26086C

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

Operation (End User) Manual

Manual 26086C
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.
© 2000 by Woodward Governor Company
All Rights Reserved
! 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.

! CAUTION
The installation must include the following:
• The power supply mains should be properly fused according to the
installation instructions and the appropriate wiring requirements.
• A switch or circuit breaker shall be included in the building installation,
that is in close proximity to the equipment and within easy reach of the
operator and that is clearly marked as the disconnecting device for the
equipment. The switch or circuit breaker will only remove power to the
unit, hazardous voltages may still be connected to other terminals on
the unit.

! CAUTION
The calibration and checkout procedure should only be performed by
authorized personnel knowledgeable of risks posed by live electrical
equipment.
 IMPORTANT DEFINITIONS
!
WARNING—indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided,
could result in damage to equipment.
NOTE—provides other helpful information that does not fall under the
warning or caution categories.
Manual 26086 EGCP-2 Engine Generator Control Package

Contents
CHAPTER 1. GENERAL INFORMATION...........................................................................1
Introduction..........................................................................................................................1
Regulatory Compliance Notes and Warnings .....................................................................1
Control Electrical Ratings ....................................................................................................1

CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS..........................................3

CHAPTER 3. CONTROL OVERVIEW ................................................................................5

Introduction..........................................................................................................................5
Operator Interface ...............................................................................................................7
Navigation Procedure ....................................................................................................11

CHAPTER 4. SOFTWARE OVERVIEW............................................................................17

Introduction........................................................................................................................17
Status Screens ..................................................................................................................17
Alarm/Event Log................................................................................................................29
Configuration Menus .........................................................................................................31
Shutdowns and Alarms .....................................................................................................38
Engine Control...................................................................................................................42
Synchroscope....................................................................................................................44
Real Load Control .............................................................................................................47
Reactive Load Control.......................................................................................................49
Process Control.................................................................................................................50
Transfer Switch..................................................................................................................53
Sequencing and Comms (Communications).....................................................................55
Calibration Menu ...............................................................................................................56

CHAPTER 5. CONTROL FEATURES AND FUNCTIONS ................................................63

Engine Control...................................................................................................................63
Engine Protection ..............................................................................................................63
Generator Voltage and Reactive Load Control..................................................................63
Generator Protection .........................................................................................................63
Mains Sensing...................................................................................................................64
Synchronizing....................................................................................................................64
Load Control......................................................................................................................64
Sequencing .......................................................................................................................64
Engine Cranking................................................................................................................65
Idle/Rated Relay Output ....................................................................................................66
Generator Voltage Control ................................................................................................66
Generator Load Control.....................................................................................................67
Power Sensor Theory of Operation ...............................................................................67
Load Sensor Hardware Description ...............................................................................68
Droop .........................................................................................................................68
Isochronous ...................................................................................................................69
Droop/Isochronous Load Sharing on an Isolated Bus ...................................................70
Isochronous Load Sharing on an Isolated Bus ..............................................................71
Base Load Against the Mains ........................................................................................71
Automatic Generator Loading Functions...........................................................................72
Process Control Description ..........................................................................................72
Reactive Load Control Description ................................................................................73
VAR Control ...................................................................................................................74
Power Factor Control .....................................................................................................74
Power Factor Sharing ....................................................................................................74
Synchronizer Description ..................................................................................................75
Functional Description ...................................................................................................75
Operating Modes ...........................................................................................................75
Dead Bus Closing ..........................................................................................................76
Voltage Matching ...........................................................................................................77
Phase Matching Synchronizing......................................................................................78
Synch-check ..................................................................................................................78
Multiple Shot Reclosing ................................................................................................79
Synchronizer Timing ......................................................................................................79

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Loss of Mains Detection and Action .............................................................................. 80
Generator Sequencing...................................................................................................... 83
Assuming a New Master – All Units Off Load................................................................ 86
Assuming a New Master – Master On Load .................................................................. 87
Changing the Priority of a Slave Unit – Slave On Load................................................. 91
Inter-control Communications (RS-485 Network) ............................................................. 92
Remote Control/Monitoring (RS-422)................................................................................ 93

CHAPTER 6. CALIBRATION OF CONTROL INPUTS AND OUTPUTS .......................... 95

Introduction ....................................................................................................................... 95
Calibration of Generator PTs and CTs.............................................................................. 96
PT Phase A Scale ........................................................................................................ 96
PT Phase B Scale ......................................................................................................... 97
CT Phase A Offset......................................................................................................... 97
CT Phase A Scale ......................................................................................................... 98
CT Phase B Offset......................................................................................................... 98
CT Phase B Scale ......................................................................................................... 99
CT Phase C Offset ........................................................................................................ 99
CT Phase C Scale ....................................................................................................... 100
Calibration of the Bus PT ................................................................................................ 100
Bus PT Scale............................................................................................................... 100
Speed Bias Output.......................................................................................................... 101
Voltage Bias Output ........................................................................................................ 102

CHAPTER 7. GENERAL STARTUP INSTRUCTIONS................................................... 103

Before Starting the Generator Set .................................................................................. 103
Sequence of Startup and Checking Parameters............................................................. 104
Loading the Generator Set.............................................................................................. 105
Mains Parallel Units..................................................................................................... 105
No Parallel and Slave Setup ....................................................................................... 106

CHAPTER 8. TROUBLESHOOTING.............................................................................. 109

Control Hardware and I/O ............................................................................................... 109
Engine Control/Sensing Parameters............................................................................... 110
Synchronization .............................................................................................................. 111
Breaker Close/Open Control........................................................................................... 112
Real Load Control ........................................................................................................... 113
Reactive Load Control .................................................................................................... 114
Sequencing ..................................................................................................................... 115
Mains/Bus Sensing ......................................................................................................... 116
Communications ............................................................................................................. 116

CHAPTER 9. DEFINITION OF TERMS .......................................................................... 117

CHAPTER 10. SERVICE OPTIONS ............................................................................... 123

Product Service Options ................................................................................................. 123
Returning Equipment for Repair ..................................................................................... 124
Replacement Parts ......................................................................................................... 125
How to Contact Woodward ............................................................................................. 125
Additional Aftermarket Product Support Services ........................................................... 126
Technical Assistance ...................................................................................................... 128

APPENDIX A. EGCP-2 SETPOINT WORKSHEET ........................................................ 129

Configuration Menu......................................................................................................... 129
Shutdown and Alarms Menu ........................................................................................... 130
Engine Control Menu ...................................................................................................... 132
Synchronizer Menu ......................................................................................................... 134
Real Load Control Menu ................................................................................................. 135
Reactive Load Control Menu........................................................................................... 136
Process Control Menu .................................................................................................... 137
Transfer Switch Menu ..................................................................................................... 138
Sequencing and Comms Menu....................................................................................... 139
Calibration Menu............................................................................................................. 140

APPENDIX B. DOWNLOAD INSTRUCTIONS ............................................................... 141

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Illustrations
1-1 Wiring Diagram for EGCP-2...............................................................................2
3-1 Operator Interface ..............................................................................................7
3-2 EGCP-2 Navigation ..........................................................................................11
4-1 System Overview Engine Off Line....................................................................17
4-2 System Status screen – Isochronous...............................................................19
4-3 System Status Screen - Baseload....................................................................19
4-4 Engine Overview ..............................................................................................20
4-5 Generator Status (Voltage Line to Line)...........................................................21
4-6 I/O Status .........................................................................................................22
4-7 Synchronizer Status .........................................................................................23
4-8 KW Load Status ...............................................................................................24
4-9 PF/KVAR Status...............................................................................................25
4-10 Sequencing Menu ............................................................................................26
4-11 Sequencing Menu (Multi-Unit)..........................................................................27
4-12 ATS (Automatic Transfer Switch) Status ..........................................................28
4-13 Alarm/Event Screen .........................................................................................29
4-14 Empty Event Log ..............................................................................................30
4-15 Security Code Display ......................................................................................31
4-16a Configuration Menu List (Screen 1)..................................................................31
4-16b Configuration Menu List (Screen 2)..................................................................32
4-16c Configuration Menu List (Screen 3)..................................................................32
4-17 AC Power Triangle ...........................................................................................35
4-18 Breaker Logic and Contactor Logic ..................................................................37
4-19 Generator High/Low Voltage Alarms................................................................39
4-20 Generator Over/Under Frequency....................................................................40
4-21 Overcurrent Inverse Time Functions ................................................................40
4-22 Overcurrent Level—High Current, Short Duration............................................41
4-23 Overcurrent Level—Area of Overcurrent is the Same......................................41
4-24 Reverse Power.................................................................................................42
4-25 Typical Circuit Using Permissive Function and
Run for Auto/Manual Synchronizing.................................................................43
4-26 Voltage Matching (1% Setpoint).......................................................................43
4-27 Maximum Phase Window = 10 Degrees ..........................................................44
4-28 Direct (Export) Process Action ........................................................................50
4-29 Indirect (Import Power) Process Action ...........................................................50
4-30 Direct (Import/Export) Process Action .............................................................51
4-31 EGCP-2 Control Dip Switch ............................................................................51
4-32 Measured vs. Monitored ..................................................................................57
4-33 Typical AVR with Aux Input (Newage SX-440).................................................58
4-34 Typical AVR with External Voltage Adjust Potentiometer ................................58
4-35 AVR Droop ......................................................................................................58
4-36 Direct Proportional Input to Water Temp or Oil Pressure Input........................60
4-37 Voltage Controlled Oscillators—Effect of Offset ..............................................60
4-38 Voltage Controlled Oscillators—Effect of Gain ................................................60
4-39 Battery VCO ....................................................................................................61
4-40 Oil Pressure VCO ............................................................................................61
4-41 Water Temperature VCO ................................................................................62
5-1 Droop Mode......................................................................................................69
5-2 Isochronous Mode............................................................................................69
5-3 Droop/Isochronous Load Sharing ....................................................................70
5-4 Synchronizer Time Line—Standard Sequence ................................................79
5-5 Loss of Mains Detection Active ........................................................................80
5-6 Generator Off Line............................................................................................81
5-7 Mains Parallel Unit with Voltage/Frequency Detect .........................................81
5-8 Mains Parallel Unit(s) with Load Surge Detect.................................................82
5-9 Typical Automatic Sequencing Routine............................................................84
5-10 Original System Configuration..........................................................................86
5-11 After a Change of Priority—Units Not Operating..............................................87
5-12 Original System Configuration..........................................................................87
5-13 A New Master Takes Over—Single Unit
Operating on the Isolated Bus..........................................................................88
5-14 Changing the Priority of a Slave Unit ...............................................................89

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5-15 Changing the Priority of a Slave Unit ............................................................... 90
5-16 Changing the Priority of a Slave Unit ............................................................... 90
5-17 Changing the Priority of a Slave Unit ............................................................... 91
5-18 Changing the Priority of a Slave Unit ............................................................... 91
5-19 Changing the Priority of a Slave Unit ............................................................... 92
6-1 Relationship Between Voltage Bias and Generator Voltage.......................... 102

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Manual 26086 EGCP-2 Engine Generator Control Package

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).

Regulatory Compliance Notes And Warnings

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 degrees C.
• Connect ground terminal to PE (Protective Earth).
• More than one live circuit (see wiring diagram)

Control Electrical Ratings

Nominal Maximum Power Maximum PT Maximuml CT Maximum
Part Number Supply Consumption at Input Voltage Input Current Generator
Voltage Rated Voltage Range Range Frequency
Range range
8406-115 10-29 Vdc 20watts 150–300 Vac rms 0–5 A rms 40 to 70 Hz
8406-116 (12 or 14 Volt 50-150 Vac rms
Systems)

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Figure 1-1. Wiring diagram for EGCP-2

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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-2 is a microprocessor based complete generator load control and
engine management package designed for use with an Electronic engine 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
• Idle/Rated Relay Output

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 2º phase 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-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 detection
-Over/Under Voltage
-Over/Under Frequency
-Generator Load Surge
• Speed/Frequency Mismatch
• Load Surge
• KVA Load Switch

Engine Protective Features

• High/Low Coolant Temperature
• High/Low Oil Pressure
• Overspeed
• Over Crank
• Start Failure
• Six User Configurable Discrete Fault Inputs

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 or ServLink
protocol.

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Operator Interface
The EGCP-2 Operator Interface is designed for simplicity and redundancy of
function in all operating modes. The backlit LCD screens are used to display
various operating and status information to the operator, as well as for reading
configuration setpoints and alarm information. 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-2 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-2’s front
panel.

! CAUTION
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.

The screens provide eight lines of Status Information, with the option of
displaying four lines of Setpoint tuning or Alarm Log information. These screens
allow the user to monitor and tune related parameters at the same time.

Figure 3-1. 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.

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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 alarm

and event menu in the right hand display screen. When pressed, this key will
cause the right hand LCD display to show the current alarm and event status of
the generator set.

ALARM CLEAR

The ALARM CLEAR KEY is used to acknowledge and

clear alarm events from the event log. When pressed, this key will acknowledge the
selected alarm. When pressed a second time this key will cause the selected alarm
event item to be removed from the event log. 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. If the AUDIBLE ALARM output is active (energized), the
ALARM CLEAR KEY will also remove the AUDIBLE ALARM output when it is
pressed for the first time. A security code of Operator Level or higher is required to
acknowledge and clear alarms.

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).

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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 CONGURATION KEYS:

STATUS

i
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.

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 4 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.

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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.

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.

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 Manual 26086 EGCP-2 Engine Generator Control Package

ATS

The ATS STATUS key, when pressed, displays the status

information for the Automatic Transfer Switch functions.

Navigation Procedure

The following drawings detail a step-by-step procedure for navigating through

the EGCP-2 software. Additionally, the typical display entries seen at each step
are shown.

LEFT HAND LCD DISPLAY RIGHT HAND LCD DISPLAY

KEYPRESS
Power Up
system status system status

ENGINE

prime mover status prime mover status

SYNC

synchronizer status synchronizer status

CONFIG
SECURITY CODE
... synchronizer status ****

ENTER
SECURITY CODE
_ 0
+ +
SCROLL synchronizer status ----------------------------------------------------
ENTER SECURITY CODE

ENTER
Configuration
Shutdowns and Alarms
synchronizer status Engine Control
Synchronizer

VIS-140A
00-6-20
Configuration
Shutdowns and Alarms
SCROLL synchronizer status Engine Control
Synchronizer

Figure 3-2. EGCP-2 Navigation

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From Previous Page

SCROLL C onfiguration (*first item in list)
Shutdowns and Alarms
synchronizer status
Engine Control
S ynchronizer

Shutdowns and Alarms

SCROLL
Engine Control
synchronizer status Synchronizer
R eal Load Control

Process Control
Transfer Switch
SCROLL
synchronizer status Sequencing and Comms
C alibration (*last item in list)

Process Control
Transfer Switch
SCROLL synchronizer status S equencing and Comms
C alibration (*last item in list)

ENTER
>AUTO SEQUENCING (*first item is list)
>MAX GEN LOAD
synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY

>AUTO SEQUENCING (*first item is list)

SCROLL >M AX GEN LOAD
synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY

>AUTO SEQUENCING (*first item is list)

>MAX GEN LOAD
SCROLL synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY
VIS-140B
00-6-20

Figure 3-2. EGCP-2 Navigation (contd.)

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ENTER From Previous Page

NEXT GENSET DLY

30 Sec
synchronizer status -------------------WOODWARD EGCP2-------------
CONFIGURATION MENUS

SCROLL NEXT GENSET DLY

29 Sec
synchronizer status -------------------WOODWARD EGCP2-------------
CONFIGURATION MENUS

ENTER
>AUTO SEQUENCING (*first item is list)
>MAX GEN LOAD
synchronizer status >NE X T G E N S E T D L Y
>RATED LOAD DLY

>AUTO SEQUENCING (*first item is list)

>M AX GEN LOAD
SCROLL synchronizer status >NE X T G E N S E T D L Y
>RATED LOAD DLY

ENTER MAX GEN LOAD

60 %
synchronizer status ---------------------SEQUENCING--------------------
%KW: 0.0

ESC
>AUTO SEQUENCING (*first item is list)
>M AX GEN LOAD
synchronizer status >N E X T G E N S E T D L Y
>RATED LOAD DLY

ESC Process Control

Transfer Switch
synchronizer status Sequencing and Comms
VIS-140C
Calibration (*last item in list)
00-6-20

Figure 3-2. EGCP-2 Navigation (contd.)

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CONFIG from previous page

... C onfiguration
Shutdowns and Alarms
synchronizer status
Engine Control
Synchronizer
I/O
C onfiguration
Shutdowns and Alarms
input/output status Engine Control
Synchronizer
STATUS

i input/output status input/output status

ALARM / EVENT
CRANK FAIL
12:00 1 - 1
input/output status MAIN VOLT LOW ALM
12:00 1 - 1
ENGINE
C RANK FAIL
12:00 1 - 1
engine status
MAIN VOLT LOW ALM
12:00 1 - 1

C RANK FAIL
SCROLL 12:00 1 - 1
engine status M AIN VOLT LOW ALM
12:00 1 - 1

M AIN VOLT LOW ALM

12:00 1 - 1
SCROLL engine status ----------------------------------------------------
VIS-140D
00-6-20
-------------------End of List-----------------

Figure 3-2. EGCP-2 Navigation (contd.)

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ENTER
from previous page
M AIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ENTER
M AIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
M AIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
C RANK FAIL
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
CRANK FAIL
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR

engine status None Recorded

SYSTEM

system status None Recorded

STATUS

i system status system status

VIS-140E
00-6-20

Figure 3-2. EGCP-2 Navigation (contd.)

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Chapter 4
Software Overview

Introduction
The software used in the EGCP-2 uses state machine logic to operate all modes.
State machine logic relies upon discrete inputs, and specific operating conditions
to trigger a sequence of operations. The state machine logic uses the following
State Machines to operate the generator set:
• Close Mains Breaker • Synchronize
• Open Mains Breaker • Load Control
• Start Engine • Close Gen Breaker
• Off • Open Gen Breaker

Various inputs and actions determine which state machine is in operation at any given
time.

Status Screens
There are a total of nine status menus in the EGCP-2. Use the status keys on the face of
the EGCP-2 to access these status menus. The information in the status menus is
dynamic, and updates about every 200 milliseconds (ms).

When the EGCP-2 is initially powered up, it will default to the System Status Screen.
Below is an example of what the Screen may look like. The System Status Screen can
be accessed while in any other status screen by pressing the SYSTEM key

Figure 4-1. System Overview Engine Off Line

The screen displays the following information:
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Alarms:Number of active alarms on the unit.
Unit #:The network address of the unit.
Mains: A graphic display of the mains condition. Two minus symbols (--) indicates the
mains are out of spec, one plus symbol indicates the mains are in spec, but not
declared stable (+-), two plus symbols (++) indicates the mains are in spec and stable.
Gen: A graphic display of the status of the generator. Two minus symbols (--) indicates
the generator is out of spec, one plus symbol indicates the gen is in spec, but not
declared stable (+-) two plus symbols (++) indicates the generator is in spec and stable.
Engine: The operating state of the engine.
Engine Control States:
• OFF
• PREGLOW
• CRANK
• RUN
• COOLDOWN
• SPINDOWN
• RETRY
Operating State: Shows if the EGCP-2 is in AUTO
or MAN(ual) mode.
Control State: Shows the state of the load control logic of the EGCP-2. The load
control
states are:
Load Control States:
• OFF
• DROOP
• ISOCHRONOUS
• BASELOAD
• PROCESS
KW: The total KW load on the generator.
Hz: The frequency, in Hertz, of the generator set.
PF: The average three phase power factor of the generator set.
KW-Hrs: The total accumulated kW hours produced by the generator set. This display
automatically switches to MW –Hrs when the kW-Hour value exceeds 10,000.
Run-Time: The total accumulated run time of the generator set.

All the display information will update automatically as operating modes and conditions
to the EGCP-2 change.

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This is what the System Status screen would look like with the mains out of spec, the
engine running, carrying 100kW 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, and the mains had failed.

Figure 4-2. System Status Screen - Isochronous

This is what the control overview screen looks like for a generator set that is base
loaded to the mains AT 500Kw, .80 lagging PF, with one unacknowledged alarm.

Figure 4-3. System Status Screen - Baseload

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The following is an overview of each of the status menu screens, starting with engine
overview :

Figure 4-4. Engine Overview

HH:MM: 24 hour clock readout.

MM-DD: Date (MM-DD).
Engine: The state of the engine control function.
RPM: Engine rpm.
Battery Volts: Battery Voltage in Volts DC.
H2O Temp: Water Temperature in degrees C, or F, depending upon the units selected
in configuration.
OIL Press: Oil Pressure in Bar, or PSI, depending upon the units selected in
configuration.
Gen Breaker: The Status of the generator breaker as provided by the gen cb aux
discrete input.
Gen: The status of the generator. Two minus symbols (--) indicates the generator is out
of spec, one plus symbol indicates the gen is in spec, but not declared stable (+-) two
plus symbols (++) indicates the generator is in spec and stable.

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Figure 4-5. Generator Status (Voltage Line to Line)

A B C:Three phase readings for the generator.

KVA:Three phase KVA readings.
KW:Three phase KW readings.
KVR:Three phase KVAR readings.
V:Volts for each phase of the generator.
A:Amps per phase for the generator.
PF:Power Factor for each generator phase.

 NOTE
Generator voltage label (VLL or VLN) will automatically switch
depending on the voltage input configuration setting. See the
configuration menu section of this manual for more detail.

 NOTE
Generator voltage readings and labels will automatically switch from
“V” (volts) to “KV” (kilovolts), when the voltage exceeds 9999V for
that input.

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Figure 4-6. I/O Status

DI:Discrete Inputs 1 through 16.

DO:Discrete Outputs 1 through 12.
Volt Bias:% voltage bias output (±100% range).
Speed Bias:% speed bias output (±100% range).
Process In:Process Input in milliAmperes (mA).

Discrete Inputs Discrete Outputs

1. Automatic Switch 1. Mains Breaker Close/Contactor
2. Test Switch Close
3. Run with Load Switch 2. Gen Breaker/Contactor Close
4. Volts Raise 3. Engine Preglow
5. Volts Lower 4. Fuel Solenoid
6. Speed Raise 5. Engine Crank
7. Speed Lower 6. Visual Alarm Relay
8. Gen Circuit Breaker Aux Contact 7. Local Bus PT Connect
9. Mains Circuit Breaker Aux Contact 8. Mains PT Disconnect
10. Process Switch 9. Mains Breaker Trip
11-16. Remote Alarm/Shutdown 10. Gen Breaker Trip
Inputs 11. Audible Alarm
12. KVA load switch, or Idle/Rated
Switch, depending on configuration

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Figure 4-7. Synchronizer Status

Slip: The slip frequency in Hz. of the generator with relationship to the bus or mains it is
paralleling to.
Phase: The phase angle difference in degrees between the generator and the bus or
mains it is paralleling to.
Volts: The voltage differential in percent between the generator and the bus or mains it
is paralleling to.
Mains/Bus: The active PT input being monitored by the EGCP-2.
Dead Bus: Indicates if the PT input (mains or bus) being measured is dead.
Synchronizer Status: Displays the status of the synchronizer. These are as follows:
Close Gen Breaker Open Mains Breaker
Open Gen Breaker Sync. Timer
Close Mains Breaker
VB: Voltage Bias Output (%)
SB: Speed Bias Output (%)
GEN A: Voltage of the generator.
MAINS: Voltage of the active PT input being sensed by the synchronizer.

 NOTE
Generator and Mains voltage label (VLL or VLN) will automatically
switch depending on the voltage input configuration setting. See the
configuration menu section of this manual for more detail.

 NOTE
Generator and Mains voltage readings and labels will automatically
switch from “V” (volts) to “KV” (kilovolts), when the voltage exceeds
9999V for that input.

