Woodward EGCP-2 User manual

Installation (Set Builder) Manual
EGCP-2
Engine Generator Control Package
8406-115, 150–300 Vac PT Input, 9–32 Vdc
8406-116, 50–150 Vac PT Input, 9–32 Vdc
Manual 26076 (Revision F)

WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
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.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
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.
WARNING—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.
CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY
CAUTION—BATTERY CHARGING
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.
CAUTION—ELECTROSTATIC DISCHARGE
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.
IMPORTANT DEFINITIONS
•A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
•A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
•A NOTE provides other helpful information that does not fall under the warning or caution
categories.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 2000
All Rights Reserved

Manual 26076 EGCP-2 Engine Generator Control Package
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Contents
REGULATORY COMPLIANCE.........................................................................V
ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Control Electrical Ratings .......................................................................................1
CHAPTER 2. CONTROL OVERVIEW ...............................................................2
Introduction.............................................................................................................2
Operator Interface ..................................................................................................5
Hardware ................................................................................................................9
Environmental Specification .................................................................................10
Physical Specification...........................................................................................10
Accessories ..........................................................................................................10
CHAPTER 3. ELECTRICAL INSTALLATION AND SPECIFICATIONS...................12
Electrical Connections..........................................................................................12
Input Power ..........................................................................................................16
Potential Transformer (PT) Inputs ........................................................................17
Current Transformer (CT) Inputs..........................................................................25
MPU (Speed) Input...............................................................................................26
Process Import/Export Input.................................................................................27
Coolant Temperature and Oil Pressure Inputs.....................................................28
Speed Bias and Voltage Bias Outputs .................................................................30
Discrete Inputs......................................................................................................31
Relay Outputs.......................................................................................................33
AC Inputs..............................................................................................................42
DC Inputs and Outputs.........................................................................................42
Discrete Inputs......................................................................................................43
Discrete Outputs...................................................................................................43
Communication Ports: RS-485 & RS-422 (1 each)..............................................44
Hardware Connections.........................................................................................44
Inter-control Communications (RS-485 Network) ................................................46
Alarms and Shutdowns ........................................................................................47
CHAPTER 4. OPERATIONAL DESCRIPTION:SINGLE NO PARALLEL ..............50
CHAPTER 5. OPERATIONAL DESCRIPTION:SINGLE UNIT PARALLEL............57
CHAPTER 6. OPERATING MODE:MULTIPLE NO PARALLEL .........................64
CHAPTER 7. OPERATING MODE:MULTIPLE PARALLEL ...............................73
CHAPTER 8. MANUAL OPERATION............................................................109
CHAPTER 9. EGCP-2 COMMUNICATIONS .................................................112
Overview.............................................................................................................112
Modbus RTU Communications for the EGCP-2 Panel ......................................113
CHAPTER 10. SERVICE OPTIONS .............................................................121
Product Service Options.....................................................................................121
Woodward Factory Servicing Options................................................................122
Returning Equipment for Repair.........................................................................123
Replacement Parts .............................................................................................123
Engineering Services .........................................................................................124
How to Contact Woodward.................................................................................124
Technical Assistance..........................................................................................125

