Woodward EGCP-2 User manual

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

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 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, 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 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, 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 Out-of-date translations are marked with .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.
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. Copyright © Woodward 2002
All Rights Reserved

Manual 26174 EGCP-2 Engine Generator Control Package
Woodward i
Contents
WARNINGS AND NOTICES...........................................................................VII
ELECTROSTATIC DISCHARGE AWARENESS ................................................VIII
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Regulatory Compliance ..........................................................................................1
Control Electrical Ratings .......................................................................................1
Technical Specifications .........................................................................................1
CHAPTER 2. CONTROL OVERVIEW...............................................................2
Introduction.............................................................................................................2
Hardware ................................................................................................................4
Environmental Specification ...................................................................................4
Physical Specification.............................................................................................4
Accessories ............................................................................................................4
Operator Interface ..................................................................................................7
Navigation Procedure ...........................................................................................12
CHAPTER 3. ELECTRICAL INSTALLATION AND SPECIFICATIONS...................17
Electrical Connections ..........................................................................................17
Input Power ..........................................................................................................21
Potential Transformer (PT) Inputs ........................................................................22
Current Transformer (CT) Inputs..........................................................................30
MPU (Speed) Input...............................................................................................31
Process Import/Export Input.................................................................................32
Coolant Temperature and Oil Pressure Inputs.....................................................33
Speed Bias and Voltage Bias Outputs .................................................................36
Discrete Inputs......................................................................................................38
Relay Outputs.......................................................................................................39
AC Inputs..............................................................................................................48
DC Inputs and Outputs .........................................................................................48
Discrete Inputs......................................................................................................49
Discrete Outputs...................................................................................................49
Communication Ports: RS-485 & RS-422 (1 each)..............................................50
Hardware Connections .........................................................................................50
Inter-control Communications (RS-485 Network) ................................................52
Alarms and Shutdowns.........................................................................................53
CHAPTER 4. SOFTWARE OVERVIEW...........................................................56
Introduction...........................................................................................................56
Status Screens .....................................................................................................56
Security Access ....................................................................................................68
Alarm / Event Log .................................................................................................69
Configuration Menus ............................................................................................71
Shutdowns and Alarms.........................................................................................80
Engine Control......................................................................................................86
Synchronizer.........................................................................................................88
Real Load Control.................................................................................................91
Reactive Load Control ..........................................................................................94
Process Control ....................................................................................................95
Transfer Switch...................................................................................................100
Sequencing and Comms (Communications)......................................................102
Calibration Menu ................................................................................................104

EGCP-2 Engine Generator Control Package Manual 26174
ii Woodward
Contents
CHAPTER 5. CONTROL FEATURES AND FUNCTIONS ..................................117
Engine Control....................................................................................................117
Engine Protection ...............................................................................................117
Generator Voltage and Reactive Load Control ..................................................117
Generator Protection ..........................................................................................117
Mains Sensing ....................................................................................................118
Synchronizing .....................................................................................................118
Load Control .......................................................................................................118
Sequencing.........................................................................................................118
Engine Cranking .................................................................................................119
Idle/Rated Relay Output .....................................................................................120
Generator Voltage Control..................................................................................120
Generator Load Control......................................................................................121
Automatic Generator Loading Functions............................................................125
Synchronizer Description....................................................................................128
Generator Sequencing .......................................................................................135
CHAPTER 6. CALIBRATION OF CONTROL INPUTS AND OUTPUTS................146
Introduction .........................................................................................................146
Calibration of Generator PTs and CTs ...............................................................147
Calibration of the Bus PT....................................................................................151
Speed Bias Output .............................................................................................152
Voltage Bias Output............................................................................................152
CHAPTER 7. GENERAL START-UP INSTRUCTIONS......................................154
Before Starting the Generator Set......................................................................154
Sequence of Start-up and Checking Parameters...............................................155
Loading the Generator Set .................................................................................155
CHAPTER 8. TROUBLESHOOTING .............................................................158
Control Hardware and I/O...................................................................................158
Engine Control/Sensing Parameters ..................................................................159
Synchronization ..................................................................................................160
Breaker Close/Open Control ..............................................................................161
Real Load Control...............................................................................................162
Reactive Load Control ........................................................................................163
Sequencing.........................................................................................................164
Mains/Bus Sensing.............................................................................................165
Communications .................................................................................................165
CHAPTER 9. DEFINITION OF TERMS ..........................................................166
CHAPTER 10. SERVICE OPTIONS..............................................................172
Product Service Options.....................................................................................172
Woodward Factory Servicing Options ................................................................173
Returning Equipment for Repair .........................................................................173
Replacement Parts .............................................................................................174
Engineering Services..........................................................................................174
How to Contact Woodward.................................................................................175
Technical Assistance..........................................................................................175
APPENDIX A. CONNECTOR INFORMATION .................................................176
APPENDIX B. SPEED BIAS CONNECTIONS.................................................178