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 NOTE
The synchronizer displays **** in the place of Slip, Phase, and Volts
when the synchronizer is inactive, or off.

Figure 4-8. KW Load Status

Generator KW: The sum of the three phase generator KW.
Load Reference: The load reference, in KW for the generator.
System Load: The calculated system load for all units operating in isochronous
load sharing mode. This reading is only active in loadsharing units.
Control: The current load control mode in operation.
Process In: The sensed value of the 4-20 mA or 1-5 VDC process input.

 NOTE
The process input reading is always scaled to mA. If a voltage input
is used, the Process In reading multiplied by 243 will convert the mA
reading directly to the voltage at the input.

Process Ref: The process reference for the process control.

Master Sync Cmd: The master synchronizing and load control bias command (%).
Master Volt Cmd: The master voltage bias command (%).

 NOTE
The master sync and master volt commands are only active in units
in AUTO in multiple unit systems.

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Figure 4-9. PF /KVAR Status

VAR/PF MODE: The configured VAR/PF control mode.

PF REFERENCE: The PF control reference value for the control.

 NOTE
Power Factor (PF) reference changes to KVAR REF when in VAR control.

PF: The average three phase PF of the generator.

A B C: A, B, C phase generator reading indication.
V: Three phase voltage readings for the generator.
A: Three phase current readings for the generator.
KVAR: Total KVAR reading for the generator.

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Figure 4-10. Sequencing Menu

Unit: Network Address of all units in Auto on the network.

Oper: Units in auto, and on the network with their breakers closed and on load.
Prty: Network Priority of all units in auto on the network.
Master Unit: The unit with the highest priority (lowest priority number) that is on the
network and in auto.
Next On: Network address of next unit to be sequenced onto the network.
Next Off: Network address of next unit to be sequenced off the network.
Total On Load: Total number of loadsharing units operating in isochronous loadsharing.
Gen Breaker: The status of the generator breaker as determined by the gen cb aux discrete
input.

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The example below is a typical sequencing screen for a 5 unit system.

Figure 4-11. Sequencing Menu (Multi-Unit)

As displayed on the sequencing screen:
Units 1 3, and 5 are on load with their generator breakers closed.
Next On is unit number 2, which has a network priority of 4.
Next Off is unit number 5, which has a network priority of 3.
Master Unit in this system is the unit with the highest priority, which is unit number one.

 NOTE
The sequencing status display when the unit is in Auto and set for
Multiple Units.

 NOTE
Units which have active shutdowns will remove themselves from the
sequencing menu until the shutdown condition(s) are cleared.

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Figure
4-12. ATS (Automatic Transfer Switch) Status.
Mains: A graphic display of the mains condition. Two minus symbols (--) indicates the
mains are out of spec, one plus symbol indicates the mains are in spec, but not declared
stable (+-) two plus symbols (++) indicates mains are in spec and stable.
Gen: A graphic display of the gen condition. Two minus symbols (--) indicates the
generator is out of spec, one plus symbol indicates the generator is in spec, but not
declared stable (+-) two plus symbols (++) indicates generator is in spec and stable.
Mains Breaker: The state of the mains breaker as determined by the mains cb aux
discrete input.
Gen Breaker: The state of the generator breaker as determined by the gen cb aux
discrete input.
Synch: The synchronizer control mode.
Mains/Bus: The PT input being sensed by the mains/bus PT input through the mains
disconnect, bus connect discrete output logic.
Bus Dead: An indication of a live or dead local bus as determined by the voltage on the
bus, and state of the generator and mains breaker inputs.
Master Sync Cmd: The master synchronizing and load control bias command (%).
Master Volt Cmd: The master voltage bias command (%).

 NOTE
The master sync and master volt commands are only active in units
in AUTO in multiple unit systems.

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Alarm / Event Log

The Alarm / Event button provides access to the EGCP-2’s Alarm and Event Log. This
log contains up to eight individual warning, alarm, or shutdown items. When the
Alarm / Event button is pressed on the EGCP-2 keypad, the right hand LCD screen will
switch to the Alarm/Event log. This log displays the following information. For
navigation within the Alarm / Event log see the menu navigation section of this manual.

Figure 4-13. Alarm / Event Screen

ALARM NAME: The name, as defined by the particular warning, alarm, or shutdown
event.
HH:MM The hour and minute of the alarm occurrence.
MM-DD The Month and Day of the alarm occurrence.
#### The value of the input at the time of the alarm. This value is only visible
with a supervisor level, or higher, password.

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In the event that the Alarm /Event Log key is pressed, and there are no active or logged
alarms, the display will look like this:

Figure 4-14 . Empty Event Log

The alarms displayed in the alarm / event log are arranged in a first in, last out (FILO)
order. The most recent alarms will appear at the top of the list, followed by older
alarms. In the event that the total number of logged and unacknowledged alarms
exceeds sixteen, the oldest alarms will be dropped off the list to make room for the
newer alarm events.

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Configuration Menus
If the Config key on the EGCP-2 keypad is pressed, the right had LCD screen will
switch to the configuration menus. The first item in this menu is the Security Code. The
Security Code value determines which configuration menus are accessed. The Security
Code is also used to determine the access level used for the Alarm / Event log.

Figure 4-15. Security Code Display

When a valid security code is entered, the configuration menu list will be displayed.
The configuration list allows the user to configure, calibrate, and adjust all relative
items to the EGCP-2 operation.

Figure 4-16a. Configuration Menu List (Screen 1)

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Figure 4-16b. Configuration Menu List (Screen 2)

Figure 4-16c. Configuration Menu List (Screen 3)

 NOTE
See manual 26108 (included with the control) for security code and
access level information.

Various Security codes access different portions of the configuration screens, depending
on the level of security code used. The up and down keys are used to move the blinking
cursor to the tuning menu that the user wants to enter. Pressing the enter key will enter
that configuration menu. See the Menu Navigation section of this manual for more
information on navigating through the configuration menus.

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Configuration Menu Items

Security Code Required For Access

A four digit security code is required for access to the configuration menus. If an
incorrect code is entered, or a proper code is not entered within 60 seconds, the displays
will default to the System Status.

Security Code
• Levels Of Access
− Monitor (no security code)
Access to all Status Screens, and Alarm / Event Log Display.
− Operator
Access to Alarm Log and Network Priority (acknowledge and commit), and all items
allowed by the Monitor Security Code.
− Supervisor
Allows access to Network Address and Time Set, and all items allowed access by the
Operator Security Code.
− Technician
Allows access to all setpoints except engine run time and calibration. And all items
allowed access by the Supervisor Security Code.
− Factory
Allows access to engine run time and calibration settings (Full Access).

Sanity Checks:
In order to prevent improper configuration of the control, the following “sanity checks”
are made automatically in software.
• All Items in Configuration Menu must be Committed before engine operation will
be allowed. Uncommitted items will have an asterisk (*) next to them on the screen.
Typically this step is done at the factory, and the asterisk sign will not appear in
most circumstances.
• Configuration Items which have been assigned values outside of calculated normal
values will be indicated by a pound sign (#). These values must be entered properly
before engine operation will be allowed. Warning, Shutdown and Alarm conditions
are also ignored by the control until the values are correct.

All Generator Parameters (KVA, KW, KVAR, Frequency, and Rated Voltage)
must be within sanity check ranges as defined by the following:
• PT and CT Ratios
• Voltage Reference
• Number of Poles
• Rated Speed
• Rated Frequency

Network Address (1 to 8)
• Unique Address for Each Unit in the System.
• Maximum of 8 units on network.

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Network Priority (1 to 8)
• Unique Priority for Each Unit in the System.
• Lowest Active Priority is considered Master.
• Maximum of 8 units on network.
• Sequencing effective from lowest to highest priority.
• When priority is reduced below 1, the value will change to “Set All”. If the commit
key is pressed when this value is on the display, the display will change to represent
all units in auto on the network, and their priority. The network priority of any unit
can be changed by using the left/right and up/down keys on the control. Once
changes are made, the changes are committed by pressing the commit key twice.
Pressing the escape key from within the set all setting will restore the previous
priorities.

Number of Poles (numeric)

• Determines Speed/Frequency Relationship.
• Used for Speed/Frequency Mismatch Alarm/Shutdown.

Number of Teeth (numeric)

• Determines rpm Scaling.
• Engine Speed Readouts/Alarms.

System Frequency (50/60 Hz.)

• Used as a basis for generator waveform analysis.
• Defines typical operating frequency of generator.

Rated Speed (numeric)

• Synchronous Speed Of Generator Set.
• Used in Speed Calculation to determine “sample” period for MPU input.

Rated KW (numeric)
• Rated KW of Generator.

Rated KVA (numeric)

• Used to determine Rated Current of Generator for minimum overcurrent level.
• Equation: I=KVA/Rated Voltage.

Rated KVAR (numeric)

• Rated KVAR of Unit.
• Typically .6 x Rated KVA.
• Rated KVA must be less than or equal to the Voltage Reference x CT Ratio
Primary.
• Rated KW must be less than or equal to the Rated KVA.
• Rated KVAR must be less than or equal to the Rated KVA.
• Any values falling out side of these ranges will appear on the screen with a pound
sign (#) next to them. This indicates the value is out of range, and the engine will
not operate until the # symbol is cleared by entering the correct values.

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KVA
KVAR

KW
KW/KVA=PF
COS =KW/KVA
KVA^2=KW^2+KVAR^2
KVA= (KW^2 + KVAR^2)
Figure 4-17. AC Power Triangle

CT Ratio (numeric :5)

• Scales sensed CT input for Amperage as seen at generator.
• Used for Load Sensing Algorithm.
• (KVA, KW, KVAR, PF)
• Used for Alarms/Shutdowns.
• Over Current, KW Limits, Reverse Current, etc.

PT Ratio (numeric : 1)
• Scales sensed PT input to Voltage Levels as measured at the Generator.
• Used in Load Sensing Algorithm.
• (KVA, KW, KVAR, PF)
• Used for Voltage Matching.
• Used for Generator Frequency Detection.
• Used for Alarm/Shutdown sensing.
• Over/Under Voltage
• KW Limits, etc.

Voltage Input (Wye L-N, Delta L-L)

• Set for sensing/transformer used between generator and EGCP-2.
• Defines which calculations will be used for KW, KVA, KVAR, etc.
• Defines the expected input type for voltage levels in the setpoint menus.
• Sets the label used for all generator and mains voltage Status readings.
• Wye (Star) Generator or Transformer Connection
− 4 Wire
− Volts Line to Neutral expected for all setpoint menu items requiring voltage
settings.
• Delta Generator or Transformer Connection
− 3 Wire
− Volts Line to Line expected for all setpoint menu items requiring voltage settings.

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Voltage Reference (numeric)
• Operating Voltage of Generator per Generator Nameplate.
− Used for VAR/PF Sharing as the Reference that multiple generators share reactive
load to. This maintains the voltage reference while in Power Factor Sharing or
KVAR Control mode on an isolated bus.

Display Units
• American
– Sets temperature readings to degrees Fahrenheit (F), and pressure to Pounds Per
Square Inch (PSI).
• Metric
– Sets temperature readings to degrees Celsius (C) , and pressure to Bar (BAR).
Set Date
• Sets the date used by the control for Alarm / Event time stamps, and displays.
Set Time
• Sets the time used by the control for Alarm / Event time stamps, and displays.

Relay #12 Function

• KVA Load Switch
– Defines Discrete Output #12 as a KVA load switch.
– Uses KVA High and KVA Low value items in the Load Control Configuration
Menu.
• Idle / Rated Switch
– Defines Discrete Output #12 as an Idle / Rated speed switch. This output is
typically used to automatically send the engine speed control an idle/rated command
upon start up.
– Uses the Idle Speed and Idle Time items in the Engine Control Configuration
Menu.

Speed Bias Type

• +/- 3VDC (WGC)
– Sets the speed bias output to +/- 3VDC range. 0VDC is zero output,
– -3VDC is –100% speed bias output,
– +3VDC is +100% speed bias output.
• .5 to 4.5VDC (DDEC)
– Sets the speed bias output to .5 to 4.5VDC range.
– 2.5VDC is zero,
– .5VDC is –100% speed bias output,
– 4.5VDC is +80% speed bias output.
• 500 Hz PWM (adem)
– Sets the speed bias output to 500 Hz Pulse Width Modulated (PWM) range.
– 50% duty cycle = 0% speed bias output,
– 0% duty cycle = -100% speed bias output,
– 100% duty cycle = +100% speed bias output.

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Voltage Bias Type
Sets the voltage bias output voltage range.
• +/- 9VDC Bias
– 0 VDC = 0% voltage bias
– –9 VDC = -100% voltage bias
– +9 VDC = +100% voltage bias
• +/- 3VDC Bias
– 0 VDC = 0% voltage bias
– –3 VDC = -100% voltage bias
– +3 VDC = +100% voltage bias
• +/- 1VDC Bias
– 0 VDC = 0% voltage bias
– –1 VDC = -100% voltage bias
– +1 VDC = +100% voltage bias

Circuit Breaker Control (Breaker/Contactor)

• Defines action of Generator and Mains closure command.
• Breaker issues momentary breaker close signal, and a separate momentary breaker
open signal independently.
• Contactor issues continuous breaker close signal through the breaker close
command relay output. Removes this signal to open contactor.

EGCP-2 Internal Relay +V External Wiring

8
Connections
Gen Breaker Close
9
Generator Breaker
+V
Close Coil
28
Gen Breaker Trip
29
Generator Breaker Trip
Coil

Typical Breaker Configuration Based Logic.

(Generator Breaker Output Shown)

EGCP-2 Internal Relay +V External Wiring Connection

8
Gen Breaker Close
9
Generator Contactor
Close/Open Coil
28
Gen Breaker Trip No Connection.
29
VIS-142a
00-08-29

Typical Contactor Configuration Based Logic.

(Generator Breaker Output Shown)

Figure 4-18. Breaker Logic and Contactor Logic

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Operating Mode
• Mains Parallel or No Parallel
• Mains Parallel will allow the unit to synchronize to the mains, and carry load while
in parallel with the mains as well (closed transition).
• No Parallel will not allow the unit to operate with load until the mains breaker is
sensed as being open (open transition).
• All units operating in a load sharing system must be set for the same parameter, i.e.
mains parallel, or no parallel.

Number of Units (single, multiple)

• Defines whether unit is part of a multiple unit system or not.
• If single unit, there is no auto starting, auto sequencing, load or PF sharing with
other units under any circumstances. Unit displays “single unit no sequencing” on
sequencing screen. Network Priority and Network Address setpoints are removed
from the configuration setpoint menu automatically.

• If multiple unit, auto starting, auto sequencing, load and VAR/PF sharing are
available between all units in multiple. Unit displays system sequencing
information on sequencing screen. Network Priority and Network Address setpoints
are added to the configuration setpoint menu automatically. Unit must be in Auto
mode to communicate over the inter-control network (RS-485).

Shutdowns and Alarms

Shutdowns and Alarms menu is used to configure the various safety functions of the
EGCP-2.

Each alarm setpoint can be set for:

• Disabled
• Warning—LED on control flashes.
• Visual Alarm—LED flashes, and Visual Alarm relay energizes.
• Audible Alarm—LED flashes, Visual and Audible Alarm relays energize.
• Soft Shutdown—LED turns on, Visual and Audible Alarm relays energize, Fuel
Solenoid relay de-energizes. Unit soft unloads and cycles through cool down timer
when applicable. Unit removes itself from auto sequencing order.
• Hard Shutdown--Same as above, but immediately opens generator breaker and de-
energizes the fuel solenoid.

Voltage Range Alarm

• Alarm/Shutdown point for an excess of voltage bias signal from the EGCP-2 to
AVR.
• Preset to trigger at ±100% voltage bias output.
• Indicates that the AVR is not responding to the voltage bias output as expected.

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Generator High Voltage Limit (Voltage Bias Cutout)

Opegrating
Rated Generator Voltage

Range
Generator Low Voltage Limit (Voltage Bias Cutout)

Figure 4-19. Generator High/Low Voltage Alarms

Generator Volt High Limit (numeric)

• Sets maximum allowable generator voltage level.
• If voltage is above High Limit, generator is not considered stable, and is unfit for
breaker closure.

Generator Volt Low Limit (numeric)

• Sets minimum allowable generator voltage level.
• If voltage is below Low Limit, generator is not considered stable, and is unfit for
breaker closure
• Voltage Bias will not decrease while generator voltage is below the low limit.

Generator High/Low Volt Limit Alarm

• Even if the Alarm Setpoints for the High/Low Limits are Disabled, the Voltage Bias
will not allow adjustment beyond these limits.
• The same is true for the synchronizer, which will not allow a gen breaker closure if
the High or Low Voltage limits are met or exceeded for a period of time which
exceeds the Gen Volt Timer Setpoint.

Voltage Alarm Delay

• Sets minimum time, in seconds, allowed prior to activating either Generator
High/Low Voltage Limit Alarms. This allows for short period transient over/under
voltages to occur on the generator without setting off the Generator Voltage
Alarms.

Generator Frequency High Limit (numeric)

• Sets maximum allowable generator frequency level.
• If frequency is above High Limit, generator is not considered stable, and is unfit for
breaker closure.

Generator Frequency Low Limit (numeric)

• Sets minimum allowable generator frequency level.
• If frequency is below Low Limit, generator is not considered stable, and is unfit for
breaker closure.

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Generator High Frequency Limit (Speed Bias Cutout)

Opegrating Synchronous Speed (50/60 Hz)

Range

Generator Low Frequency Limit (Speed Bias Cutout)

Figure 4-20. Generator Over/Under Frequency

Generator High/Low Frequency Limit Alarm

• Even if the Alarm Setpoints for the High/Low Limits are Disabled, the Speed Bias
will not allow adjustment beyond these limits.
• The same is true for the synchronizer, which will not allow a gen breaker closure if
the High or Low Frequency limits are met or exceeded.

Speed/Frequency Mismatch Alarm

• Compares generator frequency to engine rpm and alarms on difference.
• Used to indicate loss of MPU, or Loss of Generator Field Voltage.

Overcurrent Level (numeric)

• 3 Phase sensing, selects the phase with the highest current.
• Set for Per Phase Overcurrent.
• Overcurrent Detection begins when current exceeds rated current as determined by
Voltage Reference and Rated KVA values in Configuration menu: (KVA/Voltage
Ref)/3.
• Uses Inverse Time Function as basis for overcurrent detection. This allows different
levels of overcurrent based on time span.

Overcurrent Delay (Numeric)

Per Phase
amps
Overcurrent Trip Zone
overcurrent level

100% rated current

overcurrent time
delay
Figure 4-21. Overcurrent Inverse Time Function

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amps Overcurrent Trip Zone

overcurrent level

overcurrent time
delay
Figure 4-22. Overcurrent Level—High Current, Short Duration

amps
Overcurrent Trip Zone
overcurrent level

overcurrent time
delay
Figure 4-23. Overcurrent Level—Notice Area of Overcurrent is the Same

Reverse Power Level (numeric)

• Reverse Power Condition begins when sensed KW on generator goes negative.
Reverse Power Trip levels depend upon amplitude and duration of reverse power
condition.

Reverse Power Delay (numeric)

• Reverse Power also uses an inverse time function.

Minimum Reverse Pwr (numeric)

• Minimum Reverse Power Level which can trigger a reverse power alarm condition.
Reverse power levels below this setpoint will not cause a reverse power alarm
condition, regardless of duration. When the reverse power level exceeds this setting,
the Reverse power Delay begins, and the accumulation of the reverse power
amplitude is monitored by the control.

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Reverse
KW Power
+ Delay Start
Time
0 Min
KW Rev
- Power
Reverse Power
Reverse Power
Level

Figure 4-24. Reverse Power

Loss of Excitation (LOE) (numeric)

• Set as a percentage of total KVAR load on the generator that can be applied as a
block reactive load to the unit. If control senses changes in KVAR loads instantly
applied greater than this value the LOE alarm triggers.
• Used to indicate loss of field excitation to the generator.

Remote Faults #1 through #6

• Each fault is programmable for:
disabled
warning
visual alarm
audible alarm
soft shutdown
hard shutdown

Remote Faults #1 through #6:

• Each alarm has a programmable time delay (0 to 30000 seconds).
• Each alarm can be set for any of the standard alarm or shutdown levels.
• External Faults #1 and #2 do not start time delay until after gen stable period has
expired.

Engine Control
Preglow Time
• Time of preglow allowed prior to engine crank cycle.
• Maintained through engine cranking.
• Resets after every crank attempt.

Crank Time
• Maximum Allowable Time for Engine Cranking.

Crank Cutout
• Engine rpm level where crank command is canceled.

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Manual 26086 EGCP-2 Engine Generator Control Package
Crank Delay
• Time between Engine Crank Attempts.

Crank Repeats
• Number of times EGCP-2 will attempt to re-start engine. Cranking attempts will
equal the value of Crank Repeats +1.

Crank Fail
• Alarm Setpoint.
• Activates when Number of Crank Repeats is depleted.

Idle/Rated Speed
• If the Relay #12 output is configured for Idle/Rated switch, this value will set the
speed at which the Idle/Rated Time begins.
• Value should be approx. 10% less than the actual idle speed of the generator set.

Idle/Rated Time
• Timer which sets the delay in seconds the EGCP-2 waits once the Idle/Rated Speed
setpoint is exceeded. Once the Idle/Rated Time is passed, the EGCP-2 will energize
the #12 Discrete Output (if the Relay #12 output is configured for the idle/rated
function).

Cooldown Time
• Time allowed for cooldown once engine achieves a stop cycle.
• Must exceed Cooldown Limit (see next display) before activated.

Cooldown Limit
• KVA setpoint at which, when exceeded, will cause the engine to go to a cooldown
during a stop cycle.

Engine Run Time

• Hours of Run Time on Engine
• Increments in hours.
• Retained in EE memory—Does not require power to maintain previous value.
Updated every 4 hours of operation, and every time the engine is stopped.

MW Hours
• MW Hours on Generator
• Increments in .1 MWH.
• Retained in EE memory. Updated every 4 hours of operation, and every time the
engine is stopped.

Overspeed (numeric)
• Set for overspeed limit of engine.
• Typically set for Hard Shutdown for safety.
• Typically set for 10% above Rated Speed of engine.

Battery Volt High Limit (numeric)

• Sensed DC voltage supply to EGCP-2.
• Can be used to detect faulty charging circuit.

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EGCP-2 Engine Generator Control Package Manual 26086
Battery Voltage Low Limit (numeric)
• Used to detect weak battery/failed charger.
• Automatically Disabled during engine cranking.

High H2O Temperature (numeric)

• Uses engine mounted temperature sensor.
• Active once Gen is considered stable.
• Display is selectable for degrees F (American) or degrees C (Metric).

Low H2O Temperature (numeric)

• Useful for detection of failed jacket water heater.
• Always active.

High Oil Pressure (numeric)

• Uses Engine mounted pressure sensor.
• Active when generator is stable.
• Display is selectable for PSI (American) or Bar (Metric).

Low Oil Pressure

• Used to sense failure of lube oil system.
• Active when generator is stable.

Synchroscope
Synchronizer Mode

Permissive
• Acts as a synch check device.
• EGCP-2 will not issue speed or voltage bias commands, but if synchronization
conditions are within spec (phase and voltage), control will issue a breaker close
command.

Check
• Used for checking synchronizer prior to commissioning.
• EGCP-2 control actively synchronizes generator by issuing speed and voltage bias
commands, but does not issue breaker closure command.

Run
• Normal operating mode.
• Actively synchronizes and issues breaker closure command.
• EGCP-2 control MUST be in RUN to operate as a dead bus closing device.
• In multiple unit systems EGCP-2 control MUST have AUTO input active to enable
breaker control.

44 Woodward
Manual 26086 EGCP-2 Engine Generator Control Package

m a n u a l c lo s e

B re a k e r C lo s e

52G
a u to /m a n
s w itc h

Figure 4-25. Typical Circuit Using Permissive Function

and Run for Auto/Manual Synchronizing

Synchronizer Gain
• Sets Gain of Synchronizer speed bias output.

