EGCP-2 Engine Generator Control Package

26174
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
Manual 26174
WARNING
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment. Practice all
plant and safety instructions and precautions. Failure to follow instructions can
cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed (overtemperature, or overpressure, where applicable) shutdown
device(s), that operates totally independently of the prime mover control device(s)
to protect against runaway or damage to the engine, turbine, or other type of prime
mover with possible personal injury or loss of life should the mechanical-hydraulic
governor(s) or electric control(s), the actuator(s), fuel control(s), the driving
mechanism(s), the linkage(s), or the controlled device(s) fail.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging
device, make sure the charging device is turned off before disconnecting the
battery from the system.
Electronic controls contain static-sensitive parts. Observe the following

precautions to prevent damage to these parts.
• Discharge body static before handling the control (with power to the control
turned off, contact a grounded surface and maintain contact while handling the
control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around
printed circuit boards.
• Do not touch the components or conductors on a printed circuit board with
your hands or with conductive devices.
The installation must include the following:

• The power supply mains should be properly fused according to the installation
instructions and the appropriate wiring requirements.
• A switch or circuit breaker must be included in the building installation, that is
near the equipment and within easy reach of the operator, and that is clearly
marked as the disconnecting device for the equipment. The switch or circuit
breaker will only remove power to the unit, hazardous voltages may still be
connected to other terminals on the unit.
The calibration and checkout procedure should only be performed by authorized

personnel knowledgeable of risks posed by live electrical equipment.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© 2002 by Woodward Governor Company
All Rights Reserved
Manual 26174 EGCP-2 Engine Generator Control Package
Contents
ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction.............................................................................................................1
Regulatory Compliance Notes And Warnings........................................................1
Control Electrical Ratings .......................................................................................1
Technical Specifications.........................................................................................1
CHAPTER 2. CONTROL OVERVIEW ............................................................... 3
Introduction.............................................................................................................3
Hardware ................................................................................................................5
Environmental Specification ...................................................................................5
Physical Specification.............................................................................................5
Accessories ............................................................................................................5
Operator Interface ..................................................................................................8
Navigation Procedure ...........................................................................................13
CHAPTER 3. ELECTRICAL INSTALLATION AND SPECIFICATIONS ................... 19
Electrical Connections..........................................................................................19
Input Power ..........................................................................................................23
Potential Transformer (PT) Inputs ........................................................................24
Current Transformer (CT) Inputs..........................................................................33
MPU (Speed) Input...............................................................................................34
Process Import/Export Input.................................................................................35
Coolant Temperature and Oil Pressure Inputs.....................................................36
Speed Bias and Voltage Bias Outputs .................................................................39
Discrete Inputs......................................................................................................41
Relay Outputs.......................................................................................................42
AC Inputs ..............................................................................................................51
DC Inputs and Outputs .........................................................................................51
Discrete Inputs......................................................................................................52
Discrete Outputs...................................................................................................52
Communication Ports: RS-485 & RS-422 (1 each)..............................................53
Hardware Connections.........................................................................................53
Inter-control Communications (RS-485 Network) ................................................55
Alarms and Shutdowns ........................................................................................56
CHAPTER 4. SOFTWARE OVERVIEW ........................................................... 59
Introduction...........................................................................................................59
Status Screens .....................................................................................................59
Security Access ....................................................................................................71
Alarm / Event Log .................................................................................................72
Configuration Menus ............................................................................................74
Shutdowns and Alarms ........................................................................................82
Engine Control......................................................................................................89
Synchronizer.........................................................................................................91
Real Load Control.................................................................................................94
Reactive Load Control ..........................................................................................97
Process Control ....................................................................................................98
Transfer Switch...................................................................................................103
Sequencing and Comms (Communications)......................................................105
Calibration Menu ................................................................................................107
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EGCP-2 Engine Generator Control Package Manual 26174
Contents
CHAPTER 5. CONTROL FEATURES AND FUNCTIONS ..................................121

Engine Control ................................................................................................... 121
Engine Protection .............................................................................................. 121
Generator Voltage and Reactive Load Control ................................................. 121
Generator Protection ......................................................................................... 121
Mains Sensing ................................................................................................... 122
Synchronizing .................................................................................................... 122
Load Control ...................................................................................................... 122
Sequencing........................................................................................................ 122
Engine Cranking ................................................................................................ 123
Idle/Rated Relay Output .................................................................................... 124
Generator Voltage Control................................................................................. 124
Generator Load Control..................................................................................... 125
Automatic Generator Loading Functions........................................................... 129
Synchronizer Description .................................................................................. 133
Generator Sequencing ...................................................................................... 140
CHAPTER 6. CALIBRATION OF CONTROL INPUTS AND OUTPUTS ................151
Introduction ........................................................................................................ 151
Calibration of Generator PTs and CTs .............................................................. 152
Calibration of the Bus PT................................................................................... 156
Speed Bias Output ............................................................................................ 157
Voltage Bias Output........................................................................................... 157
CHAPTER 7. GENERAL STARTUP INSTRUCTIONS .......................................159
Before Starting the Generator Set..................................................................... 159
Sequence of Startup and Checking Parameters............................................... 160
Loading the Generator Set ................................................................................ 160
CHAPTER 8. TROUBLESHOOTING .............................................................163
Control Hardware and I/O.................................................................................. 163
Engine Control/Sensing Parameters ................................................................. 164
Synchronization ................................................................................................. 165
Breaker Close/Open Control ............................................................................. 166
Real Load Control.............................................................................................. 167
Reactive Load Control ....................................................................................... 168
Sequencing........................................................................................................ 169
Mains/Bus Sensing............................................................................................ 170
Communications................................................................................................ 170
CHAPTER 9. DEFINITION OF TERMS ..........................................................171
CHAPTER 10. SERVICE OPTIONS ..............................................................177
Product Service Options.................................................................................... 177
Returning Equipment for Repair........................................................................ 178
Replacement Parts ............................................................................................ 179
How to Contact Woodward................................................................................ 180
Engineering Services......................................................................................... 180
Technical Assistance......................................................................................... 182
APPENDIX A. CONNECTOR INFORMATION .................................................183
APPENDIX B. SPEED BIAS CONNECTIONS.................................................185
ii Woodward
Contents
APPENDIX C. VOLTAGE BIAS CONNECTIONS ............................................ 191

Basler SSR .........................................................................................................191
Basler SR4A or SR8A ........................................................................................192
Caterpillar Digital Voltage Regulator ..................................................................193
Caterpillar VR3 ...................................................................................................194
KATO KCR360 or 760 ........................................................................................195
KATO K65-12B or K125-10B .............................................................................196
Marathon 2000E .................................................................................................197
Newage MX321/341 ...........................................................................................198
Newage MA325 ..................................................................................................199
APPENDIX D. EGCP-2 SETPOINT WORKSHEET........................................ 201
Configuration Menu ............................................................................................201
Shutdown and Alarms Menu ..............................................................................202
Engine Control Menu..........................................................................................205
Synchronizer Menu.............................................................................................207
Real Load Control Menu ....................................................................................208
Reactive Load Control Menu..............................................................................209
Process Control Menu........................................................................................210
Transfer Switch Menu ........................................................................................211
Sequencing and Comms Menu ..........................................................................212
Calibration Menu ................................................................................................213
APPENDIX E. APPLICABLE DOCUMENTS .................................................. 215
EGCP-2 CONTROL SPECIFICATIONS ....................................................... 217
Illustrations and Tables
Figure 2-1. Physical Outline with Dimensions of EGCP-2 .....................................6

Figure 2-2. EGCP-2 Interface Connections ...........................................................7
Figure 2-3. Operator Interface................................................................................8
Figure 2-4a. EGCP-2 Navigation (1) ....................................................................13
Figure 2-4b. EGCP-2 Navigation (2) ....................................................................14
Figure 2-4c. EGCP-2 Navigation (3) ....................................................................15
Figure 2-4d. EGCP-2 Navigation (4) ....................................................................16
Figure 2-4e. EGCP-2 Navigation (5) ....................................................................17
Figure 3-1. CageClamp Termination Blocks (example photos) ...........................19
Figure 3-2. Recommended Single Point Grounding Scheme ..............................20
Figure 3-3. Wiring Diagram for EGCP-2 ..............................................................22
Figure 3-4. Dip Switch Locations..........................................................................23
Figure 3-5. Three Wire Delta PT Connections for EGCP-2 .................................25
Figure 3-6. Four Wire Wye PT Connections ........................................................25
Figure 3-7. Utility/Local Bus Single PT Wiring for Delta and Wye Configuration for
Multiple or Single Engine Applications ............................................26
Single Engine applications ..............................................................27
Multiple or Single Engine Prime Power Applications ......................28
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Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....29
Figure 3-11a. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....31
Figure 3-11b. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....32
Figure 3-12. Current Transfer Wiring Diagram for EGCP-2.................................33
Figure 3-13. Wiring Diagram for MPU Input .........................................................34
Figure 3-14a. Wiring Diagram for Process Import/Export Input ...........................35
Figure 3-14b. Connecting a KW Transducer Signal to Multiple EGCP-2s...........35
Figure 3-15. Wiring Diagram for Pressure Inputs.................................................36
Figure 3-16. Wiring Diagram for Temperature Inputs ..........................................37
Figure 3-17. Wiring Diagram for Speed Bias and Voltage Bias Outputs .............40
Figure 3-18. Wiring Diagram for Typical Discrete I/O Connections .....................42
Figure 3-19. Example of the Mains Breaker NO Output Connected to Close the
Mains (Utility) Breaker (ENERGIZE TO CLOSE) ............................43
Figure 3-20. Example Using the NC Output to Control the Mains (Utility)
Contactor (ENERGIZE TO OPEN) ..................................................44
Figure 3-21. Example of the Generator Breaker Close NO Output Connected to
Close the Generator Breaker (ENERGIZE TO CLOSE) .................45
Figure 3-22. Example Using the NO Contacts to Control the Generator’s
Contactor (ENERGIZE TO CLOSE) ................................................45
Figure 3-23. Example Using the NO Contacts to Control the Mains Breaker Trip
(Open) Coil (ENERGIZE TO OPEN) ...............................................48
Figure 3-24. Example Using the NC Contacts to Control the Generator Breakers
Open Coil (DE-ENERGIZE TO OPEN) ...........................................49
Figure 3-25. Generator Breaker and Contactor Close and Open Logic ..............49
Figure 3-26. RS-422 Communications .................................................................54
Figure 3-27. RS-485 and RS-422 Termination Diagrams....................................55
Figure 3-28. RS-485 Inter-Control Communications............................................56
Figure 4-1. System Overview Engine Off Line .....................................................59
Figure 4-2. System Status Screen—Isochronous ................................................61
Figure 4-3. System Status Screen—Baseload.....................................................61
Figure 4-4. Engine Status.....................................................................................62
Figure 4-5. Generator Status (Voltage Line to Neutral) .......................................63
Figure 4-6. I/O Status ...........................................................................................64
Figure 4-7. Synchronizer Status...........................................................................65
Figure 4-8. KW Load Status .................................................................................66
Figure 4-9. PF /KVAR Status................................................................................67
Figure 4-10. Sequencing Menu ............................................................................68
Figure 4-11. Sequencing Menu (Multi-Unit) .........................................................69
Figure 4-12. ATS (Automatic Transfer Switch) Status. ........................................70
Figure 4-13. Security Code Display......................................................................71
Figure 4-14. Alarm / Event Screen .......................................................................72
Figure 4-15. Empty Event Log..............................................................................73
Figure 4-16a. Configuration Menu List (Screen 1) ...............................................74
Figure 4-16b. Configuration Menu List (Screen 2) ...............................................74
Figure 4-16c. Configuration Menu List (Screen 3) ...............................................75
Figure 4-17. Program Configuration Error............................................................76
Figure 4-18. AC Power Triangle...........................................................................78
Figure 4-19. Breaker Logic and Contactor Logic .................................................82
Figure 4-20. Generator High/Low Voltage Alarms ...............................................83
Figure 4-21. Generator Over/Under Frequency ...................................................84
Figure 4-22. Delay Time is 10 Seconds, Current goes to 190 Amps, an Alarm or
Shutdown will be received in 3 seconds..........................................86
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Shutdown will be received in 30 seconds........................................86
Shutdown will be received in 60 seconds........................................86
Figure 4-25. Reverse Power ................................................................................88
Figure 4-26. Typical Circuit Using Permissive Function and Run for Auto/Manual
Synchronizing ..................................................................................91
Figure 4-27. Voltage Matching (1% setpoint).......................................................92
Figure 4-28. Maximum Phase Window = 10 Degrees .........................................93
Figure 4-29. EGCP-2 Control Dip Switch.............................................................98
Figure 4-30. Direct (Export) Process Action.........................................................99
Figure 4-31. Indirect (Import Power) Process Action ...........................................99
Figure 4-32. Direct (Import/Export) Process Action .............................................99
Figure 4-33. Process In Scale ............................................................................108
Figure 4-34. Measured vs. Monitored ................................................................108
Figure 4-35. Typical AVR with Aux Input (Newage SX-440)..............................110
Figure 4-36. Typical AVR with External Voltage Adjust Potentiometer..............110
Figure 4-37. AVR Droop.....................................................................................111
Figure 4-38. Oil Pressure Sensor Curve ............................................................115
Figure 4-39. Water Temperature Curves ...........................................................118
Figure 4-40. EGCP-2 Water Temperature Characteristics ................................118
Figure 5-1. Droop Mode .....................................................................................127
Figure 5-2. Isochronous Mode ...........................................................................127
Figure 5-3. Droop/Isochronous Load Sharing ....................................................128
Figure 5-4. Synchronizer Time Line—Standard Sequence ...............................137
Figure 5-5. Loss of Mains Detection Active........................................................138
Figure 5-6. Generator Off Line ...........................................................................138
Figure 5-7. Mains Parallel Unit with Voltage/Frequency Detect.........................139
Figure 5-8. Mains Parallel Unit(s) with Load Surge Detect ................................139
Figure 5-9. Typical Automatic Sequencing Scenario .........................................141
Figure 5-10. Original System Configuration .......................................................144
Figure 5-11. After a Change of Priority—Units Not Operating ...........................144
Figure 5-12. Original System Configuration .......................................................145
Figure 5-13. Master transfers to Unit 2 ..............................................................145
Figure 5-14. Changing the Priority of a Slave Unit.............................................147
Figure 6-1. Relationship Between Voltage Bias and Generator Voltage ...........158
Table 5-1. Overcurrent Level Chart......................................................................85

Table 5-2. Reverse Power Chart..........................................................................87
CAUTION
Only authorized personnel knowledgeable of the risks posed by live
electrical equipment should perform the calibration and checkout
procedure.
Woodward v
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded
metal object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
WARNING
Protective Earth (PE) must be connected to the termination point on
the backside of the unit next to the label with the symbol (or 1 of 3
other similar termination points without label) to reduce the risk of
electric shock. This connection will be made using a thread-forming
screw. The conductor providing the connection must have a properly
sized ring lug and wire larger than or equal to 3.0 mm² (12 AWG).
vi Woodward
Chapter 1.
General Information
Introduction
This manual describes how to Install and Operate the Woodward EGCP-2 Engine
Generator Control Package, models 8406-120 and 8406-121.
Associated manuals:
26175—Application Manual
26181—Communications Manual
26108—Security Levels Guide
Regulatory Compliance Notes And Warnings

General Installation and Operation Notes and Warnings
• The EGCP-2 is suitable for use in non-hazardous locations only.
• Wiring must be in accordance with applicable electrical codes and in
accordance with the authority having jurisdiction.
• Field wiring must be suitable for at least 90 °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 20 W
at rated voltage
Maximum PT input voltage range 150–300 Vac rms (8406-120)
Maximum PT input voltage range 50–150 Vac rms (8406-121)
Maximum CT current input range 0–6 A rms
Maximum generator frequency range 40–70 Hz
Technical Specifications
The relevant accuracies for this product are:
Element Accuracy Description

Voltage Metering 1.0% at rated voltage At 23±5 °C
Current Metering 1.0% at 5 A ac At 23±5 °C
Power Metering 2.0% at rated V & I At 23±5 °C
Woodward 1
2 Woodward
Chapter 2.
Control Overview
Introduction
The EGCP-2 is a microprocessor based complete generator load control and
engine management package. It will operate with an automatic voltage regulator
and various speed controls to automate and protect diesel or gas engine based
generator sets.
Designed for generator sets up to 30,000Kw, the EGCP-2 can be configured to

operate stand-alone or utility paralleled. A network of EGCP-2 controls is
capable of controlling up to eight un-manned generator sets for backup power,
baseload, or peak shaving applications.
Engine Control
• Engine Pre-glow 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 harmonic content causing multiple zero crossing of voltage waveforms.
• Adjustable maximum phase window, voltage window, and dwell times—
windows as small as 2° phase error and 0.1% voltage matching respectively.
• Safe dead bus closing logic internal to the control.
• Multiple shot re-closing with adjustable time delays, auto-resynchronizing,
and synchronizer time-outs all available.
• Manual voltage and speed adjusts for manual synchronizing (Sync-Check
still active during manual parallels).
• Synchronization across generator and mains breakers.
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Real (KW) Load Control
• True RMS power calculations for rapid, accurate load control even in the
presence of harmonics.
• Smooth user chosen ramp rates into and out of each mode of operation.
• Isochronous load-sharing of up to 8 units based on percentage loading
(allows different rated machines to proportionally balance KW loads).
• Constant base loading for optimum fuel efficiency with discrete inputs to
change load levels remotely.
• Import/Export control with an external watt transducer.
• Soft Utility Transfer Function
• Externally adjustable Base Load or Process Reference Levels with
independent ramp rates
• KW droop provided for manual load control.
Reactive (KVAR) Control

• VAR sharing on isolated busses based on percentage reactive load (allows
different rated machines to proportionally balance KVAR loads).
• Constant Power Factor or VAR control on units in Base Load or Process
control mode.
• Externally adjustable VAR 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 changed from any unit or from a PC to
equalize run-time.
Generator Protective Features

• Over/Under Voltage
• Over/Under Frequency
• Reverse Power (Inverse time delay)
• Reverse VARs
• Overcurrent (Inverse time delay)
• Loss of Mains (Utility) detection
• Speed/Frequency Mismatch
• Load Surge
• KVA Load Switch
Engine Protective Features

• High/Low Coolant Temperature
• High/Low Oil Pressure
• Overspeed
• Start Failure
• Six user configurable, discrete fault inputs
4 Woodward
Communication – PC Interface
• Easy upload and download of unit configuration parameters
• A PC can control or monitor any unit at a site via RS-422 serial port using
Modbus® * or ServLink protocol
• For complete details see Communication Manual 26181
*—Modbus is a registered trademark of Modicon, Inc.
Hardware
The EGCP-2 is an integrated control package. All control hardware is contained
in one compact enclosure.
Figure 2-1 is a physical outline drawing with dimensions of the EGCP-2 for
reference during the construction of mounting panels, etc.
To mount the EGCP-2 panel use type M5 x 12mm thread forming screws
(Woodward part number 1029-529). Eight mounting screws are shipped with
each control.
NOTE
When mounting into an enclosure, make sure the enclosure is vented
to atmosphere through a Type 4 vent tube or unsealed conduit.
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
separately.
• 8928-301—EGCP-2 connector kit. Contains all of the mating terminal
blocks for the EGCP-2. See Appendix A for mating connector information.
• 5417-551—Communication Cable for RS422. This cable will connect your
PC to the EGCP-2 RS422 port. This is a point-to-point connection. It can be
used with EGCP-2 software tools. Communication Manual 26181 contains
the software tool information.
Woodward 5
Figure 2-1. Physical Outline with Dimensions of EGCP-2
6 Woodward
UTILITY
Woodward
Watt
Manual 26174
Transducer
Operator Control Panel
EGCP-2 Interfaces
Process
Input Fault 1
Fault 2
Automatic
Utility Utility TB Aux Process I/E
Test Engine
Speed Raise
Breaker Speed Lower PC
Voltage Raise
Utility TB Open/Close PC Interface
Voltage Lower
Run With Load

RS-422
*K1 TO Other
Mains PT RS-485
EGCP-2s
Disconnect Port
*K2
Utility/Bus Input
(single phase)
EGCP
ALARM (VISUAL)
Local Bus Connect LAMP
GB Aux In ALARM (AUDIBLE)
Gen Breaker
Open/Close
Plant Load
Gen PT Inputs (3 phases)
HORN
Oil Pressure Gen CT inputs (3 phases)
Figure 2-2. EGCP-2 Interface Connections

Engine Preglow
Engine Crank
Fuel Shutoff Solenoid
Water Temperature MPU Speed Bias Voltage Bias
GEN
Generator Speed Voltage
Breaker Control Regulator
TO Other
Generators
7
EGCP-2 Engine Generator Control Package
Operator Interface
The EGCP-2 Operator Interface is designed for simplicity and redundancy of
function in all operating modes. Two backlit Liquid Crystal Display screens are
used to display various operating and status information to the operator, as well
as for tuning set points. The backlight on the LCD screens will stay on whenever
the engine speed is above 50 rpm. When the engine is not running, the backlight
will turn on whenever any key is pressed on the front panel. The backlight will
turn off after 5 minutes of non-use, when the engine is not running. Additionally,
in the event of a drop in supply voltage where the monitored battery voltage
drops below 9.0 Vdc, the LCD back light will shut off to conserve power.
NOTE
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.
CAUTION
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
The unit’s front panel screens provide eight lines of Status Information, with the
option of displaying four lines of configuration or Alarm Log information. These
screens allow the user to monitor and tune related parameters at the same time.
ALARM
LED
Display
Keypad
Figure 2-3. Operator Interface
A red Light Emitting Diode (LED) on the face of the control is used to indicate
an alarm condition by flashing repeatedly, and to indicate a shutdown condition
by staying on continuously.
8 Woodward
There are a total of 19 keys on the keypad. Each key has the following
function(s):
ALARM/EVENT LOG KEYS:
ALARM / EVENT
The ALARM/EVENT key is used to access the Event

log. When pressed, the current alarm events will be displayed on the right hand
LCD screen. When multiple alarms are logged, the up and down scroll keys will
allow you to navigate within the Event log. The Event log will store up to 16
events, as more events happen the oldest alarms will be dropped off to make
room for the newer events. If power is cycled to the control, the Event log will be
cleared.
ALARM CLEAR
The ALARM CLEAR key is used to acknowledge and

clear alarm events from the Event log. To acknowledge and clear alarm 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/Shutdown mode is Audible, Soft Shutdown, or Hard Shutdown—

1. Pressing the ALARM CLEAR key once will de-energize Discrete Output
#11, Audible Alarm. This will happen without selecting the
ALARM/EVENT key and without a Security Code entered.
2. With the ALARM/EVENT key pressed, so the Event log is being displayed:
Pressing the ALARM CLEAR key a second time will acknowledge the
selected alarm. This means the cursor will move from the Alarm Name line
down to the Time and Date line.
3. Pressing the Alarm Clear key a third time will remove the event from the log.
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NAVIGATION and ADJUSTMENT KEYS:
SCROLL
The SCROLL KEY is used to move the cursor up, down,

left and right. It also is used to increment and decrement values while in the
configuration menus.
ESC
The ESCAPE KEY is used to move upwards (out of )the

configuration menu levels. It also is used when tuning a value to restore the
previous value, if the new value is not entered into memory (see the enter key,
below).
ENTER
The ENTER KEY is used to move downwards (into) the

configuration menu levels. It is also used to when tuning a value to enter the new
value to memory. It also serves as a means to commit alarm event items to the
alarm event list without removing them. This is known as logging the alarm
event item. Pressing the Enter key while on the selected alarm/event item will
“save” that item to the event list. If the selected alarm event was an active alarm
event, the action(s) associated with the alarm event will also be cleared from the
control logic.
STATUS and CONFIGURATION KEYS:
STATUS
i
The STATUS KEY, when pressed, will put both left and
right LCDs into the status display mode. The status displays provide information
about different items of engine and generator set operation. See the STATUS
MENU buttons, below for details on the various status keys. There are no
adjustment values in the status menus.
10 Woodward
CONFIG
...
The CONFIG KEY, when pressed, will put the right
hand LCD into the configuration mode. Configuration menu items will be
displayed in the right hand screen. Status information will continue to be
displayed in the left hand screen. Since there are various menu items and
adjustments in the configuration menu, a blinking cursor is provided in the right
hand display when the configure mode is active.
STATUS MENU KEYS:
The contents of the various status 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, when pressed displays

status information about the engine functions and operation.
GEN
The GEN STATUS key shows three phase generator

parameters when pressed.
I/O
The I/O STATUS key provides the status of all the

discrete inputs and outputs, as well as information on analog inputs and outputs.
Woodward 11
SYNC
The SYNC STATUS key shows status information

regarding the generator breaker and utility breaker synchronizer.
KW LOAD
The KW LOAD STATUS key, when pressed, shows the

status information for the KW load control of the EGCP-2.
PF / KVAR
Press the PF/KVAR STATUS key to display VAR/PF

Mode information, as well as three phase generator voltage and current.
SEQUENCE
The SEQUENCE STATUS key provides sequencing

information for multiple unit systems. Single unit systems, and units not in the
AUTO mode will not provide status information in this screen.
ATS
The ATS STATUS key, when pressed, displays the

status information for the Automatic Transfer Switch functions.
12 Woodward
Navigation Procedure
Figure 2-4(a-e) details a step-by-step procedure for navigating through the
EGCP-2 Status screens and Configuration menus. The Keypad entries with the
associated Display screens are shown.
LEFT HAND LCD DISPLAY RIGHT HAND LCD DISPLAY

KEYPRESS
Power Up
system status system status
ENGINE
prime mover status prime mover status
SYNC
synchronizer status synchronizer status
CONFIG
SECURITY CODE
... synchronizer status ****
ENTER
SECURITY CODE
_ 0
+ +
SCROLL synchronizer status ----------------------------------------------------
ENTER SECURITY CODE
ENTER
Configuration
Shutdowns and Alarms
synchronizer status Engine Control
Synchronizer
VIS-140A
00-6-20
Configuration
SCROLL synchronizer status Engine Control
Synchronizer
Figure 2-4a. EGCP-2 Navigation (1)
Woodward 13
From Previous Page

SCROLL Configuration (*first item in list)
synchronizer status
Engine Control
Synchronizer

SCROLL
Engine Control
synchronizer status Synchronizer
Real Load Control
Process Control
Transfer Switch
SCROLL synchronizer status Sequencing and Comms
Calibration (*last item in list)
Process Control
Transfer Switch
SCROLL synchronizer status Sequencing and Comms
ENTER
>AUTO SEQUENCING (*first item is list)
>MAX GEN LOAD
synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY

SCROLL >MAX GEN LOAD
>RATED LOAD DLY

>MAX GEN LOAD
SCROLL synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY
VIS-140B
00-6-20
Figure 2-4b. EGCP-2 Navigation (2)
14 Woodward
ENTER From Previous Page
NEXT GENSET DLY

30 Sec
synchronizer status -------------------WOODWARD EGCP2-------------
CONFIGURATION MENUS
SCROLL NEXT GENSET DLY

29 Sec
synchronizer status -------------------WOODWARD EGCP2-------------
CONFIGURATION MENUS
ENTER
>MAX GEN LOAD
>RATED LOAD DLY

>MAX GEN LOAD
SCROLL synchronizer status >NEXT GENSET DLY
>RATED LOAD DLY
ENTER MAX GEN LOAD

60 %
synchronizer status ---------------------SEQUENCING--------------------
%KW: 0.0
ESC
>MAX GEN LOAD
>RATED LOAD DLY
ESC Process Control

Transfer Switch
synchronizer status Sequencing and Comms
VIS-140C
00-6-20
Figure 2-4c. EGCP-2 Navigation (3)
Woodward 15
CONFIG from previous page
... Configuration
synchronizer status
Engine Control
Synchronizer
I/O
Configuration
input/output status Engine Control
Synchronizer
STATUS
i input/output status input/output status
ALARM / EVENT
CRANK FAIL
12:00 1 - 1
input/output status MAIN VOLT LOW ALM
12:00 1 - 1
ENGINE
CRANK FAIL
12:00 1 - 1
engine status
MAIN VOLT LOW ALM
12:00 1 - 1
CRANK FAIL
SCROLL 12:00 1 - 1
engine status MAIN VOLT LOW ALM
12:00 1 - 1
MAIN VOLT LOW ALM

12:00 1 - 1
SCROLL engine status ----------------------------------------------------
VIS-140D
00-6-20
-------------------End of List-----------------
Figure 2-4d. EGCP-2 Navigation (4)
16 Woodward
ENTER
from previous page
MAIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ENTER
MAIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
MAIN VOLT LOW ALM
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
CRANK FAIL
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
CRANK FAIL
12:00 1 - 1
engine status ----------------------------------------------------
-------------------End of List-----------------
ALARM CLEAR
engine status None Recorded
SYSTEM
system status None Recorded
STATUS
i system status system status

VIS-140E
00-6-20
Figure 2-4e. EGCP-2 Navigation (5)
Woodward 17
18 Woodward
Chapter 3.
Electrical Installation and Specifications
Electrical Connections
All inputs and outputs to the EGCP-2 are made through “CageClamp” terminal
blocks. For noise suppression, it is recommend that all low-current wires be
separated from all high-current wire.
The terminal blocks are screwless CageClamp style blocks. The spring clamp can
be actuated by using a standard 3.5 mm or 1/8 inch flat bladed screwdriver (see
Figure 3-1). The EGCP-2 pluggable terminal blocks accept wires from 0.08–2.5
mm² (28–12 AWG). Fixed terminal blocks accept wires from 0.08–2.5 mm²
(27–12 AWG). Two 0.8 mm² (18 AWG) or three 0.5 mm² (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 applied)
Wiring Fixed Terminal
Figure 3-1. CageClamp Termination Blocks (example photos)
Most of the EGCP-2 control’s terminal blocks are designed to be removed by

hand. After EGCP-2 input power is disconnected, the terminal blocks can be
removed one at a time by pulling them straight out. Care should be taken not to
pull the plug out at an angle as this will fracture the end terminal.
Woodward 19
NOTE
Do not tin (add solder to) the wires that terminate at the EGCP-2
terminal blocks. The spring-loaded CageClamp terminal blocks are
designed to flatten stranded wire, and if those strands are tinned
together, the connection loses surface area and is degraded.
Grounding for Protection Against Electric Shock

Protective Earth (PE) must be connected to the termination point on the backside
of the unit next to the label with the symbol (or 1 of 3 other like termination
points without label) to reduce the risk of electric shock. The EGCP-2 ships with
2 thread forming screws (M4 x 6 mm, Woodward #1029-525) for this
connection. The conductor providing the connection must have a properly sized
ring lug and wire larger than or equal to 3.0 mm² (12 AWG).
Recommended Grounding Practices

