Woodward EGCP-2 Use and care manual

EGCP-2 Communications Manual
EGCP-2
Engine Generator Control Package
Manual 26181 (Revision A)

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WARNING—OUT-OF-DATE PUBLICATION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 2002
All Rights Reserved

Manual 26181 EGCP-2 Communications
Woodward i
Contents
ELECTROSTATIC DISCHARGE AWARENESS .................................................. II
CHAPTER 1. GENERAL INFORMATION...........................................................1
Overview.................................................................................................................1
ServLink Overview..................................................................................................2
Specifications .........................................................................................................2
CHAPTER 2. EGCP-2 HMI SOFTWARE INSTALLATION ..................................3
CHAPTER 3. HARDWARE CONNECTIONS.......................................................5
CHAPTER 4. MONITORING SERVLINK SOFTWARE OPERATION ......................6
Operating EGCP-2 Monitoring Software..............................................................11
CHAPTER 5. SERVLINK AND WATCH WINDOW CONFIGURATION SOFTWARE 18
ServLink Variable List...........................................................................................21
CHAPTER 6. MODBUS RTU COMMUNICATIONS FOR THE EGCP-2 PANEL....35
Introduction...........................................................................................................35
Modbus Configuration Items ................................................................................35
CHAPTER 7. DOWNLOAD.EXE SETPOINT UTILITY........................................52
Introduction...........................................................................................................52
Requirements.......................................................................................................52
Instructions...........................................................................................................52
CHAPTER 8. SERVICE OPTIONS .................................................................55
Product Service Options.......................................................................................55
Woodward Factory Servicing Options..................................................................56
Returning Equipment for Repair...........................................................................57
Replacement Parts...............................................................................................57
Engineering Services ...........................................................................................58
How to Contact Woodward...................................................................................58
Technical Assistance............................................................................................59
Illustrations and Tables
Table 5-1. ServLink Variable List <<no category>> Category............................22
Table 5-2. ServLink Variable List Control Overview Category...........................23
Table 5-3. ServLink Variable List Front Panel Category.....................................24
Table 5-4. ServLink Variable List Gen Overview Category ................................25
Table 5-5. ServLink Variable List SPt (SetPoint) Category..................................26
Table 6-1. Common Modbus Error Numbers.......................................................37
Table 6-2. Modbus Addresses for the RTU Protocol...........................................44

EGCP-2 Communications Manual 26181
ii Woodward
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 26181 EGCP-2 Communications
Woodward 1
Chapter 1.
General Information
Overview
The EGCP-2 has two communication ports: the inter-control RS-485 port and
the configurable RS-422 port. EGCP-2 controls communicate with each other
over the RS-485 network. This network uses a proprietary protocol and is not
intended to be accessed for information. The configurable RS-422 port protocol
may be selected for one of three options: ServLink communications protocol,
which uses the Woodward PC Tools interface exclusively, Modbus®* RTU
protocol, which uses an open protocol used by many third party software
manufacturers, or Upload Setpoints, which is a Microsoft DOS based program
used to transfer setpoint files between the control and a PC.
*—Modbus is a registered trademark of Schneider Automation Inc.
To select which protocol will be used, enter the Sequencing and Comms
configuration menu of the EGCP-2 panel using the proper software password,
and scroll to the menu item labeled “422 Protocol”. The selections under this
menu item are:
1. ServLink
2. Modbus
3. Upload Setpoints
NOTE
Whenever the RS-422 protocol setpoint is changed, the EGCP-2 must be
powered down, then powered up again to reset to the new protocol.
If ServLink is chosen for the protocol selection, the EGCP-2 will communicate in
the ServLink protocol, which is used with the Woodward EGCP-2 HMI software
P/N 8928-364 (see Chapter 2, EGCP-2 HMI Software Installation) or with the
Woodward Watch Window Professional software P/N 8928-800 (see Chapter 5,
ServLink and Watch Window Configuration Software).
If Modbus is chosen, the EGCP-2 will communicate in MODBUS RTU protocol,
and make its information available according to the address list shown in Table
6-2, Modbus Addresses for the RTU Protocol. Also, when the RS-422 Protocol is
set to Modbus, the Modbus Address, Modbus Time-out, and Modbus Reset
menu items of the Sequencing and Communications menu become functional.
If Upload Setpoints is chosen, the EGCP-2 panel will switch to a communications
mode where it is waiting to see characters on the 422 serial port that set it to
transfer the contents of the setpoint file to the PC. This task is run on the PC
using the download.exe DOS program (see Chapter 7, Download.exe Setpoint
Utility for more information).

