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EGCP-2
Operation Manual
Woodward EGCP-2 - Operation Manual
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Operation (End User) Manual
EGCP-2
Engine Generator Control Package
8406-115, 150–300 Vac PT Input, 9–32 Vdc
8406-116, 50–150 Vac PT Input, 9–32 Vdc
Manual 26086 (Revision E)
2
Table of Contents
Main Page
Default Chapter
3
Table of Contents
3
Regulatory Compliance
7
Electrostatic Discharge Awareness
8
Chapter 1. General Information
9
Introduction
9
Control Electrical Ratings
9
Figure 1-1. EGCP-2 Wiring Diagram
10
Chapter 2. Control Overview
11
Introduction
11
Operator Interface
13
Figure 2-1. Operator Interface
13
Figure 2-2. EGCP-2 Navigation
18
Chapter 3. Software Overview
23
Introduction
23
Status Screens
23
Figure 3-1. System Overview Engine off Line
23
Figure 3-2. System Status Screen-Isochronous
25
Figure 3-3. System Status Screen-Baseload
25
Figure 3-4. Engine Overview
26
Figure 3-5. Generator Status (Voltage Line to Line)
27
Figure 3-6. I/O Status
28
Figure 3-7. Synchronizer Status
29
Figure 3-8. KW Load Status
30
Figure 3-9. PF /KVAR Status
31
Figure 3-10. Sequencing Menu
32
Figure 3-11. Sequencing Menu (Multi-Unit)
33
Figure 3-12. ATS (Automatic Transfer Switch) Status
34
Alarm / Event Log
35
Figure 3-13. Alarm / Event Screen
35
Figure 3-14. Empty Event Log
36
Configuration Menus
37
Figure 3-15. Security Code Display
37
Figure 3-16A. Configuration Menu List (Screen 1)
38
Figure 3-16B. Configuration Menu List (Screen 2)
38
Figure 3-16C. Configuration Menu List (Screen 3)
39
Figure 3-17. AC Power Triangle
42
Figure 3-18. Breaker Logic and Contactor Logic
45
Shutdowns and Alarms
46
Figure 3-19. Generator High/Low Voltage Alarms
46
Figure 3-20. Generator Over/Under Frequency
47
Figure 3-21. Current Goes to 160 Amps, an Alarm or Shutdown will be Received
49
Figure 3-22. Current Goes to 176 Amps, an Alarm or Shutdown will be Received
49
Figure 3-23. Current Goes to 152 Amps, an Alarm or Shutdown will be Received
50
Figure 3-24. Reverse Power
50
Engine Control
51
Synchroscope
53
Figure 3-25. Typical Circuit Using Permissive Function and Run for Auto/Manual Synchronizing
53
Figure 3-26. Voltage Matching (1% Setpoint)
54
Figure 3-27. Maximum Phase Window = 10 Degrees
54
Real Load Control
56
Reactive Load Control
58
Process Control
59
Figure 3-28. Direct (Export) Process Action
59
Figure 3-29. Indirect (Import Power) Process Action
59
Figure 3-30. Direct (Import/Export) Process Action
60
Figure 3-31. EGCP-2 Control Dip Switch
60
Transfer Switch
62
Sequencing and Comms (Communications)
64
Calibration Menu
66
Figure 3-32. Measured Vs. Monitored
67
Figure 3-33. Typical AVR with Aux Input (Newage SX-440)
68
Figure 3-34. Typical AVR with External Voltage Adjust Potentiometer
68
Figure 3-35. AVR Droop
68
Figure 3-36. Direct Proportional Input to Water Temp or Oil Pressure Input
70
Figure 3-37. Voltage Controlled Oscillators-Effect of Offset
70
Figure 3-38. Voltage Controlled Oscillators-Effect of Gain
70
Figure 3-39. Battery VCO
71
Figure 3-40. Oil Pressure VCO
71
Figure 3-41. Water Temperature VCO
72
Chapter 4. Control Features and Functions
74
Engine Control
74
Engine Protection
74
Generator Voltage and Reactive Load Control
74
Generator Protection
74
Mains Sensing
75
Synchronizing
75
Load Control
75
Sequencing
75
Engine Cranking
76
IDLE/RATED Relay Output
77
Generator Voltage Control
77
Generator Load Control
78
Figure 4-1. Droop Mode
79
Figure 4-2. Isochronous Mode
80
Figure 4-3. Droop/Isochronous Load Sharing
81
Automatic Generator Loading Functions
82
Synchronizer Description
85
Figure 4-4. Synchronizer Time Line-Standard Sequence
89
Figure 4-5. Loss of Mains Detection Active
90
Figure 4-6. Generator off Line
90
Figure 4-7. Mains Parallel Unit with Voltage/Frequency Detect
91
Figure 4-8. Mains Parallel Unit(S) with Load Surge Detect
91
Generator Sequencing
92
Figure 4-9. Typical Automatic Sequencing Routine
93
Figure 4-10. Original System Configuration
95
Figure 4-11. after a Change of Priority-Units Not Operating
96
Figure 4-12. Original System Configuration
96
Figure 4-13. a New Master Takes Over-Single Unit Operating on the Isolated Bus
97
Figure 4-14. Changing the Priority of a Slave Unit
98
Figure 4-15. Changing the Priority of a Slave Unit
99
Figure 4-16. Changing the Priority of a Slave Unit
99
Figure 4-17. Changing the Priority of a Slave Unit
100
Figure 4-18. Changing the Priority of a Slave Unit
100
Inter-Control Communications (RS-485 Network)
101
Figure 4-19. Changing the Priority of a Slave Unit
101
Remote Control/Monitoring (RS-422)
102
Chapter 5. Calibration of Control Inputs and Outputs
103
Introduction
103
Calibration of Generator Pts and Cts
104
Calibration of the Bus PT
108
Speed Bias Output
109
Voltage Bias Output
110
Figure 5-1. Relationship between Voltage Bias and Generator Voltage
110
Chapter 6. General Startup Instructions
111
Before Starting the Generator Set
111
Sequence of Startup and Checking Parameters
112
Loading the Generator Set
112
Chapter 7. Troubleshooting
115
Control Hardware and I/O
115
Engine Control/Sensing Parameters
116
Synchronization
117
Breaker Close/Open Control
118
Real Load Control
119
Reactive Load Control
120
Sequencing
121
Mains/Bus Sensing
122
Communications
122
Chapter 8. Definition of Terms
123
Chapter 9. Service Options
130
Product Service Options
130
Returning Equipment for Repair
131
Replacement Parts
132
How to Contact Woodward
132
Engineering Services
133
Technical Assistance
134
Egcp-2 Setpoint Worksheet
135
Configuration Menu
135
Shutdown and Alarms Menu
136
Engine Control Menu
138
Synchronizer Menu
140
Real Load Control Menu
141
Reactive Load Control Menu
142
Process Control Menu
142
Transfer Switch Menu
143
Sequencing and Comms Menu
144
Calibration Menu
145
Appendix B. Download Instructions
146
Purpose
146
Requirements
146
Instructions
146
Egcp-2 Control Specifications
151
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