Synchronizer Stability
• Sets Stability of Synchronizer speed bias output.
• Both Gain and Stability are used to tune the synchronizer dynamic response.

Gain
• Gain Multiplier for output signal proportional to phase error.

Stability
• Stability (Integrator dx/dt in seconds per repeat)

Voltage Matching (enabled or disabled)

• Enables/Disables Voltage Matching feature of EGCP-2 control.
• Enables Voltage Window Setpoint.
Voltage Window (numeric)
• Overall percentage of error allowed between generator and bus, or generator and
mains.
• EGCP-2 control will not issue a breaker closure if error is greater than voltage
window.

Gen Voltage High Bus or Mains Voltage

484.8 VAC +1%

480 VAC
475.2 VAC -1%

Gen Voltage Low

Figure 4-26. Voltage Matching (1% setpoint)

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EGCP-2 Engine Generator Control Package Manual 26086
Max. Phase Window
• Maximum allowable phase angle deviation from phase matched condition.
• EGCP-2 Control will not issue breaker closure if phase angle between generator and
bus, or generator and mains exceeds this window.

o
-10 +10

Must be within
+/- 10 deg window for
breaker closure

Figure 4-27. Maximum Phase Window = 10 Degrees

Dwell Time (numeric)

• The period of time that the generator must be within the Max. Phase Window for
before the EGCP-2 control will issue a breaker closure.
• Longer dwell times will give typically give better stability after the breaker closes.
• Shorter dwell times reduce amount of time required to synchronize unit.

C.B. Hold Time

• Time in Seconds that Breaker/Contactor Close output is held after breaker close
command is issued.

Close Attempts
• Number of Close Attempts allowed while synchronizing.
• Close attempt incremented if breaker does not send back continuous CB Aux signal
to EGCP-2.

Reclose Delay
• Time in Seconds before EGCP-2 control attempts resynchronization after failed
closure attempt.

Synch Reclose Alarm

• Alarm setpoint if number of close attempts is depleted.

Synchronizer Time Out

• Sets time allowed for synchronization in seconds.
• Begins timing when synchronizer activates.
• Active for all gen and mains breaker open and close commands from EGCP-2 control.
A setting of zero (0) seconds disables synch. time-out—infinite synch time allowed.

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Manual 26086 EGCP-2 Engine Generator Control Package
Synch Time-out Alarm
• Sets alarm mode if synch time-out is exceeded. Shutdown actions are not allowed.

Dead Bus Closure

• Enables/Disables Dead Bus Closing Feature.
• Unit must be within voltage and frequency high/low limits to be considered for dead
bus closure.
• Dead Bus Closure uses Token Passing Scheme to assure that only one unit in a
networked system will close onto the dead bus at any given time.
• Multiple unit systems must have Auto switch input to allow dead bus closing
between networked units.

Real Load Control

Load Control Mode
• Normal
− Standard setting for load control and VAR/PF functions.

• Soft Transfer
− Standard load control and VAR/PF functions, but unit will issue mains breaker open
command while in process control if process reference is reached, or while in base
load and base load reference is reached.

• Droop
− Manual Load and Voltage Control
− Used primarily for commissioning.

Load Control Gain

• Sets gain response of load control.
• Active in load ramping and base load operations.

Load Share Gain

• Sets gain response of proportional load sharing.
• Active in load sharing operations.

Load Stability
• Sets Stability response of load control.
• Active in load ramping and base load operations.

Load Derivative
• Sets Derivative response of load control.
• Active in load ramping and base load operations.

Load Control Filter

• Low Pass Filter used to attenuate higher frequency transients for better stability.
• Active in proportional load sharing, load ramping, and base load control modes.
• Higher values of filter will tend to make the unit more responsive to small, rapid
transients.
• Lower values of filter will tend to make the unit less responsive to small, rapid
transients.

Base Load Reference

• Load Level Generator will automatically ramp to when operating in Base Load.

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EGCP-2 Engine Generator Control Package Manual 26086
Unload Trip
• Load Level where Generator Breaker/Contactor open command will be issued when
EGCP-2 control is off loading generator set.

Load Droop
• Percentage of KW droop used when EGCP-2 control is operating in a droop mode.

Load Time
• Time in Seconds for generator to load from unload trip level to base load level. This
rate is applied during any automatic loading function, including ramping to load
sharing.

Unload Time
• Time in Seconds for generator to unload from base load level to unload trip level.
This ramp rate is applied during any automatic unload functions, including ramping
from load sharing.

Raise Load Rate

• Percent Load per Second ramp rate used when the raise load contact input is used
during base load operation.

Lower Load Rate

• Percent per Second Ramp Rate used when the load lower input is active in base
load control operation.

KW Load High Limit

• Maximum allowed load while operating in Base load or Process control modes.
• Prevents overload of unit.

KW High Limit Alarm

• Sets alarm mode when unit is at or above High Load Limit.
• Active during all load control operations.
• Unit will not exceed High Limit setpoint when operating in Base Load or Process
Control Modes.

KW Load Low Limit

• Active during all load control operations.
• Sets alarm mode when unit is at or below Gen Low Load Limit.
• Minimum allowed load while operating in Base load or Process control modes.
• Prevents reverse current of unit.

KW Low Load Limit Alarm

• Sets Alarm Mode when unit is at or below Low Load Limit.
• Active during all load control operations.

KVA Switch Low

• Sets level, which when exceeded, will cause the KVA relay output to energize.
Only applicable for units with the relay#12 function configured for KVA Load
Switch.

KVA Switch High

• Sets level, which when exceeded, will cause the KVA relay output to de-energize..
Only applicable for units with the relay#12 function configured for KVA Load Switch.

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Manual 26086 EGCP-2 Engine Generator Control Package

Summary of KVA load switch action:

If the relay 12 output is configured for KVA Load Switch action:

If the three phase sum of the generator KVA is greater than the KVA Switch Low
setpoint, AND less than the KVA Switch High setpoint, the K12 relay output shall
energize. Any other KVA levels relative to the Low and High switch setpoints shall
cause the K12 relay output to de-energize.

Reactive Load Control

VAR/PF Mode
• Disabled
Unit does not PF share, or control PF under any circumstances.
• VAR Control
Unit PF shares in isolated bus load sharing mode.
Unit controls KVAR in Base Load and Process Control Modes.
• PF Control
Unit PF shares in isolated bus load sharing mode.
Unit controls PF in Base Load and Process Control Modes.

VAR/PF Gain
• Controls Gain Response of unit in VAR/PF control mode.
• NOT active in PF sharing mode.

Voltage Ramp Time

• Ramp time from 0 to ±100% voltage bias output.
• Controls response of units in PF sharing modes.
• Controls ramp time of voltage during synchronization.
• Controls ramp time of voltage during manual voltage adjust.

VAR/PF Sharing Gain

• Controls Gain Response of unit in VAR/PF Sharing Mode.
• NOT active in VAR/PF Control Mode.

VAR/PF Stability
• Controls Stability Response of unit in VAR/PF control mode.
• NOT active in PF sharing mode.

KVAR Reference
• When KVAR control mode is selected, this references the amount of KVAR the
generator will produce while in Base Load or Process control modes.
• Can be set for generate or absorb levels of KVAR.
• KVAR levels limited by Rated KVAR of unit.

PF Reference
• PF level that will be maintained by the generator while in Base Load or Process
control modes.
• Can be set for leading or lagging power factor.
• Scaled from 0 (unity) to -.5 (.5 leading) to +.5 (.5 lagging).

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EGCP-2 Engine Generator Control Package Manual 26086

PF Deadband
• ± deadband around PF reference point.
• Set in PF.
• Active in PF and PF sharing modes.
• Can be used to stabilize units at low loads if needed.

Process Control
Process Action (direct, indirect)
• Defines action of speed bias when unit is operating in process control in parallel
with the mains.
• Direct action = Unit increases speed bias (fuel) to increase process 4–20 mA input.
• example: Export Power control
• Indirect action = Unit decreases speed bias (fuel) to increase process 4–20 mA
input.
• example: Import Power Control

100
20 mA

export
power

0 speed bias 100

4 mA

Figure 4-28. Direct (Export) Process Action

100
20 mA

imported
power

0 speed bias 100

4 mA
Figure 4-29. Indirect (Import Power) Process Action

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Manual 26086 EGCP-2 Engine Generator Control Package

100
20mA

speed bias -> 0 100%

0

-100
4mA

Figure 4-30. Direct (Import/Export) Process Action

Process Import/Export Hardware

• EGCP-2 Control can take a 4–20 mA, or 1–5 Vdc input signal from a transducer.
Input signal conditioning is selected by a dip switch on the back of the control,
switch position 4, switch number 4. Closing this switch selects the 4-20mA input
hardware. Opening this switch selects the 1-5VDC input hardware. See the EGCP-2
layout diagram for switch location on the unit.

SW - 4
___________________________ Dip Switch # 4
1. +5V RS-485
1
2. 123 ohm RS-485 Termination+ 2
3. 123 ohm RS-485 Termination - 3
4
4. 4-20 mA Process Input

Figure 4-31. EGCP-2 Control Dip Switch

Process Dynamics
• Process Master Uses Process PID to control.
• Gain, Stability, Derivative, Filter, Droop.
• Slaves to the Process Master use Load Control PID Values to track master system
load reference.
• Load Gain, Stability, Derivative, Filter.

Process Gain
• Sets system gain response while in process control.
• Effective at active master unit only. Slaves rely on Load Control dynamic settings
to control response to master load reference.
• Should be set with maximum number of units operating in process control mode.

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EGCP-2 Engine Generator Control Package Manual 26086
Process Stability
• Sets system stability response while in process control.
• Effective at active master unit only. Slaves rely on Load Control dynamic settings
to control response to master load reference.
• Should be set with maximum number of units operating in process control mode.

Process Derivative
• Sets system derivative response while in process control.
• Effective at active master unit only. Slaves rely on Load Control dynamic settings
to control response to master load reference.
• Should be set with maximum number of units operating in process control mode.

Process Deadband
• ± deadband around process reference point.
• Used to add stability to marginally stable process.

Process Droop
• Introduces negative feedback on the process reference as the process input
increases.
• Used to add stability to marginally stable processes.

Process Filter
• Low Pass Filter attenuates higher frequency transients on process 4–20 mA input signal.
• The higher the filter is set, the more active the process control will be to higher
frequency process transients.
• The lower the filter is set, the less active, and more stable the process control will
be to higher frequency process transients.

Process Reference
• The reference point, in mA, at which the master will control the process input.
• Also used in Soft Transfer modes to set the level of process at which the transfer
from mains to generator will occur.

Raise Rate
• Rate, in mA/Sec., at which the process reference will change when the EGCP-2
receives a raise load contact input while operating in process control mode.

Lower Rate
• Rate, in mA/Sec., at which the process reference will change when the EGCP-2
receives a lower load contact input while operating in process control mode.

Process High Limit

• Maximum allowable process reference level. Set in mA.
• Effective on active master unit only.

Process High Limit Alarm

• Sets alarm mode when process High Limit is reached.

Process Low Limit

• Minimum allowable process reference level. Set in mA.
• Effective on active master unit only.

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Manual 26086 EGCP-2 Engine Generator Control Package
Process Low Limit Alarm
• Sets alarm mode when process reference reaches the Low Limit.

Transfer Switch
Check Mains Breaker (enabled/disabled)
• Used to activate checking of mains C.B. Aux. Discrete input when enabled.
• If disabled, unit relies on other units with this setpoint enabled to broadcast state of
mains C.B. Aux. contact over network.
• Units Controlling Mains Breaker must have Check Mains Breaker Enabled.

Fast Transfer Delay

• Time required for a transition in switching from Mains to Generator operations, and
from Generator to Mains operations. This includes transition times between bus and
mains sensing.

Mains Stable Delay

• Period of time required for the mains to be declared stable (within voltage and
frequency limits for the specified time) before transition from generator(s) to mains.

Generator Stable Delay

• Period of time generator must be declared stable (within voltage and frequency
limits for the specified time) before transition from Mains to Generator, as well as
dead bus closing.

Load Surge (% rated load/sec)

• Used only in Base Load or Process Control.
(Mains Parallel Operations)
• Set to trigger at a percent setpoint of total generator load shift per second while
operating in Mains Parallel.
• Can be set for Loss of Mains Detection.
• Instantaneous Trigger.

Load Surge Alarm

The load surge condition will cause a response defined by this setpoint. The available
responses are:
• Disabled
• Warning
• Loss of Mains
• Loss of Mains with Alarms

Main Volt High Limit (numeric)

• Alarms when Mains Voltage exceeds Alarm Setpoint.
• Alarm can be set for Loss of Mains.
• If Mains Voltage is above High Limit, Mains are not considered stable, and the
EGCP-2 control will not issue a mains breaker closure command.

Main Volt High Alms

The Main Volt High condition will cause a response defined by this setpoint. The
available responses are:
• Disabled
• Warning

Woodward 53
EGCP-2 Engine Generator Control Package Manual 26086
• Loss of Mains
• Loss of Mains with Alarms

Mains Volt Low Limit (numeric)

• Alarms when Mains Voltage drops below setpoint.
• Alarm can be set for Loss of Mains.
• If Mains Voltage is below Low Limit, Mains are not considered stable, and the
EGCP-2 control will not issue a mains breaker closure command.

Main Volt Low Alm

The Main Volt Low condition will cause a response defined by this setpoint. The
available responses are:
• Disabled
• Warning
• Loss of Mains
• Loss of Mains with Alarms

Main Frequency High Limit (numeric)

• Alarms when Mains Frequency exceeds Alarm Setpoint.
• Alarm can be set for Loss of Mains.
• If Mains Frequency is above High Limit, Mains are not considered stable, and the
EGCP-2 control will not issue a mains breaker closure command.

Main Freq High Alm

The Main Frequency High condition will cause a response defined by this setpoint. The
available responses are:
• Disabled
• Warning
• Loss of Mains
• Loss of Mains with Alarms

Mains Frequency Low Limit (numeric)

• Alarms when Mains Frequency drops below setpoint.
• Alarm can be set for Loss of Mains.
• If Mains Frequency is below Low Limit, Mains are not considered stable, and the
EGCP-2 control will not issue a mains breaker closure command.

Main Freq Low Alm

The Main Frequency Low condition will cause a response defined by this setpoint. The
available responses are:
• Disabled
• Warning
• Loss of Mains
• Loss of Mains with Alarms

LOM Action Delay (numeric seconds)

• Sets Time Delay for LOM Action to begin once Loss of Mains is detected.
• Delay time From LOM detection to mains breaker open, and engine start command.
• In applications where the utility bus is somewhat unstable, this setting can be used
to prevent momentary disruption of the mains frequency or voltage on from causing
unwanted Loss of Mains actions to occur.

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Manual 26086 EGCP-2 Engine Generator Control Package

Sequencing and Comms (Communications)

Automatic Sequencing (enabled/disabled)
• Enables or Disables Auto Sequencing for that unit.
• Can be used to disable sequencing for a particular unit in a sequencing system if
needed.
• Disabling at the master disables all auto sequencing.

Maximum Generator Load

• % system load on all units with gen breakers closed, and on the same network, in
Auto, and in Load Sharing or Process control modes, at which active master unit
will begin timing to sequence next unit on line.

Next Genset Delay

• Period of time that will pass before master auto sequences an additional generator
on line after the Maximum Generator Load Setpoint is exceeded, and remains
exceeded.
• Delay is effective only in active master unit.

Rated Load Delay

• Delay when system load exceeds 100%, before master starts next genset in
sequence.
• Overload condition fast sequence operation.
• Rated Load Delay function overrides load ramping on unit being sequenced on line.
That unit will immediately assume its proportion of the system load.

Maximum Start Time

• Time allowed by master to see next unit to be sequenced on line in an “active”
condition, i.e. started and ready to load.
• This is determined by a network flag, which indicates the unit is ready to load, is
sent over the network by the unit being sequenced on by the master.
• If master does not detect this flag within the Max. Start Time allowed, it will go to
the next lower priority unit and try starting it, or if no other units are available, it
will retry the start command on the same unit.

Minimum Generator Load

• % of system load at which active master begins timing to sequence units off line.
• Master may have to wait until system load is below this level if unit next in line to
be sequenced off will cause the system load to increase above the Max Gen Load
setpoint of the Master.

Reduced Load Delay

• Time in seconds which the active master waits before sequencing units off line.
• Delay is effective only on active master unit.
• Lowest priority units are sequenced off line first.

Maximum Stop Time

• Time in seconds allowed by master for slave to sequence off line.
• Master begins sequencing next lowest priority unit off line if system load is still
above Min. Gen. Load setpoint at the end of the Max Stop Time Limit.

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 EGCP-2 Engine Generator Control Package Manual 26086
422 Protocol
This setting defines the protocol used on the EGCP-2’s RS-422 port. Make sure you are
familiar with the various settings by reading the Serial Communications section of this
manual completely before deciding on which protocol to use. Improperly setting this item
may cause a loss of communications with the EGCP-2 on the RS-422 port.

 NOTE
Changes in the 422 Protocol setpoint do not take effect until input
power is cycled to the control.

Servlink
• Sets RS-422 Serial Communications to Servlink Protocol
Modbus
• Sets RS-422 Serial Communications to Modbus RTU Protocol
Upload Setpoints
• Sets RS-422 Serial Communications to Upload Setpoint mode.
Modbus ID
• Sets the Modbus RTU network ID of the Unit. Units can only be Modbus slaves.
Modbus Timeout
• Sets the timeout time for Modbus communications. See the Serial communications
section of this manual for details.
Modbus Reset
• Can be used to reset the Modbus error indications for the unit.

Calibration Menu
While each unit will be factory calibrated at Woodward prior to shipment, there are
bound to be some inputs/outputs affected by external wiring and/or interfaces (relays,
transformers, etc.) that will require calibration at the site during commissioning.

The Calibration Menu allows calibration of all the analog inputs to the EGCP-2, as well
as the speed bias and voltage bias outputs.

All calibration points in the EGCP-2 are used to make the actual value of an input, such
as generator voltage, read out on the respective display screen of the EGCP-2 the proper
value of the signal being monitored.

In order to assist in calibrating the unit, each calibration menu item has the sensed
input being calibrated displayed on the lower two lines of the right hand LCD screen.
These values are updated every 200 milliseconds. All adjustments in the configuration
menus are immediate in their action, i.e. Values do not need to be entered into memory
to have an affect on the sensed input, or control operation.

Example: 380 Vac measured line to line on the generator A- B phase should read
380VAC in the line to line voltage measurement area of the EGCP-2 “generator status”
menu. The EGCP-2 is configured for Line to Line voltage input.

56 Woodward
Manual 26086 EGCP-2 Engine Generator Control Package
The calibration menu item “PT Phase A Scale” will display the A-B generator phase
voltage in the lower to lines of the display. This value will change as the PT Phase A
Scale value is adjusted.

Process Input Scale

• Actual Input 4–20 mA, or 1–5 Vdc process signal from external transducer.
• Monitor the Pin (process in) reading in the Load Control Monitor menu.
• Calibrate Process input scale until Pin reads accurately what measured process
signal is.
• Engine must be in a test or run mode and operating to observe the Pin value in the
lower two lines of the setpoint screen.

Measured vs Monitored
480.0 VAC Measured A -B
phase Line to Line
Measured vs. Monitored
480.0
vac

Monitored Voltage
EGCP-2 configured for Line to Line (3 wire) PT input.

Woodward

ALARMS: 1 UNIT: 1 A PHASE PT SCALE

B Mains: -- Gen: ++ 1.00
Engine: RUNNING -----------------------------------------------------------------------
AUTO: ISOCHRONOUS PHASE A VL-L: 482.5
C

E G C P - 2 'LJLWDO &RQWURO STATUS C O. N F I G

VIS-141
i .
.
00-6-20 ALARM / EVENT GE
SYSTEM ENGINE
N

ALARM CLEAR SCRO

LL
I/ SYN
KW LOAD
C
O
ESC ENTER PF /
SEQUENCE ATS
KVAR

Calibrate the Monitored Value to equal the Measured

value using Calibration menu items.

Figure 4-32. Measured vs. Monitored

Speed Bias Offset

• Factory calibrated for 0 Vdc offset on ±3 Vdc range.
• All Woodward Speed controls operate with this bias output, so no calibration
should be required.
• Calibration may be required for other manufacturer’s speed controls.

Voltage Bias Offset

• Factory set for zero Volts DC.
• Configuration selectable ±1 Vdc, ±3 Vdc, ±9 Vdc range.
• Some regulators require a positive voltage bias offset because they cannot receive a
negative voltage bias command. Any bias offset calibrated into the voltage bias will
be displayed in the I/O status menu.
• The EGCP-2control will always reset to the voltage bias offset when off line.

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EGCP-2 Engine Generator Control Package Manual 26086

Voltage Bias input from EGCP-2

trim

Trim Adj.
Internal Trim adjustment potentiometer
Volts sets effective range of +/- 1 VDC bias
from EGCP-1 control. Usually a +/- 10%
voltage change for the +/-1VDC input
is more than sufficient for good VAR
and PF control.

Figure 4-33. Typical AVR with Aux Input (Newage SX-440)

Pot Voltage Bias input

. from EGCP-2

Trim Adj.
On regulators without a trim input
Volts such as Leroy Summers AVRs,
an external trim pot must be used
to limit the range of the voltage
bias input from the EGCP-2 control.

Figure 4-34. Typical AVR with External Voltage Adjust Potentiometer

AVR DROOP
• It is highly recommended to fit the AVR with a Droop CT input, and utilize a
medium droop level on the AVR. This adds stability to the AVR for VAR/PF
sharing at low loads.
• Cross current compensation should be disabled in the AVR Droop CT circuit.

+/- 1 VDC input from EGCP-2

trim

Volts
CT
Droop

Figure 4-35. AVR Droop

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Manual 26086 EGCP-2 Engine Generator Control Package
PT Phase A Scale
• Calibrates PT phase A voltage input.
• Adjust PT Phase A scale until these values match measured generator voltage on A
phase.

PT Phase B Scale
PT Phase C Scale
• Same as above, but for B and C phases of Gen.

CT Phase A , B and C Offset

• Calibrates CT Phase A , B , Or C input sensing of EGCP-2 at zero current.
• Measure actual gen. currents with clamp on ammeter, or panel ammeter. Verify 0
Amps on the selected phase input.
• Calibrate selected phase CT reading in the calibration window.
• NOTE: The current reading does not go negative. Therefore, make sure when
zeroing the value that the offset adjustment is made so the current reading just turns
to zero. Verify this by increasing the offset value, seeing a slight positive current
reading, and then slowly adjust the offset value in small increments until the current
reading just changes from a positive value to zero (0.0).

CT Phase A Scale
• Calibrates CT Phase A sensing of EGCP-2.
• Load generator and monitor gen. currents in phase overview menu.
• Measure actual gen. currents with clamp on ammeter, or panel ammeter.
• Calibrate phase A CT reading in phase overview.

CT Phase B Scale
CT Phase C Scale
• Same as CT setup for phase A.
• If CT polarity is reversed, that phase will read negative KW when loaded in the
Phase overview menu.
• If CTs are on the incorrect phases, then KVAR readings in phase overview will be
much higher than normal.

Bus PT Scale
• Similar to Gen PT scaling, but this scale is for single phase bus PT input to the
EGCP-2.
• Put EGCP-2 synchronizer in “check” mode in synchronizer setup menu.
• Start engine in run/load mode to a live bus (either paralleling to another genset, or
the Mains).
• Monitor Synchroscope status menu. Observe and calibrate U: volts reading until
measured matches monitored.