Manual 26174 EGCP-2 Engine Generator Control Package
Woodward iii
Contents
APPENDIX C. VOLTAGE BIAS CONNECTIONS............................................183
Basler AVC63-12................................................................................................183
Basler AEC63-7..................................................................................................184
Basler APR63-5..................................................................................................185
Basler APR63-5 with AMP200 ...........................................................................186
Basler KR2F, 4F, or 7F.......................................................................................187
Basler DECS 15 .................................................................................................188
Basler DECS 100 ...............................................................................................189
Basler DECS 200 ...............................................................................................190
Basler SR4A or SR8A ........................................................................................191
Basler SSR .........................................................................................................192
Caterpillar CDVR ................................................................................................193
Caterpillar Digital Voltage Regulator ..................................................................194
Caterpillar VR3 ...................................................................................................195
Caterpillar VR6 ...................................................................................................196
KATO KCR360 or 760 ........................................................................................197
KATO K65-12B or K125-10B .............................................................................198
Leroy Somer R438, R448, or R449....................................................................199
Leroy Somer R600 .............................................................................................200
Leroy Somer R610 .............................................................................................201
Marathon PM 100/200 ........................................................................................202
Marathon 2000E .................................................................................................203
Mecc Alte UVR ...................................................................................................204
Newage MA325 ..................................................................................................205
Newage MA327 ..................................................................................................206
Newage MX321/341 ...........................................................................................207
APPENDIX D. EGCP-2 SET POINT WORKSHEET.......................................208
Configuration Menu ............................................................................................208
Shutdown and Alarms Menu ..............................................................................209
Engine Control Menu..........................................................................................212
Synchronizer Menu.............................................................................................214
Real Load Control Menu.....................................................................................215
Reactive Load Control Menu..............................................................................216
Process Control Menu ........................................................................................217
Transfer Switch Menu.........................................................................................218
Sequencing and Comms Menu ..........................................................................219
Calibration Menu ................................................................................................220
DECLARATIONS.......................................................................................222
EGCP-2 CONTROL SPECIFICATIONS .......................................................223

