Woodward EGCP-2 User Manual

Product Manual 26174
(Revision B)
Original Instructions
EGCP-2
Engine Generator Control Package
8406-120, 150–300 Vac PT Input, 9–32 Vdc
8406-121, 50–150 Vac PT Input, 9–32 Vdc
Installation and Operation Manual

Woodward EGCP-2 Specifications

General

Display Type	LCD
Isochronous Load Sharing	Yes
kW Load Control	Yes
kVAR Load Control	Yes
Power Factor Control	Yes
Output Voltage	24 VDC
Communication Protocols	J1939
Operating Temperature	-40°C to +70°C
Applications	Generator control
Operating Modes	Isochronous, Droop, Base Load
Programming	Configurable via software

Summary

Warnings and Notices

Personal Protective Equipment

Details essential PPE for handling equipment, including eye protection, hard hat, gloves, safety boots, and respirator.

Start-up Precautions

Advises preparedness for emergency shutdown during engine or prime mover startup to prevent runaway or overspeed.

Electrostatic Discharge Awareness

Electrostatic Precautions

Outlines procedures for handling static-sensitive electronic parts to prevent damage, including grounding and material avoidance.

Chapter 2. Control Overview

Chapter 3. Electrical Installation and Specifications

Grounding for Protection Against Electric Shock

Details protective earth connection requirements and recommended single-point grounding practices.

Alarms and Shutdowns

Explains configurable alarm/shutdown set points and their responses (Disabled, Warning, Visual, Audible, Soft/Hard Shutdown).

Chapter 4. Software Overview

Shutdowns and Alarms

Covers configuring generator protection functions, including voltage and frequency limits and alarms.

Chapter 5. Control Features and Functions

Generator Voltage and Reactive Load Control

Explains control of generator voltage for synchronization, load sharing, and reactive load management.

Mains Sensing

Covers sensing mains voltage, frequency, load surge, and loss of mains conditions.

Synchronizing

Details synchronization modes (Run, Check, Permissive), voltage matching, and dead bus closing.

Load Control

Describes load control functions: proportional load sharing, base load, process control, and load ramping.

Sequencing

Explains how units are sequenced on/off line based on system load, priority, and time delays.

Loss Of Mains Detection and Action

Details the EGCP-2's response to loss of mains, including isolation and transfer to on-site generators.

Generator Sequencing

Explains automatic sequencing for multiple units to maintain load capacity ratio and system stability.

Chapter 6. Calibration of Control Inputs and Outputs

Calibration of Generator PTs and CTs

Covers calibration of three-phase generator voltage and current inputs for accurate readings.

Calibration of the Bus PT

Details calibrating bus and mains PT inputs for voltage sensing during monitoring and synchronization.

Speed Bias Output

Explains setting the speed bias offset for governing speed in synchronization and load control functions.

Voltage Bias Output

Describes setting the voltage bias offset to impose an offset voltage on the AVR's bias input.

Chapter 7. General Start-up Instructions

Before Starting the Generator Set

Covers pre-start configuration of tuning set points, verifying wiring, and checking power supply.

Sequence of Start-up and Checking Parameters

Lists sequential steps for system setup, discrete input checks, and parameter verification before loading.

Loading the Generator Set

Provides instructions for loading the generator set, including mains parallel setup and phasing checks.

Chapter 8. Troubleshooting

Control Hardware and I/O

Guides users through troubleshooting issues related to control power, I/O status, and relay outputs.

Engine Control/Sensing Parameters

Addresses problems with starting, starter engagement, engine speed instability, and power loss during cranking.

Synchronization

Helps diagnose and resolve issues with phase matching, breaker closure, voltage matching, and dead bus closing.

Real Load Control

Troubleshoots problems with negative kW readings, improper load sharing, and unstable load control.

Reactive Load Control

Addresses phase power factor disagreements, improper reactive load sharing, and unstable VAR/PF control.

Sequencing

Helps resolve issues where units do not show in sequencing order or auto-sequencing fails.

Mains/Bus Sensing

Communications