EGCP-2 Communications Manual 26181
2 Woodward
ServLink Overview
Woodward’s ServLink and EGCP-2 HMI monitoring software package are
located on a single Compact Disc which ships with every unit. These software
tools are used together to establish communications with, and serve as a
monitoring and configuration interface for, the EGCP-2 platform.
When installed on a computer, the ServLink and EGCP-2 HMI files will reside in
the same directory, typically on the hard drive of the computer they are installed
on. Icons associated with the executable files for both the ServLink and EGCP-2
HMI software will be automatically generated upon installation.
These icons are used to run the programs. Using the computer’s RS-232 serial
port, the ServLink software establishes a direct serial communication link
between the computer and the EGCP-2. The ServLink software may also be
configured to operate via a modem for remote communications to the EGCP-2
control(s).
The ServLink software must always be started before the EGCP-2 HMI software
can be run. The ServLink software provides a bridge between the control and the
computer making the data from the control available to the computer software
applications.
The EGCP-2 software duplicates the front panel of the EGCP-2 hardware
platform. All the monitoring information which can be obtained from the hardware
can also be accessed by the EGCP-2 software in a format which is identical to
that of the hardware. This makes the software very familiar to those accustomed
to the EGCP-2 control keypad functions and LCD readout displays.
Specifications
Communications:
•RS-422 protocol
•9600 Baud (fixed maximum)
•No Parity
•1 Stop Bit
Minimum Computer Requirements:
•Pentium® 133 MHz PC
•32 MB of RAM
•Windows® 95, 98, NT 4.0, and 2000 or greater (Windows NT or 2000
preferred)
Modem Requirements:
•Transmitting Modem:
o 9600 Baud Capability (minimum)
o 8 Data Bits
o No Parity
o 1 Stop Bit
•Receiving Modem:
o 9600 Baud Capability (minimum)
o DTR :OFF
o Echo Offline Commands: OFF
o Auto Answer: ON
o Smart Mode (if applicable): ON
o Handshaking: OFF

Manual 26181 EGCP-2 Communications
Woodward 3
Chapter 2.
EGCP-2 HMI Software Installation
The EGCP-2 Monitoring Software is located on a single compact disc. This disc
contains self-installing software required for installation of the ServLink and
EGCP-2 Monitoring Software onto a computer hard-drive operating within a
32 bit environment.
To install the software on your computer’s hard drive, turn on your computer and
wait until the Windows desktop is displayed. Insert the compact disc (CD) into
the CD drive of the computer which the installation will take place.
Go to the task bar located at the bottom of the desktop screen, and click once on
the Windows Start button. Then click on the Run option.
A dialog box will pop up and display a prompt window asking for the program you
wish to run. If you know the drive letter allocated to your CD drive type this drive
letter, followed by a colon, and then a back slash followed by the word “setup”.
For example, if CD the drive designation for your computer is D, the following
would be typed into the dialog box:
D:\SETUP
If you are unsure of which drive on your computer is designated as the CD drive,
you can double-click on the Windows desktop icon labeled “My Computer” to
display the various drive and network connections for your computer. Look for
the icon showing the CD drive followed by the drive letter designation. This letter
is the letter which must be used when in the Run window dialog box prior to the
setup instruction.
Once you have typed the proper command in the dialog box for setup, press the
Enter (or Return) key on your computer. Windows will automatically begin
reading the CD drive for setup instructions from the EGCP-2 HMI CD setup file
located there.
The ServLink and EGCP-2 software installation will initially prompt the user if it
may automatically create a directory on the hard drive of the computer, and label
this directory “Woodward”. Press the OK button and this directory will be made.
All the ServLink and EGCP-2 software will be placed under this directory on the
computer’s hard drive.
NOTE
Items on the Windows toolbar and desktop may appear differently than is
shown in this manual, depending on active programs in windows at the time
of installation or operation.
The intent of this manual is to accurately depict the windows which are
directly associated with the installation and operation of the EGCP-2
monitoring software.