EGCP-2 Engine Generator Control Package Manual 26174
iv Woodward
Illustrations and Tables
Figure 2-1. Physical Outline with Dimensions of EGCP-2......................................5
Figure 2-2. EGCP-2 Interface Connections............................................................6
Figure 2-3. Operator Interface ................................................................................7
Figure 2-4a. EGCP-2 Navigation (1) ....................................................................12
Figure 2-4b. EGCP-2 Navigation (2) ....................................................................13
Figure 2-4c. EGCP-2 Navigation (3).....................................................................14
Figure 2-4d. EGCP-2 Navigation (4) ....................................................................15
Figure 2-4e. EGCP-2 Navigation (5) ....................................................................16
Figure 3-1. CageClamp Termination Blocks (example photos) ...........................17
Figure 3-2. Recommended Single Point Grounding Scheme ..............................18
Figure 3-3. Wiring Diagram for EGCP-2...............................................................20
Figure 3-4. Dip Switch Locations..........................................................................21
Figure 3-5. Three Wire Delta PT Connections for EGCP-2 .................................23
Figure 3-6. Four Wire Wye PT Connections ........................................................23
Figure 3-7. Utility/Local Bus Single PT Wiring for Delta and Wye Configuration for
Multiple or Single Engine Applications ............................................24
Figure 3-8. Utility/Local Bus Single PT Wiring for Delta and Wye Configuration for
Multiple or Single Engine Prime Power Applications.......................25
Figure 3-9a. PT Wiring Relationships for Generator, Bus, and Utility Inputs .......26
Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs .....28
Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs .....29
Figure 3-11. Current Transfer Wiring Diagram for EGCP-2 .................................30
Figure 3-12. Wiring Diagram for MPU Input .........................................................31
Figure 3-13a. Wiring Diagram for Process Import/Export Input ...........................32
Figure 3-13b. Connecting a kW Transducer Signal to Multiple EGCP-2s............32
Figure 3-14. Wiring Diagram for Pressure Inputs.................................................33
Figure 3-15. Wiring Diagram for Temperature Inputs...........................................34
Figure 3-16. Wiring Diagram for Speed Bias and Voltage Bias Outputs..............37
Figure 3-17. Wiring Diagram for Typical Discrete I/O Connections .....................39
Figure 3-18. Example of the Mains Breaker NO Output Connected to Close the
Mains (Utility) Breaker (ENERGIZE TO CLOSE) ............................40
Figure 3-19. Example Using the NC Output to Control the Mains (Utility)
Contactor (ENERGIZE TO OPEN) ..................................................41
Figure 3-20. Example of the Generator Breaker Close NO Output Connected to
Close the Generator Breaker (ENERGIZE TO CLOSE) .................42
Figure 3-21. Example Using the NO Contacts to Control the Generator’s
Contactor (ENERGIZE TO CLOSE) ................................................42
Figure 3-22. Example Using the NO Contacts to Control the Mains Breaker Trip
(Open) Coil (ENERGIZE TO OPEN) ...............................................45
Figure 3-23. Example Using the NC Contacts to Control the Generator Breakers
Open Coil (DE-ENERGIZE TO OPEN) ...........................................46
Figure 3-24. Generator Breaker and Contactor Close and Open Logic...............46
Figure 3-25. RS-422 Communications .................................................................51
Figure 3-26. RS-485 and RS-422 Termination Diagrams ....................................52
Figure 3-27. RS-485 Inter-Control Communications ............................................53
Figure 4-1. System Overview Engine Off Line .....................................................56
Figure 4-2. System Status Screen—Isochronous ................................................58
Figure 4-3. System Status Screen—Baseload.....................................................58
Figure 4-4. Engine Status.....................................................................................59
Figure 4-5. Generator Status (Voltage Line to Neutral) .......................................60
Figure 4-6. I/O Status ...........................................................................................61
Figure 4-7. Synchronizer Status ...........................................................................62
Figure 4-8. kW Load Status..................................................................................63

