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Woodward 8406-120 Installation And Operation Manual Download Page 71

Manual 26174 

EGCP-2 Engine Generator Control Package 

 

 

 

Woodward 

61 

 

Figure 4-6. I/O Status 

 

IN

: Discrete Inputs 1 through 16. 

OUT

: Discrete Outputs 1 through 12. 

Volt Bias

: % voltage bias output (±100% range). 

Speed Bias

: % speed bias output (±100% range). 

Process In

: Process Input will be displayed in Engineering Units configured in 

the Process menu. Shown in Milliamps. 
 

Discrete Inputs 

1. Automatic Switch 
2. Test Switch 
3. Run with Load Switch 
4. Volts Raise 
5. Volts Lower 
6. Speed Raise 
7. Speed Lower 
8. Gen Circuit Breaker Aux Contact 
9. Mains Circuit Breaker Aux Contact 
10. Process Switch 
11–16. Remote Alarm/Shutdown 
Inputs 

Discrete Outputs 

1. Mains Breaker Close/Contactor 
Close 
2. Gen Breaker/Contactor Close 
3. Engine Preglow 
4. Fuel Solenoid 
5. Engine Crank 
6. Visual Alarm Relay 
7. Local Bus PT Connect 
8. Mains PT Disconnect 
9. Mains Breaker Trip 
10. Gen Breaker Trip 
11. Audible Alarm 
12. kVA load switch, or Idle/Rated 
Switch, depending on configuration 

Summary of Contents for 8406-120

Page 1: ...roduct Manual 26174 Revision B Original Instructions EGCP 2 Engine Generator Control Package 8406 120 150 300 Vac PT Input 9 32 Vdc 8406 121 50 150 Vac PT Input 9 32 Vdc Installation and Operation Manual ...

Page 2: ...ncluding damage to the equipment Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings Translated Publications If the cover of this publication states Translation of the Original Instructions please note The original source...

Page 3: ...puts 22 Current Transformer CT Inputs 30 MPU Speed Input 31 Process Import Export Input 32 Coolant Temperature and Oil Pressure Inputs 33 Speed Bias and Voltage Bias Outputs 36 Discrete Inputs 38 Relay Outputs 39 AC Inputs 48 DC Inputs and Outputs 48 Discrete Inputs 49 Discrete Outputs 49 Communication Ports RS 485 RS 422 1 each 50 Hardware Connections 50 Inter control Communications RS 485 Networ...

Page 4: ...ation of the Bus PT 151 Speed Bias Output 152 Voltage Bias Output 152 CHAPTER 7 GENERAL START UP INSTRUCTIONS 154 Before Starting the Generator Set 154 Sequence of Start up and Checking Parameters 155 Loading the Generator Set 155 CHAPTER 8 TROUBLESHOOTING 158 Control Hardware and I O 158 Engine Control Sensing Parameters 159 Synchronization 160 Breaker Close Open Control 161 Real Load Control 162...

Page 5: ...aterpillar VR6 196 KATO KCR360 or 760 197 KATO K65 12B or K125 10B 198 Leroy Somer R438 R448 or R449 199 Leroy Somer R600 200 Leroy Somer R610 201 Marathon PM 100 200 202 Marathon 2000E 203 Mecc Alte UVR 204 Newage MA325 205 Newage MA327 206 Newage MX321 341 207 APPENDIX D EGCP 2 SET POINT WORKSHEET 208 Configuration Menu 208 Shutdown and Alarms Menu 209 Engine Control Menu 212 Synchronizer Menu 2...

Page 6: ...rocess Import Export Input 32 Figure 3 13b Connecting a kW Transducer Signal to Multiple EGCP 2s 32 Figure 3 14 Wiring Diagram for Pressure Inputs 33 Figure 3 15 Wiring Diagram for Temperature Inputs 34 Figure 3 16 Wiring Diagram for Speed Bias and Voltage Bias Outputs 37 Figure 3 17 Wiring Diagram for Typical Discrete I O Connections 39 Figure 3 18 Example of the Mains Breaker NO Output Connected...

Page 7: ...ing 88 Figure 4 27 Voltage Matching 1 set point 89 Figure 4 28 Maximum Phase Window 10 Degrees 90 Figure 4 29 EGCP 2 Control Dip Switch 95 Figure 4 30 Direct Export Process Action 96 Figure 4 31 Indirect Import Power Process Action 96 Figure 4 32 Direct Import Export Process Action 96 Figure 4 33 Process In Scale 105 Figure 4 34 Measured vs Monitored 105 Figure 4 35 Typical AVR with Aux Input Newa...

Page 8: ...gure 5 18 Changing the Priority of a Slave Unit 144 Figure 5 19 Changing the Priority of a Slave Unit 144 Figure 6 1 Relationship Between Voltage Bias and Generator Voltage 153 Table 4 1 Overcurrent Level Chart 82 Table 4 2 Reverse Power Chart 84 HIGH VOLTAGE Only authorized personnel knowledgeable of the risks posed by live electrical equipment should perform the calibration and checkout procedur...

Page 9: ...the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate Personal Protective Equipment The products described in this publication may present risks that could lead to personal injury loss of life or property damage Always wear the appropriate personal protective equipment PPE for the job at hand Equipment that should be consider...

Page 10: ...ns when working with or near the control 1 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 2 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove th...

Page 11: ...l codes and in accordance with the authority having jurisdiction Field wiring must be suitable for at least 90 C Connect ground terminal to PE Protective Earth More than one live circuit see wiring diagram Control Electrical Ratings Nominal supply voltage range 10 29 Vdc 12 or 24 volt systems Maximum power consumption at rated voltage 20 W Maximum PT input voltage range 150 300 Vac rms 8406 120 Ma...

Page 12: ...low Control Fuel Solenoid Control Engine Starter Control Cranking kVA Controlled Cool down Timer Oil Pressure Monitoring Water Temperature Monitoring Battery Voltage Monitoring Speed Monitoring with Overspeed Protection Idle Rated Relay Synchronizing Digital signal processing to eliminate problems induced in systems with high SCR content causing multiple zero crossing of voltage waveforms Adjustab...

Page 13: ... or PF control reference levels Automatic Generator Sequencing Automatically starts additional EGCP 2 equipped generators when load exceeds a user specified percentage of the rated load of the operating machines Provides controlled unloads for engines when the load is low enough that the remaining engines will not exceed a user specified percentage of the rated load Engine priority sequence can be...

Page 14: ...duit Environmental Specification Temperature Range around outside of EGCP 2 Chassis 20 to 70 C Operating Relative Humidity 95 non condensing at 20 to 55 C Physical Specification Enclosure Size 282 x 358 x 69 mm 11 1 x 14 1 x 2 7 inch Accessories Components needed for installation and remote communication These items do not ship with the 8406 120 and 8406 121 part numbers they must be ordered separ...

Page 15: ...Manual 26174 EGCP 2 Engine Generator Control Package Woodward 5 Figure 2 1 Physical Outline with Dimensions of EGCP 2 ...

Page 16: ...ains PT Process Input Utility TB Aux Automatic LAMP EGCP Gen PT Inputs 3 phases Gen CT inputs 3 phases Voltage Bias ALARM VISUAL ALARM AUDIBLE Voltage Regulator Speed Control Speed Bias Engine Crank Fuel Shutoff Solenoid MPU HORN RS 485 Port PC Interface RS 422 Voltage Lower Voltage Raise Run With Load Speed Lower Speed Raise Fault 2 Fault 1 Process I E PC TO Other EGCP 2s Operator Control Panel O...

Page 17: ...onitored battery voltage drops below 9 0 Vdc the LCD back light will shut off to conserve power The EGCP 2 Operator Interface can only be used for unit configuration and monitoring Unit start stop sync or mode selection commands cannot be given through the EGCP 2 s front panel An unsafe condition could occur with improper use of these software tools Only trained personnel should have access to the...

Page 18: ...rm and shutdown events a Security Code of Operator Level or higher is needed After selecting the ALARM EVENT key If the Alarm mode is Visual or Warning 1 Pressing the ALARM CLEAR key will acknowledge the selected alarm this means the cursor will move from the Alarm Name line down to the Time and Date line 2 Pressing the Alarm Clear key a second time will remove the event from the log If the Alarm ...

Page 19: ...alue 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 clea...

Page 20: ...ntents of the various status screens are described in Chapter 4 SYSTEM The SYSTEM STATUS key when pressed displays the system status information The system status display is also the default status display screen it is always the first display shown after a power up of the control This display shows general information about the operation of the engine generator set ENGINE The ENGINE STATUS key wh...

Page 21: ...e kW load control of the EGCP 2 PF KVAR Press the PF KVAR STATUS key to display VAR PF Mode information as well as three phase generator voltage and current SEQUENCE The SEQUENCE STATUS key provides sequencing information for multiple unit systems Single unit systems and units not in the AUTO mode will not provide status information in this screen ATS The ATS STATUS key when pressed displays the s...

Page 22: ...tem status system status Power Up prime mover status prime mover status synchronizer status synchronizer status synchronizer status SECURITY CODE synchronizer status SECURITY CODE _ 0 ENTER SECURITY CODE Configuration Shutdowns and Alarms Engine Control Synchronizer synchronizer status Configuration Shutdowns and Alarms Engine Control Synchronizer LEFT HAND LCD DISPLAY RIGHT HAND LCD DISPLAY KEYPR...