EGCP-2 Communications Manual 26181
4 Woodward
As the installation continues, the screen will momentarily show the ServLink and
EGCP-2 icons that are created during the setup process. These icons are
automatically inserted into the Program Files menu under the EGCP-2 label.
The installation process has made a new set of programs under the EGCP-2
HMI 1.00 program file. Click once on the desktop tool bar Start button, and select
the Programs option. Among the various programs on the computer hard drive
should now be one group called Woodward, then “EGCP-2 HMI 1.00”. Select this
group to display the ServLink Server, EGCP-2 HMI, and Uninstall EGCP-2 HMI
1.00 executables. These are the executables which were installed from the CD to
the computer hard drive.
The ServLink Server and the EGCP-2 HMI are both used in communicating with
and monitoring the EGCP-2 control system. The Remove EGCP-2 HMI 1.00 icon
will remove all files associated with the installation of this software from the
computer hard drive if it is selected. The Remove program prompts the user prior
to uninstalling the software to confirm this action, which greatly reduces the
chance of accidental removal of the installed software.
Here is a typical screen from the Windows desktop with the ServLink and EGCP-
2 software installed on the computer’s hard drive:
Once the software is successfully installed on the computer, it will remain
resident on the hard drive indefinitely, or until it is uninstalled.

Manual 26181 EGCP-2 Communications
Woodward 5
Chapter 3.
Hardware Connections
Once the software is installed on the computer hard drive, the hardware
connection between the computer and the EGCP-2 control must be made for
correct communication between the two devices. This hardware connection is
completed in one of two ways:
1. Direct cable connection between the computer and the EGCP-2 control(s)
RS-422 network.
2. Remote connection via modem between the computer and the EGCP-2
control(s).
Direct Cable connection between the computer and EGCP-2 control(s) will be
discussed first as it is the most straightforward of the two connection methods.
The laptop or desktop computer, which will be used with the EGCP-2 RS-422
port, will have a 9-pin serial port. This port is configured by the computer
hardware to use a serial communications protocol called RS-232. The details of
this protocol are not important to know for hardware connection to the EGCP-2
control(s), other than there is a need to convert the RS-232 protocol of the
computer port to RS-422 protocol used by the EGCP control network. This
conversion is accomplished by an external conversion module, which takes the
RS-232 serial port input from the computer, and changes it to a RS-422 protocol
for the EGCP-2. These converters can be found in most computer or electronics
stores, and are called RS-232 to RS-422 Converters. Consult the EGCP-2
Installation manual for wiring diagrams. A complete cable assembly can also be
purchased from Woodward. The part number is 5417-551.
In a system with multiple (maximum 8) EGCP-2 controls, each control is
interconnected to the others on the RS-422 network in a multidrop fashion.
Modem connections are very similar, but now a modem is required both at the
computer and at the EGCP-2 end of the network. The modem may be an internal
or external type at the computer, and must be an external type at the EGCP-2
control. The conversion from RS-232 to RS-422 communications is made at the
modem connection into the EGCP-2 control network.
For detailed wiring diagrams pertaining to the RS-422 network of the EGCP-2
controls, please consult the EGCP-2 Installation and Operation Manual, number
26174.

EGCP-2 Communications Manual 26181
6 Woodward
Chapter 4.
Monitoring ServLink Software Operation
Now that the software has been installed on the hard drive of the computer, and
the desired hardware connections are in place between the computer and the
EGCP-2 controls, the next step is to run the software and confirm operation of
the entire communications network.
To run the EGCP-2 software, first click on the Start toolbar button in Windows
desktop, then Programs, Woodward, EGCP-2 HMI 1.00, and then click on the
ServLink server as shown here.
When you click once on the Icon, this screen will appear on the desktop. This is
the Dialog Screen, where the type of communications you are using will be
established prior to operation of the EGCP-2 monitoring software.