Manual 26174 EGCP-2 Engine Generator Control Package
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Illustrations and Tables
Figure 4-9. PF /kVAR Status ................................................................................64
Figure 4-10. Sequencing Menu ............................................................................65
Figure 4-11. Sequencing Menu (Multi-Unit) .........................................................66
Figure 4-12. ATS (Automatic Transfer Switch) Status. ........................................67
Figure 4-13. Security Code Display......................................................................68
Figure 4-14. Alarm / Event Screen .......................................................................69
Figure 4-15. Empty Event Log..............................................................................70
Figure 4-16a. Configuration Menu List (Screen 1) ...............................................71
Figure 4-16b. Configuration Menu List (Screen 2) ...............................................71
Figure 4-16c. Configuration Menu List (Screen 3) ...............................................72
Figure 4-17. Program Configuration Error............................................................73
Figure 4-18. AC Power Triangle...........................................................................76
Figure 4-19. Breaker Logic and Contactor Logic .................................................79
Figure 4-20. Generator High/Low Voltage Alarms ...............................................80
Figure 4-21. Generator Over/Under Frequency ...................................................81
Figure 4-22. Delay Time is 10 Seconds, Current goes to 190 A, an Alarm or
Shutdown will be Received in 30 Seconds......................................83
Figure 4-23. Delay Time is 10 Seconds, Current goes to 200 A, an Alarm or
Shutdown will be Received in 15 Seconds......................................83
Figure 4-24. Delay Time is 10 Seconds, Current goes to 220 A, an Alarm or
Shutdown will be Received in 7.5 Seconds.....................................84
Figure 4-25. Reverse Power.................................................................................85
Figure 4-26. Typical Circuit Using Permissive Function and Run for Auto/Manual
Synchronizing ..................................................................................88
Figure 4-27. Voltage Matching (1% set point) ......................................................89
Figure 4-28. Maximum Phase Window = 10 Degrees..........................................90
Figure 4-29. EGCP-2 Control Dip Switch .............................................................95
Figure 4-30. Direct (Export) Process Action.........................................................96
Figure 4-31. Indirect (Import Power) Process Action ...........................................96
Figure 4-32. Direct (Import/Export) Process Action .............................................96
Figure 4-33. Process In Scale ............................................................................105
Figure 4-34. Measured vs. Monitored ................................................................105
Figure 4-35. Typical AVR with Aux Input (Newage SX-440)..............................107
Figure 4-36. Typical AVR with External Voltage Adjust Potentiometer..............107
Figure 4-37. AVR Droop .....................................................................................108
Figure 4-38. Oil Pressure Sensor Curve ............................................................112
Figure 4-39. Water Temperature Curves ...........................................................115
Figure 4-40. EGCP-2 Water Temperature Characteristics ................................115
Figure 5-1. Droop Mode .....................................................................................122
Figure 5-2. Isochronous Mode ...........................................................................123
Figure 5-3. Droop/Isochronous Load Sharing ....................................................124
Figure 5-4. Synchronizer Time Line—Standard Sequence................................132
Figure 5-5. Loss of Mains Detection Active........................................................133
Figure 5-6. Generator Off Line ...........................................................................133
Figure 5-7. Mains Parallel Unit with Voltage/Frequency Detect.........................134
Figure 5-8. Mains Parallel Unit(s) with Load Surge Detect ................................134
Figure 5-9. Typical Automatic Sequencing Scenario .........................................136
Figure 5-10. Original System Configuration .......................................................139
Figure 5-11. After a Change of Priority—Units Not Operating ...........................139
Figure 5-12. Original System Configuration .......................................................140
Figure 5-13. Master transfers to Unit 2...............................................................140
Figure 5-14. Changing the Priority of a Slave Unit.............................................142
Figure 5-15. Changing the Priority of a Slave Unit.............................................142

EGCP-2 Engine Generator Control Package Manual 26174
vi Woodward
Illustrations and Tables
Figure 5-16. Changing the Priority of a Slave Unit .............................................143
Figure 5-17. Changing the Priority of a Slave Unit .............................................143
Figure 5-18. Changing the Priority of a Slave Unit .............................................144
Figure 5-19. Changing the Priority of a Slave Unit .............................................144
Figure 6-1. Relationship Between Voltage Bias and Generator Voltage ...........153
Table 4-1. Overcurrent Level Chart......................................................................82
Table 4-2. Reverse Power Chart ..........................................................................84
HIGH VOLTAGE—Only authorized personnel knowledgeable of the
risks posed by live electrical equipment should perform the
calibration and checkout procedure.

Manual 26174 EGCP-2 Engine Generator Control Package
Woodward vii
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is 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.

EGCP-2 Engine Generator Control Package Manual 26174
viii Woodward
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.
HIGH VOLTAGE—Protective Earth (PE) must be connected to the
termination point on the back side of the unit next to the label with
the symbol (or 1 of 3 other similar termination points without
label) to reduce the risk of electric shock. This connection will be
made using a thread-forming screw. The conductor providing the
connection must have a properly sized ring lug and wire larger than
or equal to 3.0 mm² (12 AWG).