Page 23: ...OAD DLY synchronizer status AUTO SEQUENCING first item is list MAX GEN LOAD NEXT GENSET DLY RATED LOAD DLY Configuration first item in list Shutdowns and Alarms Engine Control Synchronizer Shutdowns and Alarms Engine Control Synchronizer Real Load Control Process Control Transfer Switch Sequencing and Comms Calibration last item in list Process Control Transfer Switch Sequencing and Comms Calibrat...

Page 24: ...SET DLY 29 Sec WOODWARD EGCP2 CONFIGURATION MENUS AUTO SEQUENCING first item is list MAX GEN LOAD NEXT GENSET DLY RATED LOAD DLY AUTO SEQUENCING first item is list MAX GEN LOAD NEXT GENSET DLY RATED LOAD DLY MAX GEN LOAD 60 SEQUENCING KW 0 0 AUTO SEQUENCING first item is list MAX GEN LOAD NEXT GENSET DLY RATED LOAD DLY Process Control Transfer Switch Sequencing and Comms Calibration last item in l...

Page 25: ...ms Engine Control Synchronizer input output status input output status input output status CRANK FAIL 12 00 1 1 MAIN VOLT LOW ALM 12 00 1 1 engine status CRANK FAIL 12 00 1 1 MAIN VOLT LOW ALM 12 00 1 1 engine status CRANK FAIL 12 00 1 1 MAIN VOLT LOW ALM 12 00 1 1 engine status MAIN VOLT LOW ALM 12 00 1 1 End of List CONFIG I O i STATUS ALARM EVENT ENGINE SCROLL SCROLL VIS 140D 00 6 20 Figure 2 4...

Page 26: ...00 1 1 End of List engine status MAIN VOLT LOW ALM 12 00 1 1 End of List engine status CRANK FAIL 12 00 1 1 End of List engine status CRANK FAIL 12 00 1 1 End of List engine status None Recorded system status None Recorded system status system status ENTER ENTER ALARM CLEAR ALARM CLEAR ALARM CLEAR ALARM CLEAR SYSTEM i STATUS VIS 140E 00 6 20 Figure 2 4e EGCP 2 Navigation 5 ...

Page 27: ...terminal blocks accept wires from 0 08 2 5 mm 27 12 AWG Two 0 8 mm 18 AWG or three 0 5 mm 20 AWG wires can be easily installed in each terminal Wires for the pluggable I O terminals should be stripped 8 9 mm 0 3 inch long wires for the fixed mounted power terminals should be stripped 5 6 mm 0 2 inch long Method 1 Method 2 Free Hand Holds spring open Bench momentarily opens spring while force is ap...

Page 28: ...tices Providing the proper ground for the EGCP 2 is important Improper connection of the EGCP 2 chassis to the ground plane may lead to stray currents between the reference point for the AC signal sources current and voltage transformers and the reference point for the sensing inputs on the EGCP 2 Differences in potential between these two points results in equalizing current flow which then produ...

Page 29: ...ck it should be ac coupled to earth All other shield terminations except at the EGCP 2 should be ac coupled to earth through a capacitor A 1000 pF 500 V capacitor is sufficient The intent is to provide a low impedance path to earth for the shield at frequencies of 150 kHz and up Multiple direct connections of a shield to earth risk high levels of current to flow within the shield exception see not...

Page 30: ...EGCP 2 Engine Generator Control Package Manual 26174 20 Woodward Figure 3 3 Wiring Diagram for EGCP 2 ...

Page 31: ...16 1 2 3 4 OPEN 1 3 2 NOTE OPEN UP away from PC b CLOSED DOWN toward PC Figure 3 4 Dip Switch Locations In the drawing above the switches will do the mentioned functions when in the CLOSED position Input Power The EGCP 2 accepts any input power source that supplies a voltage within the 9 32 Vdc voltage range It is expected that the installation of this equipment will include overcurrent protection...

Page 32: ... identical in configuration Wye or Delta phase A B or A N and amplitude for correct input readings Generator PT Input Wiring The EGCP 2 utilizes a 6 wire generator PT input configuration This type of configuration allows the EGCP 2 to be easily wired to either Delta or Wye generators or transformers The EGCP 2 control uses all three phases of the generator to sense both real and reactive generator...

Page 33: ...on as the generator PT input The potential transformer should be the same ratio as the generator PT input Two Relay outputs are used by the EGCP 2 to select which voltage source to monitor depending upon the state of the control The EGCP 2 s control logic is set up to monitor the utility tie voltage during normal operation and local bus voltage when sensing for a dead bus condition or synchronizin...

Page 34: ... not synchronize For this reason when only one PT signal is being connected the external relay logic to remove the incoming Mains Bus PT signal must still be applied The following diagrams Figures 3 7 and 3 8 show how to connect terminals 40 and 41 for different applications 40 41 Mains Bus PT Input Mains PT K1 B Mains PT Disconnect Normally Closed D08 Local Bus PT Connect Normally Open D07 23 24 ...

Page 35: ...onnect Normally Open D07 23 24 VIS 146C 02 5 29 K2 B A B or N K2 A 21 22 V EGCP 2 K2 A B or N B for Delta N for Wye B for Delta N for Wye K2 SHOWN DE ENERGIZED K2 RELAY IS NOT NOTES SUPPLIED BY WOODWARD Prime Power Applications Figure 3 8 Utility Local Bus Single PT Wiring for Delta and Wye Configuration for Multiple or Single Engine Prime Power Applications Figure 3 8 Notes 1 Multiple Engine Appl...

Page 36: ... relationships Voltage Input Delta A B C A A B B C C 480 V 120 V 480 V 120 V PT Ratio 4 1 Voltage Ref 480 Vac L L Gen PT Inputs VIS 147B 02 5 29 Mains Bus PT Input N Mains Disconnect Bus Connect 40 47 46 45 44 43 42 41 EGCP 2 8406 121 A B A C B A B 480 V 120 V A B A B C Utility Bus 480 VLL Utility Breaker Generator Breaker Generator Bus Local Bus 120 V 120 V 120 V Figure 3 9a PT Wiring Relationshi...

Page 37: ...9 Mains Bus PT Input N Mains Disconnect Bus Connect 40 47 46 45 44 43 42 41 EGCP 2 8406 120 A B A C B A B 480 V 240 V A B A B C Utility Bus 480 VLL Utility Breaker Generator Breaker Generator Bus Local Bus 240 V 240 V 240 V Figure 3 9b PT Wiring Relationships for Generator Bus and Utility Inputs Please Note 1 This drawing shows EGCP 2 part number 8406 120 2 Follow Utility Local Bus PT wiring ...

Page 38: ...2 5 29 Gen PT Inputs Mains Disconnect Bus Connect 41 45 44 43 42 47 46 A N EGCP 2 8406 121 N N N A C B A A N N Utility Bus Generator Breaker Utility Breaker Generator Bus Local Bus C B A 69 V 69 V 69 V Figure 3 10a PT Wiring Relationships for Generator Bus and Utility Inputs Please Note 1 This drawing shows EGCP 2 part number 8406 121 2 Follow Utility Local Bus PT wiring ...

Page 39: ...IS 148C 02 5 29 Gen PT Inputs Mains Disconnect Bus Connect 41 45 44 43 42 47 46 A N EGCP 2 8406 120 Utility Bus Generator Breaker Utility Breaker Generator Bus Local Bus C B A 277 V 277 V 277 V Figure 3 10b PT Wiring Relationships for Generator Bus and Utility Inputs Please Note 1 This drawing shows EGCP 2 part number 8406 120 2 Follow Utility Local Bus PT wiring ...

Page 40: ...or 2000 amps per phase at 100 load rated power factor CT Ratio 100 2000 5 the EGCP 2 will see 5 amps at 2000 generator amps 125 2500 5 the EGCP 2 will see 4 amps at 2000 generator amps Example 2 Generator rated for 150 amps per phase at 100 load rated power factor CT Ratio 100 150 5 the EGCP 2 will see 5 amps at 150 generator amps 125 188 5 the EGCP 2 will see 4 amps at 150 generator amps Current ...

Page 41: ...higher a passive MPU s output amplitude will be The EGCP 2 must sense an MPU voltage of 3 5 to 25 Vrms for proper operation MPU Input Ratings Normal Frequency Range 100 10 000 Hz 3 5 to 25 Vrms Input impedance 15 000 Ω With proper MPU gear size and MPU to gear clearance speed measurement should be capable down to 100 Hz Standard MPU clearance is recommended to be 0 010 to 0 040 from tooth face to ...

Page 42: ... 5 Vdc Input Impedance 249 Ω 4 20 mA 30 000 Ω 1 5 Vdc R R R R SW4 4 250 87 86 Process Import Export Input 4 20 mA 1 5 Vdc Switch SW4 4 Open for 1 5 volt input 30K ohms Close for 4_20 mA 250 ohms VIS 149 00 08 15 Figure 3 13a Wiring Diagram for Process Import Export Input When connecting a kW transducer signal to multiple EGCP 2s Woodward recommends converting the 4 12 20 mA signal to a 1 3 5 Vdc s...

Page 43: ...d for the type of sensor being used see Figures 3 14 and 3 15 Once the sensor type is selected and the DIP switches are set the inputs should be calibrated for proper monitoring Each input has an associated Gain and Offset setting in the Calibration menu The controls are calibrated at the factory for a 4 20 mA sensor type that represents a 0 75 psi pressure signal and a 0 300 F temperature signal ...

