Installation (Set Builder) 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 26076 (Revision F) WARNING—DANGER OF DEATH OR PERSONAL INJURY WARNING—FOLLOW INSTRUCTIONS 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. WARNING—OUT-OF-DATE PUBLICATION This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy. WARNING—OVERSPEED PROTECTION The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. WARNING—PROPER USE Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings. CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY CAUTION—BATTERY CHARGING To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. CAUTION—ELECTROSTATIC DISCHARGE 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. IMPORTANT DEFINITIONS • A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property. • A NOTE provides other helpful information that does not fall under the warning or caution categories. Revisions—Text changes are indicated by a black line alongside the text. 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. © Woodward 2000 All Rights Reserved Manual 26076 EGCP-2 Engine Generator Control Package Contents REGULATORY COMPLIANCE ......................................................................... V  ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI  CHAPTER 1. GENERAL INFORMATION ........................................................... 1  Introduction ............................................................................................................. 1  Control Electrical Ratings ....................................................................................... 1  CHAPTER 2. CONTROL OVERVIEW ............................................................... 2  Introduction ............................................................................................................. 2  Operator Interface .................................................................................................. 5  Hardware ................................................................................................................ 9  Environmental Specification ................................................................................. 10  Physical Specification ........................................................................................... 10  Accessories .......................................................................................................... 10  CHAPTER 3. ELECTRICAL INSTALLATION AND SPECIFICATIONS ................... 12  Electrical Connections .......................................................................................... 12  Input Power .......................................................................................................... 16  Potential Transformer (PT) Inputs ........................................................................ 17  Current Transformer (CT) Inputs .......................................................................... 25  MPU (Speed) Input ............................................................................................... 26  Process Import/Export Input ................................................................................. 27  Coolant Temperature and Oil Pressure Inputs ..................................................... 28  Speed Bias and Voltage Bias Outputs ................................................................. 30  Discrete Inputs ...................................................................................................... 31  Relay Outputs ....................................................................................................... 33  AC Inputs .............................................................................................................. 42  DC Inputs and Outputs ......................................................................................... 42  Discrete Inputs ...................................................................................................... 43  Discrete Outputs ................................................................................................... 43  Communication Ports: RS-485 & RS-422 (1 each) .............................................. 44  Hardware Connections ......................................................................................... 44  Inter-control Communications (RS-485 Network) ................................................ 46  Alarms and Shutdowns ........................................................................................ 47  CHAPTER 4. OPERATIONAL DESCRIPTION: SINGLE NO PARALLEL .............. 50  CHAPTER 5. OPERATIONAL DESCRIPTION: SINGLE UNIT PARALLEL ............ 57  CHAPTER 6. OPERATING MODE: MULTIPLE NO PARALLEL ......................... 64  CHAPTER 7. OPERATING MODE: MULTIPLE PARALLEL ............................... 73  CHAPTER 8. MANUAL OPERATION............................................................ 109  CHAPTER 9. EGCP-2 COMMUNICATIONS ................................................. 112  Overview ............................................................................................................. 112  Modbus RTU Communications for the EGCP-2 Panel ...................................... 113  CHAPTER 10. SERVICE OPTIONS ............................................................. 