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 produces
unacceptably high common mode voltages. Common mode voltages may result
in improper readings for the sensed AC inputs, or even damage to the EGCP-2
product in extreme cases. To minimize this problem, it is necessary to provide a
low resistance path between the AC signal reference point, and the chassis of the
EGCP-2. Typically this point is the designated ground for the generator set and
related instrument transformers.
Generator
Ground Bonding Conductor
VIS-144
00-8-23
EGCP-2 chassis ground
lug connection point (4)
TB 1 TB 2 TB 3 TB 4
Back of EGCP-2
TB 5 TB 6 TB7 TB8 TB9
Figure 3-2. Recommended Single Point Grounding Scheme
20 Woodward
Shields and Grounding
An individual shield termination is provided at the terminal block for each of the
signals requiring shielding except for oil pressure and coolant temperature. All of
these inputs should be wired using shielded, twisted-pair wiring. The exposed
wire length, beyond the shield, should be limited to one inch. Relay outputs,
contact inputs, and power supply wiring do not normally require shielding, but
can be shielded if desired.
The EGCP-2 is designed for shield termination to earth ground at the EGCP-2. If
intervening terminal blocks are used in routing a signal, the shield should be
continued through the terminal block. If shield grounding is desired at the
terminal block, 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 note on cabinet installations).
Shields can be grounded at both ends (EGCP-2 and load) if the cable length is
sufficiently short (that is, within a cabinet) to prevent ground loop current in the
shield.
Cabinet Installations: If the EGCP-2 is installed in a cabinet, shielded I/O can be

terminated directly to the cabinet (earth ground) at the entry to the cabinet, as
well as at the EGCP-2.
For noise suppression reasons, it is recommend that all low-current wires be

separated from all high-current wires. Input Power ground terminal should also
be wired to earth ground.
Woodward 21
Figure 3-3. Wiring Diagram for EGCP-2
22 Woodward
EGCP-2
Back View
DIP Switch Identification
(not to scale).
DIP SWITCHES ARE ACCESSABLE THROUGH HOLES IN THE SIDES OF THE
BACK COVER.
OPEN 1, 3, 4 = OPEN
TB 1 TB 2 TB 3 TB 4
2 = CLOSED
CLOSED
1 2 3 4
NOTE: OPEN = UP, away from PC board.
CLOSED = DOWN, toward PC board
SW-1 SW - 3
Pressure Sensor Input Hardware RS-422 Terminations
______________________________ ___________________________
1. 0-200 Sensor. 4. No Function.
2. 4-20mA Input Select. 3. 123 ohm RS-422 Termination -
3. 100 ohm dropping resistor Select. Dip Switch # 1 Dip Switch # 3
2. 123 ohm RS-422 Termination+
4. 100 ohm dropping resistor Select. 1 4
1. +5V RS-422
2 3
3 2 SW - 4
SW-2 4 1
Temperature Sensor Input Hardware RS - 485 Terminations
______________________________ Dip Switch # 2 Dip Switch # 4 ___________________________
1. 0-200 Sensor. 1 4 4. 4-20 mA Process Input
2 3
2. 4-20mA Input Select. 3 2 3. 123 ohm RS-485 Termination -
3. 100 ohm dropping resistor Select. 4 1 2. 123 ohm RS-485 Termination+
4. 100 ohm dropping resistor Select. 1. +5V RS-485
VIS-143 TB 5 TB 6 TB7 TB8 TB9
01-03-16
Figure 3-4. Dip Switch Locations
NOTE
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 between the power source and the EGCP-2. This
overcurrent protection may be accomplished by series connection of properly
rated fuses or circuit breakers (see the Input Power Ratings below for proper
sizing).
Input Power Ratings

Nominal Voltage Range: 10–29 Vdc
Maximum Voltage Range: 9–32 Vdc
Maximum Input Power: 20 W
Typical Input Power: 13 W @24Vdc
Input Fuse Rating: 5 A (time delay with melting I²t ≥ 100A²sec)
Wire Size: Up to 12 AWG
Holdup Time: 5 milliseconds @ 24 Vdc
Significant inrush currents are possible when current is applied to the EGCP-2
control. The magnitude of the inrush current depends on the power source
impedance, so Woodward cannot specify the maximum inrush current. Time-
delay fuses or circuit breakers must be used to avoid nuisance trips.
Woodward 23
Potential Transformer (PT) Inputs
Potential Transformers (PTs) are utilized with the EGCP-2 control to allow high
level circuit voltages to be stepped down to a safe level for the EGCP-2 input
circuitry. The EGCP-2 control senses generator output voltage through three
Generator PTs, and utility and plant-bus voltages via one shared utility/plant-bus
PT.
Potential Transformer Input Ratings for 8406-120

Number of inputs: 4
Maximum Voltage Rating: 150–300 Vac
Burden: 0.45 VA
Input Frequency: 40–70 Hz
Potential Transformer Input Ratings for 8406-121

Number of inputs: 4
Maximum Voltage Rating: 50–150 Vac
Burden: 0.25 VA
Input Frequency: 40–70 Hz
NOTE
Because the same EGCP-2 input is used to sense both the utility and
local bus voltages, the two PT signals must be 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 power. Refer to the Figure 3-5
for Delta based wiring diagrams and Figure 3-6 for Wye based wiring diagrams.
Once wired into a Delta or Wye circuit, the EGCP-2 must also be programmed to
sense the correct (Delta or Wye) configuration.
Configuration menu (items affected)

1. PT Ratio
2. Voltage Input
3. Voltage Ref
Shutdown and Alarms Menu
1. Gen Volt Hi Limit and Alarm
2. Gen Volt Lo Limit and Alarm
3. Gen Freq Hi Limit and Alarm
4. Gen Freq Lo Limit and Alarm
Transfer Switch Menu
1. Main Volt High Limit and Alarm
2. Main Volt Low Limit and Alarm
3. Main Freq High Limit and Alarm
4. Main Freq Low Limit and Alarm
24 Woodward
A 42 +
A PHASE PT
43
-
B 44 +
B PHASE PT
45
-
C 46 +
C PHASE PT
47
-
VIS-054b EGCP-2
00-06-19
Figure 3-5. Three Wire Delta PT Connections for EGCP-2
42 A +
A B
N
43
N
44 B +
N
N
45
N
C 46 C +
N
VIS-055a 47
00-10-17 N
EGCP-2
Figure 3-6. Four Wire Wye PT Connections
Utility (Mains) and Plant Bus PT Input Wiring

The EGCP-2 utilizes one PT input to sense both utility tie-line voltage and plant-
bus voltage. This PT input must be the same configuration 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 synchronizing the generator to
the local bus. Refer to Figures 3-7, 3-8, and 3-9, for required input wiring
configurations. This type of configuration allows the EGCP-2 to perform a
break-before-make relay action when switching between voltage sources to
assure that the utility PT and Bus PT never are connected.
Woodward 25
Sequence of Mains PT Disconnect (DO8) and Local Bus PT Connect
(DO7)
The EGCP-2 will command a Mains PT disconnect (DO8) when:
1. The EGCP-2 has an “AUTO” discrete input and either
a. A loss of Mains (LOM) is detected or
b. A “Run with load” discrete input.
2. The Generator Stable Delay time has been met.
3. The EGCP-2 is in the “Close Gen Breaker” mode.
When the Mains PT Disconnect changes state, the EGCP-2 has to measure less
than 40 Vac on the Mains/Bus PT input (terminals 40 and 41). If the EGCP-2
measures greater than 40 Vac after the Mains PT Disconnect command was
given, the EGCP-2 senses this as a fault and will 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, 3-8, and 3-9, show how to connect terminals 40
and 41 for different applications.
Multiple or Single
NOTES: Engine Applications EGCP-2
- *K1 SHOWN ENERGIZED
- *K2 SHOWN DE-ENERGIZED
- *K1 & K2 RELAYS ARE NOT (+V) 23 Mains PT
SUPPLIED BY WOODWARD Disconnect
- *K1 and K2 RELAYS SHOULD (Normally
BE CONNECTED AS NORMALLY Closed)
OPEN CONTACTS
24 (D08)
K1*
Mains PT
A K1-A
40 A
B or N K1-B
(B for Delta, N for Wye) Mains/Bus PT Input
A
Bus PT K2-A
41 B or N
B or N K2-B (B for Delta, N for Wye)
(B for Delta, N for Wye) K2*
21 Local Bus PT
Connect
(Normally
Open)
(+V) 22 (D07)
VIS-145A
02-5-29
Figure 3-7. Utility/Local Bus Single PT Wiring for Delta and Wye Configuration
for Multiple or Single Engine Applications
26 Woodward
Figure 3-7 Notes:
1. For Multiple or Single Engine Applications
a. Loss of Mains (LOM)
b. Mains Parallel or No Parallel
c. Prime Power
2. K1 and K2 relays
a. Not supplied by Woodward
b. Relays should be connected as Normally Open contacts
Single Engine
NOTES:
Applications using EGCP-2
only a Mains PT Input
- *K1 SHOWN ENERGIZED
- *K2 SHOWN DE-ENERGIZED (+V) 23 Mains PT
- *K1 & K2 RELAYS ARE NOT Disconnect
SUPPLIED BY WOODWARD
- *K1 & K2 RELAYS SHOULD
(Normally
BE CONNECTED AS NORMALLY Closed)
OPEN CONTACTS 24 (D08)
K1*
A
Mains PT K1-A
40 A
B or N K1-B
(B for Delta, N for Wye) Mains/Bus PT Input
K2-A
41 B or N
K2-B (B for Delta, N for Wye)
K2*
21 Local Bus PT
Connect
(Normally
Open)
VIS-146B
(+V) 22 (D07)
02-5-29
for Single Engine applications
Figure 3-8 Notes:

1. For Single Engine Applications
a. Loss of Mains (LOM)
b. Mains Parallel or No Parallel
2. Uses the Mains PT only
3. K1 and K2 relays:
b. Relays should be connected as Normally Open contacts
Woodward 27
EGCP-2
23 Mains PT
Prime Power Disconnect
Applications (Normally
Closed)
24 (D08)
NOTES:
- K2 SHOWN DE-ENERGIZED
- K2 RELAY IS NOT
SUPPLIED BY WOODWARD 40 A
K2*
Bus PT A K2-A
Mains/Bus PT Input
B or N K2-B
(B for Delta, N for Wye)

41 B or N
(B for Delta, N for Wye)
21 Local Bus PT
VIS-146C Connect
02-5-29
(Normally
Open)
(+V) 22 (D07)
for Multiple or Single Engine Prime Power Applications
Figure 3-9 Notes:

1. Multiple Engine Application
a. Prime Power
2. Single Engine Application
a. Prime Power
3. Uses Bus PT only
4. K2 relay
b. Relay should be connected using the Normally Open contacts
Required PT Wiring Relationships

The EGCP-2 control uses its programmed PT-Ratio setting to calculate and
compare all PT input voltages. Thus, the EGCP-2 control requires the following
generator, utility, and plant-bus PT relationships. Figures 3-10(a & b) and 3-11 (a
& b) show these relationships.
28 Woodward
Utility
A B C EGCP-2
8406-121
Bus
480 VLL
480 V A 120 V
Mains Disconnect
A
B 40
Mains/Bus
Utility
Breaker PT Input
41
480 V A 120 V B
Local Bus Connect
Bus
B
42 A+
Generator 120 V
Breaker
43 A-
480 V A 120 V 44 B+ Gen PT
B 120 V
Inputs
C 45 B-
46 C+
Generator
Bus
A B C 120 V
47 C-
N VIS-147B
02-5-29
Voltage Input: Delta
PT Ratio : 4:1
Voltage Ref: 480 Vac, L-L
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.
Woodward 29
Utility
A B C EGCP-2
Bus 8406-120
480 VLL
480 V A 240 V
Mains Disconnect
A
B 40
Mains/Bus
Utility
Breaker PT Input
41
480 V A 240 V B
Local Bus Connect
Bus
B
42 A+
Generator 240 V
Breaker
43 A-
480 V A 240 V 44 B+ Gen PT
B 240 V
Inputs
C 45 B-
46 C+
Generator
Bus
A B C 240 V
47 C-
N VIS-147C
02-5-29
Voltage Input: Delta
PT Ratio : 2:1
Voltage Ref: 480 Vac, L-L
Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs
Please Note:
30 Woodward
Utility A B C EGCP-2
Bus 8406-121
A
Mains Disconnect
N 40 A
Mains/Bus
Utility PT input
Breaker
41 N
A
Local Bus Connect
Bus N
42 A+
69 V
Generator
Breaker
A 43 N
N
B 44 B+
69 V
Gen PT
N Inputs
C 45 N
N 46 C+
Generator 69 V
Bus
A B C 47 N
N
Voltage Input: Wye VIS-148B
02-5-29
PT Ratio : 4:1
Voltage Ref: 277 Vac, L-N
Figure 3-11a. PT Wiring Relationships for Generator, Bus, and Utility Inputs
Please Note:
Woodward 31
Utility A B C
EGCP-2
Bus
8406-120
Mains Disconnect
40 A
Mains/Bus
Utility PT input
Breaker
41 N
Local Bus Connect
Bus
42 A+
Generator 277 V
Breaker
43 N
44 B+
Gen PT
277 V
45 Inputs
N
46 C+
Generator
277 V
Bus
A B C 47 N
N
Voltage Input: Wye VIS-148C
PT Ratio : 1:1 02-5-29
Voltage Ref: 277 Vac, L-N

Figure 3-11b. PT Wiring Relationships for Generator, Bus, and Utility Inputs
Please Note:
32 Woodward
Current Transformer (CT) Inputs
Current Transformers (CTs) are utilized with the EGCP-2 control to allow high
level circuit currents to be stepped down to a safe level for the EGCP-2 input
circuitry. The EGCP-2 senses generator current via external current transformers.
Refer to Figure 3-12 for CT input wiring schematic.
Current Transformer Input Ratings

For optimum control, the Current Transformers (CTs) should be sized at 100 to
125% of the generators rated current.
Example 1:
Generator rated for 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
Example 2:
Generator rated for 150 amps per phase at 100% load, rated power factor.
CT Ratio
Current Transformer Input Ratings

Number of Inputs: 3 Generator CTs
Nominal Current Ratings: 0–5 A rms
Maximum Current Rating: 7 A rms for 1 minute
Input Burden: 1.25 VA
Input Frequency Range: 40–70 Hz
CAUTION
When conducting external Protective Relay testing, if the EGCP-2 CT
inputs could measure greater than 7 A rms, bypass the EGCP-2 CT
inputs.
90 (-)
0-5 A A PHASE CT
(.050 OHMS)
89 (+)
92 (-)
B PHASE CT
(.050 OHMS)
91 (+)
(-)
94
C PHASE CT
(.050 OHMS)
93 (+)
A B C
VIS-049b
00-06-19
FIELD WIRING EGCP-2
Figure 3-12. Current Transfer Wiring Diagram for EGCP-2
Woodward 33
MPU (Speed) Input
To sense engine speed, the control accepts signals from one passive magnetic
pickup unit (MPU) mounted off of a gear, which is connected or coupled to the
engine’s main shaft.
A passive MPU provides a frequency output signal corresponding to engine

speed by sensing the movement of a gear’s teeth past the MPU’s pole piece. The
closer the MPU’s pole piece is to a gear’s teeth and the faster the gear turns the
higher a passive MPU’s output amplitude will be. The EGCP-2 must sense an
MPU voltage of 2 to 25 Vrms for proper operation.
MPU Input Ratings

Low frequency range: 100–250 Hz @ 3.5 to 25 Vrms
Normal Frequency Range: 250–15 000 Hz @ 2.0 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 .010” to .040” from tooth face to pole piece. For information on selecting the
correct MPU or gear size please refer to Woodward manual 82510. See Figure
3-13 for wiring schematic.
(+) 4.99K
70
1000pF
MPU 4.99K
Magnetic Pickup Unit (-) 4.99K

200 - 3K ohms impedance 71
1000pF
VIS-051b
01-03-18
Figure 3-13. Wiring Diagram for MPU Input
34 Woodward
Process Import/Export Input
The EGCP-2 control can be configured to control any process which is
determined or affected by generator load. The Process Import/Export input is
used by the EGCP-2 control to sense the process level being controlled. This
input can be DIP switch, switch 4, configured to accept either a 4–20 mA or 1–5
dc signal. Refer to Figure 3-4 for DIP switch location.
Process Input Ratings

Loop Voltage Source: External (4–20 mA), External (1–5 Vdc)
Input Impedance: 249 Ω (4–20 mA), 30 000 Ω (1–5 Vdc)
(+) R
86
SW4-4
Process Import/Export Input
4-20 mA / 1-5 Vdc
250
(-)
R
87
Switch SW4-4: R
Open for 1-5 volt input @ 30K ohms
Close for 4_20 mA @ 250 ohms VIS-149
00-08-15
Figure 3-14a. 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 signal by
connecting a 250 Ω resistor across the output of the KW transducer. The Vdc
signal can then be paralleled to all EGCP-2 controls.
KW +
Transducer 250 ohm
-
87 86 87 86 87 86
VIS-153
01-05-21
EGCP-2 EGCP-2 EGCP-2
Figure 3-14b. Connecting a KW Transducer Signal to Multiple EGCP-2s

(switch 4-4 is in the OPEN position)
Woodward 35
Coolant Temperature and Oil Pressure Inputs
The EGCP-2 has one analog input dedicated to sense engine coolant temperature
and one analog input dedicated to sense engine oil pressure. These inputs can be
utilized for monitoring, alarm, and shutdown. Configurable alarm setpoints are
provided for both a high and low alarms. Either one or both of these inputs can
also be disabled if they are not to be used, by setting the related alarm setpoint to
“Disabled.”
The inputs are designed to accept one of three types of signals: 4-20 mA, 1-5 V,
or a passive resistive sensor. DIP switches on the control circuit board need to be
configured for the type of sensor being used (see Figures 3-15 and 3-16). 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. If a different range 4–20 mA, 1–5 V, or passive resistive
sensor is used, the Gain and Offset values will need to be adjusted.
+12 Vdc
537.5
SW1-1
R
+ 68
Oil Pressure SW 1-2 C R

SW1-3 SW1-4
Sensor
Input
- 69
249 100 100 R
VIS-050a
00-08-24
Input 4-20mA 1-5 Volt 200 Ohm

Sensor X - May be closed to insert shunt
SW1-1 Open Open Closed resistors required to make certain 0-200
SW1-2 Closed Open X ohm sensors more linear.
SW1-3 Open Open X
SW1-4 Open Open X
Figure 3-15. Wiring Diagram for Pressure Inputs
36 Woodward
+12 Vdc
537.5
SW2-1
R
+ 66
Coolant
Temperature SW 2-2 SW2-3 SW2-4 C R
Sensor
Input
- 67
249 100 100 R
VIS-050b
01-01-31
Input 4-20mA 1-5 Volt 200 Ohm

Sensor X - May be closed to insert shunt
SW2-1 Open Open Closed resistors required to make certain 0-200
SW2-2 Closed Open X ohm sensors more linear.
SW2-3 Open Open X
SW2-4 Open Open X
Figure 3-16. Wiring Diagram for Temperature Inputs
When selected for resistive sensor, three additional 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 Temperature.
You must verify how the sensor functions so you can calibrate correctly.
The Calibration menu explains adjusting the Gain and Offset for the
different sensors.
Suggested Supplier
Water Temperature Sensor VDO 323-xxx 0-250 deg. F.(Indirect)
Oil Pressure Sensor VDO 360-xxx 0-80 psi (Direct)
Woodward 37
Here is an example using a passive resistive type sensor.
What you need to know:

1. Direct or Indirect type
o Direct – Increase in resistance is an Increase in Pressure
o Indirect – Increase in resistance is a Decrease in Pressure
2. Resistance value at High and Low Pressure or Temperature settings
wanted
3. Example: VDO Temperature sender - # 323-477
a. 0—250 °F, ¼ - 18NPT
b. Indirect type
c. Resistance at 200 °F = 48 Ω
d. Resistance at 80 °F = 506 Ω
4. Other VDO # 323 –XXX will react the same as this sender
5. DIP Switch # 2
a. Close switch 1, because of resistive sender
b. Close switch 2, Shunt resistor due to resistance range going over
500 Ω
6. Connect 1 kΩ, 10 turn, 1 W potentiometer across terminals 66(+) and
67(–)
a. Set for 48 Ω
b. Calibration Menu
i. Adjust Water Temp Gain for 200 °F reading
c. Set potentiometer for 506 Ω
d. Calibration Menu
i. Adjust Water 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 the 1 wire to terminal 66(+)
ii. Terminal 67(-) must be connected to the case ground of
the sender. This is commonly Battery Negative.
8. You need a temperature gauge on the engine to do the final calibration.
9. Start the engine and let stabilize at operating temperature.
10. Compare the Water Temperature reading on the EGCP-2 to the
Temperature gauge on the engine.
11. If they do not read within ±2 degrees, In the Calibration menu adjust the
Water Temperature Gain until the readings agree. Always press the
ENTER key to save the new value.
Temperature and Pressure Input Ratings

Number of Channels: 2
Loop Voltage Source: Internal
Input Impedance: Switch Dependant
Configuration menu (Items Affected)

1. None
38 Woodward
Calibration menu
1. Oil Pressure Gain
2. Oil Pressure Offset
3. Water Temp Gain
4. Water Temp Offset
Speed Bias and Voltage Bias Outputs

The EGCP-2’s Speed Bias output is a dedicated analog output, which is used to
bias the prime mover’s speed control for unit synchronization and load control.
The Speed Bias output is software configurable for outputs of ±3 Vdc, 0.5–4.5
Vdc, or 500 Hz PWM.
±3 Vdc—Compatible with Woodward analog and digital speed Controls via the
Aux Inputs or the load sharing lines on the 2301/2301A LSSC.
0.5–4.5 Vdc—Compatible with the Detroit Diesel Corp. DDEC-III and IV
Control and Caterpillar’s Gas Engine Control Module (GECM).
500 Hz PWM—Compatible with Caterpillar’s ADEM control (diesel engine).
Refer to Appendix B of this manual for control specific speed bias connections.
The EGCP-2’s Voltage Bias output is a dedicated analog output, which is used to
bias the generator’s automatic voltage regulator for unit synchronization and
reactive load control. The Voltage Bias output is software 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 DVR2000E
SR8A Digital VR 760 MX341
SSE K65-12B MA325
SSR K-125-10B
DECS
Appendix C shows connections and adjustment procedures for some of these

regulators. The regulators listed are examples of some of the more common
regulators. There are always new regulators being introduced in the market and
you should use these drawings as examples of possible connection scenarios.
A common connection is an Accessory or Auxiliary input. This input takes a dc

voltage, ±1 Vdc is common, to change the rated voltage of the generator by
±10%. So with any new regulator, check the specifications if this type input is
available. An example is the Basler SSR regulator, see connection diagram in
Appendix C.
The EGCP-2 only provides an analog, ± Vdc output and will not function with
any regulator that accepts discrete inputs only. An example of this is the
Marathon 2000 DVR.
The Speed and Voltage Bias Outputs will only drive into high impedance type
inputs, and are limited to inputs, which have an input impedance of 1000 Ω or
more.
Woodward 39
Speed and Voltage Bias Output Ratings
Min Drive Impedance: 1000 Ω
Configuration menu (Items Affected)

1. Speed Bias Type
2. Voltage Bias Type
Calibration menu
1. Speed Bias Offset
2. Volts Bias Offset
(+)
500 Hz PWM
73
.5 to 4.5 VDC
+/- 3VDC Speed Bias Output
Software Switch Software Configurable for :
(-) +/- 3VDC
500 Hz PWM
74 .5 to 4.5 VDC
75
(+)
+/-9VDC
37 Voltage Bias Output
+/- 3VDC
Software Configurable for:
+/- 1VDC +/- 1 Vdc
Software Switch +/- 3 Vdc
(-) +/- 9 Vdc
38
VIS-052a
00-04-19
39
Figure 3-17. Wiring Diagram for Speed Bias and Voltage Bias Outputs
40 Woodward
Discrete Inputs
Discrete inputs are used by the EGCP-2 control to determine breaker positions
and accept external control commands. Contacts must change state for a
minimum of 40 milliseconds for the control to sense and register a change in
state. All discrete inputs accept dry contacts only, with contact wetting voltage
provided by the EGCP-2 control. The following is a list of the available EGCP-2
Discrete Inputs:
ID # Description
1. Automatic Mode Select
2. Test Engine Mode Select
3. Run with Load Mode Select
4. Voltage Raise
5. Voltage Lower
6. Speed/Load Raise
7. Speed/Load Lower
8. Generator Breaker Aux Contact
9. Utility (Mains) Breaker Aux Contact
10. Process I/E Mode Select
11–16. Configurable Alarm or Shutdown Inputs
Discrete Input Ratings

Input Type: Optically isolated
Min Closed Sense Time: 40 ms
Speed/Load Raise and Lower Inputs

The Speed/Load Raise and Lower inputs change based on the control mode of
the EGCP-2. If the EGCP-2 control is in the Speed control mode (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 setpoint.
If the EGCP-2 control is in the isochronous load sharing mode, the Speed Raise
and Lower inputs are disabled.
Voltage Raise and Lower Inputs

The Voltage Raise and Lower inputs change based on the control mode of the
EGCP-2. If the EGCP-2 control is in the Speed control mode (generator breaker
open), these contact inputs can be used to raise and lower unit voltage. If the
EGCP-2 control is in the VAR control mode (VAR control programmed,
generator breaker closed, utility tie breaker closed), these contact inputs can be
used to raise and lower unit VARs. If the EGCP-2 control is in the Power Factor
control mode (Power Factor control programmed, generator breaker closed,
utility tie breaker closed), these contact inputs can be used to raise and lower unit
Power Factor. If the EGCP-2 control is in the isochronous load sharing mode, the
Voltage Raise and Lower inputs are disabled.
Gen, Tie, Alarm, and Shutdown Inputs

The Generator Breaker contact input must be wired so it is closed when the
generator breaker is closed.
The Utility Tie Breaker contact input must be wired so it is closed when the
utility tie breaker is closed.
Woodward 41
The Configurable Alarm or Shutdown Inputs must be wired so they are closed
when the alarm or shutdown condition is true.
+5 Vdc
Typical Example of Discrete Input

(Auto/Manual Contact (DI#1) Input Shown) R
+V
Note:
TB6-65 is the discrete input common for
all contact inputs
Auto/Manual
R
49
User Supplied Contact
VIS-053a
65 00--06-19
Discrete Input Common
Figure 3-18. 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 where the interfaced circuit
demands relay contacts with a higher power rating. If interposing relays are
required, it is recommended that interposing relays with surge (inductive kick-
back) protection be used. The following is a list of the available EGCP-2 Relay
Outputs:
ID# Description
1. Mains (Utility) 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. Utility (Mains) PT Disconnect
9. Utility (Mains) Breaker Trip (open)
10. Gen Breaker Trip (open)
11. Audible Alarm
12. Idle/Rated or KVA Load Switch
42 Woodward
Relay Output Ratings
Relay Type: Sealed
Relay Response Time: 15 ms (operate and release)
Relay Life Expectancy: ≥50 000 operations @ rated load (8 A @ 250 Vac
COS ≥0.7) (8 A @ 24 Vdc τ ≥0.7 ms)
Replaceability: Relays are soldered to main board and are not field
replaceable
Max. Contact Ratings:
AC: 10 A, 250 Vac Resistive
249 W (1/3 hp), 125 Vac (7.2 A, 0.4–0.5 PF)
DC: 10 A, 30 Vdc Resistive
Relay Output Functions

Discrete Output #1—Mains Utility Breaker Close
With the relay de-energized, this output has Normally Open (NO), terminals 5
and 6, and Normally Closed (NC), terminals 6 and 7, contacts 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 in the Breaker configuration, the EGCP-2 will ENERGIZE (momentary)
to close the Mains (utility) Breaker. The ENERGIZE time is determined by the
“CB Hold Time” in the Synchronizer menu. Discrete Output #9 is used to open
the mains breaker.
EGCP-2 Mains
Breaker
Close
7
+V
Discrete 6
Output #1
5 Mains (utility)
Breaker
VIS-154 Close Coil
01-06-01
Figure 3-19. Example of the Mains Breaker NO Output Connected to Close the
Mains (Utility) Breaker (ENERGIZE TO CLOSE)
Contactor
The “Mains Breaker Close” output is used to close and open the Mains
Contactor. The “Mains Breaker Trip”, discrete output #10 is NOT used in the
Contactor mode.
Woodward 43
The EGCP-2 will DE-ENERGIZE (continuously) to close the Mains Contactor
and ENERGIZE (continuously) to open the Mains Contactor. This is reverse
logic from the Generator Contactor Close, discrete output # 2. External logic will
be needed to verify the contactors state when installing or replacing EGCP-2
controls and for multiple control systems.
CAUTION
When power is removed from the EGCP-2, the “Mains Breaker Close”
output will be in the De-energized state and attempt to close the
Mains contactor.
Mains
EGCP-2 Contactor
Close
7 Mains (utility)
Contactor
+V Open/Close Coil
Discrete 6
Output #1
VIS-154a
01-06-01
Figure 3-20. Example Using the NC Output to Control the Mains (Utility)
Contactor (ENERGIZE TO OPEN)
Discrete Output #2—Generator Breaker Close

The “Generator Breaker Close” relay output is utilized by the EGCP-2 to

command the Generator Circuit breaker to close. This output is configured for
use with a BREAKER or a CONTACTOR in the Configuration menu under
“CKT Breaker Control”.
Breaker
to close the Generators Breaker. The ENERGIZE time is determined by the “CB
Hold Time” in the Synchronizer menu. Discrete Output #10 is used to open the
generators breaker.
44 Woodward
EGCP-2 Generator
Breaker
Close
10
+V
Discrete 9
Output #2
8 Generator
Breaker
VIS-154b Close Coil
01-06-01
Figure 3-21. Example of the Generator Breaker Close NO Output Connected to

Close the Generator Breaker (ENERGIZE TO CLOSE)
Contactor
The “Generator Breaker Close” output is used 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.
EGCP-2 Generator
Contactor
Close
10
+V
Discrete 9
Output #2
8 Generator
Contactor
VIS-154c Open/Close Coil
01-06-01
Figure 3-22. Example Using the NO Contacts to Control the Generator’s

Contactor (ENERGIZE TO CLOSE)
Woodward 45
Discrete Output #3—Engine Preglow
The “Engine Preglow” relay output utilizes a set of normally open (NO) contacts
on terminals 11 and 12.
The “Engine Preglow” relay output is utilized by the EGCP-2 to turn on a diesel
engine’s glow plugs, if so equipped. This relay will energize for a programmed
length of time, based on the “Preglow Time” setting, before an engine crank
command is given.
Discrete Output #4—Fuel Solenoid

The “Fuel Solenoid” relay output utilizes a set of Normally Open (NO) contacts
on terminals 13 and 14 to energize the engine’s fuel solenoid.
The Configurations menu, “Start Sequencing” setting of Enabled or Disabled,

determines the EGCP-2’s start process.
Start Sequencing—Enabled
This relay ENERGIZES at the same time an Engine Crank command is initiated,
and stays on until a shutdown command is received. The EGCP-2 must have a
Magnetic Pickup (MPU) signal to operate in this condition.
Start Sequencing—Disabled
The EGCP-2 will ENERGIZE (continuously) the Fuel Solenoid relay when 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
The “Engine Crank” relay output is utilized by the EGCP-2 to command the
engine to crank or start. This relay will energize for a programmed length of
time, based on the “Crank Time” setting, or until engine speed is sensed to be
above the “Crank Cutout” speed setting.
Discrete Output #6—Visual Alarm

With the relay de-energized, this output has Normally Open (NO) terminals 18
and 19 and Normally Closed (NC) terminals 19 and 20 contacts to select from.
The “Visual Alarm” relay output can be utilized as an option to remotely indicate
when an alarm condition has been sensed by the EGCP-2 control. This relay
energizes upon any sensed alarm condition and will remain energized until all
alarm conditions have been acknowledged or committed via the unit’s Alarm
Screen. Refer to chapter 2 for information on acknowledging and committing
alarms.
46 Woodward
Discrete Output #7—Local Bus PT Connect
The “Local Bus PT Connect” relay utilizes a set of Normally Open (NO) contacts
The “Local Bus PT connect” relay output is utilized by the EGCP-2 to connect
the Local Bus PT to 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 Local Bus PT
connection. Refer to Figures 3-7, 3-8, and 3-9 of this chapter for detailed wiring
information. This type of relay configuration allows a break-before-make action,
insuring that the Utility Tie PT and the Local Bus PT are never connected.
Discrete Output #8—Utility Tie (Mains) PT Disconnect

The “Utility Tie (Mains) PT Disconnect” relay utilizes a set of Normally Open
(NO) contacts on terminals 23 and 24.
The “Utility Tie (Mains) PT disconnect” relay output is utilized by the EGCP-2
to disconnect the Utility PT 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, 3-8, and 3-9 of this chapter for
detailed wiring information. This type of relay configuration allows a break-
before-make action, insuring that the Utility Tie PT and the Local Bus PT are
never connected.
Discrete Output #9—Mains Breaker Trip (Open)

The “Mains Breaker Trip (open)” relay output is utilized by the EGCP-2 to
command the Mains (utility) Breaker to open. This output is operational when
configured for use with a BREAKER, in the Configuration menu under “CKT
Breaker Control”. If configured for Contactor, see Discrete Output #1 for Mains
Contactor open/close operation.
Every EGCP-2 that has the capability of being a MASTER unit must have this
relay wired into the Mains (utility) Breaker open circuitry.
Breaker
to open the Mains (utility) Breaker.
Woodward 47
EGCP-2 Mains
Breaker
Trip
27
+V
Discrete 26
Output #9
25 Mains
Breaker
VIS-154d Trip (Open) Coil
01-06-01
Figure 3-23. Example Using the NO Contacts to Control the Mains Breaker Trip
(Open) Coil (ENERGIZE TO OPEN)
Discrete Output #10—Generator Breaker Trip (Open)

The “Generator Breaker Trip (open)” relay output is utilized by the EGCP-2 to
command the Generator Breaker to open. The relay output will DE-ENERGIZE
to open the Generator Breaker. This output is operational when configured for
use with a BREAKER, in the Configuration 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. And the Generator is stable (Generator Stable Delay time has been
achieved)
Manual Mode
1. “Run w/Load” mode (Discrete Input #3)
2. And the Generator is stable (Generator Stable Delay time has been
achieved)
The EGCP-2 will DE-ENERGIZE to open the Generators Breaker. The output
will stay de-energized until one of the two conditions is met.
48 Woodward
Generator
EGCP-2 Breaker
Trip
30
Generator
Breaker
+V Trip (Open) Coil
Discrete 29
Output #10
28
VIS-154e
01-06-01
Figure 3-24. Example Using the NC Contacts to Control the Generator Breakers
Open Coil (DE-ENERGIZE TO OPEN)
EGCP-2 +V External Wiring

9
Connections
Gen Breaker Close
8
Generator Breaker
+V
Close Coil
29
Gen Breaker
Trip 30
Gen Breaker Trip will energize Generator Breaker
when in "Auto" and "Gen Trip Coil
Stable Delay" is met.
Generator Breaker Configuration Based Logic.