Page 44: ...al shunt resistors are provided to match the impedance range of the given sensor to provide more range and accuracy These inputs are designed to work with a variety of manufacturer s sensors Sensors can have a Direct or Indirect relationship Direct Increase in Resistance mA or volts is an Increase in Pressure or Temperature Indirect Increase in Resistance mA or volts is a Decrease in Pressure or T...

Page 45: ...r Temp Offset for 80 F reading e Repeat steps a d until no more adjustment is needed 7 Disconnect potentiometer and connect VDO Water Temperature Sender a This is a 2 wire sender 323 477 i This is not a polarity sensitive connection The 2 wires coming from the sender should only connect to the EGCP 2 control b If you are using a different VDO sender 323 XXX that is only a 1 wire sender i Connect t...

Page 46: ... configurable for outputs of 1 Vdc 3 Vdc or 9 Vdc The voltage bias output works with many automatic voltage regulators Following is a list of manufacturers and types Basler Caterpillar KATO Newage Leroy Somer Marathon SR4A VR3 360 MX321 R438 DVR2000E SR8A Digital VR 760 MX341 R448 SSE VR6 K65 12B MA325 R449 SSR CDVR K 125 10B DECS AVC Appendix C shows connections and adjustment procedures for some...

Page 47: ... Type 2 Voltage Bias Type Calibration menu 1 Speed Bias Offset 2 Volts Bias Offset 3VDC 5 to 4 5 VDC 500 Hz PWM 74 73 Speed Bias Output Software Configurable for 3VDC 500 Hz PWM 5 to 4 5 VDC 38 37 Voltage Bias Output Software Configurable for 1 Vdc 3 Vdc 9 Vdc 39 VIS 052a 00 04 19 75 Software Switch Software Switch 1VDC 3VDC 9VDC Figure 3 16 Wiring Diagram for Speed Bias and Voltage Bias Outputs ...

Page 48: ... generator breaker open these contact inputs can be used to raise and lower speed If the EGCP 2 control is in the Baseload control mode generator breaker closed utility tie breaker closed these contact inputs can be used to raise and lower unit baseload If the EGCP 2 control is in the Process control mode Process control enabled these contact inputs can be used to raise and lower the process set p...

Page 49: ...ill result in permanent damage to the control Figure 3 17 Wiring Diagram for Typical Discrete I O Connections Relay Outputs Twelve Form C type Relay Outputs are used by the EGCP 2 control to interface with system devices Before installation verify that the EGCP 2 s relay contacts meet the power requirements of the circuit with which it is being interfaced Interposing relays are required in cases w...

Page 50: ...cts to select from The Mains utility Breaker Close relay output is utilized by the EGCP 2 to command the Mains utility Breaker to close This output is configured for use with a BREAKER or a CONTACTOR in the Configuration menu under CKT Breaker Control Every EGCP 2 that has the capability of being a MASTER unit must have this relay wired into the Mains utility Breaker close circuitry Breaker When i...

Page 51: ...1 EGCP 2 V Mains utility Contactor Open Close Coil Figure 3 19 Example Using the NC Output to Control the Mains Utility Contactor ENERGIZE TO OPEN Discrete Output 2 Generator Breaker Close With the relay de energized this output has Normally Open NO terminals 8 and 9 and Normally Closed NC terminals 9 and 10 contacts to select from The Generator Breaker Close relay output is utilized by the EGCP 2...

Page 52: ...ed to close and open the Generators Contactor The Generator Breaker Trip discrete output 10 is NOT used in the Contactor mode The EGCP 2 will DE ENERGIZE continuously to open the Generators Contactor and ENERGIZE continuously to close the Generators Contactor This is reverse logic from the Mains Contactor Close discrete output 1 8 Discrete Output 2 10 9 Generator Contactor Close VIS 154c 01 06 01 ...

Page 53: ... a start command is given It will De energize when a shutdown command is received The fuel solenoids output will function as a Run Stop relay There is no Engine Preglow or Engine Crank command in this mode The Disabled mode allows the EGCP 2 to operate without a Magnetic Pickup MPU signal Discrete Output 5 Engine Crank The Engine Crank relay output utilizes a set of Normally Open NO contacts on te...

Page 54: ...from the EGCP 2 s Utility and Local Bus PT Input on terminals 40 and 41 Due to relay load limitations it is required that this output be configured to drive an interposing relay with which to control the Utility Tie PT connection Refer to Figures 3 7 and 3 8 of this chapter for detailed wiring information This type of relay configuration allows a break before make action insuring that the Utility ...

Page 55: ...on menu under CKT Breaker Control If configured for Contactor see Discrete Output 2 for Generator Contactor open close operation Breaker In the Breaker configuration the Generator Breaker Trip open relay will energize with the EGCP 2 in Auto or Manual modes Automatic Mode 1 In the AUTO mode Discrete Input 1 2 If a LOMs start is initiated a And the Generator is stable Generator Stable Delay time ha...

Page 56: ...8 29 30 Gen Breaker Close Gen Breaker Trip Generator Breaker Close Coil Generator Breaker Trip Coil Generator Breaker Configuration Based Logic EGCP 2 External Wiring Connection External Wiring Connections VIS 142a 01 07 11 V V 9 8 29 30 Gen Breaker Close Gen Breaker Trip EGCP 2 V Generator Contactor Close Open Coil Generator Contactor Configuration Based Logic Gen Breaker Trip will energize when ...

Page 57: ...ration menu under Relay 12 Function KVA Load Switch This relay will energize when the controls kVA value is within the configured Low and High settings The relay will de energize when the kVA value is below or above the configured Low and High settings The low and high set points are configured in the Real Load Control menu under items kVA Switch Low and kVA Switch High Idle Rated Switch When sele...

Page 58: ...ns Bus PT Phase A AC Voltage 200 k Ω 41 Mains Bus PT Phase B or N AC Voltage to 70 Magnetic Pickup AC Frequency 15 k Ω 71 Magnetic Pickup AC Frequency to 72 Magnetic Pickup Shield DC Inputs and Outputs Location Description Signal I O 1 power supply 9 32 Vdc Isolated 2 power supply Input 13 W typical 20 W max 86 Process Signal 4 20 mA Isolated Input 87 Process Signal or 1 5 Vdc 249 Ω 4 20 mA 88 Pro...

Page 59: ... 6 Discrete Input DI 16 power supply internal connection 65 Switch Common Discrete Input power supply internal connection NOTE Approximately 5 mA current draw across each DI when CLOSED Discrete Outputs Location Description Signal Output Rating 7 Mains Brkr Close NC Discrete Output D01 see Relay 6 Mains Brkr Close C D01 Output Ratings 5 Mains Brkr Close NO Discrete Output D01 10 Gen Brkr Close NC ...

Page 60: ...e computer and the EGCP 2 control must be made for correct communication between the two devices This hardware connection is completed using a direct cable connection between the computer and the EGCP 2 control s RS 422 network Modbus ServLink Communications The laptop or desktop computer which will be used with the EGCP 2 RS 422 port will have a 9 pin serial port This port is configured by the co...

Page 61: ... for multiple units utilizing RS 422 communication Unit 1 Unit 2 Unit 8 SW3 1 Closed SW3 1Open SW3 1 Closed SW3 2 Closed SW3 2 Open SW3 2 Closed SW3 3 Closed SW3 3 Open SW3 3 Closed When the RS 422 to RS 232 converter is greater than 30 meters from unit 1 an isolating version will be required Cable shields must also be AC coupled to earth or connected to RS 422 to RS 232 converter chassis This cha...

Page 62: ... pair to link the EGCP 2 controls at terminals 76 and 77 with 78 the shield When EGCP 2 controls are installed with a distance of 1000 m or greater between them additional measures should be taken to ensure solid communications The wire gauge of the communications link should be upgraded to 0 5 0 8 mm 18 20 AWG where larger sizes are used for longer distances The larger size wire will exhibit smal...

Page 63: ...80 79 80 79 Figure 3 27 RS 485 Inter Control Communications Switch configuration for 2 units utilizing RS 485 communication Unit 1 Unit 2 SW4 1 Closed SW4 1Closed SW4 2 Closed SW4 2 Closed SW4 3 Closed SW4 3 Closed Switch configuration for 3 or more units utilizing RS 485 communication Unit 1 Unit 2 Unit 8 SW4 1 Closed SW4 1Open SW4 1 Closed SW4 2 Closed SW4 2 Open SW4 2 Closed SW4 3 Closed SW4 3 ...

Page 64: ...hut off The audible and visual alarm relays will energize at the time of the alarm condition and the red LED on the face of the EGCP 2 will stay on continuously Acknowledging the alarm condition will cause the alarms to reset and make the unit operational once again Hard Shutdown When an alarm set point is set for Hard Shutdown the alarm condition will cause the generator to immediately open its b...

Page 65: ... this condition Mains Frequency Low Detects Mains Under frequency condition for at least as long as the LOM Action Delay set point seconds Mains Frequency High Detects Mains Over frequency condition for at least as long as the LOM Action Delay set point seconds Mains Voltage Low Detects under voltage on the mains for at least as long as the LOM Action Delay set point seconds Mains Voltage High Det...