121  Product Service Options ..................................................................................... 121  Woodward Factory Servicing Options ................................................................ 122  Returning Equipment for Repair ......................................................................... 123  Replacement Parts ............................................................................................. 123  Engineering Services ......................................................................................... 124  How to Contact Woodward ................................................................................. 124  Technical Assistance .......................................................................................... 125  Woodward i EGCP-2 Engine Generator Control Package Manual 26076 Contents APPENDIX A. CONNECTOR INFORMATION ................................................. 126  APPENDIX B. SPEED BIAS CONNECTIONS ................................................. 128  DECLARATIONS ....................................................................................... 134  EGCP-2 CONTROL SPECIFICATIONS ........................................................ 135  Illustrations and Tables Figure 2-1. EGCP-2 Interface Connections ........................................................... 4 Figure 2-2. Operator Interface ................................................................................ 5 Figure 2-3. Physical Outline with Dimensions of EGCP-2 ...................................11 Figure 3-1. CageClamp Termination Blocks (example photos) ...........................12 Figure 3-2. Recommended Single Point Grounding Scheme ..............................13 Figure 3-3. Wiring Diagram for EGCP-2 ...............................................................15 Figure 3-4. Dip Switch Location ...........................................................................16 Figure 3-5. Three Wire Delta PT Connection for EGCP-2 ...................................17 Figure 3-6. Four Wire WYE PT Connection .........................................................18 Figure 3-7. Utility / Local Bus PT Wiring for Delta and Wye Configuration ..........19 Figure 3-8a. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration (two relay) ........................................................................................20 Figure 3-8b. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration (single relay) ....................................................................................20 Figure 3-9a. PT Wiring Relationships for Generator, Bus, and Utility Inputs .......21 Figure 3-9b. PT Wiring Relationships for Generator, Bus, and Utility Inputs .......22 Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs .....23 Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs .....24 Figure 3-11. Current Transfer Wiring Diagram for EGCP-2 .................................25 Figure 3-12. Wiring Diagram for MPU Input .........................................................26 Figure 3-13a. Wiring Diagram for Process Import/Export Input ...........................27 Figure 3-13b. Connecting a KW Transducer Signal to Multiple EGCP-2s ...........27 Figure 3-14a. Wiring Diagram for Pressure Inputs ...............................................28 Figure 3-14b. Wiring Diagram for Temperature Inputs ........................................29 Figure 3-15. Wiring Diagram for Speed Bias and Voltage Bias Outputs .............31 Figure 3-16. Wiring Diagram for Typical Discrete I/O Connections .....................33 Figure 3-17. Example of the Mains Breaker NO Output Connected to Close the Mains (Utility) Breaker (ENERGIZE TO CLOSE) ............................34 Figure 3-18. Example Using the NC Output to Control the Mains (Utility) Contactor (ENERGIZE TO OPEN) ..................................................35 Figure 3-19. Example of the Generator Breaker Close NO Output Connected to Close the Generator Breaker (ENERGIZE TO CLOSE) .................36 Figure 3-20. Example Using the NO Contacts to Control the Generator’s Contactor (ENERGIZE TO CLOSE) ................................................36 Figure 3-21. Example Using the NO Contacts to Control the Mains Breaker Trip (Open) Coil (ENERGIZE TO OPEN) ...............................................39 Figure 3-22. Example Using the NC Contacts to Control the Generator Breakers Open Coil (DE-ENERGIZE TO OPEN) ...........................................40 ii Woodward Manual 26076 EGCP-2 Engine Generator Control Package Illustrations and Tables Figure 3-23. Generator Breaker and Contactor Close and Open Logic .............. 40 Figure 3-24. RS-422 Communications ................................................................. 45 Figure 3-25. RS-485 and RS-422 Termination Diagrams .................................... 46 Figure 3-26. RS-485 Inter-Control Communications ............................................ 47 Figure 4-1. Single No Parallel Application ............................................................ 52 Figure 4-2a. Single No Parallel Overview Flow Diagram ..................................... 54 Figure 4-2b. Single No Parallel Overview Flow Diagram ..................................... 55 Figure 4-3. Single No Parallel Prime Power ......................................................... 