EGCP-2 Engine Generator Control Package Manual 26076
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Contents
APPENDIX A. CONNECTOR INFORMATION .................................................126
APPENDIX B. SPEED BIAS CONNECTIONS.................................................128
DECLARATIONS .......................................................................................134
EGCP-2 CONTROL SPECIFICATIONS........................................................135
Illustrations and Tables
Figure 2-1. EGCP-2 Interface Connections ...........................................................4
Figure 2-2. Operator Interface................................................................................5
Figure 2-3. Physical Outline with Dimensions of EGCP-2 ...................................11
Figure 3-1. CageClamp Termination Blocks (example photos) ...........................12
Figure 3-2. Recommended Single Point Grounding Scheme ..............................13
Figure 3-3. Wiring Diagram for EGCP-2...............................................................15
Figure 3-4. Dip Switch Location ...........................................................................16
Figure 3-5. Three Wire Delta PT Connection for EGCP-2 ...................................17
Figure 3-6. Four Wire WYE PT Connection .........................................................18
Figure 3-7. Utility / Local Bus PT Wiring for Delta and Wye Configuration ..........19
Figure 3-8a. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration
(two relay) ........................................................................................20
Figure 3-8b. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration
(single relay) ....................................................................................20
Figure 3-9a. PT Wiring Relationships for Generator, Bus, and Utility Inputs.......21
Figure 3-9b. PT Wiring Relationships for Generator, Bus, and Utility Inputs.......22
Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....23
Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....24
Figure 3-11. Current Transfer Wiring Diagram for EGCP-2.................................25
Figure 3-12. Wiring Diagram for MPU Input.........................................................26
Figure 3-13a. Wiring Diagram for Process Import/Export Input ...........................27
Figure 3-13b. Connecting a KW Transducer Signal to Multiple EGCP-2s...........27
Figure 3-14a. Wiring Diagram for Pressure Inputs...............................................28
Figure 3-14b. Wiring Diagram for Temperature Inputs ........................................29
Figure 3-15. Wiring Diagram for Speed Bias and Voltage Bias Outputs .............31
Figure 3-16. Wiring Diagram for Typical Discrete I/O Connections .....................33
Figure 3-17. Example of the Mains Breaker NO Output Connected to Close the
Mains (Utility) Breaker (ENERGIZE TO CLOSE) ............................34
Figure 3-18. Example Using the NC Output to Control the Mains (Utility)
Contactor (ENERGIZE TO OPEN) ..................................................35
Figure 3-19. Example of the Generator Breaker Close NO Output Connected to
Close the Generator Breaker (ENERGIZE TO CLOSE) .................36
Figure 3-20. Example Using the NO Contacts to Control the Generator’s
Contactor (ENERGIZE TO CLOSE) ................................................36
Figure 3-21. Example Using the NO Contacts to Control the Mains Breaker Trip
(Open) Coil (ENERGIZE TO OPEN) ...............................................39
Figure 3-22. Example Using the NC Contacts to Control the Generator Breakers
Open Coil (DE-ENERGIZE TO OPEN) ...........................................40

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Illustrations and Tables
Figure 3-23. Generator Breaker and Contactor Close and Open Logic ..............40
Figure 3-24. RS-422 Communications.................................................................45
Figure 3-25. RS-485 and RS-422 Termination Diagrams....................................46
Figure 3-26. RS-485 Inter-Control Communications............................................47
Figure 4-1. Single No Parallel Application............................................................52
Figure 4-2a. Single No Parallel Overview Flow Diagram.....................................54
Figure 4-2b. Single No Parallel Overview Flow Diagram.....................................55
Figure 4-3. Single No Parallel Prime Power.........................................................56
Figure 5-1. Single Unit Parallel Application..........................................................59
Figure 5-2a. Single Unit Parallel Overview Flow Diagram ...................................61
Figure 5-2b. Single Unit Parallel Overview Flow Diagram ...................................62
Figure 5-2c. Single Unit Parallel Overview Flow Diagram ...................................63
Figure 6-1. Multiple Unit No Parallel Application..................................................66
Figure 6-2a. Master Multiple Unit No Parallel Overview Flow Diagram...............68
Figure 6-2b. Master Multiple Unit No Parallel Overview Flow Diagram...............69
Figure 6-3a. Slave Multiple Unit No Parallel Overview Flow Diagram .................70
Figure 6-3b. Slave Multiple Unit No Parallel Overview Flow Diagram .................71
Figure 6-3c. Slave Multiple Unit No Parallel Overview Flow Diagram .................72
Figure 7-1. Multiple Unit No Parallel Prime Power Application ............................75
Figure 7-2. Multiple Unit Parallel Standby Power Application..............................76
Figure 7-3. Multiple Unit Parallel Peak Shaving Application ................................77
Figure 7-4a. Master Multiple Parallel Process Control Flow Diagram .................79
Figure 7-4b. Master Multiple Parallel Process Control Flow Diagram .................80
Figure 7-4c. Master Multiple Parallel Process Control Flow Diagram .................81
Figure 7-4d. Master Multiple Parallel Process Control Flow Diagram .................82
Figure 7-4e. Master Multiple Parallel Process Control Flow Diagram .................83
Figure 7-4f. Master Multiple Parallel Process Control Flow Diagram ..................84
Figure 7-4g. Master Multiple Parallel Process Control Flow Diagram .................85
Figure 7-4h. Master Multiple Parallel Process Control Flow Diagram .................86
Figure 7-5a. Slave Multiple Parallel Process Control Flow Diagram ...................87
Figure 7-5b. Slave Multiple Parallel Process Control Flow Diagram ...................88
Figure 7-5c. Slave Multiple Parallel Process Control Flow Diagram ...................89
Figure 7-5d. Slave Multiple Parallel Process Control Flow Diagram ...................90
Figure 7-5e. Slave Multiple Parallel Process Control Flow Diagram ...................91
Figure 7-5f. Slave Multiple Parallel Process Control Flow Diagram ....................92
Figure 7-5g. Slave Multiple Parallel Process Control Flow Diagram ...................93
Figure 7-5h. Slave Multiple Parallel Process Control Flow Diagram ...................94
Figure 7-5j. Slave Multiple Parallel Process Control Flow Diagram ....................95
Figure 7-5k. Slave Multiple Parallel Process Control Flow Diagram ...................96
Figure 7-5l. Slave Multiple Parallel Process Control Flow Diagram ....................97
Figure 7-5m. Slave Multiple Parallel Process Control Flow Diagram ..................98
Figure 7-6. Generator Start Sequence.................................................................99
Figure 7-7. Generator Stop Sequence ...............................................................100
Figure 7-8. Generator Breaker Close Sequence ...............................................101
Figure 7-9. Generator Breaker Close Sequence ...............................................102
Figure 7-10. Generator Breaker Close Sequence .............................................103
Figure 7-11. Main Breaker Open Sequence ......................................................104
Figure 7-12. Mains Breaker Close Sequence ....................................................105
Figure 7-13. Mains Breaker Reclose Sequence ................................................106
Figure 7-14. Mains Breaker Reclose Sequence ................................................107
Figure 7-15. Speed Raise/Lower Switch Based Logic.......................................108
Figure 7-16. Voltage Raise/Lower Switch Based Logic .....................................108