Page 66: ...ate all modes State machine logic relies on discrete inputs and specific operating conditions to trigger a sequence of operations Status Screens There are 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 When the EGCP 2 is initially powered up it will de...

Page 67: ...e 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 manual mode Load 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 t...

Page 68: ...e generator voltage and frequency 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 System status screen looks like for a generator set that is base loaded to the mains at 500 kW 0 80 lagging PF with one unacknowledged alarm Figure 4 3 System Status Screen B...

Page 69: ...in Vdc H2O Temp Water Temperature in degrees C or F depending upon the Configuration menu Display Units setting Oil Press Oil Pressure in Bar or psi depending upon the Configuration menu Display Units setting 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 ...

Page 70: ... readings V Volts for each phase of the generator A Amps per phase for the generator Will not display negative amps PF Power Factor for each generator phase Generator voltage label VLL Voltage Line to Line or VLN Voltage Line to Neutral will be determined from the Voltage Input configuration setting Generator voltage readings and labels will automatically switch from V volts to KV kilovolts when t...

Page 71: ...ts 1 Automatic Switch 2 Test Switch 3 Run with Load Switch 4 Volts Raise 5 Volts Lower 6 Speed Raise 7 Speed Lower 8 Gen Circuit Breaker Aux Contact 9 Mains Circuit Breaker Aux Contact 10 Process Switch 11 16 Remote Alarm Shutdown Inputs Discrete Outputs 1 Mains Breaker Close Contactor Close 2 Gen Breaker Contactor Close 3 Engine Preglow 4 Fuel Solenoid 5 Engine Crank 6 Visual Alarm Relay 7 Local ...

Page 72: ... dead Synchronizer Status Displays the state of the synchronizer These states are CLOSE GEN BREAKER SYNC TIMER OPEN GEN BREAKER IN SYNC CLOSE MAIN BREAKER SYNCHRO OFF OPEN MAIN 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 Generator and Mains voltage label VLL Voltage Line to Line or VLN Volt...

Page 73: ...ode Control The current load control state in operation These states are OFF DROOP ISOCHRONOUS BASELOAD PROCESS Process In The sensed value of the 4 20 mA or 1 5 Vdc process input This value will be displayed in an Engineering Unit that is configured in the Process menu under Process Units Process Ref The process reference for the process control Master Sync Cmd The master synchronizing and load c...

Page 74: ...CE The PF control reference value for the control 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 ...

Page 75: ...rities 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 load sharing units operating in isochronous load sharing Gen Breaker The status of...

Page 76: ... 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 lowest priority which is unit number one Units that have active shutdowns will remove themselves from the sequencing menu until the shutdown condition s are cle...

Page 77: ...icate 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 state 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 ...

Page 78: ...ccess Monitor no security code Access to all Status Screens view Alarm Event Log Display and ability to commit clear an Audible Alarm Operator Access to view and clear Alarm Event Log and change the Network Priority Supervisor Allows access to change the Network Address and Time Setting Clock Technician Allows access to all set points except Engine Run Time and the Calibration menu Factory Full ac...

Page 79: ...nt Log The Alarm Event button provides access to the EGCP 2 s Alarm and Event Log This log contains up to sixteen 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 t...

Page 80: ... 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 If power is cycled to the control the Event log...

Page 81: ...en 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 Figure 4 16b Configuration Menu List Screen 2 ...

Page 82: ...ning menu that the user wants to enter Pressing the enter key will access that configuration menu See the Navigation Procedure in Chapter 2 of this manual for information on navigating through the configuration menus Sanity Checks In order to prevent improper configuration that may damage the generator set when started the EGCP 2 runs through a series of sanity checks The items involved all in the...

Page 83: ... and Shutdown conditions are ignored At least one of these items must be changed to be within calculated values sanity checks to allow engine alarm and shutdown operations The sanity checks are divided into two groups o Speed Calculations pound signs will appear on all items if any test fails Number of Poles Number of Teeth System Frequency and Rated Speed o Power Calculations pound signs will app...

Page 84: ... 2 is not providing an engine start signal Check for pound signs signs and or asterisks If any item is open in the Configuration menu does not pertain to any of the other menu no start operation will be performed until this item is closed by pressing the ENTER or ESC key Example If viewing Rated KW in the Configuration menu no start signal will be provided Network Address Range 1 to 8 Unique Addre...

Page 85: ...16 450 rpm 375 rpm 18 400 rpm 333 rpm Number of Teeth Range 16 500 Determines rpm Scaling Engine Speed Readouts Alarms System Frequency Range 50 or 60 Hz Used as a basis for generator waveform analysis Defines typical operating frequency of generator Rated Speed Synchronous Speed Of Generator Set Used in Speed Calculation to determine sample period for MPU input Rated KW Range 1 30000 Rated kW of ...

Page 86: ...r Alarm Shutdown sensing Over Under Voltage kW Limits etc Voltage Input Range Wye L N or 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 set point menus Sets the label used for all generator and mains voltage Status readings Wye Star Generator or Transformer...

Page 87: ...te used by the control for Alarm Event time stamps and displays Set Time HH MM Sets the time used by the control for Alarm Event time stamps and displays Start Sequencing Range Enabled or Disabled Enabled Uses Preglow time and Engine Crank Must have MPU to function Disabled No Preglow Time or Engine Crank Will operate without an MPU Relay 12 Function Range kVA Load or Idle Rated Switch kVA Load Sw...

Page 88: ...tage bias 3 Vdc 100 voltage bias 1 Vdc Bias 0 Vdc 0 voltage bias 1 Vdc 100 voltage bias 1 Vdc 100 voltage bias Circuit Breaker Control Range Breaker or Contactor Defines action of Generator and Mains closure command Breaker issues momentary breaker close signal and a separate momentary breaker trip open signal Get complete logic for Generator and Mains breaker commands in chapter 3 under Relay Out...

Page 89: ... in multiple Unit displays system sequencing information on sequencing screen Network Priority and Network Address set points are added to the configuration set point menu automatically Unit must be in Auto mode to communicate over the inter control network RS 485 No Connection 9 8 29 30 Gen Breaker Close Gen Breaker Trip Generator Breaker Close Coil Generator Breaker Trip Coil Generator Breaker C...

Page 90: ...aker 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 Rated Generator Voltage Generator High Voltage Limit Voltage Bias Cutout Generator Low Voltage Limit Voltage Bias Cutout Operating Ran...

Page 91: ...out setting off the Generator Voltage Alarms Generator Frequency High Limit 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 Sets minimum allowable generator frequency level If frequency is below Low Limit generator is not considered stable and is unfit for breaker clo...

Page 92: ... Current Per Phase Rated Current is determined by the Configuration menu Voltage Input Wye or Delta Rated kVA Voltage Ref Per Phase Rated Current equals WYE voltage input Rated kVA Voltage Ref 3 DELTA voltage input Rated kVA Voltage Ref 1 732 Example 1 480 V L L system 277 V L N system 110 kW Generator 4 1 PT Ratio Voltage Input Delta Voltage Input Wye Rated kVA 125 Rated kVA 125 Voltage Ref 480 V...

Page 93: ...attained AMP SECONDS accumulate when current is the Overcurrent Level AMP SECONDS reset to 0 when current is the Overcurrent Level Using Figures 4 22 4 23 and 4 24 will help determine where the Overcurrent Level and Overcurrent Delay should be set for any application Rated Current 190 Time seconds Overcurrent Trip Zone Current per phase 180 0 7 5 150 200 220 Overcurrent Level 15 30 Amp Seconds Fig...

Page 94: ...Power accumulation needed to cause an Alarm or Shutdown Range 0 1 20 seconds Minimum Reverse Power The power level must exceed the Minimum Reverse Power continuously for the calculated delay time before the configured Alarm or Shutdown action is taken Reverse power levels above a less negative or positive power this setting will have no effect When the power level falls below the Minimum Reverse P...

Page 95: ...ge of the Rated kVAR If the EGCP 2 senses a kVAR load greater than this value the Reverse kVAR Delay begins When the Delay times out an alarm will trigger Used to indicate loss of field excitation to the generator Reverse KVAR Delay Range 0 1 to 5 0 seconds Provides a delay before triggering the Alarm Remote Faults 1 through 6 Each fault is programmable for disabled warning visual alarm audible al...

Page 96: ...ill equal the value of Crank Repeats 1 Crank Fail Alarm Set Point Activates when the Number of Crank Repeats is depleted Idle 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 Time The delay in seconds the EGCP 2 waits once the Idle Ra...

Page 97: ...rt Sequencing is Disabled the PT signal is used to calculate the overspeed signal No MPU is needed in this condition Woodward recommends that the Speed Frequency Mismatch Alarm be set the same as the Overspeed Alarm to protect against the loss of the MPU signal Battery Volt High Limit Sensed DC voltage supply to EGCP 2 Can be used to detect faulty charging circuit Battery Voltage Low Limit Used to...

Page 98: ... H2O Temperature Useful for detection of failed jacket water heater Always active Synchronizer 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...

Page 99: ...lity Integrator dx dt in seconds per repeat Voltage Matching Enables Disables Voltage Matching feature of EGCP 2 control Enables Voltage Window Set Point Voltage Window 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 Figure 4 27 Voltage Matching 1 set point Bus or Mains Volt...

Page 100: ...educe 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 The Breaker Contactor Close command is removed when the C B Hold Time is done if a Generator Breaker Aux feedback is received or if the synchronization conditions fall outside the voltage and or speed specifications Close Attempts Number ...