Manual 26181 EGCP-2 Communications
Woodward 7
The first action inside the ServLink screen is to set up a new network definition
file. Click once on File, and then on New as shown. The new network definition
window will pop up on the computer screen.
This will open up the Network Options screen. This screen allows the user to
configure the ServLink connection for serial COM port, or modem. When a serial
port is selected, the left side menus will be active and the right side menus will be
grayed out.
The “Use This Port” box of this screen is used to select which communication
port (COM) or modem will be used to communicate using RS-232 protocol to the
EGCP-2 control. Clicking on the drop down box will tell the ServLink software to
scan the computer and list any communications ports which are not being used
by other applications, that may be used for serial communications. If the port that
is desired does not appear, most likely it is being used by some other application
on the computer. Another port should be selected, or the application that was
using the port should be stopped.

EGCP-2 Communications Manual 26181
8 Woodward
The next block down, “In this mode”, is used to select either multidrop or point-to-
point communications over the serial port. Point-to-point communications
assumes that the computer will be communicating with only one control at the
other end of the network. Point-to-point communications should be used only
when the communications between the computer and the EGCP-2 control are
made in a direct fashion (no secondary devices or other EGCP-2 controls can
reside on the same network). There must be only the computer and one EGCP-2
control on the network for point-to-point communications.
The advantage of using the point-to-point communications mode option is speed.
Since the communications are only between the PC and one EGCP-2 control,
the ServLink software will scan for only one unit on the network. This takes less
time than a multidrop communications mode, which scans for all eight units on
the network, regardless of how many units are actually connected to it.
Use the multidrop communications option any time there are two or more
EGCP-2 units that require monitoring from the computer on the same network.
The next box down is the “At this baud rate” box. Set this to 9600 Baud. The
EGCP-2 is only capable of communicating at 9600 baud. Any other number put
in this box will cause communication failure with the EGCP-2 control.
The boxes on the right hand side of the ServLink New File setup screen are
normally turned “off” when the “Use This Port” box is configured for the COM
ports of the computer. However, when the modem option is selected in the “Use
This Port” box, the boxes on the right hand side of the screen become active, as
shown below:
The box labeled “From this location” allows the user to set up various dialing
properties for the modem, and store them under a user-defined name. These
dialing properties include such functions as tone/pulse dialing, call waiting
override, and adding any dialing prefixes to access external lines, etc.
The next box down on the right hand side of the screen is the “Using this phone
number” box. Here information about the number of origin and the number to be
dialed are entered by the user.

Manual 26181 EGCP-2 Communications
Woodward 9
When all the various communications options are selected in the ServLink
screen, press the OK button. ServLink will automatically dial the modem (if
applicable) and scan the network for active controls. This may take several
minutes, depending on network configuration. Here is what the screen of the
computer looks like when it is scanning the network for active controls:
When communications are established with the EGCP-2 control network, the
scanning screen will change to show that the ServLink software is reading the
control information. That screen will look like this:
Once communications are established, and the data is read from the EGCP-2
control network, the ServLink software will show each control it is communicating
on the network by that control’s network address. Here is a typical ServLink
network definition screen for a three-unit EGCP-2 network:

EGCP-2 Communications Manual 26181
10 Woodward
If your network configuration is constant (neither the number of controls on the
network nor the PC attached to the network will change), you may want to save
the Network Definition File you have created for ServLink. To do this, click on the
File button in the upper left hand window of ServLink. Select “Save As”. A dialog
window will pop up and ask you to name the new network definition file you have
created. Typically, this file will be stored in the EGCP-2 directory on the hard
drive of the computer ServLink is operating from. The file name given to the
network definition file will be given a “.net” extension. Once you have selected a
file name, click on the OK button in the dialog box. This saves the network
definition file you created.
Once you have created and saved the network definition file for ServLink, all you
have to do in the future to run the definition file is open ServLink from the
Programs Menu, and select File, and then Open. When Open is selected, a list
will appear containing the network definition file you created. Select the desired
network definition file, and ServLink will automatically select the necessary
communications options defined by the file and establish a communications link
with the EGCP-2 control network.
Now that ServLink has established a network connection, you may want to
“minimize” the ServLink window by clicking on the Minimize button in the upper
right hand of the ServLink Window. When you minimize an application, the
software continues running, but the window is reduced to a button on the desktop
toolbar. You can restore the application window to full size at any time by clicking
on the reduced toolbar button for that software with the left mouse button.
NOTE
Terminating ServLink will result in loss of communications with the network.
The ServLink Network Definition file will have to be executed again to re-
establish this link.