Synchronizer
• Calibrates phase angle error detection of EGCP-2.
• Factory calibrated for zero phase angle error between bus and mains A phase
(depending on synchronizing operation) and A phase generator inputs.
• With synchronizer in “check” mode, and a live bus, monitor the synchroscope menu
of the EGCP-2 for “phase angle”.
• Monitor Voltage across open gen contactor/breaker or panel synchroscope for phase
angle error between generator and bus.

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• Adjust synchroscope calibration for lowest voltage across gen breaker, or 12
o’clock reading on panel mounted synchroscope.

Freq.

(Hz)

Analog Input
Figure 4-36. Direct proportional input to Water Temp or Oil Pressure Input.

Increasing offset

Freq.

Decreasing offset

Analog Input
Figure 4-37. Voltage Controlled Oscillators—Effect of Offset

Increasing gain

Decreasing gain

Figure 4-38. Voltage Controlled Oscillators—Effect of Gain

Battery VCO Gain

• Sets slope of battery input over operating range.

Battery VCO Offset

• Sets level, or offset of Battery input over operating range.
• Battery Voltage is a linear increasing type input function.

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VCO
Freq.

Battery Voltage
Figure 4-39. Battery VCO

Oil Pressure Gain

• Oil Pressure sensor input.
• Ohm sensor on engine is a direct, mostly linear function.
• Sets slope of oil pressure input.
• Monitor Engine Overview menu of EGCP-2 and compare to measured oil pressure
of engine with engine running at rated speed.
• Adjust gain for proper oil pressure reading while engine is operating.

Oil Pressure Offset

• Sets level, or offset of oil pressure input to VCO frequency.
• Set to read 0 psi in Engine Overview menu of EGCP-2 with engine off.
• Gain and Offset DO affect each other, so it is necessary to check adjustments at
both ends of the scale (0 psi to operating psi) if an adjustment is made to either gain
or offset.

VCO
Freq.

Oil Presssure
(OHMS)

Figure 4-40. Oil Pressure VCO

Water Temperature Gain

• Water Temperature input.
• Inverse, Non-Linear 0-200 ohm engine mounted sensor shown.
• If using a non linear resistive style input, utilize Shunt resistor dip switches on back
of EGCP-2 (SW-2, 3 and 4 ON). These resistors help to linearize the sensor input.
• Sets slope of water temp. input.

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• Monitor Engine Overview menu of EGCP-2 control and compare to measured water
temperature of engine with at low operating temperature.
• Adjust gain for proper water temperature reading while engine is operating.
• Calibration Menu.

Water Temperature Offset

• Sets level, or offset of water temperature input.
• Monitor Engine overview, and with engine operating at normal temperature, adjust
Water Temperature offset for proper temperature reading.
• This is an inverse function. Sensor resistance DECREASES as engine temp
increases.

Water Temperature
• Testing of a sample of Oil pressure sensors with the EGCP-2 control has shown the
typical sensor to require the following gain/offset for Ain1 in the calibration menu:
• Gain 0.0242
• Offset -11.90
• Testing of a sample of Water Temp Sensors has shown the typical temp sensor to
require following gain and offset settings:
• Gain -0.0389.
• Offset 246.0.
• Shunt Resistor Switches 3 and 4 closed on SW-2 of EGCP-2 control.

Sensor without shunt

Sensor with shunt

VCO
Freq.

Water Temperature

Figure 4-41. Water Temperature VCO

NetComm Dropouts
• The number of lost or corrupted network communications tolerated by the receiving unit.
• Excess numbers of NetComm Dropouts on network due to faulty wiring, improper
shielding, or improper setup will result in the unit experiencing the dropouts to flash
intermittently in the Sequencing Menu of the EGCP-2. Typically set at 5 to 10 dropouts.

Unit Calibrated (true/false)

• When set for true, indicates unit has been factory calibrated. Requires Level 4
Security code to change.

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Chapter 5
Control Features and Functions

Engine Control
• Programmable Auto Start on Loss of Mains
• All units in Auto Mode with Loss of Mains detection enabled start and assume load.
• Multiple Crank Repeat Setpoint
• Crank Repeat Timer
• Crank Fail Alarm/Shutdown
• Crank Cutout (rpm)
• Preglow
• Idle/Rated Relay

Engine Protection
• Oil Pressure
• Over/Under Alarm/Shutdown Settings
• Water Temperature
• Over/Under Alarm/Shutdown Settings
• Battery Voltage
• Over/Under Alarm/Shutdown Settings
• Overspeed
• Alarm/Shutdown Settings

Generator Voltage and Reactive Load Control

• VAR or Power Factor Load Control in Mains Parallel Operation
• Power Factor Sharing in Load Sharing, No Parallel Operation
• Externally Adjustable VAR/PF Reference
• Manual Voltage Control Capability

Generator Protection
• Over/Under Voltage
• Over Current
• Reverse Current
• Loss of Excitation
• Over/Under Frequency
• Stable Generator Determined by being within Voltage and Frequency Limits for a
given period of time.
• KVA Load Switch

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Mains Sensing
• Over/Under Voltage
• Over/Under Frequency
• Load Surge
• Programmable for Alarm/Loss of Mains Detect
• Loss of Mains Action Timer
• Stable Mains determined by being within Voltage and Frequency Limits for
a given period of time

Synchronizing
• Phase Match Synchronization
• 3 Mode Operation
• run, check, permissive
• Voltage Matching
• Dead Bus Closing
• Synch Timer
• Reclose Attempt/Timer
• Manual Synchronization Capability (permissive mode)

Load Control
• Proportional Load Sharing
• Integrating Base Load and Process Control
• Load Ramping
• Remote Contact Inputs to change Base Load and Process Setpoints with
Raise/Lower ramp rates
• Unload Trip point
• Droop Load Control Capability

Sequencing
• Each Unit in the system has an assigned Priority.
• Master (Highest Priority) automatically sequences units on or off line as
determined by system load.
• Higher priority units are sequenced on in order of their priority; taken off in
reverse of priority.
• System Load setpoint determines percent system load level at which
additional units will be brought on, or taken off line.
• Time setpoints determine period of delay for sequencing units on/off line.
• Separate time delay for overload (100% +) system load levels so additional
units can be sequenced on line quickly.

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Engine Cranking
The EGCP-2 Control is designed to automatically control the cranking functions
of the engine generator set. In order to safely control engine cranking the EGCP-
2 uses the following setpoints, as found in the Engine Control tuning menu of the
software:

Preglow Time
Crank Time
Crank Cutout
Crank Delay
Crank Repeats

The description of the above items is found in the Tuning Screens section of
this manual in the Configuration Menu list.

Starting Sequence:

Upon receiving a start command the following events occur:

1. The Preglow Output Energizes for the given preglow time delay, and remains
energized through the crank cycle.
2. After the preglow time expires, the Fuel Solenoid output energizes.
3. 200 ms after the Fuel Solenoid output energizes, the Crank output energizes.

At this point, the engine should be cranking at a certain rpm, and receiving fuel.
Typically a start would occur in these conditions. To check if a start does occur,
the EGCP-2 monitors the magnetic pickup from the engine. If the magnetic
pickup input indicates that the engine is operating above the Crank Cutout speed,
the EGCP-2 will remove the Crank and Preglow outputs, leaving the fuel
solenoid energized. The engine state in the control overview menu changes from
“OFF” to “RUN”.

If for some reason the engine does not reach the crank cutout rpm level, the
EGCP-2 will crank the engine for the Crank Time. If the engine fails to rise
above the crank cutout level in this time, the EGCP-2 will remove the Crank
output signal, wait for the Crank Delay, and if allowed by the number of Crank
Repeats, will crank the engine again (RETRY). This sequence will continue until
the number of crank repeats is depleted, or until the engine speed rises above the
crank cutout rpm setting, whichever comes first. If the number of crank repeats is
depleted, the EGCP-2 will activate the Crank Fail Alarm Output based on this
Alarm setpoint’s configuration.

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 NOTE
The preglow output may stay energized between crank attempts if the
preglow time is greater than the sum of the Crank Time and Crank
Delay timers.

 IMPORTANT
Set Crank Repeats to zero when starting the engine for the first time
with the EGCP-2. This will prevent starter and ring gear damage to
the engine if the MPU input to the control should be faulty. Monitor
Engine Overview Status menu on the first start and confirm the rpm
readout during cranking. After a successful start is made, the crank
repeats may be set to the appropriate value for the application.

IDLE/RATED Relay Output

The EGCP-2 can be configured to provide a relay output which will signal the
engine electronic speed control to change from idle to rated speed operation.
When configured for this output, Discrete Output 12 will energize to provide the
idle to rated indication.

The idle to rated indication takes place after a successful start (generator above
crank cutout speed) has occurred, the engine is operating at, or above the idle
speed setpoint, and the idle delay time setpoint has expired.

Generator Voltage Control

The EGCP-2 has the ability to control the voltage of the generator set. This
ability is used to control four separate operations which require generator
voltage adjustment:
1. Manual voltage adjustment
2. Voltage Matching during Synchronization across the generator or mains
breaker
3. Reactive load sharing between multiple units on an isolated bus
4. Reactive load control while in parallel with the mains.
The generator voltage, or reactive load (depending on the operation) is
adjusted by injecting a voltage bias signal to the Automatic Voltage
Regulator. The EGCP-2 can be set for ±1 Vdc, ±3 Vdc, and ±9 Vdc outputs.
The span of the output is selected by the “Voltage Bias Type” configuration
menu item in the EGCP-2.

Select the proper voltage range input as recommended by the AVR

manufacturer.

Generator Voltage can be manually controlled from the Voltage Raise and
Voltage Lower Discrete inputs to the EGCP-2. The rate of change for manual
voltage adjustment is set in the Reactive Load Control tuning menu, at the
Voltage Ramp Time setpoint. The voltage ramp time is the amount of time it will
take for the EGCP-2 to send a 0 to 100%, or 0 to –100% voltage bias signal to
the AVR.

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When operating in the TEST mode, manual voltage adjustment is only allowed
through the voltage raise and lower inputs. This allows testing of the Voltage
Bias output, and generator voltage levels prior to operation with load on the
generator.

When operating in Isoch mode, the EGCP-2 does not allow manual adjustment
of the voltage, unless the Load Control setpoint in the Configuration tuning
menu is set for “Droop”, or the VAR/PF Control Setpoint in the Reactive Load
Control tuning menu is set to “Disabled”. Using either of these settings implies
that a manual voltage control will be used, and no automatic reactive load
control functions are active.

 NOTE
It is highly recommended that the automatic reactive load control in
the EGCP-2 be used for proper power conditioning throughout the
generator(s) load range. This is achieved by setting the Load Control
setpoint in the Configuration tuning menu to Normal, or Soft Transfer
(depending on the application), and the VAR/PF Control setpoint in
the Reactive Load Control tuning menu to VAR or PF control
(depending on the application). For more details on these functions
see the Real Load Control and Reactive Load Control sections of this
manual.

The percent level of the voltage bias output can be monitored in the I/O Display
status screen of the EGCP-2. This is a useful point to monitor during initial start
of the unit. By issuing Voltage Raise and Lower inputs to the control while
operating in the Test Mode, confirmation of proper generator voltage levels at
various voltage bias points can easily be made. Typically the generator voltage
should change no more than ±10% for a ±100% voltage bias output from the
EGCP-2.

All other modes of generator set operation rely upon the Reactive Load Control
functions of the EGCP-2. See the information in the “Reactive Load Control”
section of the manual for more details on voltage and reactive load control.

Generator Load Control

Power Sensor Theory of Operation

The digital signal processing (DSP) power measurement technique used by the
EGCP-2 control involves periodic sampling of the voltage and current over an
integral number of wave forms. The microprocessor computes the product of the
voltage and current samples, then sums and averages the products to give a
computation of power.

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Load Sensor Hardware Description

The digital load sensor gets timing information from the generator A phase
voltage signal. Voltages proportional to the voltage and load current for each
phase are routed to the sample-and-hold circuits of the A/D converters. The
simultaneous sampled values representing voltage and current are held when a
conversion-store signal is received from the microprocessor. Each input is then
converted and an interrupt is generated when all inputs are converted. The
microprocessor then reads the digital values from A/D registers. This procedure
is repeated at regular intervals to provide input for further signal processing.

To provide accuracy in the presence of noise and harmonics on the inputs,

multiple samples of each wave form over a number of cycles of the input are
taken to get the power measurement.

The EGCP-2 Control has four core modes of generator load control operation.
These four modes are:
• Droop
• Isochronous Load Sharing
• Base Load
• Process Control

The specific mode of generator control that the unit is in at any given time can be
monitored on the Control Overview Menu.

Here is a description of each of these load control modes, and the various
operating states that will put the EGCP-2 into each respective load control
operation.

Droop

Droop Load Control in the EGCP-2 uses the sensed KW on the generator to
provide negative feedback to the speed reference of the speed control governor
through the speed bias output. This will result in a decrease in generator
frequency as the load is increased while operating as a single unit on an isolated
bus. Increasing the Speed Raise input while operating in this manner will
increase the speed of the engine gradually, thereby increasing the frequency of
the generator set.

While operating in parallel with the mains, droop operation provides KW load
control of the generator through the speed raise and speed lower inputs to the
EGCP-2. Since the mains determine the frequency of the generator, changing the
speed reference while in parallel with the mains causes a change in KW.

Droop load control is typically only utilized during commissioning of the EGCP-
2. It allows complete manual control of the generator load while in parallel with
the mains.

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The EGCP-2 can only be operated in droop if the configuration tuning menu
setpoint labeled “ Load Control” is changed to the “Droop” value, or if the unit
is operated with the Generator CB Aux input open while connected to a load, or
to the mains. No other operations, or software setpoints can change the droop
load control mode setting.

Figure 5-1. Droop Mode

Isochronous

Isochronous means repeating at a single rate or having a fixed frequency or

period. A generating set operating in the isochronous mode will operate at the
same set frequency regardless of the load it is supplying up to the full load
capability of the generator set, as illustrated in Figure 5-2. This mode can be
used on one generator set running by itself in an isolated system.

Figure 5-2. Isochronous Mode

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The isochronous mode can also be used on a generator set connected in parallel
with other generator sets. Unless the generator set controls have the capacity for
load sharing and speed control, no more than one of the generator sets operating
in parallel can be in the isochronous mode. If two generator sets operating in the
isochronous mode without load sharing capability are tied together to the same
load, one of the units will try to carry the entire load and the other will shed all
of its load. In order to share load with other units, some additional means must
be used to keep each generator set from either trying to take all the load or from
motorizing.

Droop/Isochronous Load Sharing on an Isolated Bus

Droop/Isochronous combines the first two modes. All generator sets in the
system except one are operated in the droop mode. The one unit not in droop is
operated in the isochronous mode. It is known as the swing machine. In this
mode, the droop machines will run at the frequency of the isochronous unit. The
droop and speed settings of each droop unit are adjusted so that each generates a
fixed amount of power as illustrated in Figure 5-3. The output power of the
swing machine will change to follow changes in the load demand.

Figure 5-3. Droop/Isochronous Load Sharing

Maximum load for this type of system is limited to the combined output of the
swing machine the total set power of the droop machines. The minimum system
load cannot be allowed to decrease below the output set for the droop machines.
If it does, the system frequency will change, and the swing machine can be
motorized.

The machine with the highest output capacity should be operated as the swing
machine, so that the system will accept the largest load changes within its
capacity.

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Isochronous Load Sharing on an Isolated Bus

Isochronous Load Sharing is the most common means of paralleling multiple

generators together to a common load on an isolated bus. The EGCP-2 uses
Isochronous Load Sharing control when operating in a Multiple Unit mode with
the Load Control Mode in either Normal or Soft Transfer. Isochronous load
sharing operates all generator sets in a system in the isochronous mode. Load
sharing is accomplished by using the load sensor of the EGCP-2 to bias the
speed reference of the isochronous governor. The EGCP-2 load sensors are
connected by inter-control RS-485 network. In the case of the EGCP-2 control
Isochronous Load Sharing is done digitally via this network. Any imbalance in
load between units will cause a change to the regulating circuit in each governor.
While each unit continues to run at isochronous speed, these changes force each
machine to supply a proportional share of power to meet the total load demand
on the system.

Base Load Against the Mains

Base Load is a method of setting a base or fixed load on a machine operating in

parallel with the mains. The EGCP-2 control operates the generator set in base
load whenever the generator is in parallel with the utility, unless a process
control mode of operation is selected through the Process discrete input. This is
accomplished by using an isochronous load control and providing a reference at
which to control the load. The governor will force the generator output to
increase or decrease until the output of the load sensor is equal to the reference
setting. The base load reference is set in the Real Load Control tuning menu of
the EGCP-2. At this point, the system is in balance.

The advantage of base loading over droop is that when separating from a Mains,
there is no frequency change. Simply removing the bias signal required to
maintain the base load reference on breaking from the Mains (mains CB Aux
open) returns the system to isochronous load control.

The EGCP-2 is only allowed to parallel with the mains in a Mains Parallel
operating mode. When configured for this type of operation, the EGCP-2 will
operate in either a base load or process control mode while in parallel with the
mains. The EGCP-2 automatically switches between base load and isochronous
operation depending upon whether or not the Mains Breaker CB Aux input is
closed at the same time the Generator CB Aux input is closed. If both the Mains
and the Generator CB AUX are closed, then the EGCP-2 realizes it is in parallel
with the mains, an operates in a base load control mode. The EGCP-2 will
operate in a process control mode, which is discussed later in this section, if both
the Process and Run with Load discrete inputs are active (on).

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Automatic Generator Loading Functions

The automatic generator loading functions of the EGCP-2 control are designed
to be used with the speed control to automatically control the loading and
unloading of the generator. This accomplishes a bumpless transfer when
paralleling the generator to a load sharing or infinite bus system, or when
separating a generator from a system.

Process Control Description

The process control function of the EGCP-2 control will control any process
where the controlled parameter is determined by the generator load, and the
controlled parameter can be monitored as a 4–20 mA or 1–5 Vdc input signal.

The control compares the input signal to the Process Reference setpoint in the
Real Load Control tuning menu of the EGCP-2. This setpoint uses milliamps for
units so that it is easily related to the 4–20 mA or 1–5 Vdc input signal. The
EGCP-2 then adjusts the generator load to maintain the desired set point. The
EGCP-2 will only operate in a process control mode if it is configured to be a
Mains Parallel unit, and receives an Auto, Run With Load, and Process discrete
input. Also, the EGCP-2 can operate in a process soft transfer mode if the Load
Control Mode setpoint in the Configuration tuning menu is set for Soft Transfer,
and the Test discrete input is closed with the Run with Load and Process discrete
inputs. In a soft transfer mode, the EGCP-2 will load the generator or generators
(depending on the application) to the process reference level. Upon reaching the
reference value on the 4–20 mA or 1–5 Vdc input signal, the EGCP-2 will open
the mains breaker. This Soft Transfer mode is used to transfer the supply of
power for the load from the mains to the generator.

In process control mode, the Raise Load and Lower Load contact inputs operate
on the process control reference. The ramp time for these Raise and Lower Load
inputs while operating in process control mode are set in the Real Load Control
tuning menu, at the Process Raise and Process Lower Ramp Rate setpoint. This
setpoint is scaled in mA per second.

When the process function is initially selected, the reference is set equal to the
internal or remote process reference. If the process input and process reference
are not equal, the control ramps the load reference in the appropriate direction to
reduce the difference error. When the process error reaches zero or the load
reference reaches the maximum or minimum values, the process control is
enabled.

When the process control is enabled, the error signal between the process
reference and process signal is input to a PID (Proportional, Integral, Derivative)
controller operating in cascade with the load control. The output of the controller
is a load reference which is limited by the High and Low Load Limit set points
in the Real Load Control tuning screen to prevent overload or reverse power on
the generator. The load setting signal is output from the load control to the speed
control to set control at the required load to maintain the desired process level.

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In a multiple unit, mains parallel configuration, the master unit (lowest
numerical priority) operates as the process master as well. The master unit must
receive the 4–20 mA, or 1–5 Vdc process input signal. If the master is operating
in an auto mode, and is therefore part of the sequencing and control network
between units, then the master unit will control all slave units which are in Auto
mode to maintain the process reference of the master. The slave units operate in
a load sharing type mode where the total system load is equally divided between
the units in proportion to their rated load capacity. The master will also
automatically sequence slave units on and off load as required to maintain the
process reference.

Additional features of the process control are an adjustable process input signal
filter and adjustable deadband on the integrator. The adjustable filter allows
reducing bandwidth when controlling a noisy process such as experienced in
digester gas fuel applications. The deadband is useful in both noisy applications
as well as for very slow processes.

The process control function is configurable for direct and inverse action. Direct
process control is where the sensed input signal increases as the load increases
(such as where the sensed input is exhaust pressure or export power). An inverse
action control is where the sensed input signal decreases as the load increases
(such as when controlling import power where the import power will decrease as
the generating system picks up more of the local load).

Reactive Load Control Description

When a small generator is paralleled with a Mains, the synchronizer voltage

matching function adjusts the generator voltage to match that of the Mains.
Voltage variations that may occur in the Mains system after paralleling can cause
large changes in reactive current in the generator. The VAR/Power Factor
Control provides closed loop control of either VARs or power factor when
operating in parallel with another power system when that system can accept the
reactive load.

Voltage adjustment, however, can only affect reactive power when another
system is available to accept the reactive load. So the VAR/Power Factor control
functions are automatically switched to Power Factor sharing when either single
or multiple units are operating in isochronous load sharing mode on an isolated
bus (Mains CB Aux is open).

The VAR/PF control mode of operation is selected by setting the VAR/PF

Control Mode set point in the Reactive Load Control tuning menu. When either
VAR or PF control mode is selected, the control function is enabled whenever
the Generator CB Aux contact is closed, and the control is configured for either
Normal or Soft Transfer Load Control. VAR/PF control is overridden when the
Load Control Mode is set for Droop operation. The VAR/PF control can be
disabled by setting the VAR/PF Control Mode setpoint to Disabled. The voltage
bias output is reset to 0% when the generator CB Aux input is opened.

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 NOTE
If cross-current compensation is installed on the voltage regulator, it
must be removed prior to using the VAR/PF mode of control, or
instabilities may result. The droop CT must remain connected to the
voltage regulator.

VAR Control

The VAR control adjusts generator voltage to maintain a constant reactive power
(kVAR) load on the generator throughout the KW operating range while the
generator is in parallel with the mains. This assures sufficient excitation of the
generator field under all load conditions. A set point is provided to set the
desired VARs. The VAR control function may be enabled with VAR/PF Control
mode selection set point. The KVAR reference may be changed once the
generator is in parallel with the mains by issuing a raise/lower voltage contact
input to the EGCP-2. Raising the KVAR reference will raise the voltage bias
output to the voltage regulator, which will cause VARs to be exported to the
Mains. Lowering the VAR reference will decrease the voltage bias output to the
regulator which will cause VARs to be absorbed from the utility.

Power Factor Control

The power factor control adjusts generator voltage to maintain a constant power
angle throughout the KW operating range while the generator is in parallel with
the mains. A set point is provided to set the desired power factor reference. The
power factor control function may be enabled with the VAR/PF Control mode
selection set point. The PF reference may be changed once the generator is in
parallel with the mains by issuing a raise/lower voltage contact input to the
EGCP-2. Raising the PF reference will raise the voltage bias output to the
voltage regulator, which will cause the PF to move in an increasing lagging PF
angle. Lowering the PF reference will decrease the voltage bias output to the
regulator which will cause PF to move in an increasing Leading PF angle.

Power Factor Sharing

When either VAR or Power Factor Control is selected, and the EGCP-2 control
is operating in isochronous load sharing mode, power factor sharing is
automatically selected. Power factor sharing adjusts the voltage regulators so
that all generators carry the same proportion of reactive load by balancing the
power factor on all units. A voltage reference set point is provided to define the
system operating voltage. Multiple EGCP-2 controls operating in Power Factor
Sharing mode will trim their respective voltages to share the reactive load on the
isolated bus, and operate around the voltage reference setting.