Connection
9
Gen Breaker Close
8
Generator Contactor
Close/Open Coil
29
Gen Breaker
Trip No Connection.
30
VIS-142a
01-07-11
Generator Contactor Configuration Based Logic.
Figure 3-25. Generator Breaker and Contactor Close and Open Logic
Woodward 49
Discrete Output #11—Audible Alarm
With the relay de-energized, this output has Normally Open (NO) terminals 31
and 32 and Normally Closed (NC) terminals 32 and 33 contacts to select from.
The “Audible Alarm” relay output can be utilized as an option to control a plant
Alarm Horn to indicate when an alarm condition has been sensed by the EGCP-2
control. This relay energizes upon any sensed alarm condition and will remain
energized until an acknowledged command is given. Refer to chapter 2 for
information on acknowledging and committing alarms.
When an alarm setpoint is configured for Audible Alarm, the alarm condition
will cause the audible and visual alarm output relays to energize and the red LED
on the face of the EGCP-2 to flash. All alarm indicators will remain active until
the alarm condition is acknowledged. No control actions occur as a result of an
audible alarm condition.
Discrete Output #12—KVA Load or Idle/Rated Switch

This relay uses Normally Open (NO) contacts at terminal 34 and 35.
Discrete Output #12 can be configured for a “KVA Load” or an “Idle/Rated”

switch. This selection is done in the Configuration 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 setpoints are
configured in the Real Load Control menu, under items “KVA Switch Low” and
“KVA Switch High”.
Idle/Rated Switch
When selected as an Idle/Rated switch, the output must be connected to the
engines speed control. This relay is de-energized to select an idle speed settings,
and after reaching the set idle speed value and holding at that point for the set
amount of time, the relay energizes to select the speed controls rated speed
setting. The speed value and time are configured in the Engine Control menu
under items “Idle Speed” and “Idle Time”.
The engines idle speed must be equal to or greater than the configured “Idle
Speed” value to start the “Idle Time”. The EGCP-2 uses the magnetic pickup
(MPU) signal to calculate the idle speed. If no MPU is connected, the idle speed
is calculated from the Generators frequency. Remember, if the generator is NOT
excited at idle speed and there is no MPU signal, the Idle/Rated switch will not
energize.
When a Loss of Mains (LOM) or an overloaded system condition exists, the

idle/rated function is bypassed, and rated speed is selected during the start
sequencing routine.
50 Woodward
AC Inputs
The EGCP-2 receives ac inputs from the generator, bus, mains and engine. They
are as follows:
Location Description Signal Burden

42 Generator PT phase A + AC Voltage 200 kΩ
43 Generator PT phase A – AC Voltage A+ to A–
44 Generator PT phase B + AC Voltage 200 kΩ

45 Generator PT phase B – AC Voltage B+ to B–
46 Generator PT phase C + AC Voltage 200 kΩ

47 Generator PT phase C – AC Voltage C+ to C–
89 Generator CT phase A+ Current AC Current 0.050 Ω

90 Generator CT phase A– Current AC Current + to –
91 Generator CT phase B+ Current AC Current 0.050 Ω

92 Generator CT phase B– Current AC Current + to –
93 Generator CT Phase C+ Current AC Current 0.050 Ω

94 Generator CT Phase C– Current AC Current + to -
40 Mains/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 Process Signal Shield 30 k Ω (1–5 Vdc)
73 + Speed Bias ±3 Vdc, Software Configured

74 – Speed Bias 0.5 to 4.5 Vdc, 10 mA Maximum
75 Speed Bias Shield 500 Hz PWM Isolated Output
37 + Voltage Bias ±1, 3, or 9 Vdc Software Configured

38 – Voltage Bias 10mA Maximum
39 Voltage Bias Shield Isolated Output
68 Pressure Sensor + 0–200 Ω sensor, Internal Voltage Source

69 Pressure Sensor – 4-20 mA, or 1-5 Vdc Internal Source Common
Dip Switch Selected
66 Temp Sensor + 0–200 Ω sensor Internal Voltage Source

67 Temp Sensor – 4–20 mA, or 1–5 Vdc Internal Source Common
Dip Switch Selected
Woodward 51
Discrete Inputs
Loc. Description Signal Input
49 Auto Discrete Input (DI-1) – power supply (internal connection)
50 Test Discrete Input (DI-2) – power supply (internal connection)
51 Run/Ld Discrete Input (DI-3) – power supply (internal connection)
52 Volt Raise Discrete Input (DI-4) – power supply (internal connection)
53 Volt Lower Discrete Input (DI-5) – power supply (internal connection)
54 Speed Raise Discrete Input (DI-6) – power supply (internal connection)
55 Speed Lower Discrete Input (DI-7) – power supply (internal connection)
56 Gen CB Aux Discrete Input (DI-8) – power supply (internal connection)
57 Mains CB Aux Discrete Input (DI-9) – power supply (internal connection)
58 Process Discrete Input (DI-10) – power supply (internal connection)
59 Fault 1 Discrete Input (DI-11) – 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 Discrete Output (D02) “

9 Gen Brkr Close C (D02) “
8 Gen Brkr Close NO Discrete Output (D02)
12 Engine Preglow C (DO3) “

11 Engine Preglow NO Discrete Output (DO3) “
14 Fuel Solenoid C (DO4) “

13 Fuel Solenoid NO Discrete Output (DO4) “
16 Crank Engine C Discrete Output (DO5) “
15 Crank Engine NO Discrete Output (DO5) “
17 No Connection Isolation Boundary
20 Visual Alarm NC Discrete Output (DO6) “

19 Visual Alarm C (DO6) “
18 Visual Alarm NO Discrete Output (DO6)
22 Bus PT Connect C (DO7) “

21 Bus PT Connect NO Discrete Output (DO7) “
24 Mains PT Disconnect NC Discrete Output (DO8) “

23 Mains PT Disconnect C (DO8) “
27 Mains Brkr Trip NC Discrete Output (DO9) “
26 Mains Brkr Trip C (DO9) “
25 Mains Brkr Trip NO Discrete Output (DO9)
30 Gen Brkr Trip NC Discrete Output (DO10) “

29 Gen Brkr Trip C (DO10) “
28 Gen Brkr Trip NO Discrete Output (DO10)
33 Audible Alarm NC Discrete Output (DO11) “
32 Audible Alarm C Discrete Output (DO11) “
31 Audible Alarm NO Discrete Output (DO11)
52 Woodward
Location Description Signal Output Rating
35 Idle Rated/Load SW C (DO12) “
34 Idle Rated/Load SW NO Discrete Output (DO12) “
36 No Connection Isolation Boundary
Communication Ports: RS-485 & RS-422 (1 each)

Location Description Signal
77 – 485 Communication Inter-control Communications
76 + 485 Communication Inter-control Communications
78 485 Shield
80 Communication Reference
79 NC No Connection
81 422 Communication RX+ PC interface
82 422 Communication RX– PC interface
83 422 Shield
84 422 Communication TX+ PC interface
85 422 Communication TX– PC interface
Specifications
Communications:
RS-422 protocol
9600 Baud (fixed maximum)
No Parity
1 Stop Bit
Minimum Computer Requirements:

Windows 95
Hardware Connections
Once the software is installed on the computer hard drive, the hardware
connection between the computer and the EGCP-2 control must be made for
correct communication between the two devices. This hardware connection is
completed 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 computer
hardware to use a serial communications protocol called RS-232. The details of
this protocol are not important to know for hardware connection to the EGCP-2
control(s), other than there is a need to convert the RS-232 protocol of the
computer port to RS-422 protocol used by the EGCP-2 control network. This
conversion is accomplished via an external conversion module, which takes the
9-pin RS-232 serial port input from the computer, and changes it to a RS-422
protocol for the EGCP-2. These converters can be found in most computer or
electronics stores, and are called RS-232 to RS-422 Converters. Woodward
offers a cable, 5417-551, which includes this converter. This cable is designed
for point-to-point communications.
Woodward 53
In a system with multiple (8 maximum) EGCP-2 controls, each control is
interconnected to the others on the 422 network in a multi-drop fashion. The
computer is linked to the network at any control as if it were the next control on
the network, as shown below.
Unit #1 Unit #2 Unit #8

83 83 83
422Rx 422Rx 422Tx 422Tx 422Rx 422Rx 422Tx 422Tx 422Rx 422Rx 422Tx 422Tx
(+) (-) (+) (-) (+) (-) (+) (-) (+) (-) (+) (-)
81 82 84 85 81 82 84 85 81 82 84 85
Twisted shielded pair. Belden 3074F or equivalent
422Rx(-)
422Rx(+)
422Tx(-)
422Tx(+)
VIS-107a
00-10-20
IBM compatible computer

Pentium based w / Windows '9X or NT 4.0
Figure 3-26. RS-422 Communications
Switch configuration for multiple units utilizing RS-422 communication.

SW3-1 Closed SW3-1Open SW3-1 Closed
SW3-2 Closed SW3-2 Open SW3-2 Closed
NOTES
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 chassis must be Isolated from earth and may be AC
coupled to earth.
When unit 2 and/or unit 3 are more than 30 meters from unit 1, the
cable shield must be ac coupled to terminal 83. The capacitor must
be 0.01 µF with a working voltage of 1000 Vdc or greater.
The RS-422 Termination switches, switch 3, must be closed on the
end units on the network for proper communications. See Figure 3-4
for switch locations. Failure to terminate the network properly will
cause communication drop out errors.
54 Woodward
+5 +5
Vdc Vdc
24 121. 24 24 121. 24
3 5 3 3 5 3
SW4-1 SW3-1
SW3- SW3-
SW4-2 SW4-3
2 3
422 RxD
485 (+)
(+) 81
76
422 RxD (-
)
82
485 (-
) Shiel
77 d
83
Shiel
d
422 TxD
RS 422/485 78
(+)
Transceiver 84
422 TxD (-
RS 422/485 )
Transceiver 85
80
VIS-108a
RS-485 Termination 00-06-20 RS-422 Termination
Figure 3-27. RS-485 and RS-422 Termination Diagrams
Inter-control Communications (RS-485 Network)

The EGCP-2 uses a proprietary communication structure to share information
between multiple EGCP-2 controls. This structure allows accurate load sharing,
status, and command messages to be exchanged between up to 8 controls. The
network uses RS-485 protocol over a standard twisted shielded pair to link the
EGCP-2 controls at terminals 76(+) and 77(–) with 78 the shield.
NOTE
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 mm² (18–20 AWG) where larger sizes
are used for longer distances. The larger size wire will exhibit smaller
voltage drop. If communications errors are observed, terminal 80 can
be connected from control to control using 1.0 mm² (16 AWG) wiring.
Making this connection will force all communications transceivers to
the same reference.
As shown in Figure 3-27, the EGCP-2 uses Switch 4 (4-1, 4-2, and 4-3) to
terminate the 485 network. Switches 4-1, 4-2, and 4-3 will be closed (pushed
down toward the PC board, see Figure 3-4) for proper 485 network terminations.
Proper network termination will ensure robust inter-control communications.
Woodward 55
The information on the RS-485 network is for communications between controls
only and must not be interfaced in any way with external devices. There is an
RS-422 port on the EGCP-2, which is used to monitor and control the units
remotely.
Example:
2 EGCP-2s—Both EGCP-2s must have the 485 network terminated.
3 or more EGCP-2s—The end controls must have the 485 network terminated
(see Figure 3-26).

78 78 78
485 485 485 485 485 485

(+) (-) (+) (-) (+) (-)
76 77 76 77 76 77
VIS-109a
00-06-20
Twisted shielded pair. Belden 3074F or equivalent
Figure 3-28. RS-485 Inter-Control Communications

Unit #1 Unit #2
SW4-1 Closed SW4-1Closed
SW4-2 Closed SW4-2 Closed
SW4-3 Closed SW4-3 Closed

SW4-1 Closed SW4-1Open SW4-1 Closed
NOTE
When unit 2 and/or unit 3 are more than 30 m from unit 1, the cable
shield must be ac coupled to terminal 78. The capacitor must be 0.01
µF with a working voltage of 1000 Vdc or greater.
Alarms and Shutdowns

The EGCP-2 has many alarm/shutdown setpoints, which can be configured for
five different alarm/shutdown conditions. The five conditions are as follows:
Disabled
When an alarm setpoint is set for Disabled, the alarm condition will have no
external indicators to signal the event has occurred. No control actions occur as a
result of a disabled condition.
56 Woodward
Warning
When an alarm setpoint is set for Warning, the alarm condition will cause the red
LED on the face of the EGCP-2 to flash continuously until the alarm condition is
acknowledged. No control actions occur as a result of a warning condition.
Visual Alarm
When an alarm setpoint is set for Visual Alarm, the alarm condition will cause
the visual alarm output relay to energize, and the red LED on the face of the
EGCP-2 to Flash. Both indicators will remain active until the alarm condition is
acknowledged. No control actions occur as a result of a visual alarm condition.
Audible Alarm
When an alarm setpoint is set for Audible Alarm, the alarm condition will cause
the audible and visual alarm output relays to energize and the red LED on the
face of the EGCP-2 to flash. All alarm indicators will remain active until the
alarm condition is acknowledged. No control actions occur as a result of an
audible alarm condition.
Soft Shutdown
When an alarm setpoint is set for Soft Shutdown, the alarm condition will cause
the generator to ramp off load, unless it is the only unit carrying the load in
which case it will immediately open its gen breaker. If the unit has carried load
above its cooldown limit, the unit will also cool down and then shut 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 setpoint is set for Hard Shutdown, the alarm condition will cause
the generator to immediately open its breaker, and immediately shut 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. A unit,
which has experienced a hard shutdown condition, will remove itself from any
automatic sequencing displays. Acknowledging the alarm condition will cause
the alarms to reset, and make the unit operational once again.
In addition to these standard shutdowns and alarms, there are five additional
mains sensing parameters that can be programmed for Disabled, Warning, Loss
of Mains, or Loss of Mains with Alarms. Disabled and Warning setpoints actions
are identical to those described for other alarms.
Loss of Mains action will:

• Indicate a failed mains on the LCD Display (all modes)
• Issue a command to open the mains breaker or contactor (Auto mode only)
• Issue a command to start the engine(s) and put the generator(s) on load
(Auto mode only)
Loss of Mains with Alarms action will do all of the actions assigned to the Loss
of Mains condition, as well as activate the audible alarm function (audible and
visual alarm outputs energize).
Woodward 57
These 5 items, located in the Transfer Switch menu, can be configured for a Loss
of Mains condition:
Load Surge
Senses a step KW load change (% of Rated Load Setpoint per Second) on
generator. LOM indication is immediate (no delay) for this condition.
Mains Frequency Low

Detects Mains Under-frequency condition for at least as long as the LOM Action
Delay setpoint (seconds).
Mains Frequency High

Detects Mains Over-frequency condition for at least as long as the LOM Action
Delay setpoint (seconds).
Mains Voltage Low

Detects under-voltage on the mains for at least as long as the LOM Action Delay
setpoint (seconds).
Mains Voltage High

Detects over-voltage on the mains for at least as long as the LOM Action Delay
setpoint (seconds).
58 Woodward
Chapter 4.
Software Overview
Introduction
The Software Overview explains what information the EGCP-2 will display, and
describes the configuration items in each menu. Application Manual 26175
shows the different combinations of discrete inputs and configuration settings for
the various operating modes.
The software used in the EGCP-2 uses state machine logic to operate 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 default to the System Status
Screen. Below is an example of what the Screen may look like. The System
Status Screen can be accessed while in any other status screen by pressing the
SYSTEM key.
.
Figure 4-1. System Overview Engine Off Line
Woodward 59
The screen displays the following information:
Alarms: Number of active alarms on the unit.
Unit #: The network address of the unit.
Mains: A graphic display of the mains condition. Two minus symbols (--)
indicates the mains are out of spec, one plus symbol indicates the mains are in
spec, but not declared stable (+-), two plus symbols (++) indicates the mains are
in spec and stable.
Gen: A graphic display of the status of the generator. Two minus symbols (--)
indicates the generator is out of spec, one plus symbol indicates the gen is in
spec, but not declared stable (+-) two plus symbols (++) indicates the generator is
in spec and stable.
Engine: The operating state of the engine.
Engine Control States:
• OFF
• PREGLOW
• CRANK
• RUN
• COOLDOWN
• SPINDOWN
• RETRY
Operating State: Shows if the EGCP-2 is in AUTO or MAN (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 the generator set.
PF: The average three phase power factor of the generator set.
KW-Hrs: The total accumulated KW hours produced by the generator set. This
display automatically switches to MW-Hrs when the KW-Hour value exceeds 10
000. Display is updated every .1 MW-Hrs.
Run-Time: The total accumulated run time of the generator set. Display is
updated every run hour.
All the display information will update automatically as operating modes and
conditions to the EGCP-2 change.
60 Woodward
This is what the System Status screen would look like with the mains out of spec,
the engine running, carrying 100 KW load isochronously, and the 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, .80 lagging PF, with one unacknowledged alarm.
Figure 4-3. System Status Screen—Baseload

Woodward 61
The following is an overview of each of the status menu screens, starting with
Engine status:
Figure 4-4. Engine Status
HH:MM: 24 hour clock readout.

MM-DD: Date (MM-DD).
Engine: The state of the engine control function.
RPM: Engine rpm.
Battery Volts: Battery Voltage in 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 symbol indicates the gen is in spec, but not declared
stable (+-) two plus symbols (++) indicate the generator is in spec and stable.
62 Woodward
Figure 4-5. Generator Status (Voltage Line to Neutral)
A B C: Three phase readings for the generator.

KVA: Three phase KVA readings.
KW: Three phase KW readings.
KVR: Three phase KVAR readings.
V: Volts for each phase of the generator.
A: Amps per phase for the generator.
PF: Power Factor for each generator phase.
NOTE
Generator voltage label, VLL—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 the voltage exceeds 9999 V for
that input.
Woodward 63
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 Discrete Outputs

1. Automatic Switch 1. Mains Breaker Close/Contactor
2. Test Switch Close
3. Run with Load Switch 2. Gen Breaker/Contactor Close
4. Volts Raise 3. Engine Preglow
5. Volts Lower 4. Fuel Solenoid
6. Speed Raise 5. Engine Crank
7. Speed Lower 6. Visual Alarm Relay
8. Gen Circuit Breaker Aux Contact 7. Local Bus PT Connect
9. Mains Circuit Breaker Aux Contact 8. Mains PT Disconnect
10. Process Switch 9. Mains Breaker Trip
11–16. Remote Alarm/Shutdown 10. Gen Breaker Trip
Inputs 11. Audible Alarm
12. KVA load switch, or Idle/Rated
Switch, depending on configuration
64 Woodward
Figure 4-7. Synchronizer Status
Slip: The slip frequency in Hz. of the generator in relation to the bus or mains it
is paralleling to.
Phase: The phase angle difference in degrees between the generator and the bus
or mains it is paralleling to.
Volts: The voltage differential in percent between the generator and the bus or
mains it is paralleling to.
Mains/Bus: The active PT input being monitored by the EGCP-2.
Dead Bus: Indicates if the PT input (mains or bus) being measured is dead.
Synchronizer Status: Displays the 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.
NOTE
Generator and Mains voltage label, VLL—Voltage Line-to-Line or
VLN—Voltage Line-to-Neutral will be determined from the Voltage
Input configuration setting.
Generator and Mains voltage readings and labels will automatically
switch from “V” (volts) to “KV” (kilovolts), when the voltage exceeds
9999V for that input.
The synchronizer displays **** in the place of Slip, Phase, and Volts
when the synchronizer is inactive, or off.
Woodward 65
Figure 4-8. KW Load Status
Generator KW: The total, three phase KW the generator is producing.

Load Reference: The load reference, in KW for the generator.
System Load: The calculated system load for all units operating in isochronous
load sharing mode. This reading is NOT active in the Baseload mode.
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 control bias command
(%).
Master Volt Cmd: The master voltage bias command (%).
NOTE
The master sync and master volt commands are only active in Slave
units that are in AUTO.
66 Woodward
Figure 4-9. PF /KVAR Status
VAR/PF MODE: The configured VAR/PF control mode.

PF REFERENCE: The PF control reference value for the control.
NOTE
Power Factor (PF) reference changes to KVAR REF when in VAR
control.
PF: The average three phase PF of the generator.

A B C: A, B, C phase generator reading indication.
V: Three phase voltage readings for the generator.
A: Three phase current readings for the generator.
KVAR: Total KVAR reading for the generator.
Woodward 67
Figure 4-10. Sequencing Menu
Unit: Network Address of all units in Auto on the network.

Oper: Units in auto, and on the network with their breakers closed will have an
X under their Address.
Prty: Network Priorities 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 the generator breaker as determined by the gen CB
aux discrete input.
68 Woodward
The example below is a typical sequencing screen for a 5-unit system.
Figure 4-11. Sequencing Menu (Multi-Unit)
As displayed on the sequencing screen:

Units 1 3, and 5 are on load with their generator breakers closed.
Next On is unit number 2, which has a network priority of 4.
Next Off is unit number 5, which has a network priority of 3.
Master Unit in this system is the unit with the highest priority, which is unit
number one.
NOTE
Units that have active shutdowns will remove themselves from the
sequencing menu until the shutdown condition(s) are cleared.
Woodward 69
Figure 4-12. ATS (Automatic Transfer Switch) Status.
Mains: A graphic display of the mains condition. Two minus symbols (--)
indicates the mains are out of spec, one plus symbol indicates the mains are in
spec, but not declared stable (+-) two plus symbols (++) indicate mains are in
spec and stable.
Gen: A graphic display of the gen condition. Two minus symbols (--) indicates
the generator is out of spec, one plus symbol indicates the generator is in spec,
but not declared stable (+-) two plus symbols (++) indicate 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 indication of a live or dead local bus as determined by the voltage
on the bus, and state of the generator and mains breaker inputs.
Master Sync Cmd: The master synchronizing and load control bias command
(%).
Master Volt Cmd: The master voltage bias command (%).
NOTE
The master sync and master volt commands are only active in Slave
units that are in AUTO.
70 Woodward
Security Access
Security Code Required For Access
The EGCP-2 has built-in security to protect against configuration changes and
alarm purges by unauthorized personnel. There are five levels of access to the
configuration menus. They are listed below. Each successive level has access to
all of the levels above. A four-digit security code is required for access to the
configuration menus. If an incorrect code is entered, or a proper code is not
entered within 300 seconds, the displays will default to the last Status screen
selected.
Levels Of Access
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 setpoints except Engine Run Time and the Calibration
menu.
Factory
Full access, includes the Engine Run Time and the Calibration menu.
When the Config key on the EGCP-2 keypad is pressed, the right LCD screen
will switch to the configuration menus. A Security Code prompt will be provided
prior to access into the Configuration Menus. The Security Code value
determines which configuration menus are accessible and if the Alarm / Event
log can be cleared.
Figure 4-13. Security Code Display
Woodward 71
NOTE
See manual 26108 (shipped with each control) for security code and
access level information.
Once a Security Code is entered, it will stay active until:

1. The DC power is cycled, causing the EGCP-2 to re-boot.
2. When in any of the Configuration Menus, press the “ESC” key twice.
This will return you to the Security Code screen.
If neither of these steps are done, the Configuration Menus and Alarm / Event
menus will be available at the level of the last Security Code entered.
Alarm / Event 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 this manual.
Figure 4-14. Alarm / Event Screen
ALARM NAME: The name, as defined by the particular warning, alarm, or

shutdown event.
HH:MM: The hour and minute of the alarm occurrence.
MM-DD: The Month and Day of the alarm occurrence.
####: The value of the input at the time of the alarm. This value is visible with a
supervisor level, or higher, security code.
72 Woodward
In the event that the Alarm /Event Log key is pressed, and there are no active or
logged alarms, the display will look like this:
Figure 4-15. Empty Event Log
The alarms displayed in the alarm / event log are arranged in a first in, last out
(FILO) order. The most recent alarms will appear at the top of the list, followed
by older alarms. In the event that the total number of logged and
unacknowledged alarms exceeds sixteen, the oldest alarms will be dropped off
the list to make room for the newer alarm events. If power is cycled to the
control, the Event log will be cleared.
Woodward 73
Configuration Menus
When a valid security code is entered, the configuration menu list will be
displayed. The configuration list allows the user to configure, calibrate, and
adjust all relative items to the EGCP-2 operation.
Figure 4-16a. Configuration Menu List (Screen 1)
Figure 4-16b. Configuration Menu List (Screen 2)
74 Woodward
Figure 4-16c. Configuration Menu List (Screen 3)
NOTE
See Manual 26108 (shipped with each control) for security code and
access level information.
Various Security codes access different portions of the configuration screens,

depending on the level of security code used. The up and down keys are used to
move the blinking cursor to the tuning menu that the user wants to enter. Pressing
the enter key will 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 Configuration menu, for these “sanity checks” are:
1. Numbers of Poles
2. Number of Teeth
3. System Frequency
4. Rated Speed
5. Rated KW
6. Rated KVA
7. Rated KVAR
8. CT Ratio
9. PT Ratio
10. Voltage Input
11. Voltage Ref
Woodward 75
The “sanity checks” are performed when:
1. Power is cycled
2. Access any Configuration menu by pressing the ENTER key. Pressing
the ENTER key a second time will initiate a sanity check.
If a “sanity check” is present the red Alarm LED will blink on the face of the
control. Access the Alarm/ Event menu and it will say: Program Config Error
Figure 4-17. Program Configuration Error
• Items in the Configuration menu that fail the “sanity checks” will be
indicated by a pound sign (#). This pound sign will appear on the far right
side of the items value on the display screen. If any items have a pound sign,
the engine will not be allowed to start and all Alarm 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.
• All items in the Configuration menu must be Committed before engine

operation will be allowed. Uncommitted items will have an asterisk (*) next
to the item’s value on the display screen. Typically this step is done at the
factory. Asterisks will appear whenever a Setpoint file is downloaded to an
EGCP-2. To commit an item you must press the ENTER key. Open the
Configuration menu and open each item, then ENTER that item. The
asterisk will be gone.
76 Woodward
The “sanity checks” are:
1. Calculate MPU frequency = Rated Speed * Number of Teeth / System
Frequency
• Answer: 500 ≤ calculated MPU frequency ≤ 8000 = Unit OK
2. Calculate System Frequency = Rated Speed * Number of Poles / 120
• Answer: should equal System Frequency’s configured value, 50 or 60
Hertz
3. Calculate Power Factor = Rated KW / Rated KVA
• Answer: 0.7 ≤ Calculated Power Factor ≤ 1 = Unit OK
4. Calculate CT Ratio, Voltage Input is DELTA, =
KVA * 1000 / Voltage Ref * 1.73
• Answer: If value is ≤ CT Ratio = Unit OK
5. Calculate CT Ratio, Voltage Input is WYE, =
KVA * 1000 / Voltage Ref * 3
• Answer: If value is ≤ CT Ratio = Unit OK
6. Calculate Voltage = Voltage Ref / PT Ratio
• Answer: If Calculated Voltage ≤ 500 = Unit OK
7. Calculate Rated KVA, Voltage Input is DELTA,
• Answer: Calculated KVA ≤ (Voltage Ref * 1.73) * CT Ratio = Unit OK
8. Calculated Rated KVA, Voltage Input is WYE,
• Answer: Calculated KVA ≤ (Voltage Ref * 3) * CT Ratio = Unit OK
9. Rated KW ≤ Rated KVA = Unit OK
10. Rated KVAR ≤ Rated KVA = Unit OK
If the EGCP-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 process 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 Address for Each Unit in the System.
• Maximum of 8 units on network.
Network Priority
• Range: 1 to 8
• Unique Priority for Each Unit in the System.
• Lowest Active Priority is considered Master.
• Maximum of 8 units on network.
• Sequencing effective from lowest to highest priority.
• When priority is reduced below 1, the value will change to “Set All”. If the
Enter key is pressed when this value is on the display, the display will
change to represent all units in auto on the network, and their priorities.
Using the left/right and up/down keys on the control, one can change the
network priority of any unit. Once changes are made, the changes are
committed by pressing the Enter key twice. Pressing the Escape key from
within the Set All parameter will restore the previous priorities.
Woodward 77
Number of Poles
• Range: 2 - 18
• Determines Speed/Frequency Relationship.
• Used for Speed/Frequency Mismatch Alarm/Shutdown.
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 Generator
• Typically 0.8 x rated KVA
Rated KVA
• Range: 1 - 30000
• Rated KVA of Generator
Rated KVAR
• Range: 1 - 30000
• Rated KVAR of Unit.
• Typically 0.6 x Rated KVA.
KVA
KVAR
KW
KW/KVA=PF
COS =KW/KVA
KVA^2=KW^2+KVAR^2
KVA= (KW^2 + KVAR^2)
Figure 4-18. AC Power Triangle
78 Woodward
CT Ratio
• Range: 5 - 30000 :5
• Scales sensed CT input for Amperage as seen at generator.
• Used for Load Sensing Algorithm.
• (KVA, KW, KVAR, PF)
• Used for Alarms/Shutdowns.
• Over Current, KW Limits, Reverse Current, etc.
PT Ratio
• Range: 1 - 1000 : 1
• Scales sensed PT input to Voltage Levels as measured at the Generator.
• Used in Load Sensing Algorithm.
• (KVA, KW, KVAR, PF)
• Used for Voltage Matching.
• Used for Generator Frequency Detection.
• Used for Alarm/Shutdown sensing.
• 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 setpoint menus.
• Sets the label used for all generator and mains voltage Status readings.
• Wye (Star) Generator or Transformer Connection
4 Wire
Volts Line to Neutral expected for all setpoint menu items requiring voltage
settings.
• Delta Generator or Transformer Connection
3 Wire
Volts Line to Line expected for all setpoint menu items requiring voltage
settings.
Voltage Reference
• Range: 1 - 30000
• Operating Voltage of Generator per Generator Nameplate.
Used for VAR/PF Sharing as the Reference that multiple generators share
reactive load to. This maintains the voltage reference while in Power Factor
Sharing or KVAR Control mode on an isolated bus.
Display Units
• Range: American or Metric
• Metric
Sets temperature readings to degrees Celsius (C), and pressure to bar (BAR).
• American
Sets temperature readings to degrees Fahrenheit (F), and pressure to Pounds
per Square Inch (psi).
Woodward 79
Set Date
• MM-DD-YY
• Sets the date 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 Switch
Defines Discrete Output #12 as a KVA load switch.
Uses KVA High and KVA Low value items in the Load Control
Configuration Menu.
• Idle / Rated Switch
Defines Discrete Output #12 as an Idle / Rated speed switch. This output is
typically used to automatically send the engine speed control an idle/rated
command upon start up.
Uses the Idle Speed and Idle Time items in the Engine Control
Configuration Menu.
Speed Bias Type

• Range: ±3 Vdc, 0.5–4.5 Vdc, or 500 Hz PWM
• ±3 Vdc (WGC)
Sets the speed bias output to ±3 Vdc range. 0 Vdc is zero output,
–3 Vdc is –100% speed bias output,
+3 Vdc is +100% speed bias output.
• 0.5 to 4.5 Vdc (DDEC)
Sets the speed bias output to 0.5 to 4.5 Vdc range.
2.5 Vdc is zero,
0.5 Vdc is –100% speed bias output,
4.5 Vdc is +80% speed bias output.
• 500 Hz PWM (ADEM)
Sets the speed bias output to 500 Hz Pulse Width Modulated (PWM) range.
50% duty cycle = 0% speed bias output,
0% duty cycle = -100% speed bias output,
100% duty cycle = +100% speed bias output.
80 Woodward
Voltage Bias Type
• Range: ±1, 3, or 9 Vdc
• ±9 Vdc Bias
0 Vdc = 0% voltage bias
–9 Vdc = -100% voltage bias
+9 Vdc = +100% voltage bias
• ±3 Vdc Bias
• ±1 Vdc 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 Outputs”.
• Contactor issues continuous breaker close signal through the breaker close
relay output, DO2 for Generator and DO1 for the Mains.
Operating Mode
• Range: Mains Parallel or No Parallel
• Mains Parallel will allow the unit to synchronize to the mains, and carry
load while in parallel with the mains as well (closed transition).
• No Parallel will not allow the unit to operate with load until the mains
breaker is sensed as being open (open transition).
• All units operating in a load sharing system must be set for the same
parameter (that is, mains parallel, or no parallel).
Number of Units
• Range: Single or Multiple
• Defines whether unit is part of a multiple unit system or not.
• If single unit, there is no auto starting, auto sequencing, load or PF sharing
with other units under any circumstances. Unit displays “single unit no
sequencing” on sequencing screen. Network Priority and Network Address
setpoints are removed from the configuration setpoint menu automatically.
• If multiple unit, auto starting, auto sequencing, load and VAR/PF sharing
are available between all units in multiple. Unit displays system sequencing
information on sequencing screen. Network Priority and Network Address
setpoints are added to the configuration setpoint menu automatically. Unit
must be in Auto mode to communicate over the inter-control network (RS-
485).
Woodward 81

9
Connections
Gen Breaker Close
8
Generator Breaker
+V
Close Coil
29
Gen Breaker
Trip 30
Gen Breaker Trip will energize Generator Breaker
when in "Auto" and "Gen Trip Coil
Stable Delay" is met.
Generator Breaker Configuration Based Logic.