Page 101: ...assing 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 be in the AUTO mode to allow dead bus closing between networked units Real Load Control Load Control Mode Normal o Standard setting for load control and VAR PF functions Soft Transfer o Unit will issue mains breaker open command while in process control if proc...

Page 102: ...reater value than the Unload Trip Level Unload Trip Load Level where Generator Breaker Contactor open command will be issued when EGCP 2 control is off loading generator set Must be set less than the Baseload Load Reference value 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 loa...

Page 103: ...input Discrete Input 7 or Modbus address AW40300 is used in base load operation KW Load High Limit Maximum allowed load while operating in Base load or Process control modes Prevents overload of unit when in Base load or Process control modes KW High Limit Alarm Sets Alarm Action when unit is at or above High Load Limit Active during all load control operations Unit will not exceed High Limit set ...

Page 104: ...s 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 C...

Page 105: ... this switch selects the 4 20 mA input hardware Opening this switch selects the 1 5 Vdc input hardware See the EGCP 2 layout diagram for switch location on the unit Dip Switch 4 SW 4 ___________________________ 1 5V RS 485 2 123 ohm RS 485 Termination 3 123 ohm RS 485 Termination 4 4 20 mA Process Input 4 3 2 1 Figure 4 29 EGCP 2 Control Dip Switch Process Dynamics Process Master Uses Process PID ...

Page 106: ...ort Process Action Figure 4 31 Indirect Import Power Process Action Figure 4 32 Direct Import Export Process Action This example is using a 4 12 20 mA transducer 100 0 100 speed bias 4 mA 20 mA export power 100 0 100 speed bias 4 mA 20 mA imported power 100 20mA 100 4mA 0 speed bias 0 100 ...

Page 107: ... number of units operating in process control mode Process Deadband Range 0 3 5 0 o This is of full scale o Full Scale is figured from the Process Low Value and Process High Value set points 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 stabili...

Page 108: ...s Units setting Effective on active master unit only Process High Limit Alarm Sets Alarm Action when process High Limit is reached Process Low Limit Minimum allowable process reference level Dependent on Process Units setting Effective on active master unit only Process Low Limit Alarm Sets Alarm Action when process reference reaches the Low Limit Process Units Allows user to configure Process Inp...

Page 109: ...5 0 volt will be displayed as o Example Process High Value 750 kW Process Input is 20 Ma KW LOAD status screen will display 750 kW Sample Process Applications with Process Units as kW and mA kW Transducer Input 4 12 20 mA 4 mA 500 kW 12 mA 0 kW 20 mA 500 kW Process Units kW Process Action Indirect Process Deadband 0 3 Process Ref 50 kW Import Power Process High Limit 100 kW Process Low Limit 250 k...

Page 110: ...in 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 Used only in Base Load or Process Control Mains Parallel Operations Set to trigger at a p...

Page 111: ...in Frequency High Limit Alarms when Mains Frequency exceeds Alarm Set Point 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 Alarm The Main Frequency High condition will cause a response defined by this set point The available responses are Disabled Warning ...

Page 112: ... time starts when the Master unit closes its generator breaker This insures that all generator sets have ample time to synchronize and close to the bus prior to load being added or generator sets being sequenced back offline Only functions if Auto Sequencing is Enabled Maximum Generator Load system load on all units with gen breakers closed and on the same network in Auto and in Load Sharing or Pr...

Page 113: ... the Max Gen Load 10 Consult Chapter 5 Generator Sequencing for details Reduced Load Delay Time in seconds that 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 ...

Page 114: ...ke 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 th...

Page 115: ... A B C ALARMS 1 UNIT 1 Mains Gen Engine RUNNING AUTO ISOCHRONOUS A PHASE PT SCALE 1 00 PHASE A VL L 482 5 Woodward ALARM EVENT ALARM CLEAR SCRO LL ESC ENTER SYSTEM ENGINE GE N I O SYN C KW LOAD PF KVAR SEQUENCE ATS i STATUS CONFIG EGCP 2Digital Control 480 0 vac Measured vs Monitored Monitored Voltage EGCP 2 configured for Line to Line 3 wire PT input Calibrate the Monitored Value to equal the Mea...

Page 116: ...y for the generator set Calibration is required for Caterpillar s ADEM speed control o PWM range needs to be calibrated for 69 Duty Cycle as measured on Terminals 73 and 74 Preset Speed Bias Offset to 39 00 Start Engine Adjust Speed Bias Offset for rated speed of 50 or 60 Hertz Press the Enter key to save the final setting Voltage Bias Offset Range 50 to 50 of selected Speed Bias Type Factory cali...

Page 117: ...d Whenever the Generator set is started or taken offline it will control at the rated voltage when calibrated correctly Trim Adj Voltage Bias output from EGCP Internal Trim adjustment potentiometer sets effective range of 1 VDC bias from EGCP 2 control Usually a 10 voltage change for the 1VDC input is more than sufficient for good VAR and PF control trim Volts Figure 4 35 Typical AVR with Aux Inpu...

Page 118: ...rcuit 1 VDC output from EGCP 2 trim Volts Droop CT Figure 4 37 AVR Droop PT Phase A Scale Calibrates PT phase A voltage Adjust PT Phase A Scale until the monitored value matches the measured generator voltage on A phase PT Phase B Scale Calibrates PT phase B voltage Adjust PT Phase B scale until the monitored value matches the measured generator voltage on B phase PT Phase C Scale Calibrates PT ph...

Page 119: ...f Rated load Measure actual generator currents with clamp on ammeter or panel ammeter Adjust until monitored current equals measured current Calibrating the Phase A CT for 70 A CT Phase B Scale Calibrates CT Phase B o Do NOT calibrate if generator load is under 50 of Rated o Factory calibration will be within 1 Load generator to above 50 of Rated load Measure actual generator currents with clamp o...

Page 120: ... voltage equals measured voltage Synchronizer Status Screen Calibration Menu Calibrating Bus PT Input using the Bus PT Input 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...

Page 121: ...y Calibrated for a 0 75 psi signal over a 4 20 mA range o 4 mA 0 psi o 20 mA 75 psi Designed to accept a 4 20 mA or 1 5 volt transducer or a passive resistive type 0 200 Ω Sensors can have a Direct or Indirect relationship o Direct Increase in resistance mA or volts is an Increase in Pressure o Indirect Increase in resistance mA or volts is a Decrease in Pressure Direct type Gain will be a Positiv...

Page 122: ...h when the engine is 1 shut down and 2 running at rated speed Record the pressure and resistance Then connect a potentiometer or decade box to the EGCP 2 oil pressure input terminals 68 and 69 Set the resistance for the running value Adjust the Oil Pressure Gain until the Calibration reading matches the desired reading Set the resistance for the shutdown value Adjust the Oil Pressure Offset until ...

Page 123: ...ET 5 volts 0 F GAIN o 0 Ω 212 degrees OFFSET 500 Ω 0 F GAIN Resistive sensors are commonly an indirect relationship If the sensor or transducer has an Indirect relationship o Adjust the Gain for the water temperature when the engine is shut down If the sensor or transducer has a Direct relationship o Adjust the Gain for the engine s operating temperature High H2O temperature To adjust the Water Te...

Page 124: ...lues Indirect type o Connect a potentiometer or decade box to the EGCP 2 water temperature input terminals 66 and 67 o Verify DIP switch 2 settings o Set the resistance for the running at rated speed o Adjust the Water Temperature Offset until the monitored reading matches the desired reading o Set the resistance for the shutdown value o Adjust the Water Temperature Gain until the monitored readin...

Page 125: ...l EGCP 2 reading Water Temperature Resistive Sensor Ohms Water Temperature High Temperature Alarm Low Temperature Alarm Figure 4 39 Water Temperature Curves Water Temperature No shunt resistors SW 2 2 clsd 249 Ohm SW 2 3 clsd 100 Ohm SW 2 3 4 clsd 50 Ohm EGCP 2 Curve Characteristic Figure 4 40 EGCP 2 Water Temperature Characteristics ...

Page 126: ... installed with the generator set operating at rated speed and the temperature stabilized the high oil pressure and high water temperature settings be checked against an external water temperature and oil pressure reading Adjust the appropriate setting if needed NetComm Dropouts The number of lost or corrupted network communications tolerated by the receiving unit Excess numbers of NetComm Dropout...

Page 127: ...hutdown 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 Generato...

Page 128: ... Base Load and Process Control Load Ramping Remote Contact Inputs to change Base Load and Process Set Points 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 ...

Page 129: ...d 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 signa...

Page 130: ...as 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...

Page 131: ...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 waveforms The microprocessor computes the product of the voltage and current samples then sums and averages the products to give a computation of power Load Sensor Hardware D...

Page 132: ...eby 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 produced Droop load control is typically only u...

Page 133: ...Isochronous Mode 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 to...

Page 134: ...he 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 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 Loa...

Page 135: ...d 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 Automatic Generator Loading Functions The automatic generator loading functions of the EGCP 2 control will work with the speed control to automatically control the loading and unloading of the generator This accomplishes a bum...

Page 136: ...r will also automatically sequence slave units on and off as required to maintain the process reference The Process Master controls the slave units by increasing or decreasing the System Load signal The System Load is a 0 100 signal If the Process Master receives a Hard Shutdown fault it will open its breaker and shutdown The slave units are now receiving a 0 System Load signal and will operate at...

