Woodward EGCP-1 User manual

26059
EGCP-1
Engine Generator
Control Package
8406-020, 12 Vdc
8406-021, 24 Vdc
Operation (End User) Manual
Manual 26059

!
WARNING
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.
The engine, turbine, or other type of prime mover should be equipped with
an overspeed (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss
of life should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.
!
CAUTION
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
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.
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.
© 1999 by Woodward Governor Company
All Rights Reserved

Manual 26059 EGCP-1 Engine Generator Control Package
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Contents
CHAPTER 1. GENERAL INFORMATION...........................................................................1
Introduction..........................................................................................................................1
Declaration of Incorporation................................................................................................1
Control Options ...................................................................................................................1
Control Part Numbers..........................................................................................................1
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS..........................................3
CHAPTER 3. CONTROL OVERVIEW ................................................................................5
Introduction..........................................................................................................................5
Operator Interface...............................................................................................................7
CHAPTER 4. SOFTWARE OVERVIEW..............................................................................9
Introduction..........................................................................................................................9
Navigation of Menus and Setpoints.....................................................................................9
Status Screens..................................................................................................................11
Tuning Screens.................................................................................................................19
CHAPTER 5. CONTROL FEATURES AND FUNCTIONS................................................61
Engine Control...................................................................................................................61
Engine Protection..............................................................................................................61
Generator Voltage and Reactive Load Control..................................................................61
Generator Protection.........................................................................................................61
Mains Sensing...................................................................................................................62
Synchronizing....................................................................................................................62
Load Control......................................................................................................................62
Sequencing .......................................................................................................................62
Engine Cranking................................................................................................................63
Generator Voltage Control ................................................................................................64
Generator Load Control.....................................................................................................65
Automatic Generator Loading Functions...........................................................................70
Synchronizer Description ..................................................................................................73
Generator Sequencing......................................................................................................81
Inter-control Communications (RS-485 Network)..............................................................90
Remote Control/Monitoring (RS-422)................................................................................92
CHAPTER 6. CALIBRATION OF CONTROL INPUTS AND OUTPUTS ..........................93
Introduction........................................................................................................................93
Calibration of Generator PTs and CTs..............................................................................94
Calibration of the Bus PT ..................................................................................................97
Speed Bias Output............................................................................................................98
Voltage Bias Output ..........................................................................................................99
CHAPTER 7. GENERAL STARTUP INSTRUCTIONS...................................................101
Before Starting the Generator Set...................................................................................101
Sequence of Startup and Checking Parameters.............................................................102
Loading the Generator Set..............................................................................................102
CHAPTER 8. TROUBLESHOOTING..............................................................................107
Control Hardware and I/O................................................................................................107
Engine Control/Sensing Parameters...............................................................................108
Synchronization...............................................................................................................109
Breaker Close/Open Control...........................................................................................110
Real Load Control ...........................................................................................................111
Reactive Load Control.....................................................................................................112
Sequencing .....................................................................................................................113
Mains/Bus Sensing..........................................................................................................114
Communications..............................................................................................................114

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Contents
CHAPTER 9. DEFINITION OF TERMS..........................................................................115
CHAPTER 10. SERVICE OPTIONS...............................................................................121
Product Service Options.................................................................................................121
Returning Equipment for Repair .....................................................................................122
Replacement Parts .........................................................................................................123
How to Contact Woodward.............................................................................................123
Additional Aftermarket Product Support Services...........................................................124
Technical Assistance......................................................................................................126
APPENDIX A. EGCP-1 SETPOINT WORKSHEET........................................................127
Configuration Menu.........................................................................................................127
Shutdown and Alarms Menu...........................................................................................128
Engine Control Menu......................................................................................................134
Synchronizer Menu.........................................................................................................136
Real Load Control Menu.................................................................................................137
Reactive Load Control Menu...........................................................................................138
Process Control Menu ....................................................................................................139
Calibration Menu.............................................................................................................140
APPENDIX B. CONNECTOR INFORMATION...............................................................143
APPENDIX C. DOWNLOAD INSTRUCTIONS...............................................................145
APPENDIX D. SPEED BIAS CONNECTIONS...............................................................147
Illustrations
3-1 Keypad...............................................................................................................7
4-1 Control Overview Engine Off Line....................................................................11
4-2 Control Overview Screen—Set for Loss of Mains Detection............................12
4-3 Status Menu.....................................................................................................12
4-4 Status Menu (cont.)..........................................................................................13
4-5 Engine Overview..............................................................................................13
4-6 Generator Overview (Voltage Line to Line)......................................................14
4-7 Generator Phases (Voltage Line to Neutral)....................................................14
4-8 Synchroscope..................................................................................................15
4-9 Alarm/Event Log ..............................................................................................15
4-10 Example of Two Typical Fault Listings.............................................................16
4-11 I/O Status.........................................................................................................17
4-12 Sequencing Menu............................................................................................18
4-13 Sequencing Menu (Multi-Unit) .........................................................................18
4-14 Load Control Monitor.......................................................................................19
4-15 Example 1........................................................................................................20
4-16 Example 2........................................................................................................21
4-17 Example 3........................................................................................................22
4-18 Example 4........................................................................................................23
4-19 Example 5........................................................................................................24
4-20 Example 6........................................................................................................25
4-21 Example 7........................................................................................................26
4-22 Example 8........................................................................................................27
4-23 Example 9........................................................................................................28
4-24 Example 10......................................................................................................28
4-25 Example 11......................................................................................................29
4-26 Alarm Navigation Example 1............................................................................30
4-27 Alarm Navigation Example 2............................................................................31
4-28 AC Power Triangle...........................................................................................33