EGCP-2 Engine Generator Control Package Manual 26076
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Illustrations and Tables
Table 9-1. Examples of Modbus Control Mode Switching Logic....................... 114
Table 9-2. Modbus Addresses for the RTU Protocol ........................................ 117
Table 9-3. Common Modbus Error Numbers .................................................... 120
Table 9-4. Typical Modbus Communications Settings ...................................... 120
WARNING—EARTH GROUND
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).
WARNING—TRAINED PERSONNEL/HIGH VOLTAGE
The calibration and checkout procedure should only be performed by
authorized personnel knowledgeable of the risks posed by live electrical
equipment.

Manual 26076 EGCP-2 Engine Generator Control Package
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Regulatory Compliance
European Compliance for CE Mark:
EMC Directive Declared to 89/336/EEC COUNCIL
DIRECTIVE of 03 May 1989 on the
approximation of the laws of the member
states relating to electromagnetic
compatibility.
Low Voltage Directive Declared to the 73/23/EEC COUNCIL
DIRECTIVE of 19 February 1973 on the
harmonization of the laws of the Member
States relating to electrical equipment
designed for use within certain voltage
limits.
North American Compliance:
UL UL Listed for Ordinary Locations at 70 °C
maximum Ambient. For use in the United
States and Canada.
UL File E97763
CSA CSA Certified for Ordinary Locations at 70
°C maximum Ambient. For use in the
United States and Canada.
Certificate 1159277
NOTE Wiring must be in accordance with
applicable electric codes with the authority
having jurisdiction.
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).

EGCP-2 Engine Generator Control Package Manual 26076
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Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. 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.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. 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.
CAUTION—ELECTROSTATIC DISCHARGE
To prevent damage to electronic components caused by improper handling,
read and observe the precautions in Woodward manual 82715, Guide for
Handling and Protection of Electronic Controls, Printed Circuit Boards, and
Modules.

Manual 26076 EGCP-2 Engine Generator Control Package
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Chapter 1.
General Information
Introduction
This manual describes the Woodward EGCP-2 Engine Generator Control
Package, models 8406-115 and 8406-116 (9–32 Vdc maximum input voltage
range).
Control Electrical Ratings
nominal supply voltage range 10–29 Vdc (12 or 14 volt systems)
max. power consumption
at rated voltage 20 W
max. PT input voltage range 150–300 Vac rms (8406-115)
50–150 Vac rms (8406-116)
max. CT current input range 0–6 A rms
max. generator frequency range 40–70 Hz

EGCP-2 Engine Generator Control Package Manual 26076
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Chapter 2.
Control Overview
Introduction
The EGCP-2 is a microprocessor based complete generator load control and
engine management package. It is designed for use with an automatic voltage
regulator and Woodward speed control to automate and protect diesel or gas
engine based backup generator sets.
Designed for small to medium size generator sets the EGCP-2 can be configured
to operate stand-alone or utility paralleled sets. A network of EGCP-2 controls is
capable of controlling up to eight un-manned generator sets for backup power,
base-load, or peak shaving applications.
Engine Control
•Engine Pre-glow
•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
harmonic 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.
Real (kW) Load Control
•True RMS power calculations for rapid, accurate load control even in the
presence of harmonics.
•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

Manual 26076 EGCP-2 Engine Generator Control Package
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•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 base loading on units which are in kW base
load control mode, 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)
•Loss of Excitation
•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
Communication – PC Interface
•Easy upload and download and backup of unit configuration
•A PC can control or monitor any unit at a site by a single connection to the
local operating network via RS-422 serial port using Modbus®* or ServLink
protocol.
* Modbus is a registered trademark of Schneider Automation Inc.