Page 137: ...y 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 Breaker is open The VAR PF control mode of operation is selected by setting the VAR PF Control Mode set point in ...

Page 138: ...reasing lagging PF angle Lowering the PF reference will decrease the voltage bias output to the regulator that 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 reg...

Page 139: ...s for proper operation 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 Chec...

Page 140: ...centage 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 s...

Page 141: ...s 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 set points 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...

Page 142: ...LOSE CB AUX INPUT RECEIVED BREAKER CLOSED COMMAND REMOVED BREAKER OPEN COMMAND ISSUED BREAKER OPEN BREAKER MODE SYNCHRONIZER IN OPEN UNLOAD COMMAND ISSUED MATCHING CB HOLD TIME TRIP POINT AT UNLOAD TIME UNLOAD RAMP SYNCHRONIZER OFF 020 100 00 04 27 Figure 5 4 Synchronizer Time Line Standard Sequence Loss Of Mains Detection and Action The EGCP 2 can be configured to detect a loss of mains condition...

Page 143: ...aker Fast Transfer Delay Close Mains Breaker Mains In Spec and On Load VIS 110 00 04 27 Figure 5 5 Loss of Mains Detection Active Standard Sequence Single Mains Parallel Unit in Auto with Loss Of Mains Detection Enabled TIME Mains in Spec LOM Action Delay Starts Mains Out of Spec Over Under Frequency and or Over Under Voltage LOM Action Delay Expires Open Mains Breaker Start Genset Gen Stable Dela...

Page 144: ... Generator Unload Ramp Generator On Load in Baseload or Process Control Mode VIS 112 00 04 27 Figure 5 7 Mains Parallel Unit with Voltage Frequency Detect Standard Sequence Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains Detection Enabled Load Surge Event TIME Mains in Spec Load Surge Level Exceeded Load Surge detection is immediate Open Mains Breaker Genset On Load Mains in ...

Page 145: ...pear 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 Auto Sequence Delay The Auto Sequence Delay timer starts when the Master unit closes its generator breaker This will delay the Master unit from sequencing off slave units until this timer has expired Sequencing can be delayed for 20 mi...

Page 146: ...t The master control issues a start command to the next unit on network priority 2 Next Genset Delay Only on the Master controls Sequence Status screen to the right of this item you can see the delay time being counted down from 30 It will keep repeating this countdown and continue starting units until the system load level goes below the Max Gen Load set point Point C Ten seconds after receiving ...

Page 147: ...ster s Reduced Gen Dly timer has expired The master unit issues a command to Unit 3 network priority 3 to off load and opens 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...

Page 148: ...ultiple 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 set point Enabled and be physically connected to the RS 485 network between units The ability to change th...

Page 149: ...L GENERATORS OFF LOAD VIS 115 00 04 27 Figure 5 10 Original System Configuration MAINS NETWORK ADDRESS 2 NETWORK PRIORITY 1 NO MAINS FAILURE DETECTED ADDRESS 1 2 3 OPER PRIORITY 2 1 3 MASTER 2 NEXT ON ALL NEXT OFF MASTER SEQUENCING SCREEN NETWORK ADDRESS 1 NETWORK PRIORITY 2 G G SYSTEM LOAD 0 NETWORK ADDRESS 3 NETWORK PRIORITY 3 G ALL GENERATORS OFF LOAD VIS 116 00 04 27 Figure 5 11 After a Change...

Page 150: ...ny 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 NETWORK ADDRESS 2 ADDRESS 1 2 3 MASTER SEQUENCING SCREEN MAINS FAILURE DETECTED Or Run With Load and No Parallel Application SYSTEM LOAD 35 MASTER 2 NEXT ON 3 NEXT OFF 1 PRIORITY 2 1 3 OPER X X G G NETWORK A...

Page 151: ...mply 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 i...

Page 152: ...n 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...

Page 153: ...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 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...

Page 154: ...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 addr...

Page 155: ... 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 mul...

Page 156: ...on 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 s...

Page 157: ...n 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 th...

Page 158: ...erations 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 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 ...

Page 159: ...he A Phase CT calibration has an effect on kW and kVAR levels for the A phase and for the sum of all three phases of the generator The various alarm set points that 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 phas...

Page 160: ...enus Affected Changes in the calibration value will change the C phase current readout in the Generator Status screen 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 Alarms Affected The generator curre...

Page 161: ...sing which determines when the mains voltage is within spec as shown in the System Status Screen by two plus symbols following the MAINS label The Synchroscope Status screen will monitor the Mains voltage in every synch mode except Close Gen Bkr In the Close Gen Bkr mode it monitors the Bus voltage Bus Voltage Sensing The Bus PT input is used when synchronizing across the generator breaker to the ...

Page 162: ...cle as measured on Terminals 73 and 74 Preset Speed Bias Offset to 39 00 Start Engine Adjust Speed Bias Offset for rated speed of 50 or 60 Hertz Press the Enter key to save the final setting Increasing the Speed Bias Offset will increase the Speed Bias readout in the I O Display status screen of the EGCP 2 The speed bias offset imposes an offset in percent of speed bias output For example a Speed ...

Page 163: ...tage 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 Operating the unit in a test mode and measuring the generator voltage will show the effect the voltage bias offset has on the generator voltage It i...

Page 164: ...pply 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 System Status Screen 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 screens This display shows th...

Page 165: ...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 ...

Page 166: ...ions and Slave unit applications 1 Set unit for LOM on mains under frequency 2 Set Check Mains Breaker disabled 3 Set 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...

Page 167: ... 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 excee...

Page 168: ... switches Displayed generator voltages are very small Faulty wiring of generator Potential Transformers PT s Verify wiring of generator Potential Transformers PTs Generator PT inputs are improperly calibrated Calibrate the appropriate PT input channel s See section 1 10 Calibration of Control Inputs and Outputs I O STATUS shows relay s is energized but action i e alarm does not occur Faulty wiring...

Page 169: ... output contacts Starter motor stays engaged after engine starts Crank cutout set point in Engine control menu is to large Set CRANK CUTOUT set point to appropriate value See description of set points Inadequate MPU signal to EGCP 2 input Verify MPU wiring and that adequate MPU signal exists at input to EGCP 2 control Engine speed is unstable when unit is at no load Speed control dynamics are impr...

Page 170: ... point in synchroscope menu is too large Reduce Dwell Time set point in synchroscope menu See description of set points Synchronizer displays matched phase but measured phase difference is 180 degrees or when breaker closes it crash parallels the set 180 degrees out of phase Generator or bus PT is reversed polarity faulty wiring Verify correct polarity of Generator and bus PT inputs Unit won t clo...

Page 171: ...chroscope menu See description of set points Contactor closes for a brief moment and then opens C B CONTROL set point in configuration menu is set for BREAKER Appropriately set the C B CONTROL set point in configuration menu See description of set points C B HOLD TIME set point in synchroscope menu is too short Increase C B HOLD TIME set point in synchroscope menu See description of set points Fau...

Page 172: ...creased If unit is carrying too much load the speed setting needs decreased Real load control is unstable when paralleled with the mains source Real load control dynamics in real load control menu are improperly set up Tune Real load control dynamics in real load control menu See description of set points Process control operation causes overload or reverse power PROCESS ACTION set point in proces...

Page 173: ... reactive load control menu are improperly set up Tune the Reactive load control dynamics in the reactive load control menu See description of set points Unit maintains a constant VAR load rather than a constant power factor when paralleled with the mains source VAR PF set point in the reactive load control menu is set to VAR CONTROL Appropriately set the VAR PF set point in the reactive load cont...

Page 174: ...work is inadequately terminated Verify that the RS 485 Network is correctly terminated See inter control communications RS 485 When system load is large enough to require additional gen sets more than one set is sequenced on line NEXT GENSET DELAY set point in sequencing menu is too short Increase NEXT GENSET DELAY set point in sequencing menu See description of set points MAX START TIME set point...

Page 175: ...uency and voltage and decrease mains low frequency and voltage set points in the shutdown alarm menu See description of set points Communications Problem Probable Cause Corrective Action A unit number s does not show up in the sequencing order in the sequencing screen RS 485 Network is inadequately terminated Verify that the RS 485 Network is correctly terminated See inter control communications R...

Page 176: ... 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 that will initiate automatic operation of the EGCP 2 ATS Automatic Transfer Switch A device that 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...

Page 177: ...ther 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 tra...

Page 178: ...ontrol when in load sharing or when operating as a single unit This assures a constant frequency under all generator loads that are within the capacity of the generator Inverse Time Delay A time delay used for overcurrent and reverse power detection that utilizes both time and amplitude of the condition to determine the active trip level The inverse time delay accounts for rapid high amplitude con...

Page 179: ... to the EGCP 2 that 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 that is operating in an automatic system The ...

Page 180: ...ernal 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 cap...

Page 181: ...ad A variable used in the load control program of the EGCP 2 which is the ratio of total load demand to total generating capacity that 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 set point to put the...

Page 182: ...nt system documentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration solutions technical desk support and aftermarket marketing of standard Woodwa...

Page 183: ...ll Service Distributor 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 within 60 days a credit for the core charge will be issued Flat Rate Repair Flat Rate Repair is available for the majority of s...