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4-29 Direct (Export) Process Action.........................................................................35
4-30 Indirect (Import Power) Process Action............................................................35
4-31 Direct (Import/Export) Process Action..............................................................36
4-32 EGCP-1 Control Dip Switch .............................................................................36
4-33 Breaker Logic and Contactor Logic..................................................................37
4-34 Generator High/Low Voltage Alarms................................................................40
4-35 Generator Over/Under Frequency....................................................................41
4-36 Overcurrent Inverse Time Functions................................................................42
4-37 Overcurrent Level—High Current, Short Duration............................................42
4-38 Overcurrent Level—Area of Overcurrent is the Same......................................42
4-39 Reverse Power.................................................................................................43
4-40 Typical Circuit Using Permissive Function and
Run for Auto/Manual Synchronizing.................................................................46
4-41 Voltage Matching (1% Setpoint).......................................................................46
4-42 Maximum Phase Window = 10 Degrees..........................................................47
4-43 Measured vs. Monitored...................................................................................54
4-44 Typical AVR with Aux Input (Newage SX-440).................................................55
4-45 Typical AVR with External Voltage Adjust Potentiometer.................................55
4-46 AVR Droop.......................................................................................................56
4-47 Analog Inputs to VCOs (Voltage Controlled Oscillators)..................................57
4-48 Voltage Controlled Oscillators—Effect of Offset...............................................57
4-49 Voltage Controlled Oscillators—Effect of Gain.................................................58
4-50 Battery VCO.....................................................................................................58
4-51 Oil Pressure VCO.............................................................................................59
4-52 Water Temperature VCO.................................................................................60
5-1 Droop Mode......................................................................................................67
5-2 Isochronous Mode............................................................................................67
5-3 Droop/Isochronous Load Sharing ....................................................................68
5-4 Synchronizer Time Line—Standard Sequence................................................77
5-5 Loss of Mains Detection Active........................................................................78
5-6 Generator Off Line............................................................................................79
5-7 Mains Parallel Unit with Voltage/Frequency Detect .........................................79
5-8 Mains Parallel Unit(s) with Load Surge Detect.................................................80
5-9 Typical Automatic Sequencing Routine............................................................82
5-10 Original System Configuration..........................................................................84
5-11 After a Change of Priority—Units Not Operating..............................................85
5-12 Original System Configuration..........................................................................85
5-13 A New Master Takes Over—Single Unit
Operating on the Isolated Bus..........................................................................86
5-14 Changing the Priority of a Slave Unit ...............................................................87
5-15 Changing the Priority of a Slave Unit ...............................................................88
5-16 Changing the Priority of a Slave Unit ...............................................................88
5-17 Changing the Priority of a Slave Unit ...............................................................89
5-18 Changing the Priority of a Slave Unit ...............................................................89
5-19 Changing the Priority of a Slave Unit ...............................................................90
6-1 Relationship Between Voltage Bias and Generator Voltage............................99

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Manual 26059 EGCP-1 Engine Generator Control Package
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Chapter 1
General Information
Introduction
This manual describes the Woodward EGPC-1 Engine Generator Control
Package, models 8406-020 (12 Vdc) and 8406-021 (24 Vdc).
Declaration of Incorporation
In accordance with the EMC Directive 89/336/EEC and its amendments, this
controlling device, manufactured by the Woodward Governor Company, is
applied solely as a component to be incorporated into an engine prime mover
system. Woodward Governor declares that this controlling device complies with
the requirements of EN50081-2 and EN50082-2 when put into service per the
installation and operating instructions outlined in the product manual.
NOTICE: This controlling device is intended to be put into service only upon
incorporation into an engine prime mover system that itself has met the
requirements of the above Directive and bears the CE mark.
Control Options
The EGPC-1 control requires the following power supply input voltages, with 6
watts as the nominal power consumption at rated voltage:
• 9–15 Vdc (12 Vdc nominal)
• 18–32 Vdc (24 Vdc nominal)
Control Part Numbers
Part Number
12 Vdc
Supply Voltage
24 Vdc
Supply Voltage
Nominal PT
Input Voltage
Range
Nominal CT
Input Current
Range
8406-020 X 90–277 Vac rms 0–5 A rms
8406-021 X 90–277 Vac rms 0–5 A rms
Nominal AC Voltage as measured across + to – inputs for AC Mains/Bus and
Generator PT sensing.

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Manual 26059 EGCP-1 Engine Generator Control Package
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Chapter 2
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.

EGCP-1 Engine Generator Control Package Manual 26059
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