Connection
9
Gen Breaker Close
8
Generator Contactor
Close/Open Coil
29
Gen Breaker
Trip No Connection.
30
VIS-142a
01-07-11
Generator Contactor Configuration Based Logic.
Figure 4-19. Breaker Logic and Contactor Logic

The Shutdowns and Alarms menu is used to configure the generator protection
functions of the EGCP-2.
Each alarm setpoint can be set for:

• Disabled
• Warning—LED on control flashes.
• Visual Alarm—LED flashes, and Visual Alarm relay energizes.
• Audible Alarm—LED flashes, Visual and Audible Alarm relays energize.
• Soft Shutdown—LED turns on, Visual and Audible Alarm relays energize,
unit soft unloads, Fuel Solenoid relay de-energizes and cycles through cool
down timer when applicable. Unit removes itself from auto sequencing
order.
• Hard Shutdown--Same as above, but immediately opens generator breaker
and de-energizes the fuel solenoid.
82 Woodward
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.
Generator High Voltage Limit (Voltage Bias Cutout)
Operating
Range Rated Generator Voltage
Generator Low Voltage Limit (Voltage Bias Cutout)
Figure 4-20. Generator High/Low Voltage Alarms
Generator Volt High Limit

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

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

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

• Sets minimum time, in seconds, allowed prior to activating either Generator
High/Low Voltage Limit Alarms. This allows for short period transient
over/under voltages to occur on the generator without setting off the
Generator Voltage Alarms.
Woodward 83
Generator Frequency High Limit
• Sets maximum allowable generator frequency level.
• If frequency is above High Limit, generator is not considered stable, and is
Generator Frequency Low Limit

• Sets minimum allowable generator frequency level.
• If frequency is below Low Limit, generator is not considered stable, and is
Generator High Frequency Limit (Speed Bias Cutout)

Operating
Synchronous Speed (50/60 Hz)

Range
Generator Low Frequency Limit (Speed Bias Cutout)
Figure 4-21. Generator Over/Under Frequency
Generator High/Low Frequency Limit Alarm

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

• Compares generator frequency to engine rpm and alarms on difference.
• Used to indicate loss of MPU, or Loss of Generator Field Voltage.
• If Start Sequencing is Disabled and no MPU is present, then this alarm
compares Generator Frequency to Generator Frequency, so the Speed/
Frequency Mismatch Alarm will never alarm.
Overcurrent Level
• Range 5.0 – 30,000 Amps
• Set for per Phase Overcurrent
3 Phase sensing, selects phase with highest current
• Uses Inverse Time Function as basis for overcurrent detection
The overcurrent is based on AMP•SECONDS.
AMP•SECONDS are determined by:
Overcurrent Delay x (Overcurrent Level – Rated Current)
84 Woodward
• 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 L-L Voltage Ref = 277 V L-N
(125 000 / 480) / 1.732 (125 000 / 277) / 3
= per Phase Rated Current = per Phase Rated Current
150 Amps = per Phase Rated Current 150 Amps = per Phase Rated Current
Example:
OVERCURRENT 180 AMPS 180 AMPS 180 AMPS 180 180
LEVEL AMPS AMPS
Rated Current 150 Amps 150 Amps 150 Amps 150 Amps 150 Amps
Delay Time 0.1 SEC 1.0 SEC 5.0 SEC 10 SEC 20 SEC
AMP SECONDS 3.0 30.0 150 300 600
Actual Current 170 170 170 170 170

Trip Time No Trip No Trip No Trip No Trip No Trip
Actual Current 181 181 181 181 181
Trip Time 3.0 Sec 30 Sec 150 Sec 300 Sec 600 Sec
Actual Current 190 190 190 190 190
Trip Time 0.3 Sec 3 Sec 15 Sec 30 Sec 60 Sec
Actual Current 200 200 200 200 200
Trip Time 0.15 Sec 1.5 Sec 7.5 Sec 15 Sec 30 Sec
Actual Current 220 220 220 220 220
Trip Time .075 Sec 0.75 Sec 3.75 Sec 7.5 Sec 15 Sec
Table 5-1. Overcurrent Level Chart
Overcurrent Delay
• Range 0.1 – 20.0 Seconds
• Used with the Overcurrent Level and Rated Current to determine the amount
of time (AMP•SECONDS) any current can be greater than the overcurrent
level before an alarm or shutdown is received.
• Overcurrent Detection begins when current exceeds Overcurrent Level
• AMP•SECONDS
Overcurrent Delay x (Overcurrent Level – Rated Current)
• If the Overcurrent Level is set <= Rated Current, AMP•SECONDS = 0.

• This will cause an Alarm or Shutdown when Rated Current is attained.
• AMP•SECONDS accumulate when current is > the Overcurrent Level

• AMP•SECONDS reset to 0 when current is < the Overcurrent Level
Woodward 85
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.
220
Overcurrent Trip Zone
Current
(per phase)
200
190
Amp-Seconds
Overcurrent
Level
180
Rated Current 150

0 7.5 15 30
Time (seconds)
Shutdown will be received in 3 seconds
220
Current
(per phase)
200
Amp-
190 Seconds
Overcurrent
Level
180
Rated Current 150

0 7.5 15 30
Time (seconds)
220
Amp-Seconds
Current
(per phase)
200
190
Overcurrent
Level
180
Rated Current 150

0 7.5 15 30
Time (seconds)
86 Woodward
Overcurrent Alarm
If the Overcurrent Alarm is set for DISABLED, the Overcurrent Level and
Overcurrent Delay will have no effect.
Reverse Power Level

• When the Reverse Power Level is reached, an Instant trip is received.
• Configured as a percentage of Rated KW
• Range: -1.0 thru –50%
Reverse Power Delay

• Reverse Power Delay determines the amount of Reverse 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 Power level an accumulation of reverse power is started. As the
power level increases above this level, the accumulated amount will be reset
to zero.
• Configured as a percentage of Rated KW
• Range: -1.0 thru –50%
Configuration Settings
Rated KW 120 KW
Reverse Power Level - 10% (-12 KW)
Reverse Power Delay 2 Seconds
Minimum Reverse Power - 5% (-6 KW)
Reverse Power Value Trip Time

-7 KW 12 seconds
-8 KW 6.5 seconds
-9 KW 4.6 seconds
-12 KW Instant
Table 5-2. Reverse Power Chart
Woodward 87
+ Time
Power
Level
0
Minimum
Reverse Power -5%
Trip
Reverse Power Instant

Level -10% Trip
Figure 4-25. Reverse Power
Figure 4-25 shows Reverse Power. The first time the power level decreases
below the Minimum Reverse Power setting does not last long enough to cause a
trip. The second time the accumulating amount reaches the calculated delay and a
trip is received. Dropping below Reverse Power Level would cause a trip
instantly.
Reverse KVAR Limit

• Range: –.0 to –00
• Set as a percentage 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 alarm
soft shutdown
hard shutdown
Remote Faults #1 through #6:

• Each alarm has a programmable time delay (0 to 30 seconds).
• Each alarm can be set for any of the standard alarm or shutdown levels.
• Remote Faults 1 and 2 can have a Stable Delay time Enabled or Disabled.
When Enabled a 15 second timer will begin after the Gen Stable period has
expired.
88 Woodward
Engine Control
Preglow Time
• Time of preglow allowed prior to engine crank cycle.
• Maintained through engine cranking.
• Resets after every crank attempt.
Crank Time
• Maximum Allowable Time for Engine Cranking.
Crank Cutout
• Engine rpm level where crank command is canceled.
Crank Delay
• Time between Engine Crank Attempts.
• This Delay is started when in the Spindown mode and the speed of the
generator set has dropped below 50 RPM. Cannot restart engine until this
time has expired.
Crank Repeats
• Number of times EGCP-2 will repeat its attempt to start the engine.
Cranking attempts will equal the value of Crank Repeats +1.
Crank Fail
• Alarm Setpoint.
• 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/Rated Speed setpoint
is exceeded. Once the Idle/Rated Time is passed, the EGCP-2 will energize
the #12 Discrete Output (if the Relay #12 output is configured for the
idle/rated function).
Cooldown Time
• Time allowed for cooldown once engine achieves a stop cycle.
• Must exceed Cooldown Limit (see next display) before activated.
Cooldown Limit
• KVA setpoint at which, when exceeded, will cause the engine to go to a
cooldown during the next stop cycle.
Woodward 89
Engine Run Time
• Hours of Run Time on Engine
• Increments every run hour on System Status screen display.
• Retained in non-volatile memory—Does not require power to retain its
value. The memory is updated every 4 hours of continuous operation, and
every time the engine is stopped.
MW Hours
• MW Hours on Generator
• Increments in .1 MWH on System Status screen display.
• Retained in non-volatile memory, this memory is updated every 4 hours of
continuous operation, and every time the engine is stopped.
Overspeed
• Set for overspeed limit of engine.
• Typically set for 10% above Rated Speed of engine.
Overspeed Alarm
• Alarm Setpoint.
• Typically configured to Hard Shutdown for safety.
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 detect weak battery/failed charger.
• Automatically Disabled during engine cranking.
High Oil Pressure

• Uses Engine mounted pressure sensor.
• Active when generator is stable.
• Display is selectable for psi (American) or Bar (Metric).
Low Oil Pressure Pre-Limit

• Used to sense failure of lube oil system.
• Start Sequencing ENABLED, Active at 90% of Rated Speed plus 5 seconds
or when Generator Breaker closes plus 5 seconds
• Start Sequencing DISABLED, Active when Fuel Solenoid output energizes
plus 30 seconds or when Generator Breaker closes plus 5 seconds
Low Oil Pressure

• Used to sense failure of lube oil system.
• Start Sequencing ENABLED, Active at 90% of Rated Speed plus 5 seconds
or when Generator Breaker closes plus 5 seconds.
• Start Sequencing DISABLED, Active when Fuel Solenoid output energizes
plus 30 seconds or when Generator Breaker closes plus 5 seconds
90 Woodward
High H2O Temperature Pre-Limit
• Uses engine mounted temperature sensor
• Active once Generator is stable.
• Display is selectable for degrees F (American) or degrees C (Metric).
High H2O Temperature

• Uses engine mounted temperature sensor.
• Active once Generator is stable.
• Display is selectable for degrees F (American) or degrees C (Metric).
Low 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 synchronizes generator by issuing speed and
voltage bias commands, but does not issue breaker closure command.
Run
• Normal operating mode.
• Actively synchronizes and issues breaker closure command.
• EGCP-2 control MUST be in RUN to operate as a dead bus closing device.
• In multiple unit systems EGCP-2 control MUST have AUTO input active to
enable breaker control.
m a n u a l c lo s e
B re a k e r C lo s e
52G
a u to /m a n
s w itc h
Figure 4-26. Typical Circuit Using Permissive Function and Run for
Auto/Manual Synchronizing
Woodward 91
Synchronizer Gain
• Sets Gain of Synchronizer speed bias output
• Gain Multiplier for output signal proportional to phase error.
Synchronizer Stability
• Sets Stability of Synchronizer speed bias output.
• Stability (Integrator dx/dt in seconds per repeat)
Voltage Matching
• Enables/Disables Voltage Matching feature of EGCP-2 control.
• Enables Voltage Window Setpoint.
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.
Gen Voltage High Bus or Mains Voltage
484.8 VAC +1%

480 VAC
475.2 VAC -1%
Gen Voltage Low

Figure 4-27. Voltage Matching (1% setpoint)
92 Woodward
Max. Phase Window
• Maximum allowable phase angle deviation from phase matched condition.
• EGCP-2 Control will not issue breaker closure if phase angle between
generator and bus, or generator and mains exceeds this window.
o
-10 +10
Must be within
+/- 10 deg window for
breaker closure
Figure 4-28. Maximum Phase Window = 10 Degrees
Dwell Time
• The period of time that the generator must be within the Max. Phase
Window for before the EGCP-2 control will issue a breaker closure.
• Longer dwell times will give typically give better stability after the breaker
closes.
• Shorter dwell times reduce amount of time required to synchronize unit.
C.B. Hold Time

• Time in Seconds that Breaker/Contactor Close output is held after breaker
close command is issued.
• 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 of Close Attempts allowed while synchronizing.
• Close attempt incremented if breaker does not send back continuous CB
Aux signal to EGCP-2.
Reclose Delay
• Time in Seconds before EGCP-2 control attempts resynchronization after
failed closure attempt.
Synch Reclose Alarm

• Alarm setpoint if number of close attempts is depleted.
Woodward 93
Synchronizer Time Out
• Sets time allowed for synchronization in seconds.
• Begins timing when synchronizer activates.
• Active for all gen and mains breaker open and close commands from EGCP-
2 control.
• A setting of zero (0) seconds disables synch. time-out—infinite synch time
allowed.
Synch Time-out Alarm

• Sets alarm mode if synch time-out is exceeded. Shutdown actions are not
allowed.
Dead Bus Closure

• Enables/Disables Dead Bus Closing Feature.
• Unit must be within voltage and frequency high/low limits to be considered
for dead bus closure.
• Dead Bus Closure uses Token Passing Scheme to assure that only one unit
in a networked system will close onto the dead bus at any given time.
• Multiple unit systems must 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 process reference is reached, or while in base load and
base load reference is reached.
o The Test input (Discrete Input #2) must be closed to activate this
feature.
• Droop
o Manual Load and Voltage Control
o Used primarily for commissioning.
Load Control Gain

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

• Sets gain response of proportional load sharing.
• Active in load sharing operations.
94 Woodward
Load Stability
• Sets Stability response of load control.
Load Derivative
• Sets Derivative response of load control.
Load Control Filter

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

• Load Level that Generator will automatically ramp to when operating in
Base Load.
• Must be set to a greater 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 load
level. This rate is applied during any automatic loading function, including
ramping to load sharing.
• Example: Load Time = 10 seconds
o Base Load Ref = 200 KW
o Unload Trip = 25 KW
o The difference is 175 KW
o The EGCP-2 will ramp 175 KW in 10 seconds
o This breaks down to 17.5 KW per second
Remember, if the Base Load Ref or Unload Trip are changed, it will affect the
ramping rate when loading.
Woodward 95
Unload Time
• Time in Seconds for generator to unload from base load level to unload trip
level. This ramp rate is applied during any automatic unload functions,
including ramping from load sharing.
• Example: Unload Time = 10 seconds
o Base Load Ref = 200 KW
o Unload Trip = 25 KW
o The difference is 175 KW
o The EGCP-2 will ramp 175 KW in 10 seconds
o This breaks down to 17.5 KW per second
Remember, if the Base Load Ref or Unload Trip are changed, it will affect the
ramping rate when unloading.
Raise Load Rate

• Percent Load per Second ramp rate used when the Raise Load input
(Discrete Input #6) is used during base load operation.
Lower Load Rate

• Percent per Second Ramp Rate used when the Load Lower input (Discrete
Input #7) 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 setpoint when operating in Base Load or
Process Control Modes.
KW Load Low Limit

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

• Sets Alarm Action when unit is at or below Low Load Limit.
KVA Switch Low

• Sets level, which when exceeded, will cause the KVA relay output to
energize. Only applicable for units with the relay#12 function configured for
KVA Load Switch.
96 Woodward
KVA Switch High
• Sets level, which when exceeded, will cause the KVA relay output to de-
energize. Only applicable for units with the relay#12 function configured for
KVA Load Switch.
Summary of KVA load switch action:

If the relay 12 output is configured for KVA Load Switch action:
If the three phase sum of the generator KVA is greater than the KVA Switch Low
setpoint, AND less than the KVA Switch High setpoint, the K12 relay output
shall energize. Any other KVA levels relative to the Low and High switch
setpoints shall cause the K12 relay output to de-energize.
Reactive Load Control
VAR/PF Mode
• Disabled
Unit does not PF share, or control PF under any circumstances.
• VAR Control
Unit PF shares in isolated bus load sharing mode.
Unit controls KVAR in Base Load and Process Control Modes.
• PF Control
Unit PF shares in isolated bus load sharing mode.
Unit controls PF in Base Load and Process Control Modes.
VAR/PF Gain
• Controls Gain Response of unit in VAR/PF control mode.
• NOT active in PF sharing mode.
Voltage Ramp Time

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

• Controls Gain Response of unit in VAR/PF Sharing Mode.
• Not active in VAR/PF Control Mode.
VAR/PF Stability
• Controls Stability Response of unit in VAR/PF control mode.
• NOT active in PF sharing mode.
KVAR Reference
• When KVAR control mode is selected, this references the amount of KVAR
the generator will produce while in Base Load or Process control modes.
• Can be set for generate or absorb levels of KVAR.
• KVAR levels limited by Rated KVAR of unit.
Woodward 97
PF Reference
• PF level that will be maintained by the generator while in Base Load or
Process control modes.
• Can be set for leading or lagging power factor.
• Scaled from -.5 (.5 leading) to +.5 (.5 lagging).
PF Deadband
• ± deadband around PF reference point.
• Set in PF units.
• Active in PF and PF sharing modes.
• Can be used to stabilize units at low loads if needed.
Process Control
Process Import/Export Hardware
EGCP-2 Control can accept a 4–20 mA or 1–5 Vdc input signal from a KW
transducer. Input signal conditioning is selected by a dip switch on the back of
the EGCP-2 control, switch position 4, switch number 4. Closing 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.
SW - 4
___________________________ Dip Switch # 4
1. +5V RS-485
1
2. 123 ohm RS-485 Termination+ 2
3. 123 ohm RS-485 Termination - 3
4
4. 4-20 mA Process Input
Figure 4-29. EGCP-2 Control Dip Switch
Process Dynamics
• Process Master Uses Process PID to control.
• Gain, Stability, Derivative, Filter, Droop.
• Slaves to the Process Master use Load Control PID Values to track master
system load reference.
Process Action
• Defines action of speed bias when unit is operating in process control in
parallel with the mains.
• Direct action = Unit increases speed bias (fuel) to increase process 4–20 mA
input.
• example: Export Power control
• Indirect action = Unit decreases speed bias (fuel) to increase process 4–20
mA input.
• example: Import Power Control
98 Woodward
100
20 mA
export
power
0 100
speed bias
4 mA
Figure 4-30. Direct (Export) Process Action
100
20 mA
imported
power
0 100
speed bias
4 mA
Figure 4-31. Indirect (Import Power) Process Action
100
20mA
speed bias -> 0 100%

0
-100
4mA
Figure 4-32. Direct (Import/Export) Process Action

(This example is using a 4–12–20 mA transducer.)
Woodward 99
Process Gain
• Sets system gain response while in process control.
• Effective when active master unit only. Slaves rely on Load Control
dynamic settings to control response to master load reference.
• Should be set with maximum number of units operating in process control
mode.
Process Stability
• Sets system stability response while in process control.
• Effective at active master unit only. Slaves rely on Load Control dynamic
settings to control response to master load reference.
mode.
Process Derivative
• Sets system derivative response while in process control.
• Effective at active master unit only. Slaves rely on Load Control dynamic
settings to control response to master load reference.
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 setpoints.
• ± deadband around process reference point.
• Used to add stability to marginally stable process.
Process Droop
• Introduces negative feedback on the process reference as the process input
increases.
• Used to add stability to marginally stable processes.
Process Filter
• Low Pass Filter attenuates higher frequency transients on process 4–20 mA
input signal.
• The higher the filter is set, the more active the process control will be to
higher frequency process transients.
• The lower the filter is set, the less active, and more stable the process control
will be to higher frequency process transients.
Process Reference
• The reference point at which the master will control the process input.
• The reference point units are selectable under Process Units.
• Also used in Soft Transfer modes to set the level of process at which the
transfer from mains to generator(s) will occur.
100 Woodward
Raise Rate
• Rate, in %/Sec., at which the process reference will change when the EGCP-
2 receives a Raise Load input (Discrete Input #6) while operating in process
control mode.
Lower Rate
• Rate, in %/Sec., at which the process reference will change when the EGCP-
2 receives a Lower Load input (Discrete Input #7) while operating in
process control mode.
Process High Limit

• Maximum allowable process reference level.
• Dependent on Process 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 Input values to be displayed in other units
besides milliamps or voltage.
o The KW Transducer signal will still be in milliamps or volts.
• This selection effects Process Configurations:
o Process Reference
o Process High Limit
o Process Low Limit
o Process High Value
o Process Low Value
• Status screens effected
o Discrete I/O
o KW Load
Woodward 101
• Engineering unit selections
Displayed Units
o Ma
o V
o KW
o MW
o KVA
o MVA
o KVAR
o MVAR
o PF
o Deg C
o Deg F
o PSI
o KPA
o BAR
Process Low Value

• The Process Input, when at 4 mA or 1.0 volt, will be displayed as.
o Example: Process Low Value = -1000 KW
Process Input is 4 Ma
KW LOAD status screen will display: –1000 KW
Process High Value

• The Process Input, when at 20 mA or 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 KW
Process Low Value –500
Process High Value 500
Process Units mA
Process Action Indirect
Process Deadband 0.3 %
Process Ref 11.5 mA (Import Power)
Process High Limit 14 mA
Process Low Limit 10 mA
Process Low Value 4
Process High Value 20
102 Woodward
Transfer Switch
Check Mains Breaker

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

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

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

• Period of time generator must be declared stable (within voltage and
frequency limits for the specified time) before transition from Mains to
Generator, as well as dead bus closing.
Load Surge
• Used only in Base Load or Process Control. (Mains Parallel Operations)
• Set to trigger at a percent of total generator load shift per second while
operating in Mains Parallel. (% Rated Load/Second)
• Can be set for Loss of Mains Detection.
• Instantaneous Trigger.
Load Surge Alarm

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

• Alarms when Mains Voltage exceeds Alarm Setpoint.
• Alarm can be set for Loss of Mains.
• If Mains Voltage is above High Limit, Mains are not considered stable, and
the EGCP-2 control will not issue a mains breaker closure command.
Woodward 103
Main Volt High Alarm
The Main Volt High condition will cause a response defined by this setpoint. The
• Disabled
• Warning
• Loss of Mains
Main Volt Low Limit

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

The Main Volt Low condition will cause a response defined by this setpoint. The
• Disabled
• Warning
• Loss of Mains
Main Frequency High Limit

• Alarms when Mains Frequency exceeds Alarm Setpoint.
• 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
setpoint. The available responses are:
• Disabled
• Warning
• Loss of Mains
Main Frequency Low Limit

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

The Main Frequency Low condition will cause a response defined by this
setpoint. The available responses are:
• Disabled
• Warning
• Loss of Mains
104 Woodward
LOM Action Delay
• Sets Time Delay for LOM Action to begin once Loss of Mains is detected.
• Delay time From LOM detection to mains breaker open, and engine start
command.
• In applications where the utility bus is somewhat unstable, this setting can
be used to prevent momentary disruption of the mains frequency or voltage
on from causing unwanted Loss of Mains actions to occur.
Sequencing and Comms (Communications)
Automatic Sequencing
• Enables or Disables Auto Sequencing for that unit.
o Disabled and in AUTO(Discrete Input #1)
Will start on Loss of Mains
Does not start when Master Unit is put in the AUTO and
Run w/Load mode
• Disabling at the master disables all auto sequencing.
Automatic Sequence Delay

• Amount of time in seconds before Auto Sequencing begins.
• Delay 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 Process control modes, at which
active master unit will begin timing to sequence next unit on line.
• Consult Chapter 5, Generator Sequencing, for details.
Next Genset Delay

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

• Delay when system load exceeds 100%, before master starts next genset in
sequence.
• Rated Load Delay function overrides load ramping on unit being sequenced
on line. That unit will immediately assume its proportion of the system load.
Woodward 105
Maximum Start Time
• Time allowed by master to see next unit to be sequenced on line in an
“active” condition, i.e. started and ready to load.
• This is determined by a network flag, which indicates the unit is ready to
load, is sent over the network by the unit being sequenced on by the master.
• If master does not detect this flag within the Max. Start Time allowed, it will
go to the next lower priority unit and try starting it, or if no other units are
available, it will retry the start command on the same unit.
Minimum Generator Load

• % of system load at which the Master EGCP-2 begins the Reduced Load
Delay to sequence units off line.
• With only two engines operating, the Master unit will NOT sequence off the
next unit if the System Load Percentage will increase above the Max Gen
Load –10%.
• Consult Chapter 5, Generator Sequencing, for details.
Reduced Load Delay

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

• Time in seconds allowed by master for slave to sequence off line.
• Master begins sequencing next lowest priority unit off line if system load is
still above Min. Gen. Load setpoint at the end of the Max Stop Time Limit.
422 Protocol
• This setting defines the protocol used on the EGCP-2’s RS-422 port. Make
sure you are familiar with the various settings by reading the
Communication Manual 26181 completely before deciding on which
protocol to use.
NOTE
Changes in the 422 Protocol setpoint do not take effect until power is
cycled to the control.
ServLink
• Sets RS-422 Serial Communications to ServLink Protocol
Modbus®
• Sets RS-422 Serial Communications to Modbus RTU Protocol
Upload Setpoints
• Sets RS-422 Serial Communications to Upload Setpoint mode.
106 Woodward
Modbus ID
• Sets the Modbus RTU network ID of the Unit. Units will be Modbus slaves.
Modbus Timeout
• Sets the timeout time for Modbus communications. See the Communications
Manual 26181 for details.
Modbus Reset
• Can be used to zero the Modbus error counts for the unit.
Calibration Menu
While each unit will be factory calibrated at Woodward prior to shipment, there
are bound to be some inputs/outputs affected by external wiring and/or interfaces
(relays, transformers, etc.) that will require calibration at the site during
commissioning.
The Calibration Menu allows calibration of all the analog inputs to the EGCP-2,
as well as the speed bias and voltage bias outputs.
All calibration points in the EGCP-2 are used to make the actual value of an
input, such as generator voltage, read out on the respective display screen of the
EGCP-2 the proper value of the signal being monitored.
In order to assist in calibrating the unit, each calibration menu item has the
sensed input being calibrated displayed on the lower two lines of the right hand
LCD screen. These values are updated every 200 milliseconds. All adjustments in
the configuration menus are immediate in their action (that is, values do not need
to be entered into memory to have an effect on the sensed input, or control
operation).
Example: 380 Vac measured line to line on the generator A-B phase should read
380 Vac in the line to line voltage measurement area of the EGCP-2 “generator
status” menu. The EGCP-2 is configured for Line to Line voltage input.
The calibration menu item “PT Phase A Scale” will display the A-B generator
phase voltage in the lower two lines of the display. This value will change as the
PT Phase A Scale value is adjusted.
Woodward 107
Process Input Scale
• Measure the actual Process Input Signal from external transducer.
• Calibrate the Process Input Scale until the Process Input, bottom line on
display screen, reads what the measured process signal is.
Figure 4-33. Process In Scale
Measured vs Monitored
480.0 VAC Measured A -B
phase Line to Line
Measured vs. Monitored
480.0
vac
Monitored Voltage
EGCP-2 configured for Line to Line (3 wire) PT input.
Woodward
ALARMS: 1 UNIT: 1 A PHASE PT SCALE

B Mains: -- Gen: ++ 1.00
Engine: RUNNING -----------------------------------------------------------------------
AUTO: ISOCHRONOUS PHASE A VL-L: 482.5
C
EGCP-2Digital Control STATUS .

