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

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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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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.

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Chapter 3
Control Overview
Introduction
The EGCP-1 is a microprocessor based complete generator load control and
engine management package designed for use with a Woodward speed control
and a separate voltage regulator. The control's functions include:
Engine Control
• Engine Pre-glow
• Fuel Solenoid Control
• Engine Starter Control
• KVA Controlled Cool-down Timer
• Oil Pressure Monitoring
• Water Temperature Monitoring
• Battery Voltage Monitoring
• Speed Monitoring with Overspeed Protection
Synchronizing
• Digital signal processing to eliminate problems induced in systems with high
harmonic content causing multiple zero crossing of voltage wave forms.
• Adjustable maximum phase window, voltage window, and dwell times—
windows as small as 2ºphase error and 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
• Externally adjustable Base Load or Process Reference Levels with
independent ramp rates
• kW droop provided for manual load control.

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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.
• KVAR droop for manual VAR control.
Automatic Generator Sequencing
• Automatically starts additional EGCP-1 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 detection
• Speed/Frequency Mismatch
• Load Surge
Engine Protective Features
• High/Low Coolant Temperature
• High/Low Oil Pressure
• Overspeed
• Over Crank
• Start Failure
PC Interface
• Easy upload and download of configuration setpoints
• 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 protocol.

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Operator Interface
The EGCP-1 Operator Interface is designed for simplicity and redundancy of
function in all operating modes. The backlit LCD screens with contrast
adjustment are used to display various operating and status information to the
operator, as well as for reading tuning setpoints. The backlight on the LCD
screens automatically shuts off after a five minute period of non-use to reduce
power consumption. Pressing any key on the front key pad will turn the light
back on.
NOTE
The EGCP-1 Operator Interface can only be used for unit
configuration and monitoring. Unit start/stop, sync, or mode
selection commands can not be given through the EGCP-1’s front
panel.
The screens provide six lines of Status Information, and two lines of Setpoint
tuning information. These screens allow the user to monitor and tune related
parameters at the same time.
Figure 3-1. Keypad
An embedded 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.
There are seven rectangular keys on the operator interface and two “teardrop”
keys. The keys have the following functions:
AlarmReset Commit Escape
Resets Alarms Enters Setpoints Escapes Setpoints
Clears Alarm Ind. Enters Menus Escapes Menus

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Up Key Down Key Left Key Right Key
Moves Cursor Moves Cursor Moves Cursor Moves Cursor
Increments Val. Decrements Val.
■
■Right Hand Teardrop Keys
Right Hand Teardrop Keys
Upper Key
Selects Status Menu
Two Presses Selects Control Overview Screen
(From any Menu)
Lower Key
Selects Tuning Menu
Selects Setpoint Entry

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Chapter 4
Software Overview
Introduction
The software used in the EGCP-1 uses state machine logic to operate in all
modes. State machine logic relies upon discrete inputs, and specific operating
conditions to trigger a sequence of operations. The state machine logic use the
following State Machines to operate the generator set:
Close Mains Breaker
Open Mains Breaker
Start Engine
Off
Synchronize
Load Control
Close Gen Breaker
Open Gen Breaker
Various inputs and actions determine which state machine is in operation at any
given time.
Navigation of Menus and Setpoints
The status displays occupy the top six lines of the LCD display. These menus are
arranged in a hierarchical structure with an overview menu containing the names
for each menu group at the top. Pressing the “Escape”key will activate the next
higher menu level and pressing the “Commit”key will activate the next deeper
level. This navigation is illustrated below.

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Program Navigation
Status Menus Action Screen
Power Up Control Overview
Escape Button Depressed Status Overview:
Control Overview
Engine Overview
Gen. Overview
Gen. Phases
I/O Status
Alarms
Sequencing
Load Control Monitor
Up Button Depressed Moves Cursor Up Through Status
Menus
Down Button Depressed Moves Cursor Down Through Status
Menus
Enter Button Depressed Enters Selected Status Menu
Escape Button Depressed Escapes Back to Status Overview
Left Button Depressed No Action in Status Screen
Right Button Depressed No Action in Status Screen
Alarm Acknowledge/
Reset Depressed Acknowledges Alarms
Clears Alarms when in Alarm Status Menu
Teardrop Down Key Depressed From Status Screen:
Selects Tuning Menus
From Tuning Item:
Selects Tuning Setpoint
Teardrop Up Key Depressed From Tuning Screen:
Selects Status Menus
From Status Screen:
Selects Control Overview Menu
From Status Item:
Selects Status Menus