Manual 26174 EGCP-2 Engine Generator Control Package
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes how to Install and Operate the Woodward EGCP-2
Engine Generator Control Package, models 8406-120 and 8406-121.
Associated publications:
26175—Application Manual
26181—Communications Manual
26108—Security Levels Guide
03219—Product Specification
Regulatory Compliance
General Installation and Operation Notes and Warnings
The EGCP-2 is suitable for use in non-hazardous locations only.
Wiring must be in accordance with applicable electrical codes and in
accordance with the authority having jurisdiction.
Field wiring must be suitable for at least 90 °C.
Connect ground terminal to PE (Protective Earth).
More than one live circuit (see wiring diagram).
Control Electrical Ratings
Nominal supply voltage range 10–29 Vdc (12 or 24 volt systems)
Maximum power consumption
at rated voltage
20 W
Maximum PT input voltage range 150–300 Vac rms (8406-120)
Maximum PT input voltage range 50–150 Vac rms (8406-121)
Maximum CT current input range 0–6 A rms
Maximum generator frequency range 40–70 Hz
Technical Specifications
The relevant accuracies for this product are:
Element
A
ccuracy Description
Voltage Metering 1.0% at rated voltage At 23±5 °C
Current Metering 1.0% at 5 A ac At 23±5 °C
Power Metering 2.0% at rated V & I At 23±5 °C

EGCP-2 Engine Generator Control Package Manual 26174
2 Woodward
Chapter 2.
Control Overview
Introduction
The EGCP-2 is a microprocessor based complete generator load control and
engine management package. It will operate with a voltage regulator and various
speed controls to automate and protect diesel or gas engine based generator
sets from 400 to 3600 rpm.
Designed for generator sets up to 30,000 kW, the EGCP-2 can be configured to
operate stand-alone or utility paralleled. A network of EGCP-2 controls is capable
of controlling up to eight un-manned generator sets for backup power, baseload,
or peak shaving applications.
Engine Control
Engine Pre-glow Control
Fuel Solenoid Control
Engine Starter Control (Cranking)
kVA Controlled Cool-down Timer
Oil Pressure Monitoring
Water Temperature Monitoring
Battery Voltage Monitoring
Speed Monitoring with Overspeed Protection
Idle /Rated Relay
Synchronizing
Digital signal processing to eliminate problems induced in systems with high
SCR content causing multiple zero crossing of voltage waveforms.
Adjustable maximum phase window, voltage window, and dwell times—
windows as small as 2° phase error and 0.1% voltage matching
respectively.
Safe dead bus closing logic internal to the control.
Multiple shot re-closing with adjustable time delays, auto-resynchronizing,
and synchronizer time-outs all available.
Manual voltage and speed adjusts for manual synchronizing (Sync-Check
still active during manual parallels).
Synchronization across generator and mains breakers.

Manual 26174 EGCP-2 Engine Generator Control Package
Woodward 3
Real (kW) Load Control
True RMS power calculations for rapid, accurate load control.
Smooth user chosen ramp rates into and out of each mode of operation.
Isochronous load sharing of up to 8 units based on percentage loading
(allows different rated machines to proportionally balance kW loads).
Constant base loading for optimum fuel efficiency with discrete inputs to
change load levels remotely.
Import/Export control with an external watt transducer.
Soft Utility Transfer Function
Externally adjustable Base Load or Process Reference Levels with
independent ramp rates
kW droop provided for manual load control.
Reactive (kVAR) Control
VAR sharing on isolated busses based on percentage reactive load (allows
different rated machines to proportionally balance kVAR loads).
Constant Power Factor or VAR control on units in Base Load or Process
control mode.
Externally adjustable VAR or PF control reference levels.
Automatic Generator Sequencing
Automatically starts additional EGCP-2 equipped generators when load
exceeds a user specified percentage of the rated load of the operating
machines.
Provides controlled unloads for engines when the load is low enough that
the remaining engines will not exceed a user specified percentage of the
rated load.
Engine priority sequence can be changed from any unit or from a PC to
equalize run-time.
Generator Protective Features
Over/Under Voltage
Over/Under Frequency
Reverse Power (Inverse time delay)
Reverse VARs
Overcurrent (Inverse time delay)
Loss of Mains (Utility) detection
Speed/Frequency Mismatch
Load Surge
kVA Load Switch
Engine Protective Features
High/Low Coolant Temperature
High/Low Oil Pressure
Overspeed
Start Failure
Six user configurable, discrete fault inputs
Communication – PC Interface
Easy upload and download of unit configuration parameters
A PC can control or monitor any unit at a site via RS-422 serial port using
Modbus®* or ServLink protocol
For complete details see Communication Manual 26181
*—Modbus is a registered trademark of Schneider Automation Inc.