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

LL
I/ SYN
KW LOAD
O
C
ESC ENTER PF /
SEQUENCE ATS
KVAR
Calibrate the Monitored Value to equal the Measured

value using Calibration menu items.
Figure 4-34. Measured vs. Monitored
108 Woodward
Speed Bias Offset
• Range: 50% to –50% of selected Speed Bias Type
• Factory calibrated for:
Speed Bias Type Voltage at Terminals Speed Bias Offset

73(+) – 74(-)
±3 Vdc 0.00 Vdc 0.0%
0.5 – 4.5 Vdc 2.5 Vdc 0.0%
PWM 50% Duty Cycle 0.0%
• Adjust the Speed Bias Offset to obtain rated frequency 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 calibrated for:
Voltage Bias Type Voltage at Terminals Volts Bias Offset

37(+) – 38(-)
±1 Vdc 0.00 Vdc 0.0%
±3 Vdc 0.00 Vdc 0.0%
±9 Vdc 0.00 Vdc 0.0%
Woodward 109
• Adjust the Volts Bias Offset to obtain rated voltage for the generator set.
o Measure the actual generator voltage

o Follow connection procedure in Appendix D for the Voltage
Regulator being used
What Voltage Bias Type to use
Where to preset the Volts Bias Offset
• Press the Enter key to save the final Volts Bias Setting
• The EGCP-2 control will always reset to the saved Volts Bias Offset value
when the generator breaker is opened.
• Whenever the Generator set is started or taken offline, it will control at the
rated voltage when calibrated correctly.
Voltage Bias output from EGCP-
trim
Trim Adj.
Internal Trim adjustment potentiometer
Volts 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.
Figure 4-35. Typical AVR with Aux Input (Newage SX-440)
Pot Voltage Bias output

. from EGCP-2
Trim Adj.
On regulators without a trim input
Volts such as Leroy Somer AVRs,
an external trim pot must be used
to limit the range of the voltage
bias input from the EGCP-2 control.
Figure 4-36. Typical AVR with External Voltage Adjust Potentiometer
110 Woodward
AVR DROOP
• It is highly recommended to fit the AVR with a Droop CT input, and utilize
a medium droop level on the AVR. This adds stability to the AVR for
VAR/PF sharing at low loads.
• Cross current compensation must be disabled in the AVR Droop CT circuit.
+/- 1 VDC output from EGCP-2
trim
Volts
CT
Droop
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 phase C voltage.
• Adjust PT Phase C scale until the monitored value matches the measured
generator voltage on C phase.
Woodward 111
CT Phase A, B and C Offset
• Calibrates CT Phase A, B, or C input sensing of EGCP-2 at zero current.
• Measure actual generator currents with clamp on ammeter, or panel
ammeter. Verify 0 Amps on the selected phase input.
• Calibrate selected phase CT reading in the calibration window.
CT Phase A Scale
• Calibrates CT Phase A
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 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
CT Phase C Scale
• Calibrates CT Phase C
112 Woodward
Bus PT Scale
• Calibrates Mains/ Bus PT input.
• This input can be calibrated using the Mains Pt or the Bus PT.
• Mains PT calibration
o Measure the Mains voltage
o Adjust scale until Mains monitored voltage equals the mains
measured voltage.
Synchronizer Status Screen Calibration Menu

Calibrating Bus PT Input using the Mains PT Input
• Bus PT calibration
o Measure the Bus voltage. If the BUS is dead no calibration can
be done.
o To get the EGCP-2 to switch from monitoring the Mains to
monitoring the Bus, the generator must be started.
Configure Synchronizer Mode for CHECK
Close Discrete inputs AUTO and Run w/Load to start
engine.
Adjust Bus PT Scale until monitored 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 menu of the EGCP-2 for “phase angle”.
• Monitor Voltage across open gen contactor/breaker or panel synchroscope
for phase angle error between generator and bus.
• Adjust synchroscope calibration for lowest voltage across gen breaker, or 12
o’clock reading on panel mounted synchroscope.
Battery VCO Gain

• Adjustment to match the monitored High battery voltage with the measured
High battery voltage.
• This monitors the input supply voltage on terminals 1 and 2.
• Battery voltage Gain is calibrated for accurate High Battery Voltage Alarms
Woodward 113
Battery VCO Offset
• Adjustment to match the monitored Low battery voltage with the measured
Low battery voltage.
• Battery voltage Offset is calibrated for accurate Low Battery Voltage
Alarms.
Adjusting Battery Gain and Offset

• Use an adjustable power source
• Measure the input supply voltage being fed from the power source
• Set the power source for 28 volts DC
• Adjust the Gain until the monitored voltage reads 28 volts
• Set the power source for 10 volts
• Adjust the Offset until the monitored voltage reads 10 volts
• Repeat these steps until no adjustment is needed
Oil Pressure Gain

• Oil pressure sensor input, terminals 68(+) and 69(–).
• Factory 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 Positive value
o 4 mA = 0 psi, 20 mA = 100 psi
o 1 volt = 0 psi, 5 volt = 100 psi
o 0 Ω = 0 psi, 200 Ω = 100 psi
• Indirect type – Gain will be a Negative value
o 4 mA = 100 psi, 20 mA = 0 psi
o 1 volt = 100 psi, 5 volts = 0 psi
o 0 Ω = 100 psi, 200 Ω = 0 psi
• Resistive sensors are commonly a direct relationship.
• Adjust the Oil Pressure Gain, the Calibration menu will provide a monitored
reading that will be compared to a measured reading.
• Adjust gain until EGCP-2 monitored reading matches actual reading.
Example of a Direct type sensor
114 Woodward
Oil Pressure Offset
• Set to read 0 psi or bar when engine is shut down.
• Gain and Offset will affect each other, so it is necessary repeat these steps
until no adjustment is needed.
Adjusting Oil Pressure Gain and Offset

Example of a Passive Resistive sensor:
• Disconnect the sensor from the EGCP-2 and measure the resistance coming
from the sensor both 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 the Calibration reading shows 0 psi or bar.
• Repeat these steps until the EGCP-2 reads correctly with no further adjustment
to the Gain or Offset values.
Oil Pressure
(PSI or Bar)
Oil Pressure Sensor mA, V, or Ohms
Figure 4-38. Oil Pressure Sensor Curve
Woodward 115
Water Temperature Gain
• Water temperature sensor input, terminals 66(+) and 67(-).
• Factory Calibrated for 0–300 °F over a 4–20 mA range.
• Designed to accept a 4–20 mA or 1–5 volt transducer or a passive resistive
type, 0–500 Ω.
o If the passive resistive sensor is greater than 500 Ω, it may be
necessary to add one or more of the shunt resistors (DIP switch 2) to
achieve the temperature range.
• Sensors can have a Direct or Indirect relationship
o Direct – Increase in resistance, mA, or volts is an Increase in
Temperature
o Indirect – Increase in resistance, mA, or volts is a Decrease in
Temperature.
• Direct type – Gain will be a Positive value.
o 4 mA = 0 degrees (OFFSET), 20 mA = 212 °F (GAIN)
o 1 volt = 0 degrees (OFFSET), 5 volts = 212 °F (GAIN)
o 0 Ω = 0 degrees (OFFSET), 500 Ω = 212 °F (GAIN)
• Indirect type – Gain will be a Negative value.
o 4 mA = 212 degrees (OFFSET), 20 mA = 0 °F (GAIN)
o 1 volt = 212 degrees (OFFSET), 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 shutdown engine temperature.
Low H2O temperature.
• If the sensor or transducer has a Direct relationship
o Adjust the Gain for the engine operating temperature.
High H2O temperature.
• To adjust the Water Temperature Gain, the Calibration menu will provide a
monitored value that will be compared to a measured reading.
• Adjust gain until EGCP-2 monitored reading matches actual reading.
• If it is not possible to reach the high or low temperature, it may be necessary
to add one or more of the shunt resistors by closing the DIP switch 2, switch
2, 3, or 4, on the EGCP-2.
Water Temperature Offset

• Direct relationship
o Adjust to read water temperature when engine is shutdown
Low H2O temperature.
• Indirect relationship
o Adjust to read water temperature when engine is running.
High H2O temperature.
• Gain and Offset will affect each other, so it is necessary to repeat these steps
until no adjustments are needed.
116 Woodward
Adjusting Water Temperature Gain and Offset

Example of a Passive Resistive sensor.
• Disconnect the sensor from the EGCP-2 and measure the resistance
coming from the sensor both when the engine is shut down (at least 12
hours) and running at rated speed, with temperature stabilized.
• Record the actual temperature and the resistance coming from the sensor
at those temperatures.
• From these readings you know if the sensor is a Direct or Indirect type.
• Direct 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 Gain until the monitored
reading matches the desired reading.
o Set the resistance for the shutdown value.
o Adjust the Water Temperature Offset until the monitored
o Repeat these steps until the EGCP-2 reads correctly with no
further adjustment at both the shutdown and running values.
• 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
o Set the resistance for the shutdown value.
o Adjust the Water Temperature Gain until the monitored
o Repeat these steps until the EGCP-2 reads correctly with no
further adjustment at both the shutdown and running values.
Water Temperature adjustments for Resistive Sensors

In some cases the sensor has a curved shaped characteristic that cannot be
matched exactly by the EGCP-2. In these situations it will be necessary to
calibrate the EGCP-2 for the two most important readings, such as the high and
low alarm points. In between these points there might be a slight error in reading
as shown in Figure 4-39, but the reading will be correct at the two critical points.
The shunt resistors can be added to increase the degree of curve used in the
EGCP-2. Closing both SW 3&4 adds a 50 Ohm parallel resistance to the sensor
which causes the steepest degree of curve. With no shunt resistors closed the
curve is less steep, but limited in range to 500 Ω or less.
Woodward 117
Sensor Signal
EGCP-2 reading
Water
Temperature
Water Temperature mA or V Transducer
High Temperature
Alarm
Water
Temperature
Low Temperature
Alarm
Water Temperature Resistive Sensor (Ohms)
Figure 4-39. Water Temperature Curves
No shunt resistors
SW 2-2 clsd 249 Ohm
SW 2-3 clsd 100 Ohm
Water SW 2-3&4 clsd 50 Ohm
Temperature
EGCP-2 Curve Characteristic

Figure 4-40. EGCP-2 Water Temperature Characteristics
118 Woodward
Suggested Sensors and Calibration Settings
Oil Pressure sensor

Manufacturer VDO
Model 360-xxx
Range 0-80 psi
Dip Switch setting 1-closed 2-open 3-open 4-open
*Oil Pressure Offset -12.07
*Oil Pressure Gain 0.026
Water Temperature sensor

Manufacturer VDO
Model 323-xxx
Range 100-250 deg F.
Dip Switch setting 1-closed 2-closed 3-open 4-open
*Water Temp Offset 123.15
*Water Temp Gain -0.027
*—These are the suggested settings for this sensor only. Woodward recommends that
once 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 Dropouts on network due to faulty wiring,
improper shielding, or improper setup will result in the unit experiencing the
dropouts to flash intermittently in the Sequencing Menu of the EGCP-2.
Typically set at 5 to 10 dropouts.
Unit Calibrated
• When set for true, indicates unit has been factory calibrated. Requires Level
4 Security code to change.
Woodward 119
120 Woodward
Chapter 5.
Control Features and Functions
Engine Control
• Programmable Auto Start on Loss of Mains
• All units in Auto Mode with Loss of Mains detection enabled start and
assume load.
• Multiple Crank Repeat Setpoint
• Crank Repeat Timer
• Crank Fail Alarm/Shutdown
• Crank Cutout (rpm)
• Preglow
• Idle/Rated Relay
Engine Protection
• Oil Pressure
• Over/Under Alarm/Shutdown Settings
• Water Temperature
• Battery Voltage
• Overspeed
• Alarm/Shutdown Settings
Generator Voltage and Reactive Load Control

• VAR or Power Factor Load Control in Mains Parallel Operation
• Power Factor Sharing in Load Sharing, No Parallel Operation
• Externally Adjustable VAR/PF Reference
• Manual Voltage Control Capability
Generator Protection
• Over Current
• Reverse Current
• Loss of Excitation
• Stable Generator Determined by being within Voltage and Frequency Limits
for a given period of time.
• KVA Load Switch
Woodward 121
Mains Sensing
• Load Surge
• Programmable for Alarm/Loss of Mains Detect
• Loss of Mains Action Timer
• Stable Mains determined by being within Voltage and Frequency Limits for
a given period of time
Synchronizing
• Phase Match Synchronization
• 3 Mode Operation
• Run, Check, Permissive
• Voltage Matching
• Dead Bus Closing
• Synch Timer
• Reclose Attempt/Timer
• Manual Synchronization Capability (permissive mode)
Load Control
• Proportional Load Sharing
• Integrating Base Load and Process Control
• Load Ramping
• Remote Contact Inputs to change Base Load and Process Setpoints with
Raise/Lower ramp rates
• Unload Trip point
• Droop Load Control Capability
Sequencing
• Each Unit in the system has an assigned Priority.
• Master (Highest Priority) automatically sequences units on or off line as
determined by system load.
• Higher priority units are sequenced on in order of their priority; taken off in
reverse of priority.
• System Load setpoint determines percent system load level at which
additional units will be brought on, or taken off line.
• Time setpoints determine period of delay for sequencing units on/off line.
• Separate time delay for overload (100% +) system load levels so additional
units can be sequenced on line quickly.
122 Woodward
Engine Cranking
The EGCP-2 Control is designed to automatically control the cranking functions
of the engine generator set. In order to safely control engine cranking the
EGCP-2 uses the following setpoints, as found in the Engine Control tuning
menu of the software:
Preglow Time Crank Delay
Crank Time Crank Repeats
Crank Cutout
The description of the above items is found in the Tuning Screens section of this
manual in the Configuration Menu list.
Starting Sequence:
Upon receiving a start command the following events occur:
1. The Preglow Output Energizes for the given preglow time delay, and
remains energized through the crank cycle.
2. After the preglow time expires, the Fuel Solenoid output energizes.
3. 200 ms after the Fuel Solenoid output energizes, the Crank output energizes.
At this point, the engine should be cranking at a certain rpm, and receiving fuel.
Typically a start would occur in these conditions. To check if a start does occur,
the EGCP-2 monitors the magnetic pickup from the engine. If the magnetic
pickup input indicates that the engine is operating above the Crank Cutout speed,
the EGCP-2 will remove the Crank and Preglow outputs, leaving the fuel
solenoid energized. The engine state in the control overview menu changes from
“OFF” to “RUN”.
If for some reason the engine does not reach the crank cutout rpm level, the
EGCP-2 will crank the engine for the Crank Time. If the engine fails to rise
above the crank cutout level in this time, the EGCP-2 will remove the Crank
output signal, wait for the Crank Delay, and if allowed by the number of Crank
Repeats, will crank the engine again (RETRY). This sequence will continue until
the number of crank repeats is depleted, or until the engine speed rises above the
crank cutout rpm setting, whichever comes first. If the number of crank repeats is
depleted, the EGCP-2 will activate the Crank Fail Alarm Output based on this
Alarm setpoint’s configuration.
NOTE
The preglow output may stay energized between crank attempts if the
preglow time is greater than the sum of the Crank Time and Crank
Delay timers.
IMPORTANT
Set Crank Repeats to zero when starting the engine for the first time
with the EGCP-2. This will prevent starter and ring gear damage to the
engine if the MPU input to the control should be faulty. Monitor
Engine Overview Status menu on the first start and confirm the rpm
readout during cranking. After a successful start is made, the crank
repeats may be set to the appropriate value for the application.
Woodward 123
Idle/Rated Relay Output
The EGCP-2 can be configured to provide a relay output, which will signal the
engine electronic speed control to change from idle to rated speed operation.
When configured for this output, Discrete Output 12 will energize to provide the
idle to rated indication.
The idle to rated indication takes place after a successful start (generator above
crank cutout speed) has occurred, the engine is operating at, or above the idle
speed setpoint, and the idle delay time setpoint has expired.
Generator Voltage Control

The EGCP-2 has the ability to control the voltage of the generator set. This
ability is used to control four separate operations that require generator voltage
adjustment:
1. Manual voltage adjustment
2. Voltage Matching during Synchronization across the generator or mains
breaker
3. Reactive Load sharing between multiple units on an isolated bus
4. Reactive Load control while in parallel with the mains.
The generator voltage, or reactive load (depending on the operation) is adjusted
by injecting a voltage bias signal to the Automatic Voltage Regulator. The
EGCP-2 can be set for ±1 Vdc, ±3 Vdc, and ±9 Vdc outputs. The span of the
output is selected by the “Voltage Bias Type” configuration menu item in the
EGCP-2.
Select the proper voltage range input as recommended by the AVR manufacturer.
Generator Voltage can be manually controlled from the Voltage Raise and
Voltage Lower Discrete inputs to the EGCP-2. The rate of change for manual
voltage adjustment is set in the Reactive Load Control tuning menu, at the
Voltage Ramp Time setpoint. The voltage ramp time is the amount of time it will
take for the EGCP-2 to send a 0 to 100%, or 0 to –100% voltage bias signal to
the AVR.
When operating in the TEST mode, manual voltage adjustment is only allowed
through the voltage raise and lower inputs. This allows testing of the Voltage
Bias output, and generator voltage levels prior to operation with load on the
generator.
When operating in Isoch mode, the EGCP-2 does not allow manual adjustment of
the voltage, unless the Load Control setpoint in the Configuration tuning menu is
set for “Droop”, or the VAR/PF Control Setpoint in the Reactive Load Control
tuning menu is set to “Disabled”. Using either of these settings implies that a
manual voltage control will be used, and no automatic reactive load control
functions are active.
124 Woodward
NOTE
It is highly recommended that the automatic reactive load control in
the EGCP-2 be used for proper power conditioning throughout the
generator(s) load range. This is achieved by setting the Load Control
setpoint in the Configuration tuning menu to Normal, or Soft Transfer
(depending on the application), and the VAR/PF Control setpoint in
the Reactive Load Control tuning menu to VAR or PF control
(depending on the application). For more details on these functions
see the Real Load Control and Reactive Load Control sections of this
manual.
The percent level of the voltage bias output can be monitored in the I/O status
screen of the EGCP-2. This is a useful point to monitor during initial start of the
unit. By issuing Voltage Raise and Lower inputs to the control while operating in
the Test Mode, confirmation of proper generator voltage levels at various voltage
bias points can easily be made. Typically the generator voltage should change no
more than ±10% for a ±100% voltage bias output from the EGCP-2.
All other modes of generator set operation rely upon the Reactive Load Control
functions of the EGCP-2. See the information in the “Reactive Load Control”
section of the manual for more details on voltage and reactive load control.
Generator Load Control

Power Sensor Theory of Operation
The digital signal processing (DSP) power measurement technique used by the
EGCP-2 control involves periodic sampling of the voltage and current over an
integral number of 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 Description

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

multiple samples of each waveform over a number of cycles of the input are
taken to get the power measurement.
Woodward 125
The EGCP-2 Control has four core modes of generator load control operation.
These four modes are:
• Droop
• Isochronous Load Sharing
• Base Load
• Process Control
The specific mode of generator control that the unit is in at any given time can be
monitored on the Control Overview status screen.
Here is a description of each of these load control modes, and the various
operating states that will put the EGCP-2 into each respective load control
operation.
Droop
Droop Load Control in the EGCP-2 uses the sensed KW on the generator to
provide negative feedback to the speed reference of the speed control governor
through the speed bias output. This will result in a decrease in generator
frequency as the load is increased while operating as a single unit on an isolated
bus. Increasing the Speed Raise input while operating in this manner will
increase the speed of the engine gradually, thereby increasing the frequency of
the generator set.
While operating in parallel with the mains, droop operation provides KW load
control of the generator through the speed raise and speed lower inputs to the
EGCP-2. Since the mains determine the frequency of the generator, changing the
speed reference while in parallel with the mains causes a change in KW
produced.
Droop load control is typically only used during commissioning of the EGCP-2.
It allows complete manual control of the generator load while in parallel with the
mains.
The EGCP-2 can be operated in Droop if the Real Load Control menu item
“Load Control Mode” is configured for KW Droop or if the unit is operated with
the Generator CB Aux input open while connected to a load, or to the mains. No
other operations, or software setpoints can change the droop load control mode
setting.
126 Woodward
Figure 5-1. Droop Mode
Isochronous
Isochronous means repeating at a single rate or having a fixed frequency or
period. A generating set operating in the isochronous mode will operate at the
same set frequency regardless of the load it is supplying up to the full load
capability of the generator set, as illustrated in Figure 5-2. This mode can be used
on one generator set running by itself in an isolated system.
Figure 5-2. Isochronous Mode
Woodward 127
The isochronous mode can also be used on a generator set connected in parallel
with other generator sets. Unless the generator set controls have the capacity for
load sharing and speed control, no more than one of the generator sets operating
in parallel can be in the isochronous mode. If two generator sets operating in the
isochronous mode, without load sharing capability, are tied together to the same
load, one of the units will try to carry the entire load and the other will shed its
entire load. In order to share load with other units, some additional means must
be used to keep each generator set from either trying to take or shed the entire
load.
Droop/Isochronous Load Sharing on an Isolated Bus

Droop/Isochronous combines the first two modes. All generator sets in the
system except one are operated in the droop mode. The one unit not in droop is
operated in the isochronous mode. It is known as the swing machine. In this
mode, the droop machines will run at the frequency of the isochronous unit. The
droop and speed settings of each droop unit are adjusted so that each generates a
fixed amount of power as illustrated in Figure 5-3. The output power of the
swing machine will change to follow changes in the load demand.
Figure 5-3. Droop/Isochronous Load Sharing
Maximum load for this type of system is limited to the combined output of the
swing machine the total set power of the droop machines. The minimum system
load cannot be allowed to decrease below the output set for the droop machines.
If it does, the system frequency will change, and the swing machine can be
motorized.
The machine with the highest output capacity should be operated as the swing
machine, so that the system will accept the largest load changes within its
capacity.
128 Woodward
Isochronous Load Sharing on an Isolated Bus
Isochronous Load Sharing is the most common means of paralleling multiple
generators together to a common load on an isolated bus. The EGCP-2 uses
Isochronous Load Sharing control when operating in a Multiple Unit mode with
the Load Control Mode in either Normal or Soft Transfer. Isochronous load
sharing operates all generator sets in a system in the isochronous mode. Load
sharing is accomplished by using the load sensor of the EGCP-2 to bias the speed
reference of the isochronous governor. The EGCP-2 load sensors are connected
by inter-control RS-485 network. In the case of the EGCP-2 control, Isochronous
Load Sharing is done digitally via this network. Any imbalance in load between
units will cause a change to the regulating circuit in each governor. While each
unit continues to run at isochronous speed, these changes force each machine to
supply a proportional share of power to meet the total load demand on the
system.
Base Load Against the Mains

Base Load is a method of setting a base or fixed load on a machine operating in
parallel with the mains. The EGCP-2 control operates the generator set in base
load whenever the generator is in parallel with the utility, unless a process control
mode of operation is selected through the Process discrete input. This is
accomplished by using an isochronous load control and providing a reference
level at which to control the load. The governor will force the generator output to
increase or decrease until the output of the load sensor is equal to the reference
setting. The base load reference is set in the Real Load Control tuning menu of
the EGCP-2. At this point, the system is in balance.
The advantage of base loading over droop is that when separating from a Mains,
there is no frequency change. Simply removing the bias signal required to
maintain the base load reference on breaking from the Mains (mains CB Aux
open) returns the system to isochronous load control.
The EGCP-2 is only allowed to parallel with the mains in a Mains Parallel
operating mode. When configured for this type of operation, the EGCP-2 will
operate in either a base load or process control mode while in parallel with the
mains. The EGCP-2 automatically switches between base load and isochronous
operation depending upon whether or not the Mains Breaker CB Aux input is
closed at the same time the Generator CB Aux input is closed. If both the Mains
and the Generator CB AUX are closed, then the EGCP-2 realizes it is in parallel
with the mains, and operates in a base load control mode. The EGCP-2 will
operate in a process control mode, which is discussed later in this section, if both
the Process and Run with Load discrete inputs are active (on).
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 bumpless transfer when paralleling the generator
to a load sharing or infinite bus system, or when separating a generator from a
system.
Woodward 129
Process Control Description
The process control function of the EGCP-2 control will control any process
where the controlled parameter is determined by the generator load, and the
controlled parameter can be monitored as a 4–20 mA or 1–5 Vdc input signal.
The control compares the Process Input signal to the Process Reference setpoint
in the Process menu of the EGCP-2. This setpoint uses milliamps for units, so
that it is easily related to the 4–20 mA or 1–5 Vdc input signal. The EGCP-2 then
adjusts the generator load to maintain the desired value. The EGCP-2 will only
operate in a process control mode if it is configured to be a Mains Parallel unit,
and receives an Auto, Run With Load, and Process discrete inputs. Also, the
EGCP-2 can operate in a process soft transfer mode if the Load Control Mode
setpoint in the Real Load Control menu is set for Soft Transfer, and the Test
discrete input is closed with the Auto, Run with Load and Process discrete inputs.
In a soft transfer mode, the EGCP-2 will load the generator(s) (depending on the
application) to the process reference level. Upon reaching the reference value on
the 4–20 mA or 1–5 Vdc input signal, the EGCP-2 will open the mains breaker.
This Soft Transfer mode is used to transfer the supply of power for the load from
the mains to the generator(s).
In process control mode, the Raise Load and Lower Load Discrete Inputs operate
on the process control reference. The ramp rates for these Raise and Lower Load
inputs are set in the Process menu, at the Process Raise and Process Lower Rate.
These two setpoints are scaled in % per second.
When the process function is initially selected, the reference is set equal to the
internal process reference. If the process input and process reference are not
equal, the control ramps the load reference in the appropriate direction to reduce
the difference. When the process error reaches zero, the process control is
enabled.
When the process control is enabled, the error signal between the process
reference and process signal is routed to a PID (Proportional, Integral,
Derivative) controller operating in cascade with the load control. The output of
the controller is a load reference, which is limited by the KW Load High and
Low Limit set points in the Real Load Control menu. This prevents the generator
from being overloaded or reversed powered to achieve its reference point.
In a multiple unit, mains parallel configuration, the master unit (lowest numerical
priority) operates as the Process Master. The master unit must receive the 4–20
mA, or 1–5 Vdc process input signal. The master unit will control all slave units,
which are in Auto mode to maintain the process reference of the master. The
slave units operate in a load sharing mode in which the total system load is
equally divided between the units in proportion to their rated load capacity. The
master will also automatically sequence slave units on and off 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
the KW Load Low Limit setting.
130 Woodward
The Process Master EGCP-2 will not automatically pass the Master flag. When
operating multiple units in Process control there are ways to pass the Master. To
pass the Master to a slave unit, the slave unit must have the same discrete inputs
(Auto, Run w/Load, and Process) as the Master.
1. Pass the Master by changing the priority of the slave to 1. The EGCP-2 will
pass the Master to the slave, and if the new Master has the same process
reference setting there will be no noticeable change.
2. Pass the Master by removing the Auto input from the present Master. This is
the recommended way to pass the Master when the present Master receives a
shutdown fault. An external device will have to recognize that the Master is
shutdown and that there is another EGCP-2 that is available to be the Master.
The generators will unload to their KW Load Low Limit settings, and as
soon as the Master changes, the new Master will load the units until the
Process reference setting is achieved.
The Process Reference point can be scaled in any one of 14 selectable Process
Units. The Process Units selection can allow the operator to see the Process
Reference value in KW or MW instead of milliamps. The Process Low and High
Value will need to be configured whenever a different Process Unit is selected.
The Process Unit will also change the Process Reference, Process Low Limit,
and Process High Limit.
Additional features of the process control are an adjustable process input signal
filter and adjustable deadband on the integrator. The adjustable filter allows
reducing bandwidth when controlling a noisy process such as experienced in
digester gas fuel applications. The deadband is useful in noisy applications as
well as for very slow processes.
The process control function is configurable for direct and inverse action. Direct
process control is where the sensed input signal increases as the load increases
(such as where the sensed input is exhaust pressure or export power). An inverse
action control is where the sensed input signal decreases as the load increases
(such as when controlling import power where the import power will decrease as
the generating system picks up more of the local load).
Reactive Load Control Description

When a small generator is paralleled with a Mains, the synchronizer voltage
matching function adjusts the generator voltage to match that of the Mains.
Voltage variations that may occur in the Mains system after paralleling can cause
large changes in reactive current in the generator. The VAR/Power Factor
Control provides closed loop control of either VARs or power factor when
operating in parallel with another power system when that system can accept the
reactive load.
Voltage adjustment, however, can only affect reactive power when another
system is available to accept the reactive load. So the VAR/Power Factor control
functions are automatically switched to Power Factor sharing when either single
or multiple units are operating in isochronous load sharing mode on an isolated
bus (Mains Breaker is open).
Woodward 131
The VAR/PF control mode of operation is selected by setting the VAR/PF
Control Mode set point in the Reactive Load Control tuning menu. When either
VAR or PF control mode is selected, the control function is enabled whenever
the Generator CB Aux contact is closed, and the control is configured for either
Normal or Soft Transfer Load Control. VAR/PF control is overridden when the
Load Control Mode is set for Droop operation. The VAR/PF control can be
disabled by setting the VAR/PF Control Mode setpoint to Disabled. The voltage
bias output is reset to 0% when the generator breaker is opened.
NOTE
If cross-current compensation is installed on the voltage regulator, it
must be removed prior to using the VAR/PF mode of control, or
instabilities may result. The droop CT must remain connected to the
voltage regulator.
Voltage Trim Control

The EGCP-2 control will perform a Voltage Trim function when configured for
Single unit or if it’s the only Multiple unit operating on an isolated bus. The
Voltage Trim function will control the generator set at the Voltage Reference
setting (Configuration menu) when on an isolated bus.
The conditions for Voltage Trim to activate are:
• Single Unit
o Isolated bus
o VAR/PF Mode cannot be Disabled
• Multiple Unit
o Isolated bus
o Only unit operating
o VAR/PF Mode cannot be Disabled
VAR Control
The VAR control adjusts generator voltage to maintain a constant reactive power
(kVAR) load on the generator throughout the KW operating range while the
generator is in parallel with the mains. This assures sufficient excitation of the
generator field under all load conditions. A set point is provided to set the desired
VARs. The VAR control function may be enabled with VAR/PF Control mode
selection set point. The KVAR reference may be changed once the generator is in
parallel with the mains by issuing a raise/lower voltage contact input to the
EGCP-2. Raising the KVAR reference will raise the voltage bias output to the
voltage regulator, which will cause VARs to be exported to the Mains. Lowering
the VAR reference will decrease the voltage bias output to the regulator that will
cause VARs to be absorbed from the utility.
Power Factor Control

The power factor control adjusts generator voltage to maintain a constant power
angle throughout the KW operating range while the generator is in parallel with
the mains. A set point is provided for the desired power factor reference. The
power factor control function may be enabled with the VAR/PF Control mode
selection set point. The PF reference may be changed once the generator is in
parallel with the mains by issuing a raise/lower voltage contact input to the
EGCP-2. Raising the PF reference will raise the voltage bias output to the voltage
regulator, which will cause the PF to move in an increasing lagging PF angle.
Lowering the PF reference will decrease the voltage bias output to the regulator
that will cause PF to move in an increasing Leading PF angle.
132 Woodward
Power Factor Sharing
When either VAR or Power Factor Control is selected, and the EGCP-2 control is
operating in isochronous load sharing mode, power factor sharing is
automatically selected. Power factor sharing adjusts the voltage regulators so that
all generators carry the same proportion of reactive load by balancing the power
factor on all units. A voltage reference set point is provided to define the system
operating voltage. Multiple EGCP-2 controls operating in Power Factor Sharing
mode will trim their respective voltages to share the reactive load on the isolated
bus, and operate around the voltage reference setting.
Synchronizer Description
Synchronization, as normally applied to the generation of electricity, is the
matching of the output voltage waveform of one alternating current electrical
generator with the voltage waveform of another alternating current electrical
system. For the two systems to be synchronized and connected in parallel, five
conditions must be considered:
• the number of phases in each system
• the direction of rotation of the phases
• the voltage amplitudes of the two systems
• the frequencies of the two systems
• the phase angle of the voltage of the two systems
The first two conditions are determined when the equipment is specified,
installed, and wired. The synchronizer matches the remaining conditions
(voltage, frequency, and phase) before the paralleling breakers are closed.
Functional Description
This section describes how generator and bus matching occurs and how all
conditions are verified by the synchronizer functions.
Operating Modes
The EGCP-2 control is capable of synchronizing across both the generator and
mains breakers, depending on the application of the generator set, and the
configuration of the EGCP-2. An EGCP-2 configured for No Parallel operation
will never allow the generator and mains breakers to be closed at the same time,
and therefore does not synchronize across the mains breaker. Units configured
for Mains Parallel operation will actively synchronize the generator, or in the
case of a multiple unit system, generators, to the utility before closing the utility
tie breaker.
The EGCP-2 monitors the A phase of the generator and compares this with either
the A phase of the Bus PT input, or the A phase of the Mains PT input. The Bus
PT input is switched through DO7 (local bus connect). The Bus PT is always
monitored whenever the EGCP-2 is synchronizing, or dead bus closing across the
generator breaker. Bus PT sensing is a momentary condition as the EGCP-2 will
always return to sense the Mains PT input by switching to DO8 (Mains
Disconnect) whenever generator synchronization is complete. Switching to the
Mains PT allows the EGCP-2 to monitor for a loss of mains condition when
operating on a generator that is not synchronizing across its generator breaker.
Woodward 133
NOTE
In systems which operate in parallel with the mains, or with loss of
mains detection modes, it is recommended that each EGCP-2 unit in
that system receive the Mains and Bus PT inputs for proper
operation.
The synchroscope tuning menu is used to configure the synchronizing action of

the EGCP-2. The software tuning items in the synchroscope menu apply to both
the generator breaker/contactor and mains breaker/contactor synchronizing
functions.
The operation of the synchronizer is determined by the three different operating

modes available in the EGCP-2. The three modes are Run, Check, and
Permissive.
Run mode allows normal synchronizer operation and breaker closure signals. The
speed bias signal (explained below) is maintained throughout the breaker closure
signal. When the specified closure signal time has elapsed and the CB (circuit
breaker) Aux contact closure signal is received at the EGCP-2, the synchronizer
is disabled. The synchronizer is reset automatically once the generator is taken
off load and its generator breaker is opened.
Check mode allows normal synchronizing and voltage matching, but does not
issue a breaker closure signal.
Permissive mode enables the synch-check function for proper synchronization,