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Synchronizer Description
Synchronization, as normally applied to the generation of electricity, is the
matching of the output voltage wave form of one synchronous alternating current
electrical generator with the voltage wave form of another alternating current
electrical system. For the two systems to be synchronized and connected in
parallel, five conditions must be considered:
• the number of phases in each system;
• the direction of rotation of the phases;
• the voltage amplitudes of the two systems;
• the frequencies of the two systems ;
• the phase angle of the voltage of the two systems.

The first two conditions are determined when the equipment is specified,
installed, and wired. The synchronizer matches the remaining conditions
(voltage, frequency, and phase) before the paralleling breakers are closed.

Functional Description

This section describes how generator and bus matching occurs and how all
conditions are verified by the synchronizer functions.

Operating Modes

The EGCP-2 control is capable of synchronizing across both the generator and
mains breakers, depending on the application of the generator set, and the
configuration of the EGCP-2. An EGCP-2 configured for No Parallel operation
will never allow the generator and mains breakers to be closed at the same time,
and therefore does not synchronize across the mains breaker. Units configured
for Mains Parallel operation will actively synchronize the generator, or in the
case of a multiple unit system, generators, to the utility before closing the utility
tie breaker.

The EGCP-2 monitors the A phase of the generator and compares this with either
the A phase of the Bus PT input, or the A phase of the Mains PT input. The Bus
PT input is switched through DO7 (local bus connect). The Bus PT is always
monitored whenever the EGCP-2 is synchronizing, or dead bus closing across
the generator breaker. Bus PT sensing is a momentary condition as the EGCP-2
will always return to sense the Mains PT input by switching to DO8 (Mains
Disconnect) whenever generator synchronization is complete. Switching to the
Mains Pt allows the EGCP-2 to monitor for a loss of mains condition when
operating on a generator that is not synchronizing across its generator breaker.

 NOTE
In systems which operate in parallel with the mains, or with loss of
mains detection modes, it is recommended that each EGCP-2 unit in
that system receive the Mains and Bus PT inputs for proper
operation.

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 EGCP-2 Engine Generator Control Package Manual 26086
The synchroscope tuning menu is used to configure the synchronizing action of
the EGCP-2. The software tuning items in the synchroscope menu apply to both
the generator breaker/contactor and mains breaker/contactor synchronizing
functions.

The operation of the synchronizer is determined by the three different operating

modes available in the EGCP-2. The three modes are Run, Check, and
Permissive.

Run mode allows normal synchronizer operation and breaker closure signals.
The speed bias signal (explained below) is maintained throughout the breaker
closure signal. When the specified closure signal time has elapsed and the CB
(circuit breaker) Aux contact closure signal is received at the EGCP-2, the
synchronizer is disabled. The synchronizer is reset automatically once the
generator is taken off load and its generator breaker is opened.

Check mode allows normal synchronizing and voltage matching, but does not
issue a breaker closure signal.

Permissive mode enables the synch-check function for proper synchronization,

but synchronizer operation does not affect the engine's speed or generator
voltage. If phase, frequency, and voltage are within proper limits for the
specified dwell time, the synchronizer issues the breaker closure command.

Dead Bus Closing

When a dead bus is detected and dead bus closing mode is enabled in a multiple
unit system, the synchronizer will attempt to get an exclusive lock on permission
to issue a breaker closure command. This security is required to prevent two or
more units from closing their breakers at the same time. To provide this security,
a network message requesting the lock is made to all other EGCP-2 controls
currently active on the network.

When an EGCP-2 control receives a lock request, it does the following actions:

1. If a dead bus permission request is not also currently being made, a dead bus
condition is indicated, and the GENERATOR AUX CONTACT discrete input
is inactive (the EGCP-2 control returns a reply message to the requesting unit).

 NOTE
The GENERATOR AUX CONTACT open requirement backs up the
dead bus condition in the event of a bus PT failure. If a dead bus
condition is indicated by lack of bus voltage, but the generator
breaker is closed, a reply will not be sent.

2. If a dead bus permission request is also being made and that request
sequentially precedes the received request, the received request is retained,
otherwise the reply is sent. (In the event of a sequential tie, the unit with the
lower assigned network address wins.)

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Manual 26086 EGCP-2 Engine Generator Control Package
When all other units have replied verifying that they also indicate a dead bus
(bus input less than 40 Vac) and do not hold a lock, the requesting unit then
holds lock permission and may attempt to close its circuit breaker. The lock is
released automatically after issuing the circuit breaker closure command. This
will allow any other unit to get permission to lock if the breaker fails to close.

The dead bus closing function may be enabled or disabled by the user with the
Dead Bus Closure setpoint in the Synchroscope tuning menu.

Voltage Matching

The voltages of the generators in a parallel system must be matched within a

small percentage to minimize the reactive power flow in the system. If two
synchronous generators of unequal voltage are paralleled, the combined voltage
will have a value different from the voltage generated by either of the generators.
The difference in voltages results in reactive currents flowing in the system with
subsequent lowered system efficiency.

If a synchronous generator is paralleled to a larger system such as a Mains, a

difference in voltages before paralleling will not change the voltage of the bus. If
the generator voltage is lower than the bus voltage, reactive power will be drawn
from the bus and used to excite the generator to the higher bus voltage.

In the case where the generator voltage is low enough, the reactive power flow
could motorize the generator with potential damage to the generator windings.

The microprocessor then computes the RMS values of the voltages. The
processor issues appropriate adjustment of the voltage bias signal if used, to the
voltage regulator to bring the generator voltage within the specified window
above the bus voltage. To guarantee that reactive power will be generated,
window range is from equal to bus voltage to the specified percentage above bus
voltage.

The automatic voltage matching function may be enabled or disabled with a set
point. When enabled, voltage matching will occur in both the Check and Run
modes and is verified only by the sync-check function in Permissive mode.
When enabled at an EGCP-2 control which is monitoring and controlling the
mains breaker, the voltage matching will occur across both the generator and
mains breaker prior to the synchronizer issuing a breaker close command when
paralleling the generator(s) to the mains.

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EGCP-2 Engine Generator Control Package Manual 26086
Phase Matching Synchronizing

The phase matching synchronizing mode corrects the frequency and phase of the
generator to lock it to the bus frequency and phase. The microprocessor uses
signal processing techniques to derive the difference in phase of the generator A
and bus A phase voltage signals. When there is a difference, the synchronizer
sends a correction signal to the speed control. The correction signal from the
speed bias output increases or decreases engine speed depending on whether the
slip is faster or slower than the bus. A PI (proportional, integral) controller
provides the correction signal. Gain and Stability adjustments to the PI controller
are provided to allow stable operation of the automatic synchronizer function
over a wide range of system dynamics.

Synch-check

The synch-check function determines when all conditions for proper

synchronization are satisfied and energizes the breaker closure relay. The
generator and bus voltage comparison is made if the voltage matching function is
enabled. The generator voltage must be within the specified voltage window
above bus voltage before the breaker closure command may be given.

To minimize transients, the breaker must be closed when the phase difference
between the generator and bus is near zero. Also, maintaining the phase angle
error between the generator and the bus within a specified Max Phase Window
for a specific Dwell Time allows the synchronizer to be configured for a wide
range of synchronizing conditions. The Max Phase Window and Dwell Time
setpoints are found in the Synchroscope tuning menu of the EGCP-2.

A larger Max Phase Window, and Shorter Dwell time would typically be used on
emergency standby sets, where rapid synchronization is needed. The larger
window and shorter dwell time make the synchronizer less sensitive to
transitions in generator frequency and phase angle error when compared to the
bus the generator is synchronizing to. When all conditions of voltage and phase
are met, then the breaker closure command is given.

A smaller Max Phase Window and Longer Dwell Time would be used on
generating systems where smooth and precise synchronization is required, and
the time to synchronize is not as critical as would be seen in a standby
application. A smaller window and longer dwell time require the generator to be
within closer frequency and phase angle error tolerance when compared to the
bus the generator is synchronizing to. When all conditions for voltage and phase
are met, then the breaker closure command is given.

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Manual 26086 EGCP-2 Engine Generator Control Package
Multiple Shot Reclosing

The multiple shot reclosing function allows multiple closing attempts. The
control provides set points for the number of close tries and the reclosure delay
timing. Failure to get closure after the specified number of tries locks out the
synchronizer by setting it to the auto-off mode and, if the alarm is enabled,
energizing the appropriate alarm relay output. The synchronizer must then be
reset by clearing the alarm condition in the Alarm/Event Log. The multiple shot
closing function is disabled by setting the reclosing count to one.

Synchronizer Timing

The time line diagrams below illustrate the various timing sequences the
synchronizer function uses when paralleling single and multiple units across the
generator or mains breaker (depending on application).

SYNCHRONIZER TIME LINE

STANDARD SEQUENCE: SYNC TIMEOUT ACTIVE (>0 sec.)

CB HOLD TIME
TRIP POINT
AT UNLOAD
DWELL TIME

CB HOLD TIME

PHASE AND VOLTAGE UNLOAD RAMP

MATCHING TIME SYNCHRONIZER OFF
BREAKER CLOSED UNIT ON LOAD
(CB AUX INPUT RECEIVED)

UNLOAD COMMAND ISSUED

(SYNCHRONIZER IN OPEN
BREAKER MODE)
IN SYNCH.

COMMAND ISSUED
BRKR CLOSE

COMMAND REMOVED
BRKR CLOSE

COMMAND ISSUED
BREAKER OPEN

COMMAND REMOVED
BREAKER OPEN
SYNCHRONIZER
ACTIVATED

= SYNCH TIMEOUT PERIOD

WITH RECLOSE ATTEMPTS : SYNCH TIMEOUT ACTIVE AND EXCEEDED

(PARTIAL)
RECLOSE DELAY
CB HOLD TIME
DWELL TIME

PHASE AND VOLTAGE PHASE AND VOLTAGE

MATCHING SYNCHRONIZER OFF MATCHING
TIMEOUT ALARM ACTIVE 020-100
00-04-27
IN SYNCH.

COMMAND ISSUED
BRKR CLOSE

COMMAND REMOVED
BRKR CLOSE
SYNCH TIMEOUT EXCEEDED

SYNCHRONIZER ACTIVE
ALARM RESET

SYNCHRONIZER
ACTIVATED

= SYNCH TIMEOUT PERIOD

Figure 5-4. Synchronizer Time Line—Standard Sequence

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 EGCP-2 Engine Generator Control Package Manual 26086
Loss Of Mains Detection and Action

The EGCP-2 can be configured to detect a loss of mains condition, and respond
to that condition by isolating the mains from the load, and transferring the supply
of power to the load from the mains to on site engine generator sets.

The EGCP-2 can be configured for single or multiple unit, no parallel or mains
parallel system operation which will detect a loss of mains. The loss of mains
actions are a combination of synchronizing and load control functions of the
EGCP-2. These functions allow the EGCP-2 controls to operate effectively upon
a loss of mains condition.

Below are timing diagrams for mains parallel and no parallel systems. These
time lines apply to the master control in multiple unit systems, or to any single
unit application.

Standard Sequence: Single No Parallel Unit in Auto with Loss Of Mains Detection Enabled.
LOM Action Delay Expires
LOM Action Delay Starts

Fast Transfer Mains Stable Fast Transfer Mains In Spec and

Mains in Spec. Gen Stable Delay Delay Genset On Load Delay Delay On Load
Mains in Spec.

Close Mains Breaker

Open Mains Breaker

Gen Breaker Closes

Mains Out of Spec*

Open Gen Breaker

Gen Stable. Start Fast

To Dead Bus
Start Genset

Transfer Delay

TIME VIS-110
00-04-27

*Over/Under Frequency
and/or Over/Under
Voltage

Figure 5-5. Loss of Mains Detection Active

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Manual 26086 EGCP-2 Engine Generator Control Package

Standard Sequence: Single Mains Parallel Unit in Auto with Loss Of Mains Detection Enabled.

LOM Action Delay Expires

LOM Action Delay Starts
Fast Transfer Mains Stable Generator Mains In Spec and
Mains in Spec. Gen Stable Delay Delay Genset On Load Delay Unload Ramp On Load

Mains in Spec.

Synchronize and Close

Open Mains Breaker

Gen Breaker Closes

Open Gen. Breaker

Mains Out of Spec*

Gen Stable. Start Fast

To Dead Bus

Mains Breaker
Start Genset

Transfer Delay

TIME VIS-111
00-04-27
*Over/Under Frequency
and/or Over/Under
Voltage

Figure 5-6. Generator Off Line

Standard Sequence: Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains
Detection Enabled.
LOM Action Delay Expires
LOM Action Delay Starts

Mains Stable Generator Mains In Spec and

Mains in Spec. Genset On Load Delay Unload Ramp On Load
Generator On Load
in Baseload or
Mains in Spec.

Process Control Mode

Synchronize and Close
Open Mains Breaker
Mains Out of Spec*

Open Gen. Breaker

Mains Breaker

TIME

*Over/Under Frequency VIS-112

and/or Over/Under 00-04-27

Voltage

Figure 5-7. Mains Parallel Unit with Voltage/Frequency Detect

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EGCP-2 Engine Generator Control Package Manual 26086

Standard Sequence: Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains
Detection Enabled. Load Surge Event

Open Mains Breaker

Mains Stable Generator Mains In Spec and

Mains in Spec. Genset On Load Delay Unload Ramp On Load
Generator On Load
in Baseload or
Process Control Mode

Mains in Spec.

Synchronize and Close

Open Gen. Breaker

Load Surge Level

Mains Breaker
Exceeded*

TIME

VIS-113
00-04-27
* Load Surge detection is
immediate.

Figure 5-8. Mains Parallel Unit(s) with Load Surge Detect

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Generator Sequencing
Generator Sequencing is a capability of the EGCP-2 control to maintain an on
line generator capacity to Kilowatt load ratio for a multiple unit setup. In order
to activate the automatic sequencing function of the EGCP-2, each unit in a
multiple unit system must have the following software setpoints enabled:

Configuration Menu:
Number of Units Automatic Sequencing
Multiple Enabled
Each unit in the system must be in the Auto mode (Discrete Input #1 Closed) to
be an active part of the sequencing system.

When configured for automatic sequencing, as described above, the Sequencing

status screen of the EGCP-2 will show all of the active units on the network in
order of their Network Address, and the priority of those units in the sequencing
scheme. Units not in Auto mode, or with the Number of Units setpoint set for
Single, will display the message “Manual Unit No Sequencing” in the
Sequencing Status Screen. Units in Auto mode, and set for Multiple unit
operation, but with the Auto Sequencing setpoint Disabled will still appear in the
Sequencing status screen, but will not respond to automatic sequencing
commands from the Master, and are not capable of operating in a Master control
mode.

The EGCP-2 uses calculated system load levels to determine the points at which
units are sequenced on or off load by the master. The master may not sequence a
unit off load, even though it is at or below the min gen load set point, if this
would cause the system load to rise above the max gen load set point.

A typical automatic sequencing routine is shown below. The system represented

is composed of three units on an isolated bus feeding varying plant loads which
are fed by the generators. The master unit (network priority #1) has the following
set points for sequencing in the Real Load Control tuning menu:

Max Gen Load = 65% Next Genset Delay = 30 seconds Rated

Load Delay = 5 seconds Max Start Time = 60 seconds
Min Gen Load = 25% Reduced Gen Dly. = 30 seconds
Max Stop Time = 15 seconds

 NOTE
These settings are for demonstration only. Sequencing setpoints may
vary depending upon system requirements.

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 EGCP-2 Engine Generator Control Package Manual 26086

100%

65%

SYSTEM
LOAD

25%

TIME

VIS-114
00-04-27 A B C D E F G H J K L M

Figure 5-9. Typical Automatic Sequencing Routine

Point A
Master Generator carrying load isochronously on an isolated bus. System load
steps from approximately 10% to 30%.

Point B
Master Generator responds to a step load which brings the system load to
approximately 70%. This level exceeds the Max. Gen Load setpoint (65%) in the
Real Load Control tuning menu. The Master control begins timing for the Next
Genset Delay period 30 seconds. After the 30 seconds expires, the load is still
above the Max Gen Load setpoint. The master control issues a start command to
the next unit on (network priority #2).

Point C
Ten seconds after receiving its start command, network priority #2 unit closes
onto the bus and ramps into load sharing with the master.

Point D
System load levels drop to approximately 45% after unit #2 is finished ramping
into load sharing.

Point E
A very large step load on the bus loads both generators in excess of 100% of
their rated load. The system load reflects these levels. The master unit begins
timing to the Rated Load Delay (5 seconds) before starting the third unit.

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Manual 26086 EGCP-2 Engine Generator Control Package
Point F
The third unit closes its breaker to the two units already on the isolated bus.
Since the rated load delay is in effect, and the system load is above 100% of the
generating capacity on line, the third unit immediately goes to load sharing,
without any load ramping. System load drops immediately to approximately 55%
when the third unit closes its breaker to the bus.

Point G
A step load decrease on the bus brings the system load down to approximately
35%. All three generators remain on line in isochronous load sharing.

Point H
A further step load decrease on the isolated bus brings the system load below the
Min Gen Load setpoint of 25% to approximately 10%. The master begins timing
for the Reduced Gen Dly time of 30 seconds.

Point J
Since the system load is still below 25%, and the master’s Reduced Gen Dly
timer has expired. The master unit issues a command to Unit 3 (network priority
3) to off load and open its gen breaker. Unit 3 begins to ramp off load. System
load begins increasing. The master begins its Max Stop Time delay of 15
seconds before checking to see system load is low enough to allow sequencing of
another unit off line.

Point K
Unit 3 reaches its unload trip point and opens its generator breaker. The system
load is still below the Min Gen Load setpoint of 25%. The Master’s Max Stop
Time delay has expired. The master begins timing for the next gen off delay
time.

Point L
The system load remains below 25%, and the master issues a command to unit
#2 (network priority #2) to off load.

Point M
Unit 2 ramps off load and opens its generator breaker. This leaves the master
unit (network priority #1) on line supplying the load. When required the master
will sequence units on and off line as shown above and determined by the
sequencing setpoints in its Real Load Control tuning menu.

The Master unit in any multiple unit EGCP-2 system is always the unit with the
lowest Network Priority setting. All slave units are then sequenced on line in
ascending order of their Network Priority settings, and sequenced off line in
descending order of their Network Priority Settings. The Master is always
responsible for any automatic sequencing of the slave units on and off line.

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EGCP-2 Engine Generator Control Package Manual 26086
In order to give the end user of the EGCP-2 the ability to control engine run time
levels in a multiple unit system, any EGCP-2 in the system can be used to change
the network priority of any of the EGCP-2 units actively on the same network.
For a unit to be active on the network, it must have its Auto discrete input
closed, be configured for Multiple Unit operation, have its Auto Sequencing
setpoint Enabled, and be physically connected to the RS-485 network between
units.

The ability to change the priority of any unit on the network has some
fundamental rules associated with making changes to the unit priority. These
rules have to do with assuming a new master, changing the sequence of on load
units, and permissive sequence change states.

Assuming a New Master—All Units Off Load

When a unit’s priority is changed in such a manner as to make it the new master
on the system, the response of the system to the change of masters depends on
the operating state of the system at the time the change is made.

If the system is not on load and the engines are not running, and has not
experienced, or is not configured for a loss of mains condition, then switching
the priority of the master will have the following effect on the system:

After a maximum of 5 minutes, the Master indication in the Sequencing Status

screen will indicate the new master unit.

Shortly after this occurs, the new Master’s Sequencing Status screen will re-
order the Next On and Next Off slave units to fit the new system priority
configuration.

No units will start or go on load under these conditions as a result of the

assumption of the new master. See Figure 5-10.

MAINS
NO MAINS FAILURE DETECTED

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER.
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = %
NEXT ON ALL
NEXT OFF

ALL GENERATORS OFF LOAD

VIS-115
00-04-27

G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3

Figure 5-10. Original System Configuration

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MAINS
NO MAINS FAILURE DETECTED

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER.
PRIORITY 2 1 3
MASTER 2 SYSTEM LOAD = 0%

NEXT ON ALL
NEXT OFF

ALL GENERATORS OFF LOAD

VIS-116
00-04-27

G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #2 NETWORK PRIORITY #1 NETWORK PRIORITY #3

Figure 5-11. After a Change of Priority—Units Not Operating

Assuming a New Master—Master On Load

The next sequencing priority change scenario involves having the master unit on
the isolated bus due to a loss of mains condition, or from an auto and run with
load input. The two slaves units are off line because the system load does not
require them to be sequenced on line. Changing the network priority of the
master will establish a new master on the system.

In this system, the master unit will always have a Min Gen Load setting of 25%,
and a Max Gen Load setting of 65%. These values will be used through out the
remaining on load examples.
MAINS
MAINS FAILURE DETECTED
Or Run With Load and No
Parallel Application

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = 40%
NEXT ON 2
NEXT OFF

VIS-117
00-04-27

G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3

Figure 5-12. Original System Configuration

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EGCP-2 Engine Generator Control Package Manual 26086
Within a 5 minute period the sequencing screen on any unit will reflect the
change of master from unit one to unit two.

The system load is at a level somewhere between 25 and 65 percent, at which no

slave units are sequenced on or off line.
MAINS
MAINS FAILURE DETECTED
Or Run With Load and No Parallel
Application

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X X
PRIORITY 2 1 3
MASTER 2 SYSTEM LOAD = 35%

NEXT ON 3
NEXT OFF 1

VIS-118
00-04-27

G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #2 NETWORK PRIORITY #1 NETWORK PRIORITY #3

Figure 5-13. A New Master Takes Over—Single

Unit Operating on the Isolated Bus

When the sequencing screen displays the new master, the new master engine will
begin its start sequence. The new master must start and go on line in order to
take over its new role as master, which means to be in control of the load, and of
the sequencing control of the slave units.

The new master (Network Address 2) will start and parallel to the previous
master (Network Address 1). Load control will be isochronous load sharing
between the two units. See Figure 5-13. If the system load is greater than 25%,
then both units will remain on line. If the system load drops below 25%, then the
new master (Network Address 2) will sequence the slave (Network Address 1)
off line.

The new master has fully established itself on the network as the Master.

The above actions take place simply by changing the priority of any given unit so
that that unit is the New Master. As long as the unit is in auto mode, configured
for multiple unit operation and attached to the network, it will automatically
transfer itself to the Master Position.

Units operating in Auto with the Run with Load discrete input closed will
effectively transfer, or recognize the transfer of master units. However, being in
an auto and run with load mode, those particular units cannot be sequenced off
line by the master control.

If a unit is not in auto mode, or is configured for single unit operation, or is not
attached to the RS-485 network, then no transfer of master can occur.

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Also, for a transfer of master to occur, the units have to be in an auto sequencing
mode of operation. This implies either a load sharing, or process mode of load
control. Without being in these operating modes, a transfer of master cannot
occur because the New Master cannot sequence the Previous master off line. The
load control modes which does not support new master transition is the Base
Load mode. In Base Load Mode, there is no sequencing between units, and
therefore a change of master cannot take place until the units are either taken out
of base load mode, or switched to an isochronous load sharing, or process
control mode.

 NOTE
NOTE: Master Controls operating in the Process Control Mode must
have a 4–20 mA or 1–5 Vdc transducer input to function properly.

Changing the Priority of a Slave Unit—No Slaves On Load

MAINS
NO MAINS FAILURE DETECTED

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER.
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = 0%
NEXT ON ALL
NEXT OFF

ALL GENERATORS OFF LOAD

VIS-119
00-04-27

G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3

Figure 5-14. Changing the Priority of a Slave Unit

If a slave unit’s priority is changed in such a way as to simply shift that slave’s
place in the sequencing scheme without making the slave a New Master, then
one of two things will happen depending on that slaves place in the priority
order.
1) The slave will simply take its place in the new sequencing order without
having to go on load.
2) The slave will have to go on load in order to properly assume its new
priority setting in sequencing system.