Page 184: ...site Technical Support Product Training Field Service Technical Support is available from your equipment system supplier your local Full Service Distributor or from many of Woodward s worldwide locations depending upon the product and application This service can assist you with technical questions or problem solving during the normal business hours of the Woodward location you contact Emergency a...

Page 185: ...apan 81 43 213 2191 Korea 82 51 636 7080 The Netherlands 31 23 5661111 Poland 48 12 295 13 00 United States 1 970 482 5811 You can also locate your nearest Woodward distributor or service facility on our website at www woodward com directory Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before pho...

Page 186: ...l THESE CONNECTORS ARE NOT INCLUDED WITH THE EGCP 2 Woodward carries the EGCP 2 connector kit which contains all of the terminal blocks used on the EGCP 2 as part number 8928 301 EGCP 2 Connector Kit Woodward P N WAGO P N 12 pole connector 1751 760 231 112 026 000 8 pole connector 1751 756 231 108 026 000 Levers 1751 899 231 131 Woodward provides labels P N 3061 303 only as part of the connector k...

Page 187: ...22 AWG 600V Multiple conductor unshielded Discrete I O PT inputs 0 3 mm 22 AWG 300V Two conductor shielded Speed Bias Voltage Bias MPU Oil and Water Sensors 1 0 mm 16 AWG 600V Four conductor stranded unshielded CT inputs 0 3 mm 22 AWG 30V Two conductor stranded twisted pair shielded 124 Ω impedance RS 485 RS 422 TX and RX ...

Page 188: ...C EGCP 2 To EPG Speed Control Wiring and Configuration Settings Speed Bias Output EPG SPEED CONTROL VIS 126a 00 06 20 EGCP 2 73 74 Speed Bias Output Type 3VDC 0 Speed Bias Output 0 VDC Common 2301A Speed Control Part Numbers 9905 131 9905 376 9907 014 EGCP 2 To 2301A Speed Control Wiring and Configuration Settings Speed Bias Output 2301A Speed Control 15 17 ...

Page 189: ... 8290 195 8290 196 EGCP 2 To FLO TECH Speed Control Wiring and Configuration Settings Speed Bias Output FLO TECH Speed Control 11 12 VIS 128a 00 06 20 EGCP 2 73 74 Speed Bias Output Type 3VDC 0 Speed Bias Output 0 VDC Common Pro ACT Speed Control Part Numbers 9905 462 9905 463 EGCP 2 To Pro ACT Speed Control Wiring and Configuration Settings Speed Bias Output Pro ACT I II Speed Control 12 13 ...

Page 190: ...d Control Wiring and Configuration Settings Speed Bias Output CSC Speed Control 11 12 VIS 130a 00 06 20 EGCP 2 73 74 Speed Bias Output Type 3VDC 0 Speed Bias Output 0 VDC EGCP 2 To 2301A LSSC Wiring and Configuration Settings Speed Bias Output 2301A LSSC Control 10 11 NOTE 2301A LSSC must have terminal 14 powered for the load sharing line inputs 10 and 11 to be active ...

Page 191: ...iguration Settings Speed Bias Output 701 or 701A Speed Control 21 22 Common 701 and 701A Speed Control Part Numbers 8280 102 8280 193 9905 211 Common 721 Speed Control Part Numbers 9905 291 9907 206 9907 207 VIS 132a 00 06 20 EGCP 2 73 74 Speed Bias Output Type 3VDC 0 Speed Bias Output 0 VDC EGCP 2 To 701 and 701A Wiring and Configuration Settings Speed Bias Output 721 Speed Control 21 22 ...

Page 192: ... VIS 133a 00 06 20 EGCP 2 73 74 Speed Bias Output Type 3VDC 0 Speed Bias Output 0 VDC EGCP 2 To 723 or 723 Plus Wiring and Configuration Settings Speed Bias Output 723 or 723 Plus Speed Control 45 46 Common 723 or 723 Plus Speed Control Part Numbers 9907 031 8280 412 ...

Page 193: ...nect the EGCP 2 as shown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Me...

Page 194: ... to Mid range The value of the Voltage Trim Potentiometer can be anywhere from 1000 to 10 000 ohms 2 Watt The value of this pot will effect the final settings Adjustment Procedure 1 Start with the generator at rated voltage EGCP 2 Not Connected terminals 6 and 7 should be shorted Adjust the potentiometers on the AEC63 for rated voltage and stability 2 Connect the EGCP 2 to the voltage regulator as...

Page 195: ...til you measure 1 6 vdc When adjusting the VBO you will move the VBO press the Enter key then press the Status key The new value will then be seen on the voltmeter monitoring terminals 37 and 38 6 Start the generator set 7 Adjust the VoltageTrim Pot for rated voltage Do not adjust this pot after this step 8 Close the Voltage Raise discrete input The voltage on the generator should increase 9 Open ...

Page 196: ...til you measure 1 6 vdc When adjusting the VBO you will move the VBO press the Enter key then press the Status key The new value will then be seen on the voltmeter monitoring terminals 37 and 38 6 Start the generator set 7 Adjust the VoltageTrim Pot for rated voltage Do not adjust this pot after this step 8 Close the Voltage Raise discrete input The voltage on the generator should increase 9 Open ...

Page 197: ... Trim potentiometer is now calibrated and should not be adjusted anymore 4 Close the Voltage Raise discrete input 4 and verify the EGCP 2 can move the generator voltage in the increase direction 5 Close the Voltage Lower discrete input 5 and verify the EGCP 2 can move the generator voltage in the decrease direction 6 The Reactive Load Menu items may need adjusted for stable Power Factor control EG...

Page 198: ...t for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 moves the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 drives the generator voltage in the decrease direction 8 The Reactive Load Control Menu items may need adjusted for stable Power Factor control EGCP 2 settings Confi...

Page 199: ...set for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 moves the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 drives the generator voltage in the decrease direction 8 The Reactive Load Control Menu items may need adjusted for stable Power Factor control EGCP 2 settings Con...

Page 200: ...t the EGCP 2 as shown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 moves the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 drives the generator voltage in the decrease direction 8 The Reactive Load Control Menu items ma...

Page 201: ...ated and should not be adjusted anymore 4 Close the Voltage Raise discrete input 4 and verify the EGCP 2 can move the generator voltage in the increase direction 5 Close the Voltage Lower discrete input 5 and verify the EGCP 2 can move the generator voltage in the decrease direction 6 The Reactive Load Menu items may need adjusted for stable Power Factor control EGCP 2 settings Configuration Menu ...

Page 202: ...e 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction 8 The Reactive Load Control Menu items may need adjusted for stable Power Factor control EGCP 2 settings Configuration Menu Voltage Bias Type 1 VDC Calibra...

Page 203: ... 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction 8 The Reactive Load Control Menu items may need adjusted for stable Power Factor control EGCP 2 settings Configuration Menu Voltage Bias Type 9 VDC Calibration Menu Volts Bias Offset 0 Shutdown Ala...

Page 204: ... Reactive Load Control menu VAR PF Gain 0 5 Volts Ramp Time 200 Sec VAR PF Sharing Gain 0 1 VAR PF Stability 2 0 PF Deadband 0 005 these are only suggested settings External Resistors 1 62 K ohm 500 ohm Resistor Wattage 0 250 Adjustment Procedure 1 Measure across terminals 37 and 38 prior to connecting to DVR 0 0 volts 2 Connect to DVR measure across terminals 7 and 45 2 volts 3 The Cat DVR uses 2...

Page 205: ... Shutdown Alarms Menu Gen Volt Hi Lmt 10 above rated Gen Volt Lo Lmt 10 below rated Reactive Load Control menu VAR PF Gain 0 3 Volts Ramp Time 200 Sec VAR PF Sharing Gain 0 1 VAR PF Stability 4 0 PF Deadband 0 005 these are only suggested settings Voltage Trim Potentiometer 10 K ohm 10 turn 1 Watt Set to Mid Range A 5 K ohm 0 25 Watt resistor may be used in place of the pot Adjustment Procedure 1 ...

Page 206: ... shown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Menu Voltage Bias Ty...

Page 207: ...ter to fine tune the Rated Voltage This is the potentiometer shown above 3 The Voltage Trim potentiometer is now calibrated and should not be adjusted anymore 4 The Reactive Load Menu items may need adjusted for stable Power Factor control EGCP 2 settings Configuration Menu Voltage Bias Type 3 VDC Calibration Menu Volts Bias Offset 45 Shutdown Alarms Menu Gen Volt Hi Lmt 10 above rated Gen Volt Lo...

Page 208: ...CP 2 as shown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Menu Voltage ...

Page 209: ...tage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction 8 The Reactive Load Control Menu items may need adjusted for stable Power Factor control EGCP 2 settings Configuration ...

Page 210: ...ometer shown above 3 The Voltage Trim potentiometer is now calibrated and should not be adjusted anymore 4 Close the Voltage Raise discrete input 4 and verify the EGCP 2 can move the generator voltage in the increase direction 5 Close the Voltage Lower discrete input 5 and verify the EGCP 2 can move the generator voltage in the decrease direction 6 The Reactive Load Menu items may need adjusted fo...

Page 211: ...tiometer shown above 3 The Voltage Trim potentiometer is now calibrated and should not be adjusted anymore 4 Close the Voltage Raise discrete input 4 and verify the EGCP 2 can move the generator voltage in the increase direction 5 Close the Voltage Lower discrete input 5 and verify the EGCP 2 can move the generator voltage in the decrease direction 6 The Reactive Load Menu items may need adjusted ...