56 Figure 5-1. Single Unit Parallel Application .......................................................... 59 Figure 5-2a. Single Unit Parallel Overview Flow Diagram ................................... 61 Figure 5-2b. Single Unit Parallel Overview Flow Diagram ................................... 62 Figure 5-2c. Single Unit Parallel Overview Flow Diagram ................................... 63 Figure 6-1. Multiple Unit No Parallel Application .................................................. 66 Figure 6-2a. Master Multiple Unit No Parallel Overview Flow Diagram ............... 68 Figure 6-2b. Master Multiple Unit No Parallel Overview Flow Diagram ............... 69 Figure 6-3a. Slave Multiple Unit No Parallel Overview Flow Diagram ................. 70 Figure 6-3b. Slave Multiple Unit No Parallel Overview Flow Diagram ................. 71 Figure 6-3c. Slave Multiple Unit No Parallel Overview Flow Diagram ................. 72 Figure 7-1. Multiple Unit No Parallel Prime Power Application ............................ 75 Figure 7-2. Multiple Unit Parallel Standby Power Application .............................. 76 Figure 7-3. Multiple Unit Parallel Peak Shaving Application ................................ 77 Figure 7-4a. Master Multiple Parallel Process Control Flow Diagram ................. 79 Figure 7-4b. Master Multiple Parallel Process Control Flow Diagram ................. 80 Figure 7-4c. Master Multiple Parallel Process Control Flow Diagram ................. 81 Figure 7-4d. Master Multiple Parallel Process Control Flow Diagram ................. 82 Figure 7-4e. Master Multiple Parallel Process Control Flow Diagram ................. 83 Figure 7-4f. Master Multiple Parallel Process Control Flow Diagram .................. 84 Figure 7-4g. Master Multiple Parallel Process Control Flow Diagram ................. 85 Figure 7-4h. Master Multiple Parallel Process Control Flow Diagram ................. 86 Figure 7-5a. Slave Multiple Parallel Process Control Flow Diagram ................... 87 Figure 7-5b. Slave Multiple Parallel Process Control Flow Diagram ................... 88 Figure 7-5c. Slave Multiple Parallel Process Control Flow Diagram ................... 89 Figure 7-5d. Slave Multiple Parallel Process Control Flow Diagram ................... 90 Figure 7-5e. Slave Multiple Parallel Process Control Flow Diagram ................... 91 Figure 7-5f. Slave Multiple Parallel Process Control Flow Diagram .................... 92 Figure 7-5g. Slave Multiple Parallel Process Control Flow Diagram ................... 93 Figure 7-5h. Slave Multiple Parallel Process Control Flow Diagram ................... 94 Figure 7-5j. Slave Multiple Parallel Process Control Flow Diagram .................... 95 Figure 7-5k. Slave Multiple Parallel Process Control Flow Diagram ................... 96 Figure 7-5l. Slave Multiple Parallel Process Control Flow Diagram .................... 97 Figure 7-5m. Slave Multiple Parallel Process Control Flow Diagram .................. 98 Figure 7-6. Generator Start Sequence ................................................................. 99 Figure 7-7. Generator Stop Sequence ............................................................... 100 Figure 7-8. Generator Breaker Close Sequence ............................................... 101 Figure 7-9. Generator Breaker Close Sequence ............................................... 102 Figure 7-10. Generator Breaker Close Sequence ............................................. 103 Figure 7-11. Main Breaker Open Sequence ...................................................... 104 Figure 7-12. Mains Breaker Close Sequence .................................................... 105 Figure 7-13. Mains Breaker Reclose Sequence ................................................ 106 Figure 7-14. Mains Breaker Reclose Sequence ................................................ 107 Figure 7-15. Speed Raise/Lower Switch Based Logic ....................................... 108 Figure 7-16. Voltage Raise/Lower Switch Based Logic ..................................... 108 Woodward iii EGCP-2 Engine Generator Control Package Manual 26076 Illustrations and Tables Table 9-1. Examples of Modbus Control Mode Switching Logic ....................... 114 Table 9-2. Modbus Addresses for the RTU Protocol ........................................ 117 Table 9-3. Common Modbus Error Numbers .................................................... 120 Table 9-4. Typical Modbus Communications Settings ...................................... 120 WARNING—EARTH GROUND Protective Earth (PE) must be connected to the termination point on the back side 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). WARNING—TRAINED PERSONNEL/HIGH VOLTAGE The calibration and checkout procedure should only be performed by authorized personnel knowledgeable of the risks posed by live electrical equipment. iv Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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. 