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Status Screens
When the EGCP-1 is initially powered up, it will default to the Control
Overview Screen. Here is what the Screen looks like. The Control Overview
Screen can also be accessed while in any other status screen by pressing the UP
teardrop key twice.
Figure 4-1. Control Overview Engine Off Line
The screen displays the following information:
Unit #:The network address of the unit.
Alarms:Number of active alarms on the unit.
Engine:The operating state of the engine.
Mains:A graphic display of the mains condition. A flat line
indicates the mains are out of spec, a sine
wave indicates the mains are in spec.
Gen:A graphic display of the generator condition. A flat line
indicates the generator is out of spec, a
sine wave indicates the generator is in spec
Operating State: Shows if the EGCP-1 is in Auto
or Man(ual) mode.
Load Control State: Shows the state of the load control
logic of the EGCP-1. The modes identified here
are: Droop, Isoch, Baseload, and Process.
Unit:The network address of the unit, and any other units in
auto on the same network.
Priority:The network priority of the unit, and any other units in
auto on the same network.
NOTE
The Unit and Priority Lines are only active when the unit is in Auto
and set for Multiple Units.
All the display information will update automatically as operating modes and
conditions to the EGCP-1 change.
UNIT: 1
PRIORITY: 1
UNIT: 1 ALARMS: 0
ENGINE: OFF
MAINS: GEN:
AUTO OFF

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This is what the Control Overview screen would look like with the mains out of
spec, the engine running, carrying load isochronously, and the generator voltage
is within specified limits. This would be a typical screen if the unit was set for
loss of mains detection.
UNIT: 1 ALARMS: 0
ENGINE: RUN
MAINS: -- GEN: ++
AUTO ISOCH
Figure 4-2. Control Overview Screen—Set for Loss of Mains Detection
This is what the control overview screen looks like for a generator set that is
base loaded to the mains.
Pressing the ESCAPE KEY will take the display from the Control Overview
menu to the Status Menu. The Status Menu is the menu which gives an overview
of all the status menus available in the EGCP-1. This is what the Status Menu
looks like:
UNIT: 1 ALARMS: 0
ENGINE: RUN
MAINS: ++ GEN: ++
AUTO BASELOAD
Figure 4-3. Status Menu

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There are a total of nine status menus. Use the down arrow key on the face of the
EGCP-1 to access the other three status menus.
I/O STATUS
SEQUENCING
LOAD CONTROL MON
Figure 4-4. Status Menu (cont.)
Use the up and down arrow keys to move the blinking cursor to the desired status
menu that will be viewed. When the cursor is on the desired menu press the
commit key. This will take you into the desired menu. Pressing the escape key
while in any of these menus will take the display back to the Status Menus
screen.
The following is an overview of each of the status menu screens, starting with
engine overview (control overview has been shown previously), and moving
down through the status menus.
H2O OIL BATT
XXC XXb V
TIME DATE RPM
12:00 DD-MM 0
KW-HRS RUN TIME
0 0
1996
Figure 4-5. Engine Overview
H2O: Water Temperature in degrees C.
OIL: Oil Pressure in Bar.
BATT: Battery Voltage in Volts DC.
Time: 24 hour readout.
Date: MM-DD.
RPM: Engine rpm.
KW-Hrs: KW hours on the unit.
Run Time: Engine operating hours.
Pressing the commit key will give the year readout on this screen if necessary.

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#1 A B C
V 0.00 0.00 0.00
A 0.0 0.0 0.0
Hz: 00.0 KW: 00.0
PF: 1.00 LAGGING
(LOADCONT. STATUS)
Figure 4-6. Generator Overview (Voltage Line to Line)
#1: The Unit network address is displayed here.
Aφ, Bφ, Cφ:Three phase readings for the generator.
V: Volts Line to Line for each phase of the generator.
A: Amps per phase for the generator.
Hz: Generator Frequency.
KW: Total three phase Generator Load.
PF: Average three phase Generator Power Factor.
Load Cont.
Status: This area of the screen shows the status of the Load Control in
the EGCP-1.
1 A B C
V 0.00 0.00 0.00
A 0.0 0.0 0.0
KW0.00 0.00 0.00
kvar 0.0 0.0 0.0
kva 0.0 0.0 0.0
Figure 4-7. Generator Phases (Voltage Line to Neutral)
1: Unit Network Address.
Aφ, Bφ, Cφ:Three phase sensing for the generator.
V: Volts Line to Neutral for each phase of the generator.
A: Amps per phase of the generator.
KW: KW per phase of the generator.
KVAR: KVAR per phase of the generator.
KVA: KVA per phase of the generator.