EGCP-2 Engine Generator Control Package Manual 26174
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Hardware
The EGCP-2 is an integrated control package. All control hardware is contained
in one compact enclosure.
Figure 2-1 is a physical outline drawing with dimensions of the EGCP-2 for
reference during the construction of mounting panels, etc.
To mount the EGCP-2 panel use type M5 x 12mm thread forming screws
(Woodward part number 1029-529). Eight mounting screws are shipped with
each control.
When mounting into an enclosure, make sure the enclosure is vented
to atmosphere through a Type 4 vent tube or unsealed conduit.
Environmental Specification
Temperature Range around outside
of EGCP-2 Chassis –20 to +70 °C — Operating
Relative Humidity 95% non-condensing at 20 to 55 °C
Physical Specification
Enclosure Size 282 x 358 x 69 mm
11.1 x 14.1 x 2.7 inch
Accessories
Components needed for installation and remote communication. These items do
not ship with the 8406-120 and 8406-121 part numbers—they must be ordered
separately.
8928-301—EGCP-2 connector kit. Contains all of the mating terminal blocks
for the EGCP-2. See Appendix A for mating connector information.
5417-551—Communication Cable for RS422. This cable will connect your
PC to the EGCP-2 RS422 port. This is a point-to-point connection. It can be
used with EGCP-2 software tools. Communication Manual 26181 contains
the software tool information.

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

EGCP-2 Engine Generator Control Package Manual 26174
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Utility/BusInput
TestEngine
Generator
Breaker
TOOther
Generators
PlantLoad
GEN
GenBreaker
EnginePreglow
OilPressure
WaterTemperature
LocalBusConnect
GBAuxIn
Utility
Breaker
UTILITY
Watt
Transducer
UtilityTBOpen/Close
MainsPT
Process
Input
UtilityTBAux
Automatic
LAMP
EGCP
GenPTInputs(3phases)
GenCTinputs(3phases)
VoltageBias
ALARM(VISUAL)
ALARM(AUDIBLE)
Voltage
Regulator
Speed
Control
SpeedBias
EngineCrank
FuelShutoffSolenoid
MPU
HORN
RS-485
Port
PCInterface
RS-422
VoltageLower
VoltageRaise
RunWithLoad
SpeedLower
SpeedRaise
Fault2
Fault1
ProcessI/E
PC
TOOther
EGCP-2s
OperatorControlPanel
Open/Close
EGCP-2Interfaces
Disconnect
(singlephase)
*K1
*K2
Figure 2-2. EGCP-2 Interface Connections

Manual 26174 EGCP-2 Engine Generator Control Package
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Operator Interface
The EGCP-2 Operator Interface is designed for simplicity and redundancy of
function in all operating modes. Two backlit Liquid Crystal Display screens are
used to display various operating and status information to the operator, as well
as for tuning set points. The backlight on the LCD screens will stay on whenever
the engine speed is above 50 rpm. When the engine is not running, the backlight
will turn on whenever any key is pressed on the front panel. The backlight will
turn off after 5 minutes of non-use, when the engine is not running. Additionally,
in the event of a drop in supply voltage where the monitored battery voltage
drops below 9.0 Vdc, the LCD back light will shut off to conserve power.
The EGCP-2 Operator Interface can only be used for unit
configuration and monitoring. Unit start/stop, sync, or mode
selection commands cannot be given through the EGCP-2’s front
panel.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
The unit’s front panel screens provide eight lines of Status Information, with the
option of displaying four lines of configuration or Alarm Log information. These
screens allow the user to monitor and tune related parameters at the same time.
Figure 2-3. Operator Interface
A red Light Emitting Diode (LED) on the face of the control is used to indicate an
alarm condition by flashing repeatedly, and to indicate a shutdown condition by
staying on continuously.
ALARM
LED Display
Keypad