EGCP-2 Engine Generator Control Package Manual 26076
4 Woodward
Utility/BusInput
TestEngine
Generator
Breaker
TOOther
Generators
PlantLoad
GEN
GenBreaker
EnginePreglow
OilPressure
WaterTemperature
LocalBusDisconnect
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
EGCPs
OperatorControlPanel
Open/Close
EGCP-2Interfaces
Disconnect
Figure 2-1. EGCP-2 Interface Connections

Manual 26076 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 with
contrast adjustment 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.
NOTE
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.
WARNING—TRAINED PERSONNEL
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 2-2. 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.

EGCP-2 Engine Generator Control Package Manual 26076
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There are a total of 19 keys on the keypad. Each of the keys has the following
function(s):
ALARM/EVENT LOG KEYS:
ALARM / EVENT
The ALARM/EVENT key is used to access the Event
log. 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 26076 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.

EGCP-2 Engine Generator Control Package Manual 26076
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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 menus are described in the Status Screens
section in Chapter 3 of this manual.
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.

Manual 26076 EGCP-2 Engine Generator Control Package
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SYNC
The SYNC STATUS key shows status information regarding the
generator breaker and utility breaker synchronizer.
KW LOAD
The KW LOAD STATUS key, when pressed, shows the
status information for the KW load control of the EGCP-2.
PF / KVAR
Press the PF/KVAR STATUS key to display VAR/PF Mode
information, as well as three phase generator voltage and current.
SEQUENCE
The SEQUENCE STATUS key provides sequencing
information for multiple unit systems. Single unit systems, and units not in the
AUTO mode will not provide status information in this screen.
ATS
The ATS STATUS key, when pressed, displays the status
information for the Automatic Transfer Switch functions.
Hardware
The EGCP-2 is an integrated control package. All control hardware is contained
in one compact enclosure.
Figure 2-3 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).
NOTE
When mounting into an enclosure, make sure the enclosure is vented to
atmosphere through a Type 4 vent tube or unsealed conduit.

EGCP-2 Engine Generator Control Package Manual 26076
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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
Other components you may need. These items do not ship with the 8406-115 or
8406-116 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.
•Download.exe—see manual 26086, Appendix B.
•EGCP-2 HMI—see manual 26099.

Manual 26076 EGCP-2 Engine Generator Control Package
Woodward 11
Figure 2-3. Physical Outline with Dimensions of EGCP-2

EGCP-2 Engine Generator Control Package Manual 26076
12 Woodward
Chapter 3.
Electrical Installation and Specifications
Electrical Connections
All inputs and outputs to the EGCP-2 are made through “CageClamp” terminal
blocks. For noise suppression, it is recommend that all low-current wires be
separated from all high-current wire.
The terminal blocks are screwless CageClamp style blocks. The spring clamp
can be actuated by using a standard 3.5 mm or 1/8 inch flat bladed screwdriver
(see Figure 3-1). The EGCP-2 pluggable terminal blocks accept wires from 0.08–
2.5 mm² (28–12 AWG). Fixed terminal blocks accept wires from 0.08–2.5 mm²
(27–12 AWG). Two 0.8 mm² (18 AWG) or three 0.5 mm² (20 AWG) wires can be
easily installed in each terminal. Wires for the pluggable I/O terminals should be
stripped 8–9 mm (0.3 inch) long, wires for the fixed mounted power terminals
should be stripped 5–6 mm (0.2 inch) long.
Method #1 Method #2
Free Hand (Holds spring open) Bench (momentarily opens spring
while force is applied)
Wiring Fixed Terminal
Figure 3-1. CageClamp Termination Blocks (example photos)
Most of the EGCP-2 control’s terminal blocks are designed to be removed by
hand. After EGCP-2 input power is disconnected, the terminal blocks can be
removed one at a time by pulling them straight out. Care should be taken not to
pull the plug out at an angle as this will fracture the end terminal.