Page 212: ...et 0 Shutdown Alarms Menu Gen Volt Hi Lmt 10 above rated Gen Volt Lo Lmt 10 below rated Reactive Load Control menu VAR PF Gain 0 3 Volts Ramp Time 200 Sec VAR PF Sharing Gain 0 1 VAR PF Stability 4 0 PF Deadband 0 005 these are only suggested settings Voltage Trim Potentiometer 10 K ohm 10 turn 1 Watt Set to Mid Range A 5 K ohm 0 25 Watt resistor may be used in place of the pot Adjustment Procedur...

Page 213: ...nnected and set for rated voltage 2 Connect the EGCP 2 as shown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease dir...

Page 214: ...Calibration Menu Volts Bias Offset 0 Shutdown Alarms Menu Gen Volt Hi Lmt 10 above rated Gen Volt Lo Lmt 10 below rated Reactive Load Control menu VAR PF Gain 1 0 Volts Ramp Time 100 Sec VAR PF Sharing Gain 0 1 VAR PF Stability 2 0 PF Deadband 0 005 these are only suggested settings Voltage Trim Potentiometer 100 K ohm 10 turn 1 Watt Set to Mid Range Adjustment Procedure 1 Start Generator 2 Adjust...

Page 215: ... Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Menu Voltage Bias Type 3 VDC...

Page 216: ... Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Menu Voltage Bias Type 3 VDC...

Page 217: ...hown 3 Start Generator 4 Adjust the Volts Bias Offset for rated voltage 5 Press ENTER to save this value 6 Close the Voltage Raise discrete input 4 and verify the EGCP2 can move the generator voltage in the increase direction 7 Close the Voltage Lower discrete input 5 to verify the EGCP 2 can drive the generator voltage in the decrease direction EGCP 2 settings Configuration Menu Voltage Bias Type...

Page 218: ...W Min 1 Max 30000 0 kW RATED kVA Min 1 Max 30000 0 kVA RATED kVAR Min 1 Max 30000 0 kVAR CT RATIO Min 5 5 Max 30000 5 5 5 PT RATIO Min 1 0 1 Max 1000 0 1 1 0 1 VOLTAGE INPUT Wye line neutral Delta line line Wye line neutral VOLTAGE REF Min 1 Max 30000 220 Volts DISPLAY UNITS American Metric American SET DATE MM DD YY 6 15 2001 SET TIME HH MM 12 00 24 Hr CLOCK START SEQUENCING Enable Disable Enable...

Page 219: ...LM DLY Min 0 1 Max 30 0 5 0 s GEN FREQ HI LMT Min 40 Max 75 65 Hz GEN FREQ HI ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Warning GEN FREQ LO LMT Min 40 Max 75 55 Hz GEN FREQ LO ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Warning SPD FREQ MISMTCH Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Disabled OVERCURR...

Page 220: ...MER Min 0 0 Max 30 0 0 0 s REMFLT 1 STABLE DLY Enabled Disabled Enabled Enabled 15 Second Delay REMOTE FAULT2 Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Disabled FAULT2 TIMER Min 0 0 Max 30 0 0 0 s REMFLT 2 STABLE DLY Enabled Disabled Enabled Enabled 15 Second Delay REMOTE FAULT3 Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Hard Shutdown FAUL...

Page 221: ...P 2 Engine Generator Control Package Woodward 211 Item Range Default As Set Value Note REMOTE FAULT6 Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Disabled FAULT6 TIMER Min 0 0 Max 30 0 0 0 s ...

Page 222: ...0000 20 kVA ENGINE RUN TIME Min 0 Max 32000 0 Hours MW HOURS Min 0 0 Max 32000 0 0 0 MW Hours OVERSPEED Min 5 0 Max 30000 0 1980 rpm OVERSPEED ALARM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Hard Shutdown BATT VOLT HI LMT Min 5 0 Max 50 0 28 5 Volts BATT VOLT HI ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Warning BATT VOLT LO LMT Min 5 ...

Page 223: ...LM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Soft Shutdown HI H20 TEMP PRE LMT Min 50 0 Max 300 0 125 0 C or F HI H20 TEMP PRE ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Disabled HI H20 TEMP Min 50 0 Max 300 0 212 0 C or F HI H20 TEMP ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Soft Shutdown LO H20 TEMP ...

Page 224: ...CHING Disabled Enabled Enabled VOLTAGE WINDOW Min 0 1 Max 10 0 1 0 MAX PHASE WINDOW Min 2 0 Max 20 0 10 0 DWELL TIME Min 0 1 Max 30 0 0 5 s CB HOLD TIME Min 0 1 Max 30 0 1 0 s CLOSE ATTEMPTS Min 1 Max 20 2 RECLOSE DELAY Min 2 Max 1200 30 s SYNC RECLOSE ALM Warning Visual Alarm Audible Alarm Warning SYNC TIMEOUT Min 0 Max 1200 0 s 0 NO LIMIT SYNC TIMEOUT ALM Warning Visual Alarm Audible Alarm Warni...

Page 225: ... 0 0 Max 30000 0 50 0 kW UNLOAD TRIP Min 10 0 Max 30000 0 10 kW Must be set less than Baseload Ref LOAD DROOP Min 0 0 Max 50 0 5 0 LOAD TIME Min 1 0 Max 7200 0 10 s UNLOAD TIME Min 1 0 Max 7200 0 10 s RAISE LOAD RATE Min 0 01 Max 100 0 2 00 s LOWER LOAD RATE Min 0 01 Max 100 0 2 00 s KW LOAD HIGH LIMIT Min 0 0 Max 30000 0 30 kW KW HIGH LIMIT ALARM Disabled Warning Visual Alarm Audible Alarm Warnin...

Page 226: ...trol VAR Control PF Control VAR PF GAIN Min 0 01 Max 20 0 1 00 VOLTS RAMP TIME Min 0 Max 1000 60 0 s VAR PF SHARING GAIN Min 0 01 Max 20 0 1 00 VAR PF STABILITY Min 0 0 Max 20 00 1 00 kVAR REFERENCE Min 20 000 Max 20 000 10 0 kVAR generate Lag absorb Lead PF REF Min 0 5 5 Lead Max 5 5 Lag 0 0 1 00 Lag 0 0 Unity PF Lag Lead PF DEADBAND Min 0 0 Max 1 0 0 005 ...

Page 227: ...z PROCESS REFERENCE Min 32 768 Max 32 767 12 0 Process Units RAISE RATE Min 0 0 Max 100 0 0 1 s LOWER RATE Min 0 0 Max 100 0 0 1 s PROCESS HIGH LMT Min 32 768 Max 32 767 20 0 Process Units PROC HI LMT ALM Disabled Warning Visual Alarm Audible Alarm Soft Shutdown Hard Shutdown Disabled PROCESS LOW LMT Min 32 768 Max 32 767 4 0 Process Units PROC LO LMT ALM Disabled Warning Visual Alarm Audible Alar...

Page 228: ...ins w alarms Warning MAIN VOLT HIGH LMT Min 50 0 Max 30000 0 240 Volts MAIN VOLT HIGH ALARM Disabled Warning Loss of Mains Loss of Mains w alarms Warning MAIN VOLT LOW LMT Min 50 0 Max 30000 0 200 Volts MAIN VOLT LOW ALARM Disabled Warning Loss of Mains Loss of Mains w alarms Warning MAIN FREQ HIGH LMT Min 40 0 Max 75 0 61 0 Hz MAIN FREQ HIGH ALARM Disabled Warning Loss of Mains Loss of Mains w al...

Page 229: ...ax 1200 120 s MAX GEN LOAD Min 1 Max 100 60 NEXT GENSET DLY Min 1 Max 1200 30 s RATED LOAD DELAY Min 1 Max 1200 5 s MAX START TIME Min 1 Max 1200 30 s MIN GEN LOAD Min 1 Max 100 30 REDUCED LOAD DLY Min 1 Max 1200 60 s MAX STOP TIME Min 1 Max 1200 60 s 422 PROTOCOL ServLink Modbus Upload Set Points Modbus Modbus ID Min 1 Max 247 1 Modbus Timeout Min 0 1 Max 20 0 3 0 s Modbus Reset False True False ...

Page 230: ...et Min 90 0 Max 90 0 CT Phase A scale Min 0 5 Max 5 0 CT Phase B offset Min 90 0 Max 90 0 CT Phase B scale Min 0 5 Max 5 0 CT Phase C offset Min 90 0 Max 90 0 CT Phase C scale Min 0 5 Max 5 0 Bus PT scale Min 0 5 Max 10 0 Synchronizer Min 1 0 Max 1 0 Battery VCO Gain Min 0 1000 Max 0 1000 Batt VCO offset Min 900 0 Max 900 0 Oil Pres Gain Min 1 000 Max 1 000 Oil Pres Offset Min 900 0 Max 900 0 Wate...

Page 231: ...Manual 26174 EGCP 2 Engine Generator Control Package Woodward 221 ...

Page 232: ...Declarations ...

Page 233: ... Mechanical Vibration SV2 5 2000 Hz 4 G and RV1 10 2000 Hz 0 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 Class 1 grounded equipment Air Quality Pollution Degree II Installation Overvoltage Category III Ingress Protection Will meet the requirements of IP56 as defined i...

Page 234: ...ast Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 2012 11 Colorado ...

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