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). Woodward v EGCP-2 Engine Generator Control Package Manual 26076 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—ELECTROSTATIC DISCHARGE 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. vi Woodward Manual 26076 EGCP-2 Engine Generator Control Package Chapter 1. General Information Introduction This manual describes the Woodward EGCP-2 Engine Generator Control Package, models 8406-115 and 8406-116 (9–32 Vdc maximum input voltage range). Control Electrical Ratings nominal supply voltage range 10–29 Vdc (12 or 14 volt systems) max. power consumption at rated voltage 20 W max. PT input voltage range 150–300 Vac rms (8406-115) 50–150 Vac rms (8406-116) max. CT current input range 0–6 A rms max. generator frequency range 40–70 Hz Woodward 1 EGCP-2 Engine Generator Control Package Manual 26076 Chapter 2. Control Overview Introduction The EGCP-2 is a microprocessor based complete generator load control and engine management package. It is designed for use with an automatic voltage regulator and Woodward speed control to automate and protect diesel or gas engine based backup generator sets. Designed for small to medium size generator sets the EGCP-2 can be configured to operate stand-alone or utility paralleled sets. A network of EGCP-2 controls is capable of controlling up to eight un-manned generator sets for backup power, base-load, or peak shaving applications. Engine Control • Engine Pre-glow • 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. 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 2 Woodward Manual 26076 EGCP-2 Engine Generator Control Package • 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 base loading on units which are in kW base load control mode, 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) • Loss of Excitation • 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 Communication – PC Interface • Easy upload and download and backup of unit configuration • A PC can control or monitor any unit at a site by a single connection to the ® local operating network via RS-422 serial port using Modbus * or ServLink protocol. * Modbus is a registered trademark of Schneider Automation Inc. Woodward 3 EGCP-2 Engine Generator Control Package Manual 26076 Figure 2-1. EGCP-2 Interface Connections 4 Woodward UTILITY Watt Operator Control Panel Transducer EGCP-2 Interfaces Process Input Utility TB Aux Utility PC Breaker Utility TB Open/Close PC Interface RS-422 TO Other RS-485 Mains PT EGCPs Port Disconnect EGCP Utility/Bus Input ALARM (VISUAL) Local Bus Disconnect LAMP GB Aux In ALARM (AUDIBLE) Gen Breaker Open/Close Gen PT Inputs (3 phases) HORN Gen CT inputs (3 phases) Oil Pressure Water Temperature MPU Speed Bias Voltage Bias GEN Generator Speed Voltage Breaker Regulator Control TO Other Generators Plant Load Automatic Engine Preglow Test Engine Run With Load Engine Crank Voltage Raise Fuel Shutoff Solenoid Voltage Lower Speed Raise Speed Lower Process I/E Fault 1 Fault 2 Manual 26076 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 with contrast adjustment 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. WARNING—TRAINED PERSONNEL 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. Figure 2-2. 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. Woodward 5 EGCP-2 Engine Generator Control Package Manual 26076 There are a total of 19 keys on the keypad. Each of the keys has the following function(s): ALARM/EVENT LOG KEYS: ALARM / EVENT The ALARM/EVENT key is used to access the 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. 6 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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. Woodward 7 EGCP-2 Engine Generator Control Package Manual 26076 CONFIG ... The CONFIG KEY, when pressed, will put the right hand LCD into the configuration mode. Configuration menu items will be displayed in the right hand screen. Status information will continue to be displayed in the left hand screen. Since there are various menu items and adjustments in the configuration menu, a blinking cursor is provided in the right hand display when the configure mode is active. STATUS MENU KEYS: The contents of the various status menus are described in the Status Screens section in Chapter 3 of this manual. SYSTEM The SYSTEM STATUS key, when pressed displays the system status information. The system status display is also the default status display screen (it is always the first display shown after a power up of the control). This display shows general information about the operation of the engine generator set. 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. 8 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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. Hardware The EGCP-2 is an integrated control package. All control hardware is contained in one compact enclosure. Figure 2-3 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). NOTE When mounting into an enclosure, make sure the enclosure is vented to atmosphere through a Type 4 vent tube or unsealed conduit. Woodward 9 EGCP-2 Engine Generator Control Package Manual 26076 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 Other components you may need. These items do not ship with the 8406-115 or 8406-116 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. • Download.exe—see manual 26086, Appendix B. • EGCP-2 HMI—see manual 26099. 10 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Figure 2-3. Physical Outline with Dimensions of EGCP-2 Woodward 11 EGCP-2 Engine Generator Control Package Manual 26076 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. 