Case 1 will occur if the slave’s priority is changed either when there are no units
running, and no Loss of Mains detection has occurred, or if the slave itself is not
running due to system load levels not requiring the unit to be on line, and the
priority of the slave is decreased (taken to a higher numerical value).

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MAINS
MAINS FAILURE DETECTED
OR RUN WITH LOAD AT MASTER

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = 50%
NEXT ON 2
NEXT OFF 3

VIS-120
00-04-27 G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3

Figure 5-15. Changing the Priority of a Slave Unit

Master running on load against the isolated bus (Figure 5-15). System load level
is at 40%, so no slave units are sequenced on line.

MAINS
MAINS FAILURE DETECTED
OR RUN WITH LOAD AT MASTER

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = 50%
NEXT ON 3
NEXT OFF 2

VIS-121
00-04-27
G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #3 NETWORK PRIORITY #2

Figure 5-16. Changing the Priority of a Slave Unit

A priority change at units with the network addresses of #2 and #3 switches the
network priority between these two units. Since neither unit is operating (only
the master is on load) the priority change takes place, and is recognized by the
master. The change is seen in the next on /next off display at the master
sequencing status screen. See Figure 5-16.

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Changing the Priority of a Slave Unit—Slave On Load

Case 2 will occur if the slave unit is not running, and no Loss of Mains detection
has occurred, and the slave’s priority is increased (taken to a lower numerical
value) to a level which replaces another slave which is operating on load.

MAINS
MAINS FAILURE DETECTED
OR RUN WITH LOAD AT MASTER

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X X
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = 50%
NEXT ON 3
NEXT OFF 2

VIS-122 G G G
00-04-27
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3

Figure 5-17. Changing the Priority of a Slave Unit

Above figure represents system on load on an isolated bus in load sharing. The
master unit has sequenced on the priority 2 slave unit. System load is at 50%.

MAINS
MAINS FAILURE DETECTED
OR RUN WITH LOAD AT MASTER

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X X X
PRIORITY 1 3 2
MASTER 1 SYSTEM LOAD = 50%

NEXT ON
NEXT OFF 2

VIS-123
00-04-27
G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #3 NETWORK PRIORITY #2

Figure 5-18. Changing the Priority of a Slave Unit

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The network priority of the priority 2 and 3 units are switched so now the unit
with network address #3 is priority 2, and network address #2 is priority #3.
After a time delay of less than 5 minutes, the #3 network address (priority 2) unit
is started by the master and paralleled to the bus. Now all three units are on line.
See Figure 5-18. The master recognizes the proper on/off sequence for the new
priority settings, and will sequence off network address #2 unit when system
load levels fall below 25%. See Figure 5-19.
MAINS
MAINS FAILURE DETECTED
OR RUN WITH LOAD AT MASTER

MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER. X X X
PRIORITY 1 3 2
MASTER 1 SYSTEM LOAD = 50%

NEXT ON 2
NEXT OFF 3

VIS-124
00-04-27
G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #3 NETWORK PRIORITY #2

Figure 5-19. Changing the Priority of a Slave Unit

System load levels have dropped below 25%, and the master has sequenced
network address #2, priority #3 unit off line. The master has fully recognized the
priority change, and the new priority settings are in effect.

The above examples are typical sequencing functions of the EGCP-2. Isolated
bus applications were shown for clarity. The EGCP-2 is capable of automatic
sequencing while in parallel with the mains in the process control, or process
control soft transfer operating modes. The examples shown above for priority
changing and its effects are accurate in mains parallel multiple unit process
control modes as well.

Inter-control Communications (RS-485 Network)

The EGCP-2 uses a proprietary communication structure to share information
between multiple EGCP-2 controls in a system. This communication structure
allows accurate load sharing, status, and command messages to be exchanged
between up to 8 units. The network uses RS-485 protocol over a standard twisted
shielded pair to link the units in the system together. The end units of the
network must have the proper network termination switches selected at Switch
Location 4. Switches 1, 2, and 3 must be closed to ensure robust inter-control
communications, and prevent reflected data from propagating on the network.

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The information on the RS-485 network is for communications between controls
only and must not be interfaced in any way with external devices. There is an
RS-422 port on the EGCP-2 which is used to monitor and control the units
remotely.

Remote Control/Monitoring (RS-422)

To facilitate the use of external computer connections, the EGCP-2 has an RS-
422 port which allows direct access to the various operating and monitoring
functions within the control. The RS-422 network is a multi-drop line which
allows connection of an external device at any point on the network. This allows
monitoring and control of up to 8 units simultaneously from a PC.

The RS-422 network is dedicated to the control and monitoring of the EGCP-2.

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Chapter 6
Calibration of Control Inputs and Outputs

Introduction
The EGCP-2 can be thought of as a digital metering device which monitors
engine, generator, bus, and mains analog signals. Being a digital metering
device, the EGCP-2 must be properly calibrated in order to perform its role as a
controlling device accurately. This chapter discusses the calibration of these
various inputs and outputs of the EGCP-2, and the effects of the calibration on
the metering and control functions of the EGCP-2.

The EGCP-2 inputs and outputs are factory calibrated for the best possible
tolerance between the input signal, and the signal as sensed by the EGCP-2. All
analog signals coming into the EGCP-2 are routed through analog to digital
(A/D) converters. These converters have the ability to be “calibrated” so that the
input signals sensed by the EGCP-2 software are equal to the true input signal.

While the factory calibration brings the EGCP-2 control within close tolerance
of the various inputs as fed into the control, it cannot account for losses in field
wiring that are common in power generation applications. Signal loss due to wire
length and impedance, transformer primary to secondary losses, and non-
linearity of sending devices cannot be calibrated out at the factory. This is why
the EGCP-2 must be calibrated upon commissioning.

The intent of calibrating the EGCP-2 is to make the unit read out the various
voltages, currents, frequencies, and temperatures in the various status menu
display screens as close as possible to what is actually occurring at the true
source of these signals.

For example, assume there is a 480 volt line-to-line generator set operating in a
system which uses 4:1 voltage transformers to feed the EGCP-2. The input AC
line to line voltage at the EGCP-2 is 118 volts due to primary to secondary losses
across the voltage transformers. The EGCP-2 Generator Status status menu will
display a generator voltage of 472 Vac L-L for each phase, which is not truly
what the generator is producing. In this case, the Calibration tuning menu would
be used to adjust the A/D converters on the three generator voltage transformer
inputs until the Generator Status status menu reads 480 Vac L-L for each phase.
This is how the calibration menu is used to compensate for losses in signal
between the source, and the EGCP-2. The calibration menu allows adjustment of
all the analog inputs and outputs of the EGCP-2 for this purpose.

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Calibration of Generator PTs and CTs

The calibration tuning menu of the EGCP-2 contains calibration points for three
phase generator voltage and current calibration. These calibration points are
labeled as follows:

PT Phase A Scale

Calibrates the A phase generator PT input.

Menus Affected
Changes in the calibration setpoint will change the generator A phase voltage as
read in the Generator Status Menu. Changing this value will also have an effect
on generator KW and KVAR levels.

The generator A phase voltage is also used as part of the function which
determines when the generator is in spec as shown in the control overview menu
by a sinusoidal wave under the GEN label. If the generator A phase PT is not
properly calibrated, the level at which the generator is shown as in spec may not
be a true indication of an in spec condition.

Operations Affected
The EGCP-2 uses the A phase generator voltage for voltage matching when
synchronizing across the generator breaker. Accurate calibration of the
Generator A phase PT is critical for proper voltage matching operation.

The sensed generator voltage on the A phase is used in Power Factor/VAR

sharing mode when the EGCP-2 is in parallel with other units on an isolated bus.
The EGCP-2 uses the Voltage Reference as found in the Configuration tuning
menu as a generator voltage reference point when balancing the reactive load on
the bus between generators. If the A phase PT voltage is out of calibration at the
EGCP-2 the bus voltage may be off of this reference when in Power Factor/VAR
sharing mode. Also, poor VAR/PF sharing may occur if the A phase PT is not
properly calibrated.

Generator Voltage is also used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The PT Phase A voltage is used for the Voltage High and Low limit setpoints
which are found in the Shutdown and Alarm tuning menu. The voltage limit
setpoints can be configured for various alarm indications. Also, if the generator
voltage as sensed by the EGCP-2 exceeds the Voltage High limit, or falls below
the Voltage Low limit, the voltage bias output will stop moving in the direction
which the alarm occurred.

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The A phase PT voltage is used in the calculations for KW load, and KVAR
load. All alarms monitoring these conditions will be affected if the A phase PT is
not properly calibrated.

PT Phase B Scale

Calibrates the B phase generator PT input.

Menus Affected
Changes in the calibration setpoint will change the generator B phase voltage as
read in the Generator Status menu. Changing this value will also have an effect
on generator KW and KVAR levels.

Operations Affected
Generator Voltage is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The B phase PT voltage is used in the calculations for KW load, and KVAR
load. All alarms monitoring these conditions will be affected if the B phase PT is
not properly calibrated.

PT Phase C Scale

Calibrates the C phase generator PT input.

Menus Affected
Changes in the calibration setpoint will change the generator C phase voltage as
read in the Generator Status menu. Changing this value will also have an effect
on generator KW and KVAR levels.

Operations Affected
Generator Voltage is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The C phase PT voltage is used in the calculations for KW load, and KVAR
load. All alarms monitoring these conditions will be affected if the A phase PT is
not properly calibrated.

CT Phase A Offset

Calibrates the A phase generator CT input offset (zero current) reading.

Menus Affected
Changes in the calibration value will change the A phase current readout in the
Generator Status menu. Changing this value will also have an effect on the
generator KVA, KW, and KVAR levels.

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Operations Affected
Generator Current is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The generator current on A phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated A phase CT levels will affect the point of
Overcurrent detection on the generator.

The A Phase CT calibration has an affect on KW and KVAR levels for the A
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

CT Phase A Scale

Calibrates the A phase generator CT input.

Menus Affected
Changes in the calibration value will change the A phase current readout in both
the Generator Status menu. Changing this value will also have an effect on the
generator KW and KVAR levels.

Operations Affected
Generator Current is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The generator current on A phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated A phase CT levels will affect the point of
Overcurrent detection on the generator.

The A Phase CT calibration has an affect on KW and KVAR levels for the A
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

CT Phase B Offset

Calibrates the B phase generator CT input offset (zero current) reading.

Menus Affected
Changes in the calibration value will change the B phase current readout in the
Generator Status menu. Changing this value will also have an effect on the
generator KVA, KW, and KVAR levels.

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Operations Affected
Generator Current is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

Alarms Affected
The generator current on A phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated B phase CT levels will affect the point of
Overcurrent detection on the generator.

The A Phase CT calibration has an affect on KW and KVAR levels for the B
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

CT Phase B Scale

Calibrates the B phase generator CT input.

Menus Affected
Changes in the calibration value will change the B phase current readout in both
the Generator Status menu. Changing this value will also have an effect on the
generator KW and KVAR levels.

Alarms Affected
The generator current on B phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated B phase CT levels will affect the point of
Overcurrent detection on the generator.

The B Phase CT calibration has an affect on KW and KVAR levels for the B
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

CT Phase C Offset

Calibrates the C phase generator CT input offset (zero current) reading.

Menus Affected
Changes in the calibration value will change the C phase current readout in the
Generator Status menu. Changing this value will also have an effect on the
generator KVA, KW, and KVAR levels.

Operations Affected
Generator Current is used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.

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Alarms Affected
The generator current on C phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated A phase CT levels will affect the point of
Overcurrent detection on the generator.

The A Phase CT calibration has an affect on KW and KVAR levels for the C
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

CT Phase C Scale

Calibrates the C phase generator CT input.

Menus Affected
Changes in the calibration value will change the C phase current readout in both
the Generator Status menu. Changing this value will also have an effect on the
generator KW and KVAR levels.

Alarms Affected
The generator current on C phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated C phase CT levels will affect the point of
Overcurrent detection on the generator.

The C Phase CT calibration has an affect on KW and KVAR levels for the B
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.

Calibration of the Bus PT

The bus PT input to the EGCP-2 plays a “dual role” in that it is used to sense
both the bus, and the mains PT voltage sensing. The EGCP-2 automatically
switches between the Bus and the Mains PT input when performing mains
monitoring, synchronizing and dead bus closing actions.

Bus PT Scale

Calibrates the Bus and Mains Voltage readouts on the EGCP-2.

Menus Affected

Mains Voltage Sensing

The Bus PT input is used as part of the sensing which determines when the
mains voltage is within spec as shown in the Control Overview Menu by a
sinusoidal wave under the MAINS label. The Bus PT also monitors the mains

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when paralleling the generator to the mains in mains parallel applications. The
U: value in the Synchroscope status menu will reflect the Mains voltage when
operating in a Close Mains Breaker mode.

Bus Voltage Sensing

The Bus PT input is used when synchronizing across the generator breaker to the
bus (live or dead bus closing). The Synchroscope status menu will display the
Bus voltage at the U: value when performing Close Gen Breaker Functions.

Operations Affected
The Bus PT Scale calibration will affect the Voltage matching accuracy when
the generator is paralleling to other generators on the isolated bus (Bus PT
monitored), or when the generator is paralleling to the mains (Mains PT
monitored). Improper calibration of the Bus PT sensing of the EGCP-2 may
cause large reactive load swings when paralleling into the bus or mains when the
generator breaker closes.

Alarms Affected
The Bus PT scale calibration will affect the Mains High and Low Voltage Limit
alarm setpoints in the Shutdown and Alarms tuning menu. If the Bus PT scale is
improperly calibrated, the sensed voltage for these high and low alarm setpoints
may cause alarms and/or loss of mains action to occur at the wrong voltage
levels.

Speed Bias Output

The Speed Bias Offset calibration point sets an offset on the speed bias output of
the EGCP-2. This output is fed into the speed control governor to bias the
governing speed for synchronization and load control functions. This offset is
the starting point from which the EGCP-2 begins all of its speed biasing
operations. The Speed Bias Offset value is factory calibrated for 0.0 Vdc.

Usually the speed bias output should remain at the factory calibrated level. The
speed control governor is used to set the synchronous speed of the generator, and
no additional bias is required.

However, if interfacing the EGCP-2 with speed controls other than those
manufactured by Woodward Governor Company, an offset may be required for
proper operation.

Increasing the Speed Bias Offset will increase the Speed Bias readout in the I/O
Display status menu of the EGCP-2. The speed bias offset imposes an offset in
percent of speed bias output. For example a Speed Bias offset of 3% will give a
3% speed bias reading in the I/O Display status menu. Decreasing the Speed
Bias Offset has just the opposite effect in that the values will read negative
instead of positive.

When initially powered up, the EGCP-2 will always apply the value for the
speed bias offset to the speed bias output. With the factory settings, the speed
bias output should always go to 0.0 Vdc on initial power up.

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Speed bias offset will affect the bus frequency of a single unit machine operating
on an isolated bus. Speed bias offset will also affect the load sharing between
machines operating on an isolated bus. It is recommended that the speed bias
output be calibrated for 0% ( 0.0 Vdc) when using Woodward Governor speed
controls.

Voltage Bias Output

The Voltage Bias Offset in the Calibration menu is used to impose an offset
voltage on the voltage bias output to the automatic voltage regulator. This DC
voltage offset is applied to the voltage bias input of the automatic voltage
regulator, and is maintained as a starting point for all voltage bias operations
used by the EGCP-2.

Most regulators which have a voltage trim bias input require a 0.0 Vdc voltage
bias offset. These types of regulators operate with a ±DC voltage applied to this
trim input. The voltage is then centered around zero volts offset, or zero Voltage
Bias.

Relationship Between Voltage Bias and Generator Voltage

(Voltage Regulators which take a +/0/- voltage bias input)
+100% B ias 110% R ated G enerator V oltage

Rated Generator Voltage

0% V oltage B ias O ffset (0.0 V D C )

-100% B ias 90% R ated G enerator V oltage

Figure 6-1. Relationship Between Voltage Bias and Generator Voltage

Some regulators cannot accept a ± voltage trim input, and require a voltage bias
signal that is only positive (or negative) in value. In cases such as these the
Voltage Bias offset can be used to raise the offset of the voltage bias output to a
level which allows more positive and less positive voltage adjustment around a
positive offset voltage.

Voltage Bias Offset will affect the rated voltage of the generator at synchronous
speed prior to the generator breaker closing. The effect the voltage bias offset
has on the generator voltage can be observed by running the unit in a test mode,
and measuring the generator voltage. It is recommended that the voltage
adjustment of the automatic voltage regulator be set for the desired rated voltage
of the generator with the EGCP-2 Voltage Bias Offset applied to the regulator.

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Chapter 7
General Startup Instructions

Before Starting the Generator Set

Before starting the generator set, configure the tuning setpoints in the EGCP-2
for values which best match the machines operating and performance
characteristics. Double check these values prior to starting the unit.

Verify Proper wiring to the EGCP-2. Check the following items for proper
polarity and configuration:
• Power Supply Input
• Generator CT Inputs
• Generator PT Inputs
• Mains and Bus PT Inputs
• Magnetic Pickup Input
• Voltage Bias Output
• Speed Bias Output

Once these items have been checked for proper polarity, check the power supply
voltage for proper amplitude. When this is confirmed, apply the power supply to
the EGCP-2.

With the EGCP-2 Powered Up the unit will go through a RAM test, and after a
self check period, will display the Control Overview Menu. If the Control fails to
power up properly, remove the power supply input and re check the polarity and
amplitude of the voltage feeding the EGCP-2 Control.

With the EGCP-2 powered, go to the I/O Status Display in the Status menus.
This display shows the state of the various discrete inputs and outputs of the
control. Monitor this screen and close the discrete inputs to the EGCP-2 that are
being used in this particular application. Verify that the EGCP-2 recognizes
these inputs in the I/O Status screen.

Verify that the Speed Bias, and Voltage Bias outputs are at zero percent, or the
proper levels if there is a bias offset used.

! WARNING
Make sure that a means exist of performing an emergency stop on
the unit prior to starting it. Check the emergency stop devices to
make sure they are functioning properly prior to starting the unit.

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Sequence of Startup and Checking Parameters

1. Enter program Setpoints in all menus.
2. Check discrete inputs in I/O status menu.
3. Set crank repeats to 0.
4. Set synchronizer mode to check.
5. Set load control mode to normal.
6. Start engine using test switch of EGCP-2.
7. Check engine overview status screen for engine rpm readout confirm rpm is
correct for unit.
8. Check voltage of unit in Generator Status menu—calibrate voltage if needed.
9. Adjust AVR voltage at AVR if needed to achieve rated generator voltage.
10. Check that voltage raise/lower switches operate properly.
a. Set voltage ramp time if needed.
11. Adjust AVR trim pot. (if equipped) for ±10% of rated voltage for ±100%
voltage bias output from EGCP-2. If this range cannot be achieved, shut
down the generator set, and select the next highest voltage bias output level
on dip switch SW-2 located on the back of the EGCP-2. Repeat steps 9
through 11 until satisfactory results are achieved.
12. Check that load raise/lower switches operate properly.
a. Set load raise/lower rates if needed.
b. Verify speed change with raise/lower load inputs.
13. Check mains voltage in synchroscope status menu (if available)—calibrate
if needed.
14. Calibrate synchronizer if possible.
15. Remove Test Input. Verify engine shuts down properly.

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Loading the Generator Set

! WARNING
Operation of the engine/generator set with incorrect CT and PT
phasing could cause serious injury or damage to equipment. If the
load on the unit rises rapidly when the generator or mains breaker is
closed, immediately open the breaker and shut the unit down. Check
the phasing of the PT and CTs. DO NOT permit the unit to continue to
pick up load or operate the system without correcting this condition.

Mains Parallel Units

Follow these steps if you are configuring a Mains Parallel Master Unit, or a
Mains Parallel Slave unit which will operate as a redundant master. Redundant
master units must have the Mains CB Aux hardwired into them. All other wiring
to the Master and Redundant Master Units must be identical for proper operation
of the Redundant units in the event of a loss of master.
1. Start unit with an Auto and Run with Load Input.
a. Unit will start and attempt to synchronize.
2. Adjust synchronizer dynamics for best control of phase matching (monitor
synchroscope status menu to see phase error.).
3. Use voltmeter to check voltage across generator breaker to assure proper phase
rotation and mains PT input polarity.
4. Set load/unload ramp times to at least 60 seconds.
5. Set base load level to 30% of rated load.
6. Shut down the unit by removing the Auto and Run with Load Inputs.
7. Set synchronizer to run mode.
8. Start unit with an Auto and Run with Load Input.
9. Monitor synchroscope status menu.
a. Verify action of synchronizer.

 NOTE
If using Process 4–20mA input, Set Process Reference to Proper
Level.

10. After generator breaker closes to the mains, monitor Generator Status menu.
a. Monitor KW load on unit.
b. Monitor KVAR/PF on unit.
1. As set by reactive load control setting.
11. Adjust load control gain, stability, derivative for stable load control.
12. Once satisfied with load control operation, switch to process control (if
applicable).
13. Confirm ramp to process reference level.
a. Tune process control for best response.

14. Remove run with load input to unit.

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a. Verify unload ramping.
b. Verify unload trip point.
c. Verify generator breaker opens.
d. Verify cooldown timer (if reached).
15. Set crank repeats, base load reference, process reference, load ramp times,
and load control mode as required for proper operation.
This concludes the Mains Parallel Master Setup.

No Parallel and Slave Setup

Use the following instructions for setup of No Parallel Applications, and Slave
unit applications.

1. Set unit for LOM on mains under frequency.

2. Set unit for check mains breaker disabled.
3. Set for dead bus closing enabled.
4. Remove mains PT and mains CB Aux input by opening mains breaker if
necessary.
5. Start unit with auto switch input.
6. Unit will start and close generator breaker to bus.
a. Verify dead bus closing.
b. Apply load to unit using load bank or plant load as applies.
c. Calibrate CT readings if needed.
7. If in a multi unit system, repeat previous steps for all units. Set all units to be
tested synchronizers to check mode prior to start.
8. The unit currently on the bus carrying the load will act as a synchronizing
reference for the other units.
9. Verify voltage matching, phase relationships of additional units by monitoring
the synchroscope status menu.
a. Verify voltage levels across generator breakers.
10. Tune individual synchronizer dynamics.
a. Calibrate synchronizer if needed.
11. Once satisfied with each synchronizers operation, shut down these units by
removing the auto input.
12. Change synch mode settings to run on all units.
a. This will enable generator breaker closure to live bus.

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13. Start one unit in auto and allow it to close to the dead bus.
a. Verify isochronous operation.
b. Verify correct voltage level on bus.
14. Start another unit and allow it to parallel to the live bus.
a. Confirm phase match and synchronizer action.
b. Verify generator breaker closure.
15. Load Control
a. Verify load sharing.
b. Verify VAR/PF sharing.
16. Start additional units and parallel to the bus in the same manner as previous
units.
a. Load must be sufficient to prevent sequencing of lower priority units off
line.
b. Confirm unit address and priority settings.
c. Adjust load control gain lower if unstable during ramp to load sharing.
d. Adjust load share gain if unstable in load share.
17. Remove units from isolated bus one at a time by opening the auto input.
a. Verify unload ramp.
b. Verify unload trip.
c. Verify cooldown if unit has exceeded cooldown limit.
18. When all units are off line, close mains breaker if applicable.
a. Set all units to auto for LOM detection.

This concludes the No Parallel setup.