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

When a dead bus is detected and dead bus closing mode is enabled in a multiple
unit system, the synchronizer will attempt to get an exclusive lock on permission
to issue a breaker closure command. This security is required to prevent two or
more units from closing their breakers at the same time. To provide this security,
a network message requesting the lock is made to all other EGCP-2 controls
currently active on the network.
When an EGCP-2 control receives a lock request, it does the following actions:
1. If a dead bus permission request is not also currently being made, a dead bus
condition is indicated, and the GENERATOR AUX CONTACT discrete
input is inactive (the EGCP-2 control returns a reply message to the
requesting unit).
NOTE
The GENERATOR AUX CONTACT open requirement backs up the
dead bus condition in the event of a bus PT failure. If a dead bus
condition is indicated by lack of bus voltage, but the generator
breaker is closed, a reply will not be sent.
134 Woodward
2. If a dead bus permission request is also being made and that request
sequentially precedes the received request, the received request is retained,
otherwise the reply is sent. (In the event of a sequential tie, the unit with the
lower assigned network address wins.)
When all other units have replied verifying that they also indicate a dead bus
(bus input less than 40 Vac) and do not hold a lock, the requesting unit then
holds lock permission and may attempt to close its circuit breaker. The lock
is released automatically after issuing the circuit breaker closure command.
This will allow any other unit to get permission to lock if the breaker fails to
close.
The dead bus closing function may be enabled or disabled by the user with
the Dead Bus Closure setpoint in the Synchroscope tuning menu.
Voltage Matching
The voltages of the generators in a parallel system must be matched within a
small percentage to minimize the reactive power flow in the system. If two
synchronous generators of unequal voltage are paralleled, the combined voltage
will have a value different from the voltage generated by either of the generators.
The difference in voltages results in reactive currents flowing in the system with
subsequent lowered system efficiency.
If a synchronous generator is paralleled to a larger system such as a Mains, a

difference in voltages before paralleling will not change the voltage of the bus. If
the generator voltage is lower than the bus voltage, reactive power will be drawn
from the bus and used to excite the generator to the higher bus voltage.
In the case where the generator voltage is low enough, the reactive power flow
could motorize the generator with potential damage to the generator windings.
The microprocessor then computes the RMS values of the voltages. The
processor issues appropriate adjustment of the voltage bias signal if used, to the
voltage regulator to bring the generator voltage within the specified window
above the bus voltage. To guarantee that reactive power will be generated,
window range is from equal to bus voltage to the specified percentage above bus
voltage.
The automatic voltage matching function may be enabled or disabled with a set
point. When enabled, voltage matching will occur in both the Check and Run
modes and is verified only by the sync-check function in Permissive mode. When
enabled at an EGCP-2 control which is monitoring and controlling the mains
breaker, the voltage matching will occur across both the generator and mains
breaker prior to the synchronizer issuing a breaker close command when
paralleling the generator(s) to the mains.
Woodward 135
Phase Matching Synchronizing
The phase matching synchronizing mode corrects the frequency and phase of the
generator to lock it to the bus frequency and phase. The microprocessor uses
signal processing techniques to derive the difference in phase of the generator A
and bus A phase voltage signals. When there is a difference, the synchronizer
sends a correction signal to the speed control. The correction signal from the
speed bias output increases or decreases engine speed depending on whether the
slip is faster or slower than the bus. A PI (proportional, integral) controller
provides the correction signal. Gain and Stability adjustments to the PI controller
are provided to allow stable operation of the automatic synchronizer function
over a wide range of system dynamics.
Synch-Check
The synch-check function determines when all conditions for proper
synchronization are satisfied and energizes the breaker closure relay. The
generator and bus voltage comparison is made if the voltage matching function is
enabled. The generator voltage must be within the specified voltage window
above bus voltage before the breaker closure command may be given.
To minimize transients, the breaker must be closed when the phase difference
between the generator and bus is near zero. Also, maintaining the phase angle
error between the generator and the bus within a specified Max Phase Window
for a specific Dwell Time allows the synchronizer to be configured for a wide
range of synchronizing conditions. The Max Phase Window and Dwell Time
setpoints are found in the Synchroscope tuning menu of the EGCP-2.
A larger Max Phase Window, and Shorter Dwell time would typically be used on
emergency standby sets, where rapid synchronization is needed. The larger
window and shorter dwell time make the synchronizer less sensitive to transitions
in generator frequency and phase angle error when compared to the bus the
generator is synchronizing to. When all conditions of voltage and phase are met,
then the breaker closure command is given.
A smaller Max Phase Window and Longer Dwell Time would be used on
generating systems where smooth and precise synchronization is required, and
the time to synchronize is not as critical as would be seen in a standby
application. A smaller window and longer dwell time require the generator to be
within closer frequency and phase angle error tolerance when compared to the
bus the generator is synchronizing to. When all conditions for voltage and phase
are met, then the breaker closure command is given.
Multiple Shot Reclosing

The multiple shot reclosing function allows multiple closing attempts. The
control provides set points for the number of Close Attempts and the Reclose
Delay time. Failure to get closure after the specified number of attempts triggers
the Sync Reclose Alarm and locks out the synchronizer by setting it to the auto-
off mode. Clearing the alarm condition, in the Alarm/Event Log, will reset the
synchronizer.
136 Woodward
Synchronizer Timing
The time line diagrams below illustrate the various timing sequences the
synchronizer function uses when paralleling single and multiple units across the
generator or mains breaker (depending on application).
SYNCHRONIZER TIME LINE

STANDARD SEQUENCE: SYNC TIMEOUT ACTIVE (>0 sec.)
CB HOLD TIME
TRIP POINT
AT UNLOAD
DWELL TIME
CB HOLD TIME
PHASE AND VOLTAGE UNLOAD RAMP
MATCHING TIME SYNCHRONIZER OFF
BREAKER CLOSED UNIT ON LOAD
(CB AUX INPUT RECEIVED)
UNLOAD COMMAND ISSUED

(SYNCHRONIZER IN OPEN
BREAKER MODE)
IN SYNCH.
COMMAND ISSUED
BRKR CLOSE
COMMAND REMOVED
BRKR CLOSE
COMMAND ISSUED
BREAKER OPEN
COMMAND REMOVED
BREAKER OPEN
SYNCHRONIZER
ACTIVATED
= SYNCH TIMEOUT PERIOD
WITH RECLOSE ATTEMPTS : SYNCH TIMEOUT ACTIVE AND EXCEEDED

(PARTIAL)
RECLOSE DELAY
CB HOLD TIME
DWELL TIME
PHASE AND VOLTAGE PHASE AND VOLTAGE

MATCHING SYNCHRONIZER OFF MATCHING
TIMEOUT ALARM ACTIVE 020-100
00-04-27
IN SYNCH.
COMMAND ISSUED
BRKR CLOSE
COMMAND REMOVED
BRKR CLOSE
SYNCH TIMEOUT EXCEEDED
SYNCHRONIZER ACTIVE
ALARM RESET
SYNCHRONIZER
ACTIVATED
= SYNCH TIMEOUT PERIOD
Figure 5-4. Synchronizer Time Line—Standard Sequence
Loss Of Mains Detection and Action

The EGCP-2 can be configured to detect a loss of mains condition, and respond
to that condition by isolating the mains from the load, and transferring the supply
of power to the load from the mains to on site engine generator sets.
The EGCP-2 can be configured for single or multiple unit, no parallel or mains
parallel system operation, which will detect a loss of mains. The loss of mains
action is a combination of synchronizing and load control functions of the
EGCP-2. These functions allow the EGCP-2 controls to operate effectively upon
a loss of mains condition.
Below are timing diagrams for mains parallel and no parallel systems. These time
lines apply to the master control in multiple unit systems, or to any single unit
application.
Woodward 137
Standard Sequence: Single No Parallel Unit in Auto with Loss Of Mains Detection Enabled.
LOM Action Delay Expires

LOM Action Delay Starts
Fast Transfer Mains Stable Fast Transfer Mains In Spec and

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

Open Mains Breaker
Gen Breaker Closes

Mains Out of Spec*
Open Gen Breaker

Gen Stable. Start Fast
To Dead Bus
Start Genset
Transfer Delay
TIME VIS-110
00-04-27
*Over/Under Frequency
and/or Over/Under
Voltage
Figure 5-5. Loss of Mains Detection Active
Standard Sequence: Single Mains Parallel Unit in Auto with Loss Of Mains Detection Enabled.
Fast Transfer Mains Stable Generator Mains In Spec and

Mains in Spec. Gen Stable Delay Delay Genset On Load Delay Unload Ramp On Load
Mains in Spec.
Synchronize and Close

Open Mains Breaker
Gen Breaker Closes
Open Gen. Breaker

Mains Out of Spec*
Gen Stable. Start Fast
To Dead Bus
Mains Breaker
Start Genset
Transfer Delay
TIME VIS-111
00-04-27
*Over/Under Frequency
and/or Over/Under
Voltage
Figure 5-6. Generator Off Line
138 Woodward
Standard Sequence: Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains
Detection Enabled.

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

Open Mains Breaker
Mains Out of Spec*
Open Gen. Breaker

Mains Breaker
TIME
*Over/Under Frequency VIS-112

and/or Over/Under 00-04-27
Voltage
Figure 5-7. Mains Parallel Unit with Voltage/Frequency Detect
Standard Sequence: Single Mains Parallel Unit Running On Load in Auto with Loss Of Mains
Detection Enabled. Load Surge Event
Open Mains Breaker
Mains Stable Generator Mains In Spec and

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

Load Surge Level
Mains Breaker
Exceeded*
TIME
VIS-113
00-04-27
* Load Surge detection is
immediate.
Figure 5-8. Mains Parallel Unit(s) with Load Surge Detect
Woodward 139
Generator Sequencing
Generator Sequencing is a capability of the EGCP-2 control to maintain an on-
line generator capacity to Kilowatt load ratio for a multiple unit setup. In order to
activate the automatic sequencing function of the EGCP-2, each unit in a
multiple unit system must have the following software setpoints enabled:
Configuration Menu:
Number of Units Automatic Sequencing
Multiple Enabled
Each unit in the system must be in the Auto mode (Discrete Input #1 Closed) to
be an active part of the sequencing system.
When configured for automatic sequencing, as described above, the Sequencing

status screen of the EGCP-2 will show all of the active units on the network in
order of their Network Address, and the priority of those units in the sequencing
scheme. Units not in Auto mode, or with the Number of Units setpoint set for
Single, will display the message “Manual Unit No Sequencing” in the
Sequencing Status Screen. Units in Auto mode, and set for Multiple unit
operation, but with the Auto Sequencing setpoint Disabled will still appear in the
Sequencing status screen, but will not respond to automatic sequencing
commands from the Master, and are not capable of operating in a Master control
mode.
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 minutes, allowing the
system load to stabilize.
The EGCP-2 uses calculated system load levels to determine the points at which
the master sequences on or off units. The master may not sequence a unit off
load, even though it is at or below the min gen load set point, if this would cause
the system load to rise above the Max Gen Load minus 10%.
A typical automatic sequencing scenario is shown below. The system represented

is composed of three units on an isolated bus feeding varying plant loads that are
fed by the generators. The master unit (network priority #1) has the following set
points for sequencing in the Sequencing and Comms menu:
Max Gen Load = 65% Next Genset Delay = 30 seconds

Rated Load Delay = 5 seconds Max Start Time = 60 seconds
Min Gen Load = 25% Reduced Gen Dly. = 30 seconds
Max Stop Time = 15 seconds
NOTE
These settings are for demonstration only. Sequencing setpoints may
vary depending upon system requirements.
140 Woodward
100%
65%
SYSTEM
LOAD
25%
TIME
VIS-114
00-04-27 A B C D E F G H J K L M
Figure 5-9. Typical Automatic Sequencing Scenario
Point A
Master Generator carrying load isochronously on an isolated bus. System load
steps from approximately 10% to 30%.
Point B
Master Generator responds to a step load that brings the system load to
approximately 70%. This level exceeds the Max. Gen Load setpoint (65%) in the
Real Load Control tuning menu. The Master control begins timing for the Next
Genset Delay period 30 seconds. After the 30 seconds expires, the load is still
above the Max Gen Load setpoint. The master control issues a start command to
the next unit on (network priority #2).
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 setpoint.
Point C
Ten seconds after receiving its start command, network priority #2 unit closes
onto the bus and ramps into load sharing with the master.
Point D
System load levels drop to approximately 45% after unit #2 is finished ramping
into load sharing.
Point E
A very large step load on the bus loads both generators in excess of 100% of
their rated load. The system load reflects these levels. The master unit begins
timing to the Rated Load Delay (5 seconds) before starting the third unit.
Woodward 141
Point F
The third unit closes its breaker to the two units already on the isolated bus.
Since the rated load delay is in effect, and the system load is above 100% of the
generating capacity on line, the third unit immediately goes to load sharing,
without any load ramping. System load drops immediately to approximately 55%
when the third unit closes its breaker to the bus.
Point G
A step load decrease on the bus brings the system load down to approximately
35%. All three generators remain on line in isochronous load sharing.
Point H
A further step load decrease on the isolated bus brings the system load below the
Min Gen Load setpoint of 25% to approximately 10%. The master begins timing
for the Reduced Gen Dly time of 30 seconds.
Reduced Load Dly—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 to stop units until the system
load level increases above the Min Gen Load setpoint or until all units have been
sequenced off.
Point J
Since the system load is still below 25%, and the master’s Reduced Gen Dly
timer has expired. The master unit issues a command to Unit 3 (network priority
3) to off load and open its gen breaker. Unit 3 begins to ramp off load. System
load begins increasing. The master begins its Max Stop Time delay of 15 seconds
before checking to see system load is low enough to allow sequencing of another
unit off line.
Point K
Unit 3 reaches its unload trip point and opens its generator breaker. The system
load is still below the Min Gen Load setpoint of 25%. The Master’s Max Stop
Time delay has expired. The master begins timing for the next gen off delay time.
Point L
The system load remains below 25%, and the master issues a command to unit #2
(network priority #2) to off load.
Point M
Unit 2 ramps off load and opens its generator breaker. This leaves the master unit
(network priority #1) on line supplying the load. When required the master will
sequence units on and off line as shown above and determined by the sequencing
setpoints in its Sequencing and Comms menu.
The Master unit in any multiple unit EGCP-2 system is always the unit with the
lowest Network Priority setting. All slave units are then sequenced on line in
ascending order of their Network Priority settings, and sequenced off line in
descending order of their Network Priority Settings. The Master is always
responsible for any automatic sequencing of the slave units on and off line.
142 Woodward
When the application consist of multiple units of different sizes, the sequencing
of units offline changes. The Master cannot look only at the System Load level to
determine when to sequence off a unit. The Master also knows the KW load the
slave unit is carrying. This allows the Master to determine when it can unload a
unit without increasing its load over the Max Gen Load level.
Example:
Generator 1 = 500 KW Generator 2 = 1000 KW
Master Slave
Max Gen Load = 60%
Min Gen Load = 25%
Isolated bus, both units are online.

System Load = 50% No Change
System Load = 25% No Change
There is no change because 25% means
500 KW has 125 KW of load
1000 KW has 250 KW of load
• If the Master unit sequenced off the 1000 KW generator, the 500 KW would
be carrying 375 KW, System Load = 75%
• The Master cannot sequence off Generator 2 until the System Load will be
50% or less after generator 2 is offline.
• What is 50% load to Generator 1? System Load = 50% = 250 KW
• So the total system load must be 250 KW or less before generator 1 can be
sequenced off. This is a System Load of 16% or less with both generators
operating.
Network Priority
In order to give the end user of the EGCP-2 the ability to control engine run time
levels in a multiple unit system, any EGCP-2 in the system can be used to change
the network priority of any of the EGCP-2 units actively on the same network.
For a unit to be active on the network, it must have its Auto discrete input closed,
be configured for Multiple Unit operation, have its Auto Sequencing setpoint
Enabled, and be physically connected to the RS-485 network between units.
The ability to change the priority of any unit on the network has some
fundamental rules associated with making changes to the unit priority.
These rules have to do with assuming a new master, changing the sequence of on
load units, and permissive sequence change states.
Here are some reasons the Master will NOT pass to another unit:
1. If the System Load is greater than the Max Gen Load level of the Master.
2. Auto Sequencing = Disabled
3. EGCP-2s operating in the Base Load mode
Assuming a New Master—All Units Off Load

When a unit’s priority is changed in such a manner as to make it the new master
on the system, the response of the system to the change of masters depends on
the operating state of the system at the time the change is made.
Woodward 143
If the system is not on load and the engines are not running, and has not
experienced, or is not configured for a loss of mains condition, then switching the
priority of the master will have the following effect on the system:
After a maximum of 5 seconds, the Master indication in the Sequencing Status

screen will indicate the new master unit.
Shortly after this occurs, the new Master’s Sequencing Status screen will re-order
the Next On and Next Off slave units to fit the new system priority configuration.
No units will start or go on load under these conditions as a result of the

assumption of the new master.
MAINS
NO MAINS FAILURE DETECTED
MASTER SEQUENCING SCREEN

ADDRESS: 1 2 3
OPER.
PRIORITY 1 2 3
MASTER 1 SYSTEM LOAD = %
NEXT ON ALL
NEXT OFF
ALL GENERATORS OFF LOAD
VIS-115
00-04-27
G G G
NETWORK ADDRESS #1 NETWORK ADDRESS #2 NETWORK ADDRESS #3
NETWORK PRIORITY #1 NETWORK PRIORITY #2 NETWORK PRIORITY #3
Figure 5-10. Original System Configuration
MAINS

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

VIS-116
00-04-27
G G G
Figure 5-11. After a Change of Priority—Units Not Operating
144 Woodward
Assuming a New Master—Master On Load
The next sequencing priority change scenario involves having the master unit on
the isolated bus due to a loss of mains condition. The two slaves units are off line
because the system load does not require them to be sequenced on line. Changing
the network priority of the master will establish a new master on the system.
The master unit will always have a Min Gen Load setting of 25%, and a Max
Gen Load setting of 65%. These values will be used throughout the remaining
examples.
MAINS
MAINS FAILURE DETECTED
Or Run With Load and No
Parallel Application

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
NEXT ON 2
NEXT OFF
VIS-117
00-04-27
G G G
Figure 5-12. Original System Configuration
Within a 1-minute period the sequencing screen on any unit will reflect the
change of master from unit one to unit two.
The system load is at a level somewhere between 25 and 65 percent, at which no

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

ADDRESS: 1 2 3
OPER. X X
PRIORITY 2 1 3
NEXT ON 3
NEXT OFF 1
VIS-118
00-04-27
G G G
Figure 5-13. Master transfers to Unit 2
Woodward 145
When the sequencing screen displays the new master, the new master engine will
begin its start sequence. The new master must start and go on line in order to take
over its new role as master, which means to be in control of the load, and of the
sequencing control of the slave units.
Remember: The new Master needs a reason to start. If the original Master was
started with a Run w/Load input and you switch the Master to another unit that
only has the AUTO input closed, the new Master will NOT start. This example
shows that the new Master will start due to a LOMs condition.
If all 3 units are in the AUTO mode, and a LOMs is detected. All 3 units will be
told to start by the Master. Once online the Master could sequence the slave units
off if the system load was low. Now if I switch Masters, the new Master will start
and synchronize on to the bus. The new Master will now follow its sequencing
values for starting and stopping the slaves.
The new master (Network Address 2) will start and parallel to the previous
master (Network Address 1). Load control will be isochronous load sharing
between the two units. See Figure 5-13. If the system load is greater than 25%,
then both units will remain on line. If the system load drops below 25%, then the
new master (Network Address 2) will sequence the slave (Network Address 1)
off line.
The new master has fully established itself on the network as the Master.
The above actions take place simply by changing the priority of any given unit so
that that unit is the New Master. As long as the unit is in auto mode, configured
for multiple unit operation and attached to the network, it will automatically
transfer itself to the Master Position.
Units operating in Auto with the Run with Load discrete input closed will
effectively transfer, or recognize the transfer of master units. However, being in
an auto and run with load mode, those particular units cannot be sequenced off
line by the master control.
If a unit is not in auto mode, or is configured for single unit operation, or is not
attached to the RS-485 network, then no transfer of master can occur.
Also, for a transfer of master to occur, the units have to be in an auto sequencing
mode of operation. This implies either a load sharing, or process mode of load
control. Without being in these operating modes, a transfer of master cannot
occur because the New Master cannot sequence the Previous master off line. The
load control mode which does not support master transition is the Base Load
mode. In Base Load Mode, there is no sequencing between units, and therefore a
change of master cannot take place until the units are either taken out of base
load mode, or switched to an isochronous load sharing, or process control mode.
NOTE
Master Controls operating in the Process Control Mode must have a
4–20 mA or 1–5 Vdc transducer input to function properly.
146 Woodward
Changing the Priority of a Slave Unit—No Slaves On Load
MAINS

ADDRESS: 1 2 3
OPER.
PRIORITY 1 2 3
NEXT ON ALL
NEXT OFF
VIS-119
00-04-27
G G G
Figure 5-14. Changing the Priority of a Slave Unit
If a slave unit’s priority is changed in such a way as to simply shift that slave’s
place in the sequencing scheme without making the slave a New Master, then one
of two things will happen depending on that slaves place in the priority order:
1. The slave will simply take its place in the new sequencing order without
having to go on load.
2. The slave will have to go on load in order to properly assume its new
priority setting in sequencing system.
Case 1 will occur if the slave’s priority is changed either when there are no units
running, and no Loss of Mains detection has occurred, or if the slave itself is not
running due to system load levels not requiring the unit to be on line, and the
priority of the slave is decreased (taken to a higher numerical value).
MAINS
OR RUN WITH LOAD AT MASTER

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
NEXT ON 2
NEXT OFF 3
VIS-120
00-04-27 G G G
Woodward 147
Master running on load against the isolated bus (Figure 5-15). System load level
is at 40%, so no slave units are sequenced on line.
MAINS

ADDRESS: 1 2 3
OPER. X
PRIORITY 1 2 3
NEXT ON 3
NEXT OFF 2
VIS-121
00-04-27
G G G
A priority change at units with the network addresses of #2 and #3 switches the
network priority between these two units. Since neither unit is operating (only the
master is on load) the priority change takes place, and is recognized by the
master. The change is seen in the next on /next off display at the master
sequencing status screen. See Figure 5-16.
Changing the Priority of a Slave Unit—Slave On Load

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

ADDRESS: 1 2 3
OPER. X X
PRIORITY 1 2 3
NEXT ON 3
NEXT OFF 2
VIS-122 G G G
00-04-27
148 Woodward
Above figure represents system on load on an isolated bus in load sharing. The
master unit has sequenced on the priority 2 slave unit. System load is at 50%.
MAINS

ADDRESS: 1 2 3
OPER. X X X
PRIORITY 1 3 2 SYSTEM LOAD = 50%
MASTER 1
NEXT ON
NEXT OFF 2
VIS-123
00-04-27
G G G
The network priority of the priority 2 and 3 units are switched so now the unit
with network address #3 is priority 2, and network address #2 is priority 3. After
a time delay of less than 5 minutes, the #3 network address (priority 2) unit is
started by the master and paralleled to the bus. Now all three units are on line.
See Figure 5-18. The master recognizes the proper on/off sequence for the new
priority settings, and will sequence off network address #2 unit when system load
levels fall below 25%. See Figure 5-19.
MAINS

ADDRESS: 1 2 3
OPER. X X X
PRIORITY 1 3 2
NEXT ON 2
NEXT OFF 3
VIS-124
00-04-27
G G G
Woodward 149
System load levels have dropped below 25%, and the master has sequenced
network address #2, priority 3 unit off line. The master has fully recognized the
priority change, and the new priority settings are in effect.
The above examples are typical sequencing functions of the EGCP-2. Isolated
bus applications were shown for clarity. The EGCP-2 is capable of automatic
sequencing while in parallel with the mains in the process control, or process
control soft transfer operating modes. The examples shown above for priority
changing and its effects are accurate in mains parallel multiple unit process
control modes as well.
150 Woodward
Chapter 6.
Calibration of Control Inputs and Outputs
Introduction
The EGCP-2 can be thought of as a digital metering device that monitors engine,
generator, bus, and mains analog signals. Being a digital metering device, the
EGCP-2 must be properly calibrated in order to perform its role as a controlling
device accurately. This chapter discusses the calibration of these various inputs
and outputs of the EGCP-2, and the effects of the calibration on the metering and
control functions of the EGCP-2.
The EGCP-2 inputs and outputs are factory calibrated for the best possible
tolerance between the input signal, and the signal as sensed by the EGCP-2. All
analog signals coming into the EGCP-2 are routed through analog to digital
(A/D) converters. These converters have the ability to be “calibrated” so that the
input signals sensed by the EGCP-2 software are equal to the true input signal.
While the factory calibration brings the EGCP-2 control within close tolerance of
the various inputs as fed into the control, it cannot account for losses in field
wiring that are common in power generation applications. Signal loss due to wire
length and impedance, transformer primary to secondary losses, and non-linearity
of sending devices cannot be calibrated out at the factory. This is why the EGCP-
2 must be calibrated upon commissioning.
The intent of calibrating the EGCP-2 is to make the unit read out the various
voltages, currents, frequencies, and temperatures in the various status menu
display screens as close as possible to what is actually occurring at the true
source of these signals.
For example, assume there is a 480 volt line-to-line generator set operating in a
system which uses 4:1 voltage transformers to feed the EGCP-2. The input AC
line to line voltage at the EGCP-2 is 118 volts due to primary to secondary losses
across the voltage transformers. The EGCP-2 Generator Status menu will display
a generator voltage of 472 Vac L-L for each phase, which is not truly what the
generator is producing. In this case, the Calibration tuning menu would be used
to adjust the A/D converters on the three generator voltage transformer inputs
until the Generator Status menu reads 480 Vac L-L for each phase. This is how
the calibration menu is used to compensate for losses in signal between the
source, and the EGCP-2. The calibration menu allows adjustment of all the
analog inputs and outputs of the EGCP-2.
Woodward 151
Calibration of Generator PTs and CTs
The Calibration menu of the EGCP-2 contains calibration adjustments for three
phase generator voltage and current. These calibration adjustments are labeled as
follows:
PT Phase A Scale
Calibrates the A phase generator PT input.
Menus Affected
Changes in the calibration setpoint will change the generator A phase voltage as
seen on the Generator Status screen. Changing this value will also have an effect
on generator KW and KVAR levels.
The generator A phase voltage is also used as part of the function which
determines when the generator is stable as shown in the System Status menu by a
++ following the GEN label. If the generator A phase PT is not properly
calibrated, the level at which the generator is shown as stable may not be a true
indication of a stable condition.
Operations Affected
The EGCP-2 uses the A phase generator voltage for voltage matching when
synchronizing across the generator breaker. Accurate calibration of the Generator
A phase PT is critical for proper voltage matching operation.
The sensed generator voltage on the A phase is used in Power Factor/VAR

sharing mode when the EGCP-2 is in parallel with other units on an isolated bus.
The EGCP-2 uses the Voltage Reference as found in the Configuration tuning
menu as a generator voltage reference point when balancing the reactive load on
the bus between generators. If the A phase PT voltage is out of calibration at the
EGCP-2 the bus voltage may be off of this reference when in Power Factor/VAR
sharing mode. Also, poor VAR/PF sharing may occur if the A phase PT is not
properly calibrated.
Generator Voltage is also used in real and reactive load calculations. These
calculations are used in all real and reactive power control functions.
Alarms Affected
The PT Phase A voltage is used for the Voltage High and Low limit setpoints
which are found in the Shutdown and Alarm tuning menu. The voltage limit
setpoints can be configured for various alarm indications. Also, if the generator
voltage as sensed by the EGCP-2 exceeds the Voltage High limit, or falls below
the Voltage Low limit, the voltage bias output will stop moving in the direction
that the alarm occurred.
The A 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
152 Woodward
PT Phase B Scale
Calibrates the B phase generator PT input.
Menus Affected
Changes in the calibration setpoint will change the generator B phase voltage as
read in the Generator Status screen. Changing this value will also have an effect
Operations Affected
Generator Voltage is used in real and reactive load calculations. These
Alarms Affected
The B phase PT voltage is used in the calculations for KW and KVAR load. All
alarms monitoring these conditions will be affected if the B phase PT is not
PT Phase C Scale
Calibrates the C phase generator PT input.
Menus Affected
Changes in the calibration setpoint will change the generator C phase voltage as
read in the Generator Status screen. Changing this value will also have an effect
Operations Affected
Generator Voltage is used in real and reactive load calculations. These
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
CT Phase A Offset
Calibrates the A phase generator CT input offset (zero current) reading.
Menus Affected
Changes in the calibration value will change the A phase current readout in the
Generator Status 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
Alarms Affected
The generator current on A phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three phase CT inputs for sensing
overcurrent conditions, and selects the phase with the highest current at any
given moment. Improperly calibrated A phase CT levels will affect the point of
Overcurrent detection on the generator.
Woodward 153
The A Phase CT calibration has an affect on KW and KVAR levels for the A
phase, and for the sum of all three phases of the generator. The various alarm
setpoints which monitor real and reactive load levels are affected by this
calibration point.
CT Phase A Scale
Calibrates the A phase generator CT input.
Menus Affected
Changes in the calibration value will change the A phase current readout in both
the Generator Status screen. Changing this value will also have an effect on the
generator KW and KVAR levels.
Operations Affected
Alarms Affected
The A Phase CT calibration has an affect on KW and KVAR levels for the A
calibration point.
CT Phase B Offset
Calibrates the B phase generator CT input offset (zero current) reading.
Menus Affected
Changes in the calibration value will change the B phase current readout in the
Operations Affected
Alarms Affected
given moment. Improperly calibrated B phase CT levels will affect the point of
The A Phase CT calibration has an affect on KW and KVAR levels for the B
calibration point.
154 Woodward
CT Phase B Scale
Calibrates the B phase generator CT input.
Menus Affected
Changes in the calibration value will change the B phase current readout in both
Alarms Affected
The generator current on B phase is monitored and used as an input for the
given moment. Improperly calibrated B phase CT levels will affect the point of
The B Phase CT calibration has an affect on KW and KVAR levels for the B
calibration point.
CT Phase C Offset
Calibrates the C phase generator CT input offset (zero current) reading.
Menus Affected
Changes in the calibration value will change the C phase current readout in the
Operations Affected
Alarms Affected
The generator current on C phase is monitored and used as an input for the
The A Phase CT calibration has an affect on KW and KVAR levels for the C
phase, and for the sum of all three phases of the generator. This calibration point
affects the various alarm setpoints that monitor real and reactive load levels.
CT Phase C Scale
Calibrates the C phase generator CT input.
Menus Affected
Changes in the calibration value will change the C phase current readout in both
Woodward 155
Alarms Affected
The generator current on C phase is monitored and used as an input for the
Overcurrent alarm. The EGCP-2 uses all three-phase CT inputs for sensing
given moment. Improperly calibrated C phase CT levels will affect the point of
The C Phase CT calibration has an affect on KW and KVAR levels for the B
phase, and for the sum of all three phases of the generator. This calibration point
affects the various alarm setpoints that monitor real and reactive load levels.
Calibration of the Bus PT

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

The Bus PT input is used as part of the sensing, which determines when the
mains voltage is within spec as shown in the 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
bus (live or dead bus closing). The Synchroscope status screen will display the
Bus voltage at the “Mains VL-L:” value when performing Close Gen Breaker
Functions.
Operations Affected
The Bus PT Scale calibration will affect the Voltage matching accuracy when the
generator is paralleling to other generators on the isolated bus (Bus PT
monitored), or when the generator is paralleling to the mains (Mains PT
monitored). Improper calibration of the Bus PT sensing of the EGCP-2 may
cause large reactive load swings when paralleling into the bus or mains when the
generator breaker closes.
Alarms Affected
The Bus PT scale calibration will affect the Mains High and Low Voltage Limit
alarm setpoints in the Shutdown and Alarms tuning menu. If the Bus PT scale is
improperly calibrated, the sensed voltage for these high and low alarm setpoints
may cause alarms and/or loss of mains action to occur at the wrong voltage
levels.
156 Woodward
Speed Bias Output
The Speed Bias Offset calibration point sets an offset on the speed bias output of
the EGCP-2. This output is fed into the speed control governor to bias the
governing speed for synchronization and load control functions. This offset is the
starting point from which the EGCP-2 begins all of its speed biasing operations.
Factory calibrated for:
Speed Bias Type Voltage at Terminals Speed Bias Offset

73(+) – 74(–)
±3 Vdc 0.00 Vdc 0.0%
0.5 – 4.5 Vdc 2.5 Vdc 0.0%
PWM 50% Duty Cycle 0.0%
The Speed Bias will be calibrated to have the generator set operating at 50.0 or
60.0 hertz.
Calibration is required for Caterpillars ADEM speed control.