Manual 26181 EGCP-2 Communications
Woodward 11
Operating EGCP-2 Monitoring Software
Now that the communications link is established between the computer and the
EGCP-2 controls, the EGCP-2 Monitoring Software Tool can be used to view the
various parameters of each control on the RS-422 network.
To open the EGCP-2 controls program, click once on the Start button in the
desktop toolbar. Select Programs, Woodward, EGCP-2 HMI 1.00, and EGCP-2
HMI. Click once on the EGCP-2 HMI icon to execute the monitoring program, as
shown below:
Provided that the ServLink software is currently connected to the control network,
clicking this icon will start the HMI program. The HMI program cannot be run
without being connected to a control.
When the control is linked to the EGCP-2 monitoring software, the LCD display
on the hardware units will display an asterisk (*) cursor instead of the usual solid
block cursor. This allows operators of the EGCP-2 to recognize the units are
being accessed by remote control simply by looking at the display screen of the
hardware units.
When the control is linked to the EGCP-2 monitoring software, the Master
Situation Monitor screen will appear. This screen will show all EGCP-2 controls
connected to the network, and their various status information, as shown here:

EGCP-2 Communications Manual 26181
12 Woodward
This Master Situation Monitor Screen is showing three EGCP-2’s. Unit one is
generating power with no alarms. Units two and three are not generating power,
and unit three has an active alarm.
To view a specific unit’s front panel display, highlight the unit you wish to observe
using a single click of your mouse on that unit’s display line in the Master
Situation Monitor, as shown here. Then click the Front Panel icon on the lower
section of the screen next to the Woodward logo or simply double-click the unit
that is to be observed.

Manual 26181 EGCP-2 Communications
Woodward 13
The Front Panel Display for that unit EGCP-2 (Unit 1 in this case) will pop up as
shown below:
Multiple units can be viewed on the Windows desktop simultaneously. Each unit
is “stacked” on top of the others. You can view any unit by clicking the left mouse
key once on any part of that unit’s Front Panel display window, or if the front
panel display has been minimized, by clicking on the minimized bar for that front
panel on the desktop. Here is a screen showing a two unit system with both front
panels on the desktop. Notice that the unit is identified on the upper left hand
side of the front panel display bar.

EGCP-2 Communications Manual 26181
14 Woodward
The front panel display of the EGCP-2 monitoring software allows access to any
monitoring information available on the actual unit. The buttons of the front panel
operate in the same manner as the EGCP-2 as well. The front panel display
operates in the same manner as most desktop windows, except that the size of
the front panel display cannot be changed or maximized. The front panel display
can be closed by clicking the X button in the upper right hand corner, or
minimized to toolbar buttons using the under bar [_] button in the upper right
hand corner. If a front panel display window is closed, it must be re-opened from
the Master Situation Monitor.
In the following example there is an alarm condition on Unit #1. Highlighting Unit
#1, and then clicking on the front panel display icon in the lower left corner of the
Master Situation Monitor displays the front panel display for Unit #1.

Manual 26181 EGCP-2 Communications
Woodward 15
The front panel display for Unit 1 indicates two alarms in the System Status
menu. Clicking the Alarm/Event button with the left mouse button displays the
Alarm / Event Log of the control to the right hand LCD display as shown below:
The alarm event list shows two alarms. The most recent is a Mains Frequency
Low Alarm logged on June 17 at 13:21, and the other is a Remote Fault 3
discrete input driven alarm logged on the same date at 13:19.
Pressing the Scroll Down key as shown below scrolls the alarm event list in the
right hand display to show the end of the alarm event log list, as shown below.

EGCP-2 Communications Manual 26181
16 Woodward
Pressing the Alarm Clear Button results in the logged alarm events being
removed from the alarm event list. When all alarms have been cleared, the list
displays “None Recorded” as shown.
Pressing the Status button on the front panel display will revert the EGCP-2
display back to the status mode. Now both left and right displays show the status
information for the item selected.