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There are a total of 19 keys on the keypad. Each key has the following
function(s):
ALARM/EVENT LOG KEYS:
ALARM / EVENT
The ALARM/EVENT key is used to access the Event
log. When pressed, the current alarm events will be displayed on the right hand
LCD screen. When multiple alarms are logged, the up and down scroll keys will
allow you to navigate within the Event log. The Event log will store up to 16
events, as more events happen the oldest alarms will be dropped off to make
room for the newer events. If power is cycled to the control, the Event log will be
cleared.
ALARM CLEAR
The ALARM CLEAR key is used to acknowledge and
clear alarm events from the Event log. To acknowledge and clear alarm and
shutdown events a Security Code of Operator Level or higher is needed. After
selecting the ALARM/EVENT key:
If the Alarm mode is Visual or Warning—
1. Pressing the ALARM CLEAR key will acknowledge the selected alarm, this
means the cursor will move from the Alarm Name line down to the Time and
Date line.
2. Pressing the Alarm Clear key a second time will remove the event from the
log.
If the Alarm/Shutdown mode is Audible, Soft Shutdown, or Hard Shutdown—
1. Pressing the ALARM CLEAR key once will de-energize Discrete Output #11,
Audible Alarm. This will happen without selecting the ALARM/EVENT key
and without a Security Code entered.
2. With the ALARM/EVENT key pressed, so the Event log is being displayed:
Pressing the ALARM CLEAR key a second time will acknowledge the
selected alarm. This means the cursor will move from the Alarm Name line
down to the Time and Date line.
3. Pressing the Alarm Clear key a third time will remove the event from the log.

Manual 26174 EGCP-2 Engine Generator Control Package
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NAVIGATION and ADJUSTMENT KEYS:
SCROLL
The SCROLL KEY is used to move the cursor up, down,
left and right. It also is used to increment and decrement values while in the
configuration menus.
ESC
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).
ENTER
The ENTER KEY is used to move downwards (into) the
configuration menu levels. It is also used to when tuning a value to enter the new
value to memory. It also serves as a means to commit alarm event items to the
alarm event list without removing them. This is known as logging the alarm event
item. Pressing the Enter key while on the selected alarm/event item will “save”
that item to the event list. If the selected alarm event was an active alarm event,
the action(s) associated with the alarm event will also be cleared from the control
logic.
STATUS and CONFIGURATION KEYS:
i
STATUS
The STATUS KEY, when pressed, will put both left and
right LCDs into the status display mode. The status displays provide information
about different items of engine and generator set operation. See the STATUS
MENU buttons, below for details on the various status keys. There are no
adjustment values in the status menus.

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CONFIG
...
The CONFIG KEY, when pressed, will put the right hand
LCD into the configuration mode. Configuration menu items will be displayed in
the right hand screen. Status information will continue to be displayed in the left
hand screen. Since there are various menu items and adjustments in the
configuration menu, a blinking cursor is provided in the right hand display when
the configure mode is active.
STATUS MENU KEYS:
The contents of the various status screens are described in Chapter 4.
SYSTEM
The SYSTEM STATUS key, when pressed displays the
system status information. The system status display is also the default status
display screen (it is always the first display shown after a power up of the
control). This display shows general information about the operation of the
engine generator set.
ENGINE
The ENGINE STATUS key, when pressed displays
status information about the engine functions and operation.
GEN
The GEN STATUS key shows three phase generator
parameters when pressed.
I/O
The I/O STATUS key provides the status of all the
discrete inputs and outputs, as well as information on analog inputs and outputs.