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
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 Bias offset of 3% will give a
3% speed bias reading in the I/O Display status screen. Decreasing the Speed
Bias Offset has just the opposite effect in that the values will read negative
instead of positive.
Voltage Bias Output

The Voltage Bias Offset in the Calibration menu is used to impose an offset
voltage on the voltage bias output to the automatic voltage regulator. This dc
voltage offset is applied to the voltage bias input of the automatic voltage
regulator, and is maintained as a starting point for all voltage bias operations used
by the EGCP-2.
Woodward 157
Most regulators, which have a voltage trim bias input, require a 0.0 Vdc voltage
bias offset. These types of regulators operate with a ±dc voltage applied to this
trim input. The voltage is then centered around zero volts offset, or zero Voltage
Bias.
Relationship Between Voltage Bias and Generator Voltage

(Voltage Regulators which take a +/0/- voltage bias input)
+100% Bias 110% Rated Generator Voltage
0% Voltage Bias Offset (0.0 VDC) Rated Generator Voltage
-100% Bias 90% Rated Generator Voltage
Figure 6-1. Relationship Between Voltage Bias and Generator Voltage
Some regulators cannot accept a ± voltage trim input, and require a voltage bias
signal that is only positive (or negative) in value. In cases such as these the
Voltage Bias offset can be used to raise the offset of the voltage bias output to a
level, which allows more positive and less positive voltage adjustment around a
positive offset voltage.
Voltage Bias Offset will affect the rated voltage of the generator at synchronous
speed prior to the generator breaker closing. 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 is recommended that the voltage adjustment of the automatic voltage regulator

be set for the desired rated voltage of the generator with the EGCP-2 not
connected.
158 Woodward
Chapter 7.
General Startup Instructions
Before Starting the Generator Set

Before starting the generator set, configure the tuning setpoints in the EGCP-2
for values which best match the machines operating and performance
characteristics. Double-check these values prior to starting the unit.
Verify Proper wiring to the EGCP-2. Check the following items for proper
polarity and configuration:
• Power Supply Input
• Generator CT Inputs
• Generator PT Inputs
• Mains and Bus PT Inputs
• Magnetic Pickup Input
• Voltage Bias Output
• Speed Bias Output
Once these items have been checked for proper polarity, check the power supply
voltage for proper amplitude. When this is confirmed, apply the power supply to
the EGCP-2.
With the EGCP-2 powered up, the unit will go through a RAM test, and after a
self check period, will display the Control Overview 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 the state of the various discrete inputs and outputs of the
control. Monitor this screen and close the discrete inputs to the EGCP-2 that are
being used in this particular application. Verify that the EGCP-2 recognizes these
inputs in the I/O Status screen.
Verify that the Speed Bias and Voltage Bias outputs are at the proper levels for
the devices being used.
WARNING
Make sure that a means exist of performing an emergency stop prior
to starting the unit. Check the emergency stop devices to make sure
they are functioning properly prior to starting the unit.
Woodward 159
Sequence of Startup and Checking Parameters
1. Enter program Setpoints in all menus.
2. Check discrete inputs in I/O status menu.
3. Set crank repeats to 0.
4. Set synchronizer mode to check.
5. Set load control mode to normal.
6. Start engine using test switch (discrete input 2) of EGCP-2.
7. Check Engine Status screen for engine rpm readout confirm rpm is correct
for unit.
8. Check voltage of unit in Generator Status screen—calibrate voltage if
needed.
9. Adjust AVR voltage at AVR if needed to achieve rated generator voltage.
10. Follow AVR connection and setup procedure in Appendix C.
11. Check that voltage raise/lower switches (discrete inputs 4 and 5) operate
properly.
• Set voltage ramp time if needed.
12. Check that load raise/lower switches (discrete inputs 6 and 7) operate
properly.
• Set load raise/lower rates if needed.
• Verify speed change with raise/lower load inputs.
13. Check mains voltage in synchroscope status menu (if available)—calibrate
if needed.
14. Calibrate synchronizer if possible.
15. Remove Test Input. Verify engine shuts down properly.
Loading the Generator Set

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

Follow these steps if you are configuring a Mains Parallel Master Unit, or a
Mains Parallel Slave unit, which will operate as a redundant master. Redundant
master units must have the Mains CB Aux hardwired into them. All other wiring
to the Master and Redundant Master Units must be identical for proper operation
of the redundant units in the event of a loss of master.
1. Set load/unload ramp times to at least 60 seconds.
2. Set base load level to 30% of rated load.
3. Start unit with an Auto and Run with Load Input.
a. Unit will start and attempt to synchronize.
4. Adjust synchronizer dynamics for best control of phase matching (monitor
synchroscope status menu to see phase error.).
5. Use voltmeter to check voltage across generator breaker to assure proper
phase rotation and mains PT input polarity.
160 Woodward
6. Shut down the unit by removing the Auto and Run with Load Inputs.
7. Set synchronizer to run mode.
8. Start unit with an Auto and Run with Load Input.
9. Monitor synchroscope status menu.
a. Verify action of synchronizer.
NOTE
If using Process 4–20 mA input, set Process Reference to proper
level.
10. After generator breaker closes to the mains, monitor Generator Status
screen.
a. Monitor KW load on unit.
b. Monitor KVAR/PF on unit.
1. As set by reactive load control setting.
11. Adjust load control gain, stability, and derivative for stable load control.
12. Once satisfied with load control operation, switch to process control (if
applicable).
13. Confirm ramp to process reference level.
a. Tune process control for best response.
14. Remove run with load input to unit.
a. Verify unload ramping.
b. Verify unload trip point.
c. Verify generator breaker opens.
d. Verify cooldown timer (if reached).
15. Set crank repeats, base load reference, process reference, load ramp times,
and load control mode as required for proper operation.
This concludes the Mains Parallel Master Setup.
No Parallel and Slave Setup

Use the following instructions for setup of No Parallel Applications, and Slave
unit applications.
1. Set unit for LOM on mains under frequency.

2. Set 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. Calibrate CT readings if needed.
7. If in a multi unit system, repeat previous steps for all units. Set all units to
be tested synchronizers to check mode prior to start.
8. The unit currently on the bus carrying the load will act as a synchronizing
reference for the other units.
9. Verify voltage matching, phase relationships of additional units by
monitoring the synchroscope status menu.
a. Verify voltage levels across generator breakers.
10. Tune individual synchronizer dynamics.
a. Calibrate synchronizer if needed.
Woodward 161
11. Once satisfied with each synchronizers operation, shut down these units by
removing the auto input.
12. Change synch mode settings to run on all units.
a. This will enable generator breaker closure to live bus.
13. Start one unit in auto and allow it to close to the dead bus.
a. Verify isochronous operation.
b. Verify correct voltage level on bus.
14. Start another unit and allow it to parallel to the live bus.
a. Confirm phase match and synchronizer action.
b. Verify generator breaker closure.
15. Load Control
a. Verify load sharing.
b. Verify VAR/PF sharing.
16. Start additional units and parallel to the bus in the same manner as previous
units.
a. Load must be sufficient to prevent sequencing of lower priority
units off line.
b. Confirm unit address and priority settings.
c. Adjust load control gain lower if unstable during ramp to load
sharing.
d. Adjust load share gain if unstable in load share.
17. Remove units from isolated bus one at a time by opening the auto input.
a. Verify unload ramp.
b. Verify unload trip.
c. Verify cooldown if unit has exceeded cooldown limit.
18. When all units are off line, close mains breaker if applicable.
a. Set all units to auto for LOM detection.
This concludes the No Parallel setup.
162 Woodward
Chapter 8.
Troubleshooting
Control Hardware and I/O

Problem Probable Cause Corrective Action
Unit does not power up No input power supply Check input power supply
on terminals 1 and 2. This
input must be 9 to 32 Vdc.
Input power supply reversed Ensure proper polarity of
power supply to EGCP-2.
Unit powers up and then Weak Engine Battery or Charge Engine Battery, or
cycles on and off when Engine Battery voltage Replace Engine Battery.
cranking dropping below 6 Vdc on
cranking
Discrete inputs don’t show Faulty wiring of discrete Verify wiring of discrete
active in I/O STATUS input switches input switches.
screen when switches are
activated
Displayed generator Faulty wiring of generator Verify wiring of generator
voltages are very small Potential Potential Transformers
Transformers(PT’s) (PTs).
Generator PT inputs are Calibrate the appropriate
improperly calibrated PT input channel(s). See
section 1.10 Calibration of
Control Inputs and Outputs.
I/O STATUS shows relay(s) Faulty wiring of relay output Verify wiring of relay output
is energized, but action(i.e. contacts contacts.
alarm) does not occur
Generator voltage AVR dynamics are Tune the AVR dynamics for
fluctuates or is unstable at improperly set up stable operation. See AVR
no load on generator manufacturer’s instruction
manual for more details.
Voltages or currents EGCP-2 PT inputs are Calibrate the appropriate
displayed by EGCP-2 are inaccurately calibrated PT input channel(s). See
different than measured section 1.10 Calibration of
parameter Control Inputs and Outputs.
Woodward 163
Engine Control/Sensing Parameters
Start command(i.e. test or Configuration menu has not Enter the configuration set
run with load) does not start been accepted or entered points in the Configuration
engine properly menu such that all “*” and
“#” symbols are removed
from the display. See
section 1.3.4 Description of
set points for more details.
An active alarm condition Commit or reset alarm
exists condition(s). See section
1.3.2 Description of
Screens.
Relay output contacts are Verify wiring of relay output
not properly connected to contacts.
engine starter, fuel solenoid
Starter motor stays Crank cutout set point in Set CRANK CUTOUT set
engaged after engine starts Engine control menu is to point to appropriate value.
large See description of set
points.
Inadequate MPU signal to Verify MPU wiring, and that
EGCP-2 input adequate MPU signal exists
at input to EGCP-2 control.
Engine speed is unstable Speed control dynamics are Tune the speed control
when unit is at no load improperly set up dynamics for stable
operation. See speed
control manufacturer’s
instruction manual for more
details.
When crank command is Battery is too weak for the Install a higher capacity
issued, EGCP-2 loses current demand of the battery or a more efficient
power and conducts a reset starter motor starter motor.
and RAM test
Faulty wiring of power Verify wiring of power
supply to the EGCP-2 supply to the EGCP-2
control control.
164 Woodward
Synchronization
Unit never adequately Synchronizer Mode set Set synchronizer Mode to
matches phase point in synchroscope menu appropriate setting. See
set to PERMISSIVE description of set points.
Synchronizer dynamics in Tune synchronizer
synchroscope menu are dynamics. See description
improperly set up of set points.
Synchronizer displays small Generator A phase PT input Verify that Generator A
phase difference, but is L-L and bus A phase PT phase PT input bus A
measured phase difference input is L-N or vice versa phase PT input are the
is large same form (i.e. L-N or L-L).
Bus and/or generator PT Verify that Bus and
inputs are not A phase generator PT inputs are A
phase.
synchronizer improperly Calibrate synchronizer. See
calibrated calibration of control inputs
and outputs.
Synchronizer matches Synchronizer Mode set Set synchronizer Mode to
phase, but never closes point in synchroscope menu appropriate setting. See
breaker/contactor is set to CHECK description of set points.
Dwell time set point in Reduce Dwell Time set
synchroscope menu is too point in synchroscope
large menu. See description of
set points.
Synchronizer displays Generator or bus PT is Verify correct polarity of
matched phase, but reversed polarity (faulty Generator and bus PT
measured phase difference wiring) inputs.
is ~180 degrees, or when
breaker closes it crash
parallels the set 180
degrees out of phase
Unit won’t close to dead bus Multiple unit system with ENABLE DEADBUS
DEADBUS CLOSING set CLOSING set point in
point in configuration menu configuration menu. See
set to DISABLED description of set points.
Synchronizer set point is set Set synchronizer Mode to
to CHECK appropriate setting. See
description of set points.
Synchronizer won’t voltage VOLTAGE MATCHING set ENABLE the VOLTAGE

match point in synchroscope menu MATCHING set point in
is DISABLED synchroscope menu. See
Synchronizer does not Generator A phase PT Calibrate the Generator A
voltage match within spec. and/or Bus A phase PT phase PT and Bus A phase
input(s) are inadequately PT inputs. See calibration of
calibrated control inputs and outputs.
Voltage matching tolerance Appropriately set the
set point in synchroscope Voltage matching tolerance
menu is too large set point in synchroscope
menu. See description of
set points.
Woodward 165
Breaker Close/Open Control
When generator set is in Synchronizer set to CHECK Set synchronizer Mode to
synchronization, the breaker appropriate setting. See
never closes description of set points.
Faulty wiring causing the Verify wiring of the relay
relay output to not make output contacts.
connection to the breaker
Dwell time set point in the Reduce Dwell time set point
synchroscope menu is too in the synchroscope menu.
long See description of set
points.
Contactor closes for a brief C B CONTROL set point in Appropriately set the C B
moment and then opens configuration menu is set CONTROL set point in
for BREAKER configuration menu. See
C B HOLD TIME set point in Increase C B HOLD TIME
synchroscope menu is too set point in synchroscope
short menu. See description of
set points.
Faulty wiring on C.B. Aux Verify wiring of C.B. Aux
contacts contacts to EGCP-2 input.
Breaker close relay stays C B CONTROL set point is Appropriately set the C B
energized when a close set for CONTACTOR CONTROL set point in
command is given and configuration menu. See
never issues an open description of set points.
command
166 Woodward
Real Load Control
KW for a phase(s) reads Current transformer(CT) Verify/reverse polarity of
negative. has reversed polarity current transformer for
effected channel(s)
NOTE: engine generator set
must be off to safely open
circuit a current transformer.
Unit carries improper Rated KW set point in Appropriately set Rated KW
proportion of real load configuration menu set at set point in configuration
during isochronous load incorrect value menu. See description of
sharing set points.
A proportional dc speed Adjust speed setting of
error exists on the speed speed control to match the
control unit (no-load speed bus frequency. If unit is
not set to match bus carrying too little load, the
frequency) speed setting needs
increased. If unit is carrying
too much load, the speed
setting needs decreased.
Real load control is unstable Real load control dynamics Tune Real load control
when paralleled with the in real load control menu dynamics in real load
mains source are improperly set up control menu. See
Process control operation PROCESS ACTION set Appropriately set
causes overload or reverse point in process control PROCESS ACTION set
power menu set for incorrect point in process control
action menu. See description of
set points.
Loading and/or unloading is Load and/or unload ramp Appropriately
too fast/slow rates in the real load control increase/decrease the Load
menu are set incorrectly and/or unload ramp rates in
the real load control menu.
See description of set
points.
Engine speed/load has an Speed control dynamics are Tune the speed control
instability that fluctuates improperly set up dynamics for stable
very quickly. operation. See speed
control manufacturer’s
instruction manual for more
details.
Woodward 167
Reactive Load Control
Phase power factors do not CT’s are connected to Verify CT’s are connected
agree. Two of the three incorrect phase inputs to the appropriate input
phases are extremely far terminals.
out of range NOTE: engine generator set
must be off to safely open
circuit a current transformer.
Unit carries improper Rated KVA set point in the Appropriately set the Rated
proportion of reactive load configuration menu is set at KVA set point in the
during isochronous load incorrect value configuration menu. See
sharing description of set points.
Generator A phase PT Calibrate the Generator A
input(s) are improperly phase PT input(s) of the
calibrated generator set(s). See
calibration of control inputs
and outputs.
Reactive load control is Reactive load control Tune the Reactive load
unstable when paralleled dynamics in the reactive control dynamics in the
with the mains source load control menu are reactive load control menu.
improperly set up See description of set
points.
Unit maintains a constant VAR/PF set point in the Appropriately set the
VAR load rather than a reactive load control menu VAR/PF set point in the
constant power factor when is set to VAR CONTROL reactive load control menu.
paralleled with the mains See description of set
source points.
Unit maintains a constant VAR/PF set point is set to Appropriately set the
power factor load rather PF CONTROL VAR/PF set point in the
than a constant VAR when reactive load control menu.
paralleled with the mains See description of set
source points.
Multiple generator sets are VOLTS RAMP TIME set Appropriately set the
unstable when VAR/PF point in reactive load control VOLTS RAMP TIME set
sharing at light loads menu is not adjusted point in reactive load control
properly menu. See description of
set points.
Droop Current Transformer Verify the connection of the
not properly connected to Droop Current Transformer
AVR to the AVR. See AVR
manufacturer’s instruction
manual for more details.
168 Woodward
Sequencing
Unit number(s) does not switch in manual position Switch unit(s) to the Auto
show up in the sequencing switch active position. See
order in the sequencing dc inputs/outputs.
screen/unit doesn’t auto
sequence
Automatic sequencing set ENABLE the Automatic
point in the configuration sequencing set point in the
menu set to disabled configuration menu. See
Unit has an active alarm Commit or reset alarm
condition(s). See
description of screens.
RS-485 Network not Verify that the RS-485
connected at unit(s) network is connected to all
EGCP-2 controls in system.
RS-485 Network is Verify that the RS-485
inadequately terminated Network is correctly
terminated. See inter-
control communications
(RS-485).
When system load is large NEXT GENSET DELAY set Increase NEXT GENSET
enough to require additional point in sequencing menu is DELAY set point in
gen-sets, more than one set too short sequencing menu. See
is sequenced on line description of set points.
MAX START TIME set point Increase MAX START TIME
in sequencing menu is too set point in sequencing
set points.
When system load is small REDUCED LOAD DELAY Increase REDUCED LOAD
enough to take additional set point in sequencing DELAY set point in
sets off line, more than one menu is too short sequencing menu. See
set is sequenced off line description of set points.
MAX STOP TIME set point Increase MAX STOP TIME
in sequencing menu is too set point in sequencing
set points.
Woodward 169
Mains/Bus Sensing
Unit(s) do not respond to Shutdown/alarm set points Appropriately set mains
loss of mains for mains sensing not set high/low frequency and
for LOSS OF MAINS high/low voltage set points
in shutdown/alarm menu.
See description of set
points.
Unit(s) do not have an Switch unit(s) to the Auto
active auto switch input switch active position. See
dc inputs/outputs.
Unit does not recognize Set points for mains Increase Mains high
when mains are in spec. high/low frequency and frequency and voltage and
high/low voltage in decrease mains low
shutdown/alarm menu are frequency and voltage set
set too tight for sensing points in the
when mains are in spec shutdown/alarm menu. See
Communications
A unit number(s) does not RS-485 Network is Verify that the RS-485
show up in the sequencing inadequately terminated Network is correctly
order in the sequencing terminated. See inter-
screen control communications
(RS-485).
RS-485 Network not Verify that the RS-485
connected at unit(s) Network is connected to the
EGCP-2 RS-485 input at all
units.
RS-485 network is Verify the polarity of the RS-
connected with reverse 485 network on all units.
polarity at one or more units
If a unit with the network +5 Vdc power supply is not Verify that the +5 Vdc
termination is powered linked between units power supply is linked
down, communications (inadequate wiring) between all units.
become unreliable or
completely cease
170 Woodward
Chapter 9.
Definition of Terms
AMF Automatic Mains Failure. The ability of a control to

detect, and take action on a mains failure condition. The
EGCP-2, which has AMF capabilities, can be
programmed to sense a loss of mains condition based on
mains voltage, frequency, or a sudden load surge on a
generator operating in parallel with the mains. The
action taken by the EGCP-2 when it senses a mains
failure can be programmed for either an alarm action, or
a standby power action where all generators start and tie
to the load after the failed mains have been isolated from
that load.
Automatic
Control A control mode used by the EGCP-2 to activate several
automatic functions within the control. These functions,
which are dependent upon program setpoints and system
configuration, are Loss of Mains detection, Automatic
Sequencing, and Automatic dead bus closing, Automatic
control also effectively connects those EGCP-2 units in
automatic to the Local Operating Network (LON).
Auto Switch A discrete input to the control which will initiate

automatic operation of the EGCP-2.
ATS Automatic Transfer Switch. A device which isolates the

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

alarm settings which will cause the audible alarm relay
output to energize when reaching or exceeding the alarm
parameters.
Automatic
Sequencing The automatic addition, or subtraction of generators
to/from the load based on predetermined load levels
being crossed for specific periods of time. Automatic
sequencing is a function of a multiple generator system
which is operating in load sharing mode isolated from
the mains, of process control mode in parallel with the
mains.
Woodward 171
AVR Automatic Voltage Regulator. A device which controls
the field excitation of an AC generator in such a way as
to maintain a specific voltage level over the operating
load range of the generator. The EGCP-2 control biases
the voltage setting of the AVR to voltage match during
synchronization and to control reactive load during load
share and mains parallel operation.
Base Load A term used to describe a generator loading condition in

which the generator is paralleled to another source of
power, typically the mains, and loaded to a fixed KW
level. The generator maintains this KW level regardless
of load on the Mains.
Breaker A device used to connect one power source to a load, or

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

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

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

sense, and safely close on to a load which has no other
generators or sources of power tied to it. Dead Bus
Closing must not allow two generators to attempt closure
to the dead bus at the same time, since an out of phase
paralleling situation would likely occur. The EGCP-2
uses its Local Operating Network to insure safe dead bus
closing among all units tied to this network. The units
have a single dead bus token, which allows the unit
possessing it to close to the dead bus. Only one token
exists on the network, so there is no possibility of
multiple units closing to the dead bus simultaneously.
Dead Bus Closing is always active in single unit
configurations.
172 Woodward
Droop A reduction in the reference of a controlled parameter as
the amplitude of that parameter increases (negative
feedback). The EGCP-2 uses Kilowatt Droop as a
manual means of loading the generator when paralleling
to another generator, or to the mains. Droop Control is
effective only if the LOAD CONTROL MODE setpoint
in the Configuration menu is set to DROOP.
Dwell Time A term used to describe the amount of time required

during synchronization in which one power source is
within a specified phase angle window of another source
it is synchronizing to.
Hard Shutdown A shutdown condition used by the EGCP-2 for various

alarm settings which will cause the unit to immediately
open its generator breaker if on load, and shut down
when reaching or exceeding the alarm parameters.
Isochronous A term which is used to describe a generator set which

will maintain its frequency at a constant level as the load
on that generator changes. The EGCP-2 typically uses
Isochronous load control when in load sharing, or when
operating as a single unit. This assures a constant
frequency under all generator loads which are within the
capacity of the generator.
Inverse Time Delay A time delay used for over current and reverse power
detection which utilizes both time and amplitude of the
condition to determine the active trip level. The inverse
time delay accounts for rapid high amplitude conditions
to cause a trip, as well as long duration low amplitude
conditions.
Isolated Bus A bus which is electrically isolated from the mains.
KVA Kilovolt Amps. The power rating of the generator set

KVA is determined by multiplying the rated voltage of
the generator by the rated current.
KVAR Kilovolt Amps Reactive. Reactive load is produced by a

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

the generator and the current which is produced within
the voltage cycle. KW load is resistive in nature.
Load Typically the KW load on the generator at any given

time.
Woodward 173
Load Surge A condition in which a step load on the generator ,which
is operating in a mains parallel mode (base load or
process), above a certain amplitude can be used to
trigger a Loss of Mains condition.
Loss of Mains A condition in which the sensed mains PT input to the

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

mains. The EGCP-2 can be configured for Mains
Parallel operation.
Master The Highest Priority unit in an operating automatic

system. The Master Control controls load sharing,
VAR/PF sharing, sequencing, synchronization to the
mains, mains breaker closure/opening, and multiple unit
starting.
Manual A switch input to the EGCP-2 which puts the control in

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

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

automatic on the network. Network priority defines the
sequence in which units will be taken on/off load when
operating in an automatic sequencing configuration (load
sharing or process control). Automatic sequencing will
place units on load as required starting at the highest
network priority (lowest numerical value), and adding
units of lower priority (higher numerical value) as the
load on that system increases above certain defined
limits. Automatic sequencing will also remove units
from the load in a reverse order of that used for
sequencing units on load, that is from lowest priority
(highest numerical value) to highest priority (lowest
numerical value).
174 Woodward
In addition to all this, the unit with the highest network
priority on the network is considered the master, and all
other units with lower priorities are slaves to that master.
No Parallel An operating mode of the EGCP-2 which will not allow

the generators to operate in parallel with the mains under
any circumstances. All transitions to and from the mains
are completed using an open transition action.
Parallel To synchronize and close an operating generator to the

mains.
Power Triangle A right triangle which is used to determine the amplitude

relationship between KVA, KW, and KVAR.
Process Control A switch input which selects a mode of control used

while in parallel with the mains. When operating in
process control, the EGCP-2 receives a 4–20 mA, or 1–5
Vdc input from an external transducer. This transducer
monitors a variable which is affected by the generator
operation. Variables such as imported power to a site,
exported power to the mains, exhaust
temperature, and fuel gas pressure levels are typical for
monitoring with a transducer. The EGCP-2 uses an
internal reference level for the process input, and
compares this reference to the transducer input. The
EGCP-2 then raises or lowers the amount of load on the
generator to maintain the process transducer input to the
referenced value.
Proportional
Load Sharing A mode of load control used by the EGCP-2 while
operating multiple units on an isolated bus. Proportional
Load Sharing measures the total KVA capacity of all the
units on the bus and divides the total KVA load on the
bus by this capacity. This value is then sent over the
network as a load reference for all units operating in
parallel on the bus. The result of this is the ability of
various KVA rated units operating at their respective
proportion of the total load on the bus. This allows
consistent load sharing among units of various sizes
throughout their entire operating load range.
PT Potential Transformer. A device which steps down a

higher AC voltage to a lower AC voltage. Typically used
on generator set applications to step the generator
voltage down to an amplitude which is safe for use in
metering and control devices.
Run With Load A discrete input to the EGCP-2 which signals the unit to
operate the generator on load. The way that the control
puts the generator on load depends upon software
configuration, and the type of system the EGCP-2 is
configured for.
Woodward 175
Slave An EGCP-2 with lower network priority (Higher
numerical value) than the master.
Soft Shutdown A shutdown condition used by the EGCP-2 for various

alarm settings, which will cause the unit to softly unload
and cooldown when reaching or exceeding the alarm
parameters.
Soft Transfer A Load Control Mode of the EGCP-2 which allows the
unit, or group of units to transfer power from the mains
to the on site generators. Upon reaching either a base
load reference, or process control reference level, the
EGCP-2 will issue a command to open the mains
breaker. This results in a complete transition of power
from the mains to the on site generators.
Synchronize To match the frequency, phase angle, and voltage of a

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

EGCP-2, which is the ratio of total load demand to total
generating capacity which is supplying the load. System
Load = KW Load/KW Capacity.
Test A discrete input to the EGCP-2, which is used to start

the engine for test and initial start check out. The test
input is also used with the run with load or process
inputs, and a software setpoint, to put the EGCP-2 into a
soft transfer mode.
VAR/PF Control The ability to control a level of VAR or PF on a

generator while in parallel with the mains. The EGCP-2
has VAR/PF control features that allow the user to set a
desired VAR or PF level on the generator while in
parallel with the mains. The VAR or PF level is
maintained by changing the excitation level of the
generator. This is accomplished by changing the voltage
reference level of the AVR from the EGCP-2.
VAR/PF Sharing The ability to share the VAR and PF load on multiple
units operating on an isolated bus. Like load sharing, the
EGCP-2 VAR/PF sharing measures the VARs of the
load on the isolated bus, and divides this value by the
total VAR capacity of the generators tied to the load. A
proportional VAR/PF level is then maintained between
all units tied to the load based on their rated VAR
capacity.
176 Woodward
Chapter 10.
Service Options
Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205) that
is in effect at the time the product is purchased from Woodward or the service is
performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of action
you wish to pursue based on the available services listed in this section.
Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call in the event of an unexpected outage, or in

advance of a scheduled outage, to request a replacement control unit. If the unit is
available at the time of the call, it can usually be shipped out within 24 hours.
You replace your field control unit with the like-new replacement and return the
field unit to the Woodward facility as explained below (see “Returning
Equipment for Repair” later in this chapter).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Woodward 177
Return Shipment Authorization Label. To ensure prompt receipt of the core,
and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.
Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty 5-01-
1205) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in “like-new” condition and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). This option is applicable to mechanical products
only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward
for repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.
CAUTION
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
178 Woodward
Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order
through our distributors or local service facility. To expedite the repair process,
contact Woodward in advance to obtain a Return Authorization Number, and
arrange for issue of a purchase order for the item(s) to be repaired. No work can
be started until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for
return shipments. Contact a Woodward customer service
representative at 1 (800) 523-2831 in North America or
+1 (970) 482-5811 for instructions and for a Return Authorization
Number.
Replacement Parts
When ordering replacement parts for controls, include the following information:
• the part number(s) (XXXX-XXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.
Woodward 179
How to Contact Woodward
In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
Facility Phone Number

Australia +61 (2) 9758 2322
Brazil +55 (19) 3708 4800
India +91 (129) 523 0419
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult our
worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility. [For worldwide
directory information, go to www.woodward.com/ic/locations.]
Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by e-mail, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
E-mail—[email protected]
Website—www.woodward.com/ic
180 Woodward
Technical Support is available through our many worldwide locations or our
authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning our
toll-free number and stating the urgency of your problem. For technical support,
please contact us via telephone, e-mail us, or use our website and reference
Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard

classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, e-mail us, or use our website and reference Customer Services and
then Product Training.
Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface. For field service engineering assistance, please contact us via
telephone, e-mail us, or use our website and reference Customer Services and
then Technical Support.
Woodward 181
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter
Control Description or Governor Type
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
182 Woodward
Appendix A.
Connector Information
Wago pluggable style terminal blocks are used on the EGCP-2 to connect the
field wiring to the control. 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 kit.
Woodward 183
Recommended Wire Types:
Size Insulation Type Use