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Chapter 8
Troubleshooting

Control Hardware and I/O

Problem Probable Cause Corrective Action
Unit does not power up No input power supply Check input power supply
on terminals 1 and 2. This
input must be 9 to 32 VDC.
Input power supply Ensure proper polarity of
reversed power supply to EGCP-2.
Receiving data on comm Disconnect RS-422 comm
port port. Verify data rates.
Unit powers up and then Weak Engine Battery or Charge Engine Battery, or
cycles on and off when Engine Battery voltage Replace Engine Battery.
cranking dropping below 6 Vdc on
cranking
Discrete inputs don’t show Faulty wiring of discrete Verify wiring of discrete
active in I/O STATUS input switches input switches.
screen when switches are
activated
Displayed generator Faulty wiring of generator Verify wiring of generator
voltages are very small Potential Potential Transformers
Transformers(PT’s) (PTs).
Generator PT inputs are Calibrate the appropriate
improperly calibrated PT input channel(s). See
section 1.10 Calibration of
Control Inputs and Outputs.
I/O STATUS shows relay(s) Faulty wiring of relay output Verify wiring of relay output
is energized, but action(i.e. contacts contacts.
alarm) does not occur
Generator voltage AVR dynamics are Tune the AVR dynamics for
fluctuates or is unstable at improperly set up stable operation. See AVR
no load on generator manufacturer’s instruction
manual for more details.
Voltages or currents EGCP-2 PT inputs are Calibrate the appropriate
displayed by EGCP-2 are inaccurately calibrated PT input channel(s). See
different than measured section 1.10 Calibration of
parameter Control Inputs and Outputs.

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Engine Control/Sensing Parameters

Problem Probable Cause Corrective Action
Start command(i.e. test or Configuration menu has not Enter the configuration set
run with load) does not start been accepted or entered points in the Configuration
engine properly menu such that all “*” and
“#” symbols are removed
from the display. See
section 1.3.4 Description of
set points for more details.
An active alarm condition Commit or reset alarm
exists condition(s). See section
1.3.2 Description of
Screens.
Relay output contacts are Verify wiring of relay output
not properly connected to contacts.
engine starter, fuel solenoid
Starter motor stays Crank cutout set point in Set CRANK CUTOUT set
engaged after engine starts Engine control menu is to point to appropriate value.
large See description of set
points.
Inadequate MPU signal to Verify MPU wiring, and that
EGCP-2 input adequate MPU signal exists
at input to EGCP-2 control.
Engine speed is unstable Speed control dynamics are Tune the speed control
when unit is at no load improperly set up dynamics for stable
operation. See speed
control manufacturer’s
instruction manual for more
details.
When crank command is Battery is too weak for the Install a higher capacity
issued, EGCP-2 loses current demand of the battery or a more efficient
power and conducts a reset starter motor starter motor.
and RAM test
Faulty wiring of power Verify wiring of power
supply to the EGCP-2 supply to the EGCP-2
control control.

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Synchronization
Problem Probable Cause Corrective Action
Unit never adequately Synchronizer Mode set Set synchronizer Mode to
matches phase point in synchroscope appropriate setting. See
menu set to PERMISSIVE description of set points.
Synchronizer dynamics in Tune synchronizer
synchroscope menu are dynamics. See description
improperly set up of set points.
Synchronizer displays small Generator A phase PT input Verify that Generator A
phase difference, but is L-L and bus A phase PT phase PT input bus A
measured phase difference input is L-N or vice versa phase PT input are the
is large same form (i.e. L-N or L-L).
Bus and/or generator PT Verify that Bus and
inputs are not A phase generator PT inputs are A
phase.
synchronizer improperly Calibrate synchronizer. See
calibrated calibration of control inputs
and outputs.
Synchronizer matches Synchronizer Mode set Set synchronizer Mode to
phase, but never closes point in synchroscope appropriate setting. See
breaker/contactor menu is set to CHECK description of set points.
Dwell time set point in Reduce Dwell Time set
synchroscope menu is too point in synchroscope
large menu. See description of
set points.
Synchronizer displays Generator or bus PT is Verify correct polarity of
matched phase, but reversed polarity (faulty Generator and bus PT
measured phase difference wiring) inputs.
is ~180 degrees, or when
breaker closes it crash
parallels the set 180
degrees out of phase
Unit won’t close to dead Multiple unit system with ENABLE DEADBUS
bus DEADBUS CLOSING set CLOSING set point in
point in configuration menu configuration menu. See
set to DISABLED description of set points.
Synchronizer set point is Set synchronizer Mode to
set to CHECK appropriate setting. See
description of set points.

Synchronizer won’t voltage VOLTAGE MATCHING set ENABLE the VOLTAGE

match point in synchroscope MATCHING set point in
menu is DISABLED synchroscope menu. See
description of set points.
Synchronizer does not Generator A phase PT Calibrate the Generator A
voltage match within spec. and/or Bus A phase PT phase PT and Bus A phase
input(s) are inadequately PT inputs. See calibration
calibrated of control inputs and
outputs.
Voltage matching tolerance Appropriately set the
set point in synchroscope Voltage matching tolerance
menu is too large set point in synchroscope
menu. See description of
set points.

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Breaker Close/Open Control

Problem Probable Cause Corrective Action
When generator set is in Synchronizer set to CHECK Set synchronizer Mode to
synchronization, the appropriate setting. See
breaker never closes description of set points.
Faulty wiring causing the Verify wiring of the relay
relay output to not make output contacts.
connection to the breaker
Dwell time set point in the Reduce Dwell time set point
synchroscope menu is too in the synchroscope menu.
long See description of set
points.
Contactor closes for a brief C B CONTROL set point in Appropriately set the C B
moment and then opens configuration menu is set CONTROL set point in
for BREAKER configuration menu. See
description of set points.
C B HOLD TIME set point in Increase C B HOLD TIME
synchroscope menu is too set point in synchroscope
short menu. See description of
set points.
Faulty wiring on C.B. Aux Verify wiring of C.B. Aux
contacts contacts to EGCP-2 input.
Breaker close relay stays C B CONTROL set point is Appropriately set the C B
energized when a close set for CONTACTOR CONTROL set point in
command is given and configuration menu. See
never issues an open description of set points.
command

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Real Load Control

Problem Probable Cause Corrective Action
KW for a phase(s) reads Current transformer(CT) Verify/reverse polarity of
negative. has reversed polarity current transformer for
effected channel(s)
NOTE: engine generator
set must be off to safely
open circuit a current
transformer.
Unit carries improper Rated KW set point in Appropriately set Rated KW
proportion of real load configuration menu set at set point in configuration
during isochronous load incorrect value menu. See description of
sharing set points.
A proportional dc speed Adjust speed setting of
error exists on the speed speed control to match the
control unit (no-load speed bus frequency. If unit is
not set to match bus carrying too little load, the
frequency) speed setting needs
increased. If unit is carrying
too much load, the speed
setting needs decreased.
Real load control is Real load control dynamics Tune Real load control
unstable when paralleled in real load control menu dynamics in real load
with the mains source are improperly set up control menu. See
description of set points.
Process control operation PROCESS ACTION set Appropriately set
causes overload or reverse point in process control PROCESS ACTION set
power menu set for incorrect point in process control
action menu. See description of
set points.
Loading and/or unloading is Load and/or unload ramp Appropriately
too fast/slow rates in the real load control increase/decrease the Load
menu are set incorrectly and/or unload ramp rates in
the real load control menu.
See description of set
points.
Engine speed/load has an Speed control dynamics are Tune the speed control
instability that fluctuates improperly set up dynamics for stable
very quickly. operation. See speed
control manufacturer’s
instruction manual for more
details.

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Reactive Load Control

Problem Probable Cause Corrective Action
Phase power factors do not CT’s are connected to Verify CT’s are connected
agree. Two of the three incorrect phase inputs to the appropriate input
phases are extremely far terminals.
out of range NOTE: engine generator
set must be off to safely
open circuit a current
transformer.
Unit carries improper Rated KVA set point in the Appropriately set the Rated
proportion of reactive load configuration menu is set at KVA set point in the
during isochronous load incorrect value configuration menu. See
sharing description of set points.
Generator A phase PT Calibrate the Generator A
input(s) are improperly phase PT input(s) of the
calibrated generator set(s). See
calibration of control inputs
and outputs.
Reactive load control is Reactive load control Tune the Reactive load
unstable when paralleled dynamics in the reactive control dynamics in the
with the mains source load control menu are reactive load control menu.
improperly set up See description of set
points.
Unit maintains a constant VAR/PF set point in the Appropriately set the
VAR load rather than a reactive load control menu VAR/PF set point in the
constant power factor when is set to VAR CONTROL reactive load control menu.
paralleled with the mains See description of set
source points.
Unit maintains a constant VAR/PF set point is set to Appropriately set the
power factor load rather PF CONTROL VAR/PF set point in the
than a constant VAR when reactive load control menu.
paralleled with the mains See description of set
source points.
Multiple generator sets are VOLTS RAMP TIME set Appropriately set the
unstable when VAR/PF point in reactive load VOLTS RAMP TIME set
sharing at light loads control menu is not point in reactive load
adjusted properly control menu. See
description of set points.
Droop Current Transformer Verify the connection of the
not properly connected to Droop Current Transformer
AVR to the AVR. See AVR
manufacturer’s instruction
manual for more details.

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Sequencing
Problem Probable Cause Corrective Action
Unit number(s) does not switch in manual position Switch unit(s) to the Auto
show up in the sequencing switch active position. See
order in the sequencing dc inputs/outputs.
screen/unit doesn’t auto
sequence
Automatic sequencing set ENABLE the Automatic
point in the configuration sequencing set point in the
menu set to disabled configuration menu. See
description of set points.
Unit has an active alarm Commit or reset alarm
condition(s). See
description of screens.
RS-485 Network not Verify that the RS-485
connected at unit(s) network is connected to all
EGCP-2 controls in system.
RS-485 Network is Verify that the RS-485
inadequately terminated Network is correctly
terminated. See inter-
control communications
(RS-485).
When system load is large NEXT GENSET DELAY set Increase NEXT GENSET
enough to require additional point in sequencing menu is DELAY set point in
gen-sets, more than one too short sequencing menu. See
set is sequenced on line description of set points.
MAX START TIME set point Increase MAX START TIME
in sequencing menu is too set point in sequencing
short menu. See description of
set points.
When system load is small REDUCED LOAD DELAY Increase REDUCED LOAD
enough to take additional set point in sequencing DELAY set point in
sets off line, more than one menu is too short sequencing menu. See
set is sequenced off line description of set points.
MAX STOP TIME set point Increase MAX STOP TIME
in sequencing menu is too set point in sequencing
short menu. See description of
set points.

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Mains/Bus Sensing
Problem Probable Cause Corrective Action
Unit(s) do not respond to Shutdown/alarm set points Appropriately set mains
loss of mains for mains sensing not set high/low frequency and
for LOSS OF MAINS high/low voltage set points
in shutdown/alarm menu.
See description of set
points.
Unit(s) do not have an Switch unit(s) to the Auto
active auto switch input switch active position. See
dc inputs/outputs.
Unit does not recognize Set points for mains Increase Mains high
when mains are in spec. high/low frequency and frequency and voltage and
high/low voltage in decrease mains low
shutdown/alarm menu are frequency and voltage set
set too tight for sensing points in the
when mains are in spec shutdown/alarm menu. See
description of set points.

Communications
Problem Probable Cause Corrective Action
A unit number(s) does not RS-485 Network is Verify that the RS-485
show up in the sequencing inadequately terminated Network is correctly
order in the sequencing terminated. See inter-
screen control communications
(RS-485).
RS-485 Network not Verify that the RS-485
connected at unit(s) Network is connected to the
EGCP-2 RS-485 input at all
units.
RS-485 network is Verify the polarity of the
connected with reverse RS-485 network on all
polarity at one or more units units.
If a unit with the network +5 Vdc power supply is not Verify that the +5 Vdc
termination is powered linked between units power supply is linked
down, communications (inadequate wiring) between all units.
become unreliable or
completely cease

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Chapter 9
Definition of Terms

AMF Automatic Mains Failure. The ability of a control to detect, and

take action on a mains failure condition. The EGCP-2, which has
AMF capabilities, can be programmed to sense a loss of mains
condition based on mains voltage, frequency, or a sudden load
surge on a generator operating in parallel with the mains. The
action taken by the EGCP-2 when it senses a mains failure can
be programmed for either an alarm action, or a standby power
action where all generators start and tie to the load after the
failed mains have been isolated from that load.

Automatic
Control A control mode used by the EGCP-2 to activate several
automatic functions within the control. These functions, which
are dependent upon program setpoints and system configuration,
are Loss of Mains detection, Automatic Sequencing, and
Automatic dead bus closing, Automatic control also effectively
connects those EGCP-2 units in automatic to the Local
Operating Network (LON).

Auto Switch A discrete input to the control which will initiate automatic
operation of the EGCP-2.

ATS Automatic Transfer Switch. A device which isolates the mains

upon a sensed fault in the mains, or through manual operation.
The ATS selects a secondary power source, such as a diesel
generator to supply the load when the mains have been isolated.
The ATS will also re-connect the load to the mains when they
are re-established and stable. The EGCP-2 control has ATS
functions.

Audible
Alarm An alarm condition used by the EGCP-2 for various alarm
settings which will cause the audible alarm relay output to
energize when reaching or exceeding the alarm parameters.

Automatic
Sequencing The automatic addition, or subtraction of generators to/from the
load based on predetermined load levels being crossed for
specific periods of time. Automatic sequencing is a function of a
multiple generator system which is operating in load sharing
mode isolated from the mains, of process control mode in
parallel with the mains.

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AVR Automatic Voltage Regulator. A device which controls the field
excitation of an AC generator in such a way as to maintain a
specific voltage level over the operating load range of the
generator. The EGCP-2 control biases the voltage setting of the
AVR to voltage match during synchronization and to control
reactive load during load share and mains parallel operation.

Base Load A term used to describe a generator loading condition in which

the generator is paralleled to another source of power, typically
the mains, and loaded to a fixed KW level. The generator
maintains this KW level regardless of load on the Mains.

Breaker A device used to connect one power source to a load, or to

another power source. Breakers can be either manually or
automatically operated, and will usually contain overcurrent
protection. The EGCP-2 controls motorized breakers by issuing
a momentary breaker close output to energize the breaker coil,
and a separate breaker open output to shunt trip the breaker to
open it.

Contactor A device used to connect one power source to a load, or to

another power source. Contactors are typically automatic in
operation, and are energized for closure from an external source.
The EGCP-2 controls contactors by issuing a contactor close
output to close the contactor, and removing this output to open
the contactor.

CT Current Transformer. A device used to sense current levels on a

high current source, such as a generator. The secondary side of
the current transformer supplies a lower current signal which is
safe to feed into metering and control devices. The EGCP-2 uses
5A secondary current CTs for its current sensing inputs from the
three phases of the generator.

Dead Bus
Closing The ability of a generator breaker control device to sense, and
safely close on to a load which has no other generators or
sources of power tied to it. Dead Bus Closing must not allow
two generators to attempt closure to the dead bus at the same
time, since an out of phase paralleling situation would likely
occur. The EGCP-2 uses its Local Operating Network to insure
safe dead bus closing among all units tied to this network. The
units have a single dead bus token, which allows the unit
possessing it to close to the dead bus. Only one token exists on
the network, so there is no possibility of multiple units closing to
the dead bus simultaneously. Dead Bus Closing is always active
in single unit configurations.

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Droop A reduction in the reference of a controlled parameter as the
amplitude of that parameter increases (negative feedback). The
EGCP-2 uses Kilowatt Droop as a manual means of loading the
generator when paralleling to another generator, or to the mains.
Droop Control is effective only if the LOAD CONTROL MODE
setpoint in the Configuration menu is set to DROOP.

Dwell Time A term used to describe the amount of time required during
synchronization in which one power source is within a specified
phase angle window of another source it is synchronizing to.

Hard
Shutdown A shutdown condition used by the EGCP-2 for various alarm
settings which will cause the unit to immediately open its
generator breaker if on load, and shut down when reaching or
exceeding the alarm parameters.

Isochronous A term which is used to describe a generator set which will

maintain its frequency at a constant level as the load on that
generator changes. The EGCP-2 typically uses Isochronous load
control when in load sharing, or when operating as a single unit.
This assures a constant frequency under all generator loads
which are within the capacity of the generator.

Inverse
Time Delay A time delay used for over current and reverse power detection
which utilizes both time and amplitude of the condition to
determine the active trip level. The inverse time delay accounts
for rapid high amplitude conditions to cause a trip, as well as
long duration low amplitude conditions.

Isolated Bus A bus which is electrically isolated from the mains.

KVA Kilovolt Amps. The power rating of the generator set KVA is
determined by multiplying the rated voltage of the generator by
the rated current.

KVAR Kilovolt Amps Reactive. Reactive load is produced by a phase

angle differential between the volts and the amps of the
generator. KVAR can either be a product of inductive or
capacitive loads when operating on an isolated bus, or can be
produced by the generator when operating in parallel with
another power source such as the mains.

KW Kilowatts. The Watts are the product of the voltage of the

generator and the current which is produced within the voltage
cycle. KW load is resistive in nature.

Load Typically the KW load on the generator at any given time.

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Load Surge A condition in which a step load on the generator ,which is
operating in a mains parallel mode (base load or process), above
a certain amplitude can be used to trigger a Loss of Mains
condition.

Loss of Mains A condition in which the sensed mains PT input to the EGCP-2
falls below certain voltage and/or frequency setpoints for a given
period of time. Load Surge can also be used to detect a Loss of
Mains condition. The EGCP-2 can be configured to trigger a
Loss of Mains (LOM) reaction to these conditions, and provide
on site power generation to supplement the load until such time
as the mains return and are stable.

Mains
Parallel To synchronize and close an operating generator to the mains.
The EGCP-2 can be configured for Mains Parallel operation.

Master The Highest Priority unit in an operating automatic system. The

Master Control controls load sharing, VAR/PF sharing,
sequencing, synchronization to the mains, mains breaker
closure/opening, and multiple unit starting.

Manual A switch input to the EGCP-2 which puts the control in a

manual operating mode. When in manual, the EGCP-2 does not
communicate with other units on the network, and if in a
multiple unit system, will not issue a dead bus closing command.
Being in manual also cancels any Loss of Mains detection for
that particular unit.

Network
Address A unique address assigned to each unit which is operating in an
automatic system. The network address is that particular units
“name” on the network so that it can be properly identified by
other units operating on the same network.

Network
Priority A unique number assigned to each unit operating in automatic
on the network. Network priority defines the sequence in which
units will be taken on/off load when operating in an automatic
sequencing configuration (load sharing or process control).
Automatic sequencing will place units on load as required
starting at the highest network priority (lowest numerical value),
and adding units of lower priority (higher numerical value) as
the load on that system increases above certain defined limits.
Automatic sequencing will also remove units from the load in a
reverse order of that used for sequencing units on load, that is
from lowest priority (highest numerical value) to highest priority
(lowest numerical value). In addition to all this, the unit with the
highest network priority on the network is considered the master,
and all other units with lower priorities are slaves to that master.

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No Parallel An operating mode of the EGCP-2 which will not allow the
generators to operate in parallel with the mains under any
circumstances. All transitions to and from the mains are
completed using an open transition action.

Parallel To synchronize and close an operating generator to the mains.

Power
Triangle A right triangle which is used to determine the amplitude
relationship between KVA, KW, and KVAR.

Process
Control A switch input which selects a mode of control used while in
parallel with the mains. When operating in process control, the
EGCP-2 receives a 4–20 mA, or 1–5 Vdc input from an external
transducer. This transducer monitors a variable which is affected
by the generator operation. Variables such as imported power to
a site, exported power to the mains, exhaust temperature, and
fuel gas pressure levels are typical for monitoring with a
transducer. The EGCP-2 uses an internal reference level for the
process input, and compares this reference to the transducer
input. The EGCP-2 then raises or lowers the amount of load on
the generator to maintain the process transducer input to the
referenced value.

Proportional
Load Sharing A mode of load control used by the EGCP-2 while operating
multiple units on an isolated bus. Proportional Load Sharing
measures the total KVA capacity of all the units on the bus and
divides the total KVA load on the bus by this capacity. This
value is then sent over the network as a load reference for all
units operating in parallel on the bus. The result of this is the
ability of various KVA rated units operating at their respective
proportion of the total load on the bus. This allows consistent
load sharing among units of various sizes throughout their entire
operating load range.

PT Potential Transformer. A device which steps down a higher AC

voltage to a lower AC voltage. Typically used on generator set
applications to step the generator voltage down to an amplitude
which is safe for use in metering and control devices.

Run With
Load A discrete input to the EGCP-2 which signals the unit to operate
the generator on load. The way that the control puts the
generator on load depends upon software configuration, and the
type of system the EGCP-2 is configured for.

Slave An EGCP-2 with lower network priority (Higher numerical

value) than the master.

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Soft Shutdown A shutdown condition used by the EGCP-2 for various alarm
settings which will cause the unit to softly unload and cooldown
when reaching or exceeding the alarm parameters.

Soft Transfer A Load Control Mode of the EGCP-2 which allows the unit, or
group of units to transfer power from the mains to the on site
generators. Upon reaching either a base load reference, or
process control reference level, the EGCP-2 will issue a
command to open the mains breaker. This results in a complete
transition of power from the mains to the on site generators.

Synchronize To match the frequency, phase angle, and voltage of a generator

to another power source such as a generator or the mains. This
will allow a safe smooth breaker closure of that generator to the
power source. The EGCP-2 uses Phase and Voltage Matching to
ensure there is a minimum of potential across the breaker prior
to closure.

System Load A variable used in the load control program of the EGCP-2
which is the ratio of total load demand to total generating
capacity which is supplying the load. System Load = KW
Load/KW Capacity.

Test A discrete input to the EGCP-2 which is used to start the engine
for test and initial start check out. The test input is also used
with the run with load or process inputs, and a software setpoint,
to put the EGCP-2 into a soft transfer mode.

VAR/PF
Control The ability to control a level of VAR or PF on a generator while
in parallel with the mains. The EGCP-2 has VAR/PF control
features which allow the user to set a desired VAR or PF level
on the generator while in parallel with the mains. The VAR or
PF level is maintained by changing the excitation level of the
generator. This is accomplished by changing the voltage
reference level of the AVR from the EGCP-2.

VAR/PF
Sharing The ability to share the VAR and PF load on multiple units
operating on an isolated bus. Like load sharing, the EGCP-2
VAR/PF sharing measures the VARs of the load on the isolated
bus, and divides this value by the total VAR capacity of the
generators tied to the load. A proportional VAR/PF level is then
maintained between all units tied to the load based on their rated
VAR capacity.

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Chapter 10
Service Options

Product Service Options

The following are the factory options available for the service of Woodward
equipment under Woodward’s standard Product and Service Warranty (25222),
in effect at the time the product is sold from Woodward or the service is
performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of action
you wish to pursue based on the available services listed in this section.

Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a Flat Rate structured program and
includes the full standard Woodward product warranty, pursuant to Woodward’s
Product and Service Warranty (25222).

This option allows you to call in advance of a scheduled outage or an unexpected

outage and request a replacement control unit. If the unit is available at the time
of the call, it can usually be shipped out within 24 hours. You replace your field
control unit with the like-new replacement and return the field unit to the
Woodward facility as explained later in this chapter.

Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]

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Return Shipment Authorization Label. To ensure prompt receipt of the core,
and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that
leaves Woodward. The core should be repackaged and the return authorization
label affixed to the outside of the package. Without the authorization label,
receipt of the returned core could be delayed and cause additional charges to be
applied.

Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty, pursuant to Woodward’s Product and Service
Warranty (25222) on replaced parts and labor.

Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in “like new” condition and carry
with it the full standard Woodward product warranty, pursuant to Woodward’s
Product and Service Warranty (25222). This option is applicable to mechanical
products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward
for repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.

! CAUTION
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.

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Manual 26086 EGCP-2 Engine Generator Control Package

Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.

Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [(1)(800) 523-2831 in North America or
(1)(970) 482-5811]. They will help expedite the processing of your order
through our distributors or local service facility. To expedite the repair process,
contact Woodward in advance to obtain a Return Authorization Number, and
arrange for issue of a purchase order for the item(s) to be repaired. No work can
be started until a purchase order is received.

