retrofitter (RER) is an independent company that does retrofits and
upgrades on reciprocating gas engines and dual-fuel conversions, and can provide the full line of
Woodward systems and components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at www.woodward.com/directory.
Product Service Options
Depending on the type of product, the following options for servicing Woodward products may be
available through your local Full-Service Distributor or the OEM or Packager of the equipment system.
Replacement/Exchange (24-hour service)
Flat Rate Repair
Flat Rate Remanufacture

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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard mechanical products and some
of the electronic products in the field. This program offers you repair service for your products with the
advantage of knowing in advance what the cost will be.
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. This option is applicable to
mechanical products only.
Returning Equipment for Repair
If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-
Service Distributor in advance to obtain Return Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
return number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
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.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.