0.3 mm²/ Multiple conductor, Discrete I/O
600V
22 AWG unshielded PT inputs
Speed Bias, Voltage
0.3 mm²/
300V Two conductor, shielded Bias, MPU, Oil and
22 AWG
Water Sensors
1.0 mm²/ Four conductor stranded,
600V CT inputs
16 AWG unshielded
Two conductor stranded,
0.3 mm²/ RS-485
30V twisted pair, shielded, 124
22 AWG RS-422 (TX and RX)
Ω impedance
184 Woodward
Appendix B.
Speed Bias Connections
EGCP-2 EPG
Speed Bias Output
SPEED
CONTROL
+ 73
- 74
EGCP-2 To EPG Speed Control Wiring and

VIS-125a
Speed Bias Output Type = +/- 3VDC 00-06-20
EGCP-2 2301A
Speed Bias Output Speed Control
+ 73 15 +
- 74 17 -
EGCP-2 To 2301A Speed Control Wiring and

VIS-126a
00-06-20
Speed Bias Output Type = +/- 3VDC

0% Speed Bias Output = 0 VDC
Common 2301A Speed Control Part Numbers:

9905-131, 9905-376, 9907-014
Woodward 185
EGCP-2 FLO-TECH
+ 73 11 +
- 74 12 -
EGCP-2 To FLO-TECH Speed Control Wiring and

VIS-127a
00-06-20

Common FLO-TECH Speed Control Part Numbers:

8290-195, 8290-196
EGCP-2 Pro-ACT I & II

+ 73 12 +
- 74 13 -
EGCP-2 To Pro-ACT Speed Control Wiring and

VIS-128a
00-06-20

Common Pro-ACT Speed Control Part Numbers:

9905-462, 9905-463
186 Woodward
EGCP-2 CSC
+ 73 11 +
- 74 12 -
EGCP-2 To CSC Speed Control Wiring and

VIS-129a
00-06-20

EGCP-2 2301A LSSC

Speed Bias Output Control
+ 73 10 +
- 74 11 -
EGCP-2 To 2301A LSSC Wiring and Configuration

Settings
VIS-130a
00-06-20

NOTE: 2301A LSSC must have terminal 14 powered for

the load sharing line inputs (10 and 11) to be active.
Woodward 187
EGCP-2 701 or 701A

Speed
Speed Bias Output
Control
+ 73 21 +
- 74 22 -
EGCP-2 To 701 and 701A Wiring and Configuration

Settings
VIS-131a
00-06-20

Common 701 and 701A Speed Control Part Numbers:

8280-102, 8280-193, 9905-211
EGCP-2 721
Speed
Speed Bias Output
Control
+ 73 21 +
- 74 22 -
EGCP-2 To 701 and 701A Wiring and Configuration

Settings
VIS-132a
00-06-20

Common 721 Speed Control Part Numbers:

9905-291, 9907-206, 9907-207
188 Woodward
EGCP-2 723 or 723 Plus

Speed
Speed Bias Output
Control
+ 73 45 +
- 74 46 -
EGCP-2 To 723 or 723 Plus Wiring and Configuration

Settings
VIS-133a
00-06-20

Common 723 or 723 Plus Speed Control Part Numbers:

9907-031, 8280-412
Woodward 189
190 Woodward
Appendix C.
Voltage Bias Connections
Basler SSR
EGCP-2 Basler
37 24 SSR
Voltage
38 23 Regulator
EGCP-2 settings: Voltage Regulator settings:

Configuration Menu Droop - set for 2 to 5 %
Voltage Bias Type: +/- 1 VDC In a multiple generator system, set
droop the same on all regulators
Calibration Menu
Volts Bias Offset: 0% Adjustment Procedure
1. Start the generator with the
Shutdown & Alarms Menu EGCP-2 NOT connected.
Gen Volt Hi Lmt: * 10% above Set SSR for rated voltage
rated 2. Connect the EGCP-2 as shown
Gen Volt Lo Lmt: * 10% below
rated 3. Start Generator
4. Adjust the Volts Bias Offset for
Reactive Load Control Menu rated voltage.
VAR/ PF Gain: 1.0 5. Press ENTER to save this value
Volts Ramp Time: 100 6. Close the Voltage Raise discrete
VAR/ PF Sharing Gain: 0.2 input (4) and verify the EGCP2 can
VAR/ PF Stability: 2.0 move the generator voltage in the
PF Deadband: 0.005 increase direction.
7. Close the Voltage Lower discrete
input (5) to verify the EGCP-2 can drive
* - These are only the generator voltage in the decrease
suggested values direction.
8. The Reactive Load Control Menu
items may need adjusted for stable
Power Factor control.
Woodward 191
Basler SR4A or SR8A
EGCP-2 Voltage Trim

Basler
Potentiometer
250 ohm SR4A or
37 6
Clockwise
SR8A
Voltage
38 7
Counter Clockwise
Regulator

Calibration Menu
Volts Bias Offset: -45%
Voltage Trim Potentiometer:
250 ohm, 10 Turn, 1 Watt
Shutdown & Alarms Menu Set to Mid-Range
Gen Volt Hi Lmt: * 10 above Potentiometer value can be a value
rated of 150 to 250 ohms.
Gen Volt Lo Lmt: * 10 below Adjustment Procedure
rated Start Generator
1. Set the Voltage Adjust potentiometer
Reactive Load Control Menu on the SR4A or SR8A for Rated Voltage
VAR/ PF Gain: 1.0 of generator set. (course adjustment)
Volts Ramp Time: 200 2. Use the Voltage Trim potentiometer
VAR/ PF Sharing Gain: 0.2 to fine tune the Rated Voltage. This is
VAR/ PF Stability: 2.0 the potentiometer shown above.
PF Deadband: 0.005 3. The Voltage Trim potentiometer is
now calibrated and should not be
adjusted anymore.
* - These are only 4. Close the Voltage Raise discrete
suggested values input (4) and verify the EGCP-2 can
move the generator voltage in the
increase direction.
input (5) and verify the EGCP-2 can
decrease direction.
6. The Reactive Load Menu items may
need adjusted for stable Power Factor
control.
192 Woodward
Caterpillar Digital Voltage Regulator
EGCP-2
Resistor sizes:
0.250 Watts Caterpillar
1.62K Digital
37 7
500
Voltage
Regulator
38 45
EGCP-2 Settings: Voltage Regulator settings:

Calibration Menu External Resistors:

Volts Bias Offset: 0% 1.62 K ohm
500 ohm
Resistor Wattage - 0.250
Shutdown & Alarms Menu
Gen Volt Hi Lmt: * 10% above rated
Gen Volt Lo Lmt: * 10% below rated
Adjustment Procedure:
Reactive Load Control menu 1. Measure across terminals 37(+) and 38 (-)
VAR/ PF Gain: 0.5 prior to connecting to DVR = 0.0 volts
Volts Ramp Time: 200 Sec 2. Connect to DVR, measure across
VAR/ PF Sharing Gain: 0.1 terminals 7 and 45 = 2 volts
VAR/ PF Stability: 2.0 3. The Cat DVR uses 2 volts as the zero bias
PF Deadband: 0.005 point, taking a 0 - 4 volt input to change the
voltage reference +/- 10%.
4. Start Generator
* - these are only 5. Adjust Volts Bias Offset for Rated Voltage
suggested settings. 6. Press ENTER to save this value
7. The items in the Reactive Load menu may
control.
Woodward 193
Caterpillar VR3
EGCP-2
Voltage Trim
Potentiometer Caterpillar
VR3
10 K ohm
37 6
Voltage
Regulator
38 7
EGCP-2 Settings: Voltage Regulator settings:

Calibration Menu
Volts Bias Offset: -1%
Voltage Trim Potentiometer:
10 K ohm, 10 turn, 1 Watt
Set to Mid-Range
Gen Volt Hi Lmt: * 10% above rated
A 5 K ohm, 0.25 Watt resistor may be
Gen Volt Lo Lmt: * 10% below rated
used in place of the pot
Reactive Load Control menu

VAR/ PF Gain: 0.3 Adjustment Procedure:
Volts Ramp Time: 200 Sec 1. Start Generator
VAR/ PF Sharing Gain: 0.1 2. Adjust Volts Bias Offset for Rated
VAR/ PF Stability: 4.0 Voltage
PF Deadband: 0.005 3. Press ENTER to save this value
4. The items in the Reactive Load menu
may need adjusted for stable Power
* - these are only suggested settings. Factor control.
194 Woodward
KATO KCR360 or 760
EGCP-2 Voltage Trim

Kato KCR
Potentiometer
250 ohm 360, 760
37 6
Clockwise
Voltage
Regulator
38 7
Counter Clockwise

Calibration Menu Voltage Trim Potentiometer:

Volts Bias Offset: -45% 250 ohm, 10 Turn, 1 Watt
Set to Mid-Range
Potentiometer can be a value of
Shutdown & Alarms Menu 150 to 250 ohms.
Gen Volt Hi Lmt: * 10 above
rated Adjustment Procedure
Gen Volt Lo Lmt: * 10 below Start Generator
rated 1. Set the Voltage Adjust potentiometer
on the Kato for Rated Voltage of
generator set. (course adjustment)
Reactive Load Control Menu 2. Use the Voltage Trim potentiometer
VAR/ PF Gain: 1.0 to fine tune the Rated Voltage. This is
Volts Ramp Time: 200 the potentiometer shown above.
VAR/ PF Sharing Gain: 0.2 3. The Voltage Trim potentiometer is
VAR/ PF Stability: 2.0 now calibrated and should not be
PF Deadband: 0.005 adjusted anymore.
4. The Reactive Load Menu items may
* - These are only control.
suggested values
Woodward 195
KATO K65-12B or K125-10B
EGCP-2 KATO
37 3 K65-12B
K125-10B
38 2 Voltage
Regulator
Voltage Regulator settings:
EGCP-2 settings: Droop - set for 2 to 5 %
Configuration Menu In a multiple generator system, set
Voltage Bias Type: +/- 1 VDC droop the same on all regulators
Terminals 2 and 3 will

Calibration Menu provide a 10% per volt range
Volts Bias Offset: 0%
Adjustment Procedure
1. Start the generator with the EGCP-2
Shutdown & Alarms Menu NOT connected and set for rated
Gen Volt Hi Lmt: * 10% above voltage.
rated Terminals 2 and 3 on the AVR must be
Gen Volt Lo Lmt: * 10% below jumpered when doing this.
rated 2. Connect the EGCP-2 as shown.
3. Start Generator
Reactive Load Control Menu 4. Adjust the Volts Bias Offset for
VAR/ PF Gain: 1.0 rated voltage.
Volts Ramp Time: 100 5. Press ENTER to save this value
VAR/ PF Sharing Gain: 0.2 6. Close the Voltage Raise discrete
VAR/ PF Stability: 2.0 input (4) and verify the EGCP2 can
PF Deadband: 0.005 move the generator voltage in the
increase direction.
* - These are only input (5) to verify the EGCP-2 can drive
suggested values the generator voltage in the decrease
direction.
196 Woodward
Marathon 2000E
EGCP-2 Marathon
37 A 2000E
Voltage
38 B Regulator

Droop - set for 2 to 5 %
Configuration Menu
In a multiple generator system, set
Voltage Bias Type: +/- 1 VDC
Terminals A and B will
Calibration Menu
provide a 10% per volt range
Volts Bias Offset: 0%
If using a Marathon 2000EC,
the VAR/PF control must be
disabled in the AVR or the EGCP-2.
Gen Volt Hi Lmt: * 10% above
AVR - software configurable or
rated
jumpering terminals 52J and 52K.
EGCP-2 - software configurable
rated
Reactive Load Control Menu 1. Start the generator with the EGCP-2
VAR/ PF Gain: 1.0 NOT connected and set for rated
Volts Ramp Time: 100 voltage.
VAR/ PF Sharing Gain: 0.2 2. Connect the EGCP-2 as shown.
VAR/ PF Stability: 2.0 3. Start Generator
PF Deadband: 0.005 4. Adjust the Volts Bias Offset for
rated voltage.
* - These are only 5. Press ENTER to save this value
suggested values 6. Close the Voltage Raise discrete
input (4) and verify the EGCP2 can
increase direction.
the generator voltage in the decrease
direction.
Woodward 197
Newage MX321/341
EGCP-2 NEWAGE
37 A2 MX321/
341
38 A1 Voltage
Regulator

TRIM
Calibration Menu Set TRIM pot fully Clockwise. This
Volts Bias Offset: 0% will provide a 5% per volt change
on the accessory input.
NOT connected. Set the 321 or 341 for
rated
rated voltage
2. Connect the EGCP-2 as shown
rated
3. Start Generator
198 Woodward
Newage MA325
EGCP-2 NEWAGE
37 A2 MA325
Voltage
38 A1 Regulator

TRIM
Calibration Menu Set TRIM pot fully Clockwise. This
Volts Bias Offset: 0% will provide a 5% per volt change
on the accessory input.
NOT connected. Set the MA325 for rated
rated
voltage
2. Connect the EGCP-2 as shown
rated
3. Start Generator
Woodward 199
200 Woodward
Appendix D.
EGCP-2 Setpoint Worksheet
Configuration Menu
Item: Range: Default: As Set Value: Note:
SECURITY CODE Min: 0 **** See Security Access
Max: 9999
NETWORK Min: 1 1 Only accessible if
ADDRESS Max: 8 configured for multiple
units
NETWORK Min: 1 1 Only accessible if
PRIORITY Max: 8 configured for multiple
units
NUMBER OF Min: 2 4
POLES Max: 18
NUMBER OF Min: 16 60
TEETH Max: 500
SYSTEM Min: 50 60 Hz
FREQUENCY Max: 60
RATED SPEED Min: 100 1800 RPM
Max: 5000
RATED KW Min: 1 0 KW
Max: 30000
RATED KVA Min: 1 0 kVA
Max: 30000
RATED KVAR Min: 1 0 kVAR
Max: 30000
CT RATIO Min: 5:5 5:5
Max: 30000:5
PT RATIO Min: 1.0:1 1.0:1
Max: 1000.0:1
VOLTAGE INPUT Wye line-neutral Wye line-neutral
Delta line-line
VOLTAGE REF Min: 1 220 Volts
Max: 30000
DISPLAY UNITS American American
Metric
SET DATE MM-DD-YY 6-15-2001
SET TIME HH:MM 12:00 24 Hr. CLOCK
START Enable Enable
SEQUENCING Disable
RELAY #12 kVA Load Switch kVA Load Switch
FUNCTION Idle / Rated Switch
SPEED BIAS ±3 Vdc (WGC) ±3 Vdc
TYPE 0.5 to 4.5 Vdc (DDEC)
500 Hz PWM (ADEM)
VOLTAGE BIAS ±1 Vdc ±1 Vdc
TYPE ±3 Vdc
±9 Vdc
CKT BREAKER Breaker Breaker
CONTROL Contactor
OPERATING No Parallel No Parallel
MODE Mains Parallel
NUMBER OF Single Single
UNITS Multiple
Woodward 201
Shutdown and Alarms Menu
VOLTAGE RNG Audible Alarm Warning
ALM Visual Alarm
Warning
Disabled
GEN VOLT HI Min: 50 250.0 Volts
LMT Max: 30000
GEN VOLT HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
GEN VOLT LO Min: 50 200.0 Volts
LMT Max: 30000
GEN VOLT LO Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
VOLTAGE ALM Min: 0.1 5.0 Sec
DLY Max: 30.0
GEN FREQ HI Min: 40 65 Hz
LMT Max: 75
GEN FREQ HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
GEN FREQ LO Min: 40 55 Hz
LMT Max: 75
GEN FREQ LO Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
SPD FREQ Disabled Disabled
MISMTCH Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
OVERCURRENT Min: 5.0 30 Amps
LVL Max: 30000.0
OVERCURRENT Min: 0.1 1.0 Sec
DLY Max: 20.0
OVERCURRENT Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
REVERSE PWR Min: -50.0 -10.0% Instant
Max: -1.0
REV PWR DELAY Min: 0.1 5.0 Sec
Max: 20.0
MIN REVERSE Min: -50.0 -5.0%
PWR Max: -1.0
202 Woodward
REVERSE PWR Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
REVERSE KVAR Min: -100.0 -50.0%
LIMIT Max: -5.0
REVERSE KVAR Min: 0.1 5.0 Sec
DELAY Max: 5.0
REVERSE KVAR Disabled Warning
ALARM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
REMOTE FAULT1 Disabled Disabled
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
FAULT1 TIMER Min: 0.0 0.0 Sec
Max: 30.0
REMFLT 1 Enabled Enabled Enabled = 15 Second
STABLE DLY Disabled Delay
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Max: 30.0
REMFLT 2 Enabled Enabled Enabled = 15 Second
STABLE DLY Disabled Delay
REMOTE FAULT3 Disabled Hard Shutdown
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Max: 30.0
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Max: 30.0
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Max: 30.0
Woodward 203
Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Max: 30.0
204 Woodward
Engine Control Menu
PREGLOW TIME Min: 0 5 Sec
Max: 1200
CRANK TIME Min: 0 10 Sec
Max: 240
CRANK CUTOUT Min: 5 550 RPM
Max: 10000
CRANK DELAY Min: 1 30 Sec
Max: 240
CRANK Min: 0 0
REPEATS Max: 20
CRANK FAIL Warning Warning
Visual Alarm
Audible Alarm
IDLE SPEED Min: 5 1200 RPM
Max: 30000
IDLE TIME Min: 1 10 Sec
Max: 240
COOLDOWN Min: 0 120 Sec
TIME Max: 2400
COOLDOWN Min: 0 20 kVA
LIMIT Max: 10000
ENGINE RUN Min: 0 0 Hours
TIME Max: 32000
MW HOURS Min: 0.0 0.0 MW Hours
Max: 32000.0
OVERSPEED Min: 5.0 1980 RPM
Max: 30000.0
OVERSPEED Disabled Hard Shutdown
ALARM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
BATT VOLT HI Min: 5.0 28.5 Volts
LMT Max: 50.0
BATT VOLT HI Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
BATT VOLT LO Min: 5.0 10.0 Volts
LMT Max: 50.0
BATT VOLT LO Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
HI OIL PRESS Min: 0.0 65 Bar or PSI
LMT Max: 150.0
HI OIL PRESS Disabled Warning
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
Woodward 205

LO OIL PRESS Min: 0.0. 2.0 Bar or PSI
PRE-LMT Max: 120.0
LO OIL PRESS Disabled Disabled
PRE-ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
LO OIL PRESS Min: 0.0 15.0 Bar or PSI
LMT Max: 120.0
LO OIL PRESS Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
HI H20 TEMP Min: 50.0 125.0 °C or °F
PRE-LMT Max: 300.0
HI H20 TEMP Disabled Disabled
PRE-ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
HI H20 TEMP Min: 50.0 212.0 °C or °F
Max: 300.0
HI H20 TEMP Disabled Soft Shutdown
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
LO H20 TEMP Min: 0.0 20.0 °C or °F
Max: 200.0
LO H20 TEMP Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
206 Woodward
Synchronizer Menu
SYNC MODE Check Check
Permissive
Run
SYNC GAIN Min: 0.01 0.10
Max: 100.00
SYNC STABILITY Min: 0.00 1.00
Max: 20.00
VOLTAGE Disabled Enabled
MATCHING Enabled
VOLTAGE Min: 0.1 1.0%
WINDOW Max: 10.0
MAX PHASE Min: 2.0 10.0°
WINDOW Max: 20.0
DWELL TIME Min: 0.1 0.5 Sec
Max: 30.0
CB HOLD TIME Min: 0.1 1.0 Sec
Max: 30.0
CLOSE Min: 1 2
ATTEMPTS Max: 20
RECLOSE DELAY Min: 2 30 Sec
Max: 1200
SYNC RECLOSE Warning Warning
ALM Visual Alarm
Audible Alarm
SYNC TIMEOUT Min: 0 0 Sec 0 = NO LIMIT
Max: 1200
SYNC TIMEOUT Warning Warning
ALM Visual Alarm
Audible Alarm
DEADBUS Disabled Disabled
CLOSURE Enabled
Woodward 207
Real Load Control Menu
LOAD CONTROL Normal Normal
MODE Soft Transfer
Droop
LOAD CTRL GAIN Min: 0.001 0.01
Max: 100.0
LOADSHARE Min: 0.1 0.72
GAIN Max: 2.0
LOAD STABILITY Min: 0.0 2.00
Max: 20.0
LOAD Min: 0.0 0.20
DERIVATIVE Max: 20.0
LOAD CTRL Min: 0.01 1.0 Hz
FILTER Max: 10.0
BASE LOAD Min: 0.0 50.0 KW
REFERENCE Max: 30000.0
UNLOAD TRIP Min: -10.0 10 KW Must be set less than
Max: 30000.0 Baseload Ref
LOAD DROOP Min: 0.0 5.0%
Max: 50.0
LOAD TIME Min: 1.0 10 Sec
Max: 7200.0
UNLOAD TIME Min: 1.0 10 Sec
Max: 7200.0
RAISE LOAD Min: 0.01 2.00%/Sec
RATE Max: 100.0
LOWER LOAD Min: 0.01 2.00%/Sec
RATE Max: 100.0
KW LOAD HIGH Min: 0.0 30 KW
LIMIT Max: 30000.0
KW HIGH LIMIT Disabled Warning
ALARM Warning
Visual Alarm
Audible Alarm
KW LOAD LOW Min: 0.0 5.0 KW
LIMIT Max: 30000.0
KW LOW LIMIT Disabled Disabled
ALARM Warning
Visual Alarm
Audible Alarm
KVA SWITCH Min: 0 10 kVA
LOW Max: 30000
KVA SWITCH Min: 0 100 kVA
HIGH Max: 30000
208 Woodward
Reactive Load Control Menu
VAR/PF MODE Disabled PF Control
PF Control
VAR Control
VAR/PF GAIN Min: .01 1.00
Max: 20.0
VOLTS RAMP Min: 0 60.0 Sec
TIME Max: 1000
VAR/PF Min: .01 1.00
SHARING GAIN Max: 20.0
VAR/PF Min: 0.0 1.00
STABILITY Max: 20.00
KVAR Min: -20,000 10.0 kVAR + = generate (Lag)
REFERENCE Max: 20,000 - = absorb (Lead)
PF REF Min: -0.5 =.5 Lead 0.0 = 1.00 Lag 0.0 = Unity PF
Max: +.5 =.5 Lag + = Lag
- = Lead
PF DEADBAND Min: 0.0 0.005
Max: 1.0
Woodward 209
Process Control Menu
PROCESS Direct Indirect
ACTION Indirect
PROCESS GAIN Min: 0.001 0.10
Max: 100.0
PROCESS Min: 0.0 1.0 Sec
STABILITY Max: 20.0
PROCESS Min: 0.0 0.1 Sec
DERIVATIVE Max: 20.0
PROCESS Min: 0.3 0.3% % of Full Scale
DEADBAND Max: 5.0
PROCESS Min: 0.0 0.0%
DROOP Max: 50.0
PROCESS Min: 0.1 1.0 Hz
FILTER Max: 5.0
PROCESS Min: -32,768 12.0 *Process Units
REFERENCE Max: 32,767
RAISE RATE Min: 0.0 0.1 %/Sec
Max: 100.0
LOWER RATE Min: 0.0 0.1 %/Sec
Max: 100.0
PROCESS HIGH Min: -32,768 20.0 *Process Units
LMT Max: 32,767
PROC HI LMT Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
PROCESS LOW Min: -32,768 4.0 *Process Units
LMT Max: 32,767
PROC LO LMT Disabled Disabled
ALM Warning
Visual Alarm
Audible Alarm
Soft Shutdown
Hard Shutdown
PROCESS UNITS mA mA
V
KW
MW
kVA
MVA
kVAR
MVAR
PF
Degrees C
Degrees F
PSI
kPA
BAR
PROCESS LOW Min: -32,768 4.0
VALUE Max: 32,767
PROCESS HIGH Min: -32,768 20.0
VALUE Max: 32,767
210 Woodward
Transfer Switch Menu
CHECK MAINS Disabled Enabled
BREAKER Enabled
FAST XFER Min: 0.1 1.0 Sec
DELAY Max: 30.0
MAINS STABLE Min: 1 60 Sec
DLY Max: 30000
GEN STABLE Min: 1 10 Sec
DLY Max: 30000
LOAD SURGE Min: 25.0 100.0%/Sec
Max: 300.0
LOAD SURGE Disabled Warning
ALARM Warning
Loss of Mains
Loss of Mains w/alarms
MAIN VOLT HIGH Min: 50.0 240 Volts
LMT Max: 30000.0
MAIN VOLT HIGH Disabled Warning
ALARM Warning
Loss of Mains
MAIN VOLT LOW Min: 50.0 200 Volts
LMT Max: 30000.0
MAIN VOLT LOW Disabled Warning
ALARM Warning
Loss of Mains
MAIN FREQ HIGH Min: 40.0 61.0 Hz
LMT Max: 75.0
MAIN FREQ HIGH Disabled Warning
ALARM Warning
Loss of Mains
MAIN FREQ LOW Min: 40.0 59.0 Hz
LMT Max: 75.0
MAIN FREQ LOW Disabled Disabled
ALARM Warning
Loss of Mains
LOM ACTION Min: 0.1 0.1 Sec
DELAY Max: 30.0
Woodward 211
Sequencing and Comms Menu
AUTO Disabled Disabled
SEQUENCING Enabled
AUTO Min: 1 120 Sec
SEQUENCE Max: 1200
DELAY
MAX GEN LOAD Min: 1 60%
Max: 100
NEXT GENSET Min: 1 30 Sec
DLY Max: 1200
RATED LOAD Min: 1 5 Sec
DELAY Max: 1200
MAX START Min: 1 30 Sec
TIME Max: 1200
MIN GEN LOAD Min: 1 30%
Max: 100
REDUCED LOAD Min: 1 60 Sec
DLY Max: 1200
MAX STOP TIME Min: 1 60 Sec
Max: 1200
422 PROTOCOL ServLink Modbus
Modbus
Upload Setpoints
Modbus ID Min: 1 1
Max: 247
Modbus Timeout Min: 0.1 3.0 Sec
Max: 20.0
Modbus Reset False False
True
212 Woodward
Calibration Menu
Item: Range: As Set Value: Note:
Process In scale Min: 0.5
Max: 2.0
Speed Bias offset Min: -50.0
Max: 50.0
Volts Bias offset Min: -50.0
Max: 50.0
PT Phase A scale Min: 0.5
Max: 10.0
PT Phase B scale Min: 0.5
Max: 10.0
PT Phase C scale Min: 0.5
Max: 10.0
CT Phase A offset 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
Water Temp Gain Min: -1.0
Max: 1.0
Water Temp Min: -900.0
Offset Max: 900.0
NetComm Min: 0
Dropouts Max: 50
Calibrated Unit False Do Not Change
True
Woodward 213
214 Woodward
Appendix E.
Applicable Documents
Woodward 215
216 Woodward
EGCP-2 Control Specifications
Woodward Part Numbers:
8406-120 EGCP-2 Engine Generator Control, 150–300 Vac PT
input
8406-121 EGCP-2 Engine Generator Control, 50–150 Vac PT input
Power Supply Rating 9–32 Vdc (SELV) Maximum input voltage range
Power Consumption Less than or equal 13 W nominal, 20 W maximum
Input Supply Voltage Input Supply Current

12 V (nominal) 1.08 A
24 V (nominal) 542 mA
32 V 406 mA
PT input 50–150 Vac, 8406-121
150–300 Vac, 8406-120
CT input 0–5 A rms
Generator Frequency Range 40–70 Hz
Magnetic Pickup 100–15 000 Hz
Discrete Inputs (16) 5 mA source current when CLOSED to Switch Common
(65)
Process input 4–20 mA, 1–5 Vdc
Temperature and pressure inputs 0–200 Ω sensors, 4–20 mA transducer, or 0–5V
transducer
Speed Bias ±3 Vdc, 0.5–4.5 Vdc, 5 V peak 500 Hz PWM
Voltage Bias ±1 Vdc, ±3 Vdc, ±9 Vdc
Discrete Outputs (Relay Outputs) 10 A, 250 Vac Resistive
249 W (1/3 hp), 125 Vac (7.2 A, 0.4–0.5 PF)
10 A, 30 Vdc Resistive
Communication Ports RS-485, RS-422
Ambient Operating Temperature –20 to +70 °C (–4 to +158 °F)(around outside of EGCP-2
chassis)
Storage Temperature –40 to +105 °C (–40 to +221 °F)
Humidity 95% at 20 to 55 °C (68 to 131 °F)
Mechanical Vibration SV2 5–2000 Hz @ 4 G and RV1 10–2000 Hz @ .04
G²/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 in IEC529
when installed in a suitable atmospherically vented
enclosure. Also meets Type 4 requirements.
Regulatory Compliance
European Compliance for CE Mark:
EMC Directive Declared to 89/336/EEC COUNCIL DIRECTIVE of 03
May 1989 on the approximation of the laws of the
member states relating to electromagnetic compatibility.
Low Voltage Directive Declared to the 73/23/EEC COUNCIL DIRECTIVE of 19
February 1973 on the harmonization of the laws of the
Member States relating to electrical equipment designed
for use within certain voltage limits.
North American Compliance:

UL UL Listed for Ordinary Locations at 70°C maximum
Ambient. For use in the United States and Canada.
UL File E97763
CSA CSA Certified for Ordinary Locations at 70 °C maximum
Ambient. For use in the United States and Canada.
Certificate 1159277
NOTE Wiring must be in accordance with applicable electric
codes with the authority having jurisdiction.
We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please include the manual number from the front cover of this publication.
Woodward/Industrial Controls
PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
E-mail and Home Page—www.woodward.com
FM 57982
BS EN ISO 9001:1994
6 March 2001
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/e-mail information for all locations is available on our website.
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26174

8406-120, 150–300 Vac PT Input, 9–32 Vdc

Installation and Operation Manual

Electronic controls contain static-sensitive parts. Observe the following

The installation must include the following:

The calibration and checkout procedure should only be performed by authorized

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI

CHAPTER 5. CONTROL FEATURES AND FUNCTIONS ..................................121

APPENDIX C. VOLTAGE BIAS CONNECTIONS ............................................ 191

Illustrations and Tables

Figure 2-1. Physical Outline with Dimensions of EGCP-2 .....................................6

Illustrations and Tables

Illustrations and Tables

Table 5-1. Overcurrent Level Chart......................................................................85

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

• Do not touch any part of the PCB except the edges.

• Do not touch the electrical conductors, the connectors, or the

Regulatory Compliance Notes And Warnings

Control Electrical Ratings

Element Accuracy Description

Designed for generator sets up to 30,000Kw, the EGCP-2 can be configured to

Reactive (KVAR) Control

Automatic Generator Sequencing

Generator Protective Features

Engine Protective Features

*—Modbus is a registered trademark of Modicon, Inc.

Figure 2-1. Physical Outline with Dimensions of EGCP-2

Run With Load

Figure 2-2. EGCP-2 Interface Connections

Water Temperature MPU Speed Bias Voltage Bias

Figure 2-3. Operator Interface

ALARM/EVENT LOG KEYS:

The ALARM/EVENT key is used to access the Event

The ALARM CLEAR key is used to acknowledge and

If the Alarm mode is Visual or Warning—

If the Alarm/Shutdown mode is Audible, Soft Shutdown, or Hard Shutdown—

The SCROLL KEY is used to move the cursor up, down,

The ESCAPE KEY is used to move upwards (out of )the

The ENTER KEY is used to move downwards (into) the

STATUS and CONFIGURATION KEYS:

STATUS MENU KEYS:

The contents of the various status screens are described in Chapter 4.

The SYSTEM STATUS key, when pressed displays the

The ENGINE STATUS key, when pressed displays

The GEN STATUS key shows three phase generator

The I/O STATUS key provides the status of all the

The SYNC STATUS key shows status information

The KW LOAD STATUS key, when pressed, shows the

Press the PF/KVAR STATUS key to display VAR/PF

The SEQUENCE STATUS key provides sequencing

The ATS STATUS key, when pressed, displays the

LEFT HAND LCD DISPLAY RIGHT HAND LCD DISPLAY

prime mover status prime mover status

synchronizer status synchronizer status

Figure 2-4a. EGCP-2 Navigation (1)