 NOTE
We highly recommend you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
(1)(800) 523-2831 in North America or (1)(970) 482-5811 for
instructions and for a Return Authorization Number.

Replacement Parts
When ordering replacement parts for controls, include the following
information:
• the part number(s) (XXXX-XXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.

How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA

TELEPHONE: (1)(970) 482-511 (24 hours a day)

TOLL-FREE PHONE (in North America): (1)(800) 523-2831
FAX: (1)(970) 498-3058

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For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.

FACILITY PHONE NUMBER

Australia (61)(2) 9758 2322
India (91)(129) 230419
Japan (81)(476) 93-4661
The Netherlands (31)(23) 56 61111

You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s Internet website
(http://www.woodward.com) for the name of your nearest Woodward
distributor or service facility:

Additional Aftermarket Product Support Services

Woodward Aftermarket Services offers the following after-sale support for all
Woodward products:
• Customer Training
• Technical Assistance
• Field Service
• Specialized Services

Customer Training is offered at our facility in Loveland, Colorado, or at your

site. This training, conducted by experienced trainers, will assure that customer
personnel will be able to maintain system reliability and availability. For
information concerning training available, call the number above and ask for
customer training.

Technical Assistance is available using the Woodward toll-free number. The

Aftermarket application engineering group is available to assist customers with
technical questions or problem solving during normal business hours or as
emergency support 24 hours a day. This group can also provide engineering
support for changes or enhancements after the commissioning of your system.
For technical engineering assistance, call the number above and ask for technical
assistance.

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Field Service engineers are dispatched from the Woodward facility in Colorado,
or from one of many regional or worldwide offices located near the customer to
provide prompt response. Woodward field engineers are experienced and are
continually updated on all Woodward products as well as much of the non-
Woodward equipment they interface with. The field engineers ensure that all
documentation is updated, and all field engineers are well informed as to new
problems which might arise. Woodward field service engineers are on-call 24
hours a day. Call the number above and ask for field service.

Specialized Services can be tailored to your specific needs. These services can
be based on a particular aspect of a single service or a combination of services
and are covered under one low-cost service contract. A contract may be for
regularly scheduled training courses or possibly to have a field engineer visit
your site at pre-determined intervals to provide a system analysis, verify proper
operation, and make recommendations for maintenance improvements,
enhancements, or other needs. These contracts are usually custom-designed and
structured to allow ultimate flexibility, thereby allowing you to plan and budget
more accurately. For more details, contact the Woodward sales representative, or
call the number above and ask for sales support to discuss specific needs.

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Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

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Appendix A
EGCP-2 Setpoint Worksheet

Configuration Menu
Item: Range: Default: As Set Value: Note:
SECURITY Min: 0 **** See Password
CODE Max: 9999 section
NETWORK Min: 1 1 Only accessible
ADDRESS Max: 8 if configured
for multiple
units
NETWORK Min: 1 1 Only accessible
PRIORITY Max: 8 if configured
for multiple
units
NUMBER OF Min: 2 4
POLES Max: 18
NUMBER OF Min: 16 60
TEETH Max: 500
SYSTEM Min: 50 60 Hz
FREQUENCY Max: 60
RATED SPEED Min:100 1800 RPM
Max: 5000
RATED KW Min: 1 0 kW
Max: 30000
RATED KVA Min: 1 0 kVA
Max: 30000
RATED KVAR Min: 1 0 kVAR
Max: 30000
CT RATIO Min: 5:5 5:5
Max: 30000:5
PT RATIO Min: 1.0:1 1.0:1
Max: 1000.0:1
VOLTAGE Wye line-neutral Wye (line-
INPUT Delta line-line neutral))
VOLTAGE REF Min: 1 220 Volts
Max: 30000
DISPLAY UNITS AMERICAN METRIC
METRIC
SET DATE MM-DD-YY 6-16-2000
SET TIME HH :MM 12 :00 24 Hr. CLOCK
RELAY #12 KVA LOAD SWITCH KVA LOAD
FUNCTION IDLE/ RATED SWITCH
SWITCH
SPEED BIAS +/- 3VDC (wgc) +/-3VDC
TYPE .5 TO 4.5 VDC (ddec)
500 Hz PWM (adem)
VOLTAGE BIAS +/-1VDC BIAS +/- 1VDC BIAS
TYPE +/- 3VDC BIAS
+/-9VDC BIAS
CKT BREAKER Breaker Breaker
CONTROL Contactor
OPERATING No Parallel No Parallel
MODE Mains Parallel
NUMBER OF SINGLE SINGLE
UNITS MULTIPLE

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Shutdown and Alarms Menu

Item: Range: Default: As Set Value: Note:
VOLTAGE RNG Audible Alarm Disabled
ALM Visual Alarm
Warning
Disabled
GEN VOLT HI Min: 50 250.0 volts
LMT Max: 30000
GEN VOLT HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
GEN VOLT LO Min: 50 200.0 volts
LMT Max: 30000
GEN VOLT LO Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
VOLTAGE ALM Min: 0.1 5.0 sec.
DLY Max: 30.0
GEN FREQ HI Min: 40 62.5 Hz
LMT Max: 75
GEN FREQ HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
GEN FREQ LO Min: 40 58.0 Hz
LMT Max: 75
GEN FREQ LO Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
SPD FREQ Disabled Disabled
MISMTCH Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
OVERCURRENT Min: 5.0 30 Amps/phase
LVL Max: 30000.0
OVERCURRENT Min: 0.1 1.0 second
DLY Max: 20.0
OVERCURRENT Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
REVERSE PWR Min: -50.0 -10.0 %
Max: -1.0
REV PWR DELAY Min: 0.1 5.0 seconds
Max: 20.0

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Item: Range: Default: As Set Value: Note:
MIN REVERSE Min: -50.0 -5.0 %
PWR Max: -1.0
REVERSE PWR Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
LOSS OF EXCITE Min: -100.0 -50.0 %
Max: -5.0
LOE ALARM Disabled Warning
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
REMOTE FAULT1 Disabled Disabled Only active when
Warning generator is
Visual Alarm stable.
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT1 TIMER Min: 0.0 0.0 seconds
Max: 30.0
REMOTE FAULT2 Disabled Disabled Only active when
Warning generator is
Visual Alarm stable
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT2 TIMER Min: 0.0 0.0 seconds
Max: 30.0
REMOTE FAULT3 Disabled Hard Shutdown
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT3 TIMER Min: 0.0 0.0 seconds
Max: 30.0
REMOTE FAULT4 Disabled Disabled
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT4 TIMER Min: 0.0 0.0 seconds
Max: 30.0
REMOTE FAULT5 Disabled Disabled
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT5 TIMER Min: 0.0 0.0 seconds
Max: 30.0

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Item: Range: Default: As Set Value: Note:
REMOTE FAULT6 Disabled Disabled
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT6 TIMER Min: 0.0 0.0 seconds
Max: 30.0

ENGINE CONTROL MENU

Item: Range: Default: As Set Value: Note:
PREGLOW TIME Min: 0 5 sec
Max: 1200
CRANK TIME Min: 0 10 sec
Max: 240
CRANK CUTOUT Min: 5 550 RPM
Max: 10000
CRANK DELAY Min: 1 30 sec
Max: 240
CRANK Min: 0 0
REPEATS Max: 20
CRANK FAIL Warning Warning
Visual Alarm
Audible Alarm
IDLE SPEED Min: 5 1200 RPM
Max: 30000
IDLE TIME Min: 1 20 sec
Max: 240
COOLDOWN Min: 0 120 sec
TIME Max: 2400
COOLDOWN Min: 0 20 kVA
LIMIT Max: 10000
ENGINE RUN Min: 0 0 Hours
TIME Max: 32000
MW HOURS Min: 0.0 0.0 MW Hrs
Max: 32000.0
OVERSPEED Min: 5.0 1980 RPM
Max: 30000.0
OVERSPEED Disabled Hard Shutdown
ALARM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown

BATT VOLT HI Min: 5.0 27.0 VOLTS

LMT Max: 50.0
BATT VOLT HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown

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BATT VOLT LO Min: 5.0 10.0 VOLTS

LMT Max: 50.0

BATT VOLT LO Disabled Warning

ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown

HI OIL PRESS Min: 0.0 5.0 Bar or PSI

LMT Max: 10.0
HI OIL PRESS Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
LO OIL PRESS Min: 0.0 2.0 Bar or PSI
LMT Max: 10.0
LO OIL PRESS Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
HI H20 TEMP Min:75.0 125.0 C or Deg F
Max: 300.0
HI H20 TEMP Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
LO H20 TEMP Min: 0.0 20.0 C or Deg F
Max: 100.0
LO H20 TEMP Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown

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SYNCHRONIZER MENU
Item: Range: Default: As Set Value: Note:
SYNC MODE CHECK CHECK
RUN
PERMISSIVE
SYNC GAIN Min: 0.01 0.01
Max: 100.00
SYNC STABILITY Min: 0.00 1.00
Max: 20.00
VOLTAGE Disabled Enabled
MATCHING Enabled
VOLTAGE Min: 0.1 1.0 %
WINDOW Max: 10.0
MAX PHASE Min: 2.0 10.0 degrees
WINDOW Max: 20.0
DWELL TIME Min: 0.1 1.0 sec
Max: 30.0
CB HOLD TIME Min: 0.1 1.0 sec
Max: 30.0
CLOSE Min: 1 1
ATTEMPTS Max: 20
RECLOSE Min: 2 30 seconds
DELAY Max: 1200
SYNC RECLOSE Warning Warning
ALM Visual Alarm
Audible Alarm
SYNC TIMEOUT Min: 0 0 seconds 0= NO LIMIT
Max: 1200
SYNC TIMEOUT Warning Warning
ALM Visual Alarm
Audible Alarm
DEADBUS Disabled Disabled Don’t care
CLOSURE Enabled setpoint in single
unit applications
(internally
ENABLED).

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REAL LOAD CONTROL MENU

Item: Range: Default: As Set Value: Note:
LOAD CONTROL Droop Normal
MODE Normal
Soft Transfer
LOAD CTRL Min: 0.001 .010
GAIN Max: 100.0
LOADSHARE Min: 0.1 .10
GAIN Max2.0
LOAD STABILITY Min: 0.0 1.0
Max:20.0
LOAD Min: 0.0 .20
DERIVATIVE Max: 20.0
LOAD CTRL Min: 0.01 1.0 Hz
FILTER Max: 10.0
BASE LOAD Min: 0.0 50.0 kW
REFERENCE Max: 30000.0
UNLOAD TRIP Min: -10.0 10 kW
Max: 30000.0
LOAD DROOP Min: 0.0 5.0 %
Max: 50.0
LOAD TIME Min: 1.0 10 seconds
Max: 7200.0
UNLOAD TIME Min: 1.0 10 seconds
Max: 7200.0
RAISE LOAD Min: 0.01 2.00 %/second
RATE Max: 100.0
LOWER LOAD Min: 0.01 2.00 %/second
RATE Max: 100.0
KW LOAD HIGH Min: 0.0 30 kW
LIMIT Max: 30000.0
KW HIGH LIMIT Disabled Warning
ALARM Warning
Visual Alarm
Audible Alarm
KW LOAD LOW Min: 0.0 5 kW
LIMIT Max: 30000.0
KW LOW LIMIT Disabled Disabled
ALARM Warning
Visual Alarm
Audible Alarm
KVA SWITCH Min: 0 10 KVA
LOW Max: 30000
KVA SWITCH Min: 0 100 KVA
HIGH Max: 30000

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REACTIVE LOAD CONTROL MENU

Item: Range: Default: As Set Value: Note:
VAR/PF MODE Disabled PF control
PF control
VAR
VAR/PF GAIN Min: .01 3.0
Max: 20.0
VOLTS RAMP Min: 0 30 sec
TIME Max: 1000
VAR/PF Min: .01 1.00
SHARING GAIN Max: 20.0
VAR/PF Min: 0.0 1.00
STABILITY Max: 20.00
KVAR Min: 0 10 kVAR + = generate
REFERENCE Max: 30000 - = absorb
PF REF Min: -0.5 =.5 LEAD 0.0= 1.00 LAG 0.0 = UNITY PF
Max: +.5 =.5 LAG + = LAG
- = LEAD
PF DEADBAND Min: 0.0 0.0
Max: 1.0

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PROCESS CONTROL MENU

Item: Range: Default: As Set Value: Note:
PROCESS Direct Indirect
ACTION Indirect
PROCESS GAIN Min: 0.001 0.1
Max: 100.0
PROCESS Min: 0.0 1.0 sec
STABILITY Max: 20.0
PROCESS Min: 0.0 0.1 sec
DERIVATIVE Max: 20.0
PROCESS Min: 0.0 0.0 mA
DEADBAND Max: 20.0
PROCESS Min: 0.0 0.0 %
DROOP Max: 50.0
PROCESS Min: 0.1 1.0 Hz
FILTER Max: 5.0
PROCESS Min: 4.0 12.0 mA
REFERENCE Max: 20.0
RAISE RATE Min: 0.01 0.1 mA/sec
Max: 20.0
LOWER RATE Min: 0.01 0.1 mA/sec
Max: 20.0
PROCESS HIGH Min: 4.0 20.0 mA
LMT Max: 20.0
PROC HI LMT Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
PROCESS LOW Min: 4.0 4.0 mA
LMT Max: 20.0
PROC LO LMT Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown

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TRANSFER SWITCH MENU

Item: Range: Default: As Set Value: Note:
CHECK MAINS Disabled Enabled
BREAKER Enabled
FAST XFER Min: 0.1 0.1 sec
DELAY Max: 30.0
MAINS STABLE Min: 1 60 second
DLY Max: 30000
GEN STABLE Min: 1 30 second
DLY Max: 30000
LOAD SURGE Min: 25.0 100.0 % / sec
Max: 300.0
LOAD SURGE Disabled Warning
ALARM Warning
Loss of Mains
Loss of Mains
w/alarms
MAIN VOLT HIGH Min: 50.0 240 volts
LMT Max: 30000.0
MAIN VOLT HIGH Disabled Warning
ALARM Warning
Loss of Mains
Loss of Mains
w/alarms
MAIN VOLT LOW Min: 50.0 200 volts
LMT Max: 30000.0
MAIN VOLT LOW Disabled Warning
ALARM Warning
Loss of Mains
Loss of Mains
w/alarms
MAIN FREQ HIGH Min: 40.0 61.0 Hz
LMT Max: 75.0
MAIN FREQ HIGH Disabled Warning
ALARM Warning
Loss of Mains
Loss of Mains
w/alarms
MAIN FREQ LOW Min: 40.0 59.0 Hz
LMT Max: 75.0
MAIN FREQ LOW Disabled Disabled
ALARM Warning
Loss of Mains
Loss of Mains
w/alarms
LOM ACTION Min: 0.1 0.1 seconds
DELAY Max: 30.0

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SEQUENCING AND COMMS MENU

Item: Range: Default: As Set Value: Note:
AUTO Disabled Disabled
SEQUENCE Enabled
MAX GEN LOAD Min: 1 60 %
Max: 100
NEXT GENSET Min: 1 30 sec
DLY Max: 1200
RATED LOAD Min: 1 5 sec
DELAY Max: 1200
MAX START Min: 1 30 sec
TIME Max: 1200
MIN GEN LOAD Min: 1 30 %
Max: 100
REDUCED LOAD Min: 1 30 sec
DLY Max: 1200
MAX STOP TIME Min: 1 60 sec
Max: 1200
422 PROTOCOL Servlink Modbus
Modbus
Upload Setpoints
Modbus ID Min: 1 1
Max: 247
Modbus Timeout Min: 0.1 3.0 sec
Max: 20.0
Modbus Reset False False
True

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CALIBRATION MENU
Item: Range: Default: As Set Value: Note:
Process In scale Min: 0.5 1.0
Max: 2.0
Speed Bias Min: -10.0 0.0
offset Max: 10.0
Volts Bias offset Min: -25.0 0.0
Max: 25.0
PT Phase A scale Min: 0.5 2.0
Max: 10.0
PT Phase B scale Min: 0.5 2.0
Max: 10.0
PT Phase C scale Min: 0.5 2.0
Max: 10.0
CT Phase A Min: -90.0 0.0
offset Max: 90.0
CT Phase A scale Min: 0.5 1.0
Max: 5.0
CT Phase B Min: -90.0 0.0
offset Max: 90.0
CT Phase B scale Min: 0.5 1.0
Max: 5.0
CT Phase C Min: -90.0 0.0
offset Max: 90.0
CT Phase C scale Min: 0.5 1.0
Max: 5.0
Bus PT scale Min: 0.5 2.0
Max: 10.0
Synchronizer Min: -1.0 0.0
Max: 1.0
Battery VCO Gain Min: -0.1000 .0051
Max: 0.1000
Batt VCO offset Min : -900.0 5.74
Max: 900.0
Oil Press Gain Min: -0.1000 0.021
Max: 0.1000
Oil Press Offset Min: -900.0 -5.91
Max: 900.0
WaterTemp Gain Min: -0.1000 -0.0220
Max: 0.1000
Water Temp Min: -900.0 163.0
Offset Max: 900.0
NetComm Min: 0 2
Dropouts Max: 50
Calibrated Unit False True True Do Not Change
True

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Appendix B
Download Instructions

Purpose
DOWNLOAD is a DOS-based freeware program that can upload and download
configuration files through the EGCP-2's RS-422 serial port. This program is available
through the Internet at the following location:
<http://www.woodward.com/industrial/gcpinfo.htm>

Requirements
• RS-232-RS-422 converter
• EGCP Download Cable
• DOWNLOAD.EXE, part number 9926-113 Rev B or greater

Instructions
Save the DOWLOAD.EXE file to the computer. In the following example this file is
saved in a directory called EGCP2 on the c:\ drive. Then using a DOS command prompt,
go to the directory where the download file is stored and type DOWNLOAD –h (or –?)
for a complete list of the command-line options (see below).

Establishing a Connection:
Connect the RS-232 / RS-422 cable between the EGCP-2 and the computer. See the
Communication Ports section of chapter four in the Set Builder manual for more
information about this cable interface.

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 NOTE
Only one EGCP-2 can be connected to the RS-422 communication
network when uploading or downloading setpoints. If a multidrop
network has been setup linking more than one EGCP-2 on the RS-422
communication port network, it will be necessary to separate the
control from the network in order to upload or download setpoints.

Uploading Setpoints:
Saving the setpoints from the control to a file on the computer.
The following examples assume that COM1 is the available serial port on the
PC, and the download.exe program has been saved to the directory, c:\EGCP2.

On the EGCP-2, under the SEQUENCING AND COMMS menu, step to the
“422 Protocol” item. Select "Upload Setpoints" and press the Enter key.
Cycle power to the EGCP-2.
When the EGCP-2 passes the self-tests, it will be ready to start uploading
setpoints.
Using a DOS command prompt, go to the directory where the
DOWNLOAD.EXE file is stored and type "download –u –o unit1.spt" at the
DOS command prompt (see below). The –u tells the program to wait for an
upload string from the control. The –o specifies that the information should be
saved to a file, and unit1.spt is the file which will be created in the same
directory. The file name can be any name up to 8 characters long. This
command assumes that com port 1 is the com port being used on the computer.
If another port is being used add the number of this port to the end of the
command, i.e. "download –u –o unit1.spt 2” for com 2, add a 3 for com 3, etc.

The program will begin uploading setpoints within a few seconds. After the
upload is completed the text “Done” will appear on the screen.

When uploading more than one control be sure to use a different name for the
.spt files (i.e. Unit1, Unit2…).

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Downloading Setpoints:
Loading an existing setpoint file from the computer to the control.

Using a DOS command prompt, go to the directory where the

DOWNLOAD.EXE file is stored and type "download unit1.spt" at the DOS
command prompt (see below). The 422 Protocol setting can be set to any of the
three choices, Upload Setpoints, Modbus, or Servlink.

Cycle power to the EGCP-2.

When the power is restored to the control the download will begin.
A scroll bar will appear on the computer screen showing the progress of the
download (see below).

On the EGCP-2 screen the text “SETPOINTS” will be displayed.

After the download is complete press the Config key and enter the proper
password. Every item in the Configuration menu will need to be verified by
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viewing the setpoint and pressing the Enter key on the control. An “*” will be
displayed following the setpoint until this value has been committed into the
control by pressing the Enter key. This step forces the user to view each setpoint
and verify that the value that has just been downloaded is correct for this
system’s configuration. This only applies to the Configuration menu, the other
menu’s do not need to be committed, although it would be recommended to
verify every item.

It is highly recommended that Uploading and Downloading of setpoints only be

done between units with the same code revision level. The EGCP-2 will display
a warning message and reboot after the self-tests if the setpoints and labels are
not compatible with the internal code revision number. This revision number is
displayed briefly after the self-tests are complete. It will be displayed on the last
line of the lower LCD panel.

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 EGCP-2 Control Specifications
Woodward Part Numbers:
8406-115 EGCP-2 Engine Generator Control, 150-300 Vac PT input
8406-116 EGCP-2 Engine Generator Control, 50-150 Vac PT input

Power Supply Rating 9–32 Vdc (SELV) Maximum input voltage range
Power Consumption less than or equal 13 W nominal, 20 W maximum
Input Supply Voltage Input Supply Current
12 V (nominal) 1.08 A
24 V (nominal) 542 mA
32 V 406 mA
PT input 50-150 Vac, 8406-116
150-300 Vac, 8406-115
CT input 0–5 Arms
Generator Frequency Range 40–70 Hz
Magnetic Pickup 100–15000 Hz
Discrete Inputs (8) 5 mA source current when CLOSED to Switch
Common (65)
Process input 4–20 mA, 1–5 Vdc
Temperature and pressure inputs 0-200 ohms sensors, 4-20 mA transducer, or 0-5V transducer
Speed Bias ± 3 Vdc, .5–4.5 Vdc, 5V peak 500 Hz PWM
Voltage Bias ± 1 Vdc, ± 3 Vdc, ± 9 Vdc
Discrete Outputs (Relay Outputs) 10 Amp, 250 Vac Resistive
1/3 HP, 125 Vac (7.2 Amp, 0.4-0.5 P.F.)
10 Amp, 30 Vdc Resistive
Communication Ports RS-485, RS-422
Ambient Operating Temperature –20 to +70 °C (–4 to +158 °F)(around outside of EGCP-2 Chassis)
Storage Temperature –40 to +105 °C (–40 to +221 °F)
Humidity 95% at +20 to +55 °C (+68 to +131 °F)
2
Mechanical Vibration SV2 5-2000 Hz @ 4 G and RV1 10-2000 Hz @ .04 G /Hz
Mechanical Shock US MIL-STD 810C, Method 516.2, Procedure I (basic design test),
Procedure II (transit drop test, packaged), Procedure V (bench handling)
Equipment Classification 1 (grounded equipment)
Air Quality Pollution Degree II
Installation Overvoltage Category III
Ingress Protection Will meet the requirements of IP56 as defined in IEC529 when installed in
a suitable atmospherically vented enclosure. Also meets Type 4
requirements.

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 for use in the United States and Canada
CSA CSA Certified for Ordinary Locations for use in the United States and
Canada
NOTE Wiring must be in accordance with applicable electric codes with the
authority having jurisdiction.
We appreciate your comments about the content of our publications.
Please send comments to:
Woodward Governor Company
Attention: Technical Publications
PO Box 1519
Fort Collins CO 80522-1519, USA
Please include the manual number from the front cover of this publication.

Woodward Governor Company/Industrial Controls

PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone (1)(970) 482-5811 • Fax (1)(970) 498-3058
E-mail and World Wide Web Home Page—http://www.woodward.com

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ISO 9001:1994/Q9001-1994
Certificate QSR-36

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as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address/phone/fax/e-mail information for all locations is available on our website.

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