12 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 back side of the unit next to the label with e symbol (or 1 of 3 other like termination points without label) to reduce the risk of electric shock. This connection will be made using a thread forming screw (M4 x 6mm). 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 Woodward 13 EGCP-2 Engine Generator Control Package Manual 26076 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. 14 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Figure 3-3. Wiring Diagram for EGCP-2 Woodward 15 EGCP-2 Engine Generator Control Package Manual 26076 EGCP-2 Back View DIP Switch Identification (not to scale). DIP SWITCHES ARE ACCESSABLE THROUGH HOLES N 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 - Dip Switch # 1 Dip Switch # 3 3. 100 ohm dropping resistor Select. 2. 123 ohm RS-422 Termination+ 1 4 4. 100 ohm dropping resistor Select. 1. +5V RS-422 2 3 3 2 SW - 4 SW-2 4 1 RS - 485 Terminations Temperature Sensor Input Hardware Dip Switch # 2 Dip Switch # 4 ___________________________ ______________________________ 1 4 1. 0-200 Sensor. 4. 4-20 mA Process Input 2 3 2. 4-20mA Input Select. 3. 123 ohm RS-485 Termination - 3 2 4 1 3. 100 ohm dropping resistor Select. 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 Location 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 Part Number: 8406-115 and 116 Supply Voltage Rating Nominal Voltage Range: 10–29 Vdc Maximum Voltage Range: 9–32 Vdc Maximum Power: 20 W Typical Power: 13 W 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. 16 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 8406-115 Number of inputs: 4 Maximum Voltage Rating: 150–300 Vac Burden: 0.45 VA Input Frequency: 40–70 Hz Potential Transformer Input Ratings 8406-116 Number of inputs: 4 Maximum Voltage Rating: 50–150 Vac Burden: 0.25 VA Input Frequency: 40–70 Hz 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. Refer to manual 26086, Configuration menu, item “Voltage Input.” + 42 A A PHASE PT 43 - + 44 B B PHASE PT 45 - + 46 C C PHASE PT 47 - VIS-054b EGCP-2 00-06-19 Figure 3-5. Three Wire Delta PT Connection for EGCP-2 Woodward 17 EGCP-2 Engine Generator Control Package Manual 26076 A + 42 A B N 43 N B + 44 N N 45 N C C + 46 N 47 VIS-055a N 00-10-17 EGCP-2 Figure 3-6. Four Wire WYE PT Connection 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 should 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, 3-8a and b, 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. 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 (Figure 3-8a). 18 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Multiple Engine NOTES: LOM's Applications EGCP-2 - *K1 SHOWN ENERGIZED - *K2 SHOWN DE-ENERGIZED Mains PT - *K1 & K2 RELAYS ARE NOT (+V) 23 SUPPLIED BY WOODWARD Disconnect - *K1 and K2 RELAYS SHOULD (Normally BE CONNECTED AS NORMALLY Closed) OPEN CONTACTS (D08) 24 K1* A K1-A Mains PT 40 A B or N K1-B (B for Delta, N for Wye) Mains/Bus PT Input A K2-A Bus PT 41 B or N B or N (B for Delta, N for Wye) K2-B K2* (B for Delta, N for Wye) 21 Local Bus PT Connect (Normally Open) (+V) 22 (D07) VIS-145 01-05-21 Figure 3-7. Utility / Local Bus PT Wiring for Delta and Wye Configuration Please Note: 1. This wiring diagram must be used when sensing Loss of Mains (LOM) with multiple units. 2. K1 and K2 relays are not supplied by Woodward. 3. K1 and K2 relays should be connected as normally open contacts 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. Woodward 19 EGCP-2 Engine Generator Control Package Manual 26076 EGCP-2 NOTES: Prime Power or - *K1 SHOWN ENERGIZED Single - *K2 SHOWN DE-ENERGIZED Mains PT (+V) 23 Engine LOMs - *K1 & K2 RELAYS ARE NOT Disconnect SUPPLIED BY WOODWARD Applications (Normally - *K1 & K2 RELAYS SHOULD Closed) BE CONNECTED AS NORMALLY (D08) 24 OPEN CONTACTS K1* A Mains/Bus K1-A A 40 PT 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) (+V) 22 (D07) VIS-146 01-01-31 Figure 3-8a. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration (two relay) EGCP-2 23 Mains PT Prime Power Disconnect (Normally Applications Closed) (D08) 24 NOTES: - K2 SHOWN DE-ENERGIZED - K2 RELAY IS NOT SUPPLIED BY WOODWARD 40 A K2* Mains/Bus A Mains/Bus PT Input K2-A PT 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-146A Connect 01-03-29JR (Normally Open) (+V) 22 (D07) Figure 3-8b. Utility/Local Bus Single PT Wiring for Delta and WYE Configuration (single relay) 20 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Please Note: 1. Figures 3-8a and b PT wiring can only be used in a Prime Power Application. 2. Figure 3-8a can be used for a Single Engine LOMs detection. 3. K1 and K2 relays are not supplied by Woodward. 4. K1 and K2 relays should be connected as 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. Refer to Figures 3-9 and 3-10. EGCP-2 A C B 8406-116 Utility Bus 480 V 120 V A 480 VLL Mains Disconnect A 40 B Mains/Bus Utility 120 V PT Input Breaker 41 B 120 V 480 V A Local Bus Connect Bus B 42 A+ 120 V Generator Breaker 43 A- 44 A 480 V 120 V B+ Gen PT 120 V B Inputs 45 B- C 46 C+ Generator 120 V C A B Bus 47 C- N VIS-147 01-03-16 Voltage Input: Delta PT Ratio : 4:1 Voltage Ref: 480 Vac, L-L Figure 3-9a. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-116. 2. Follow Utility/Local Bus PT wiring. Woodward 21 EGCP-2 Engine Generator Control Package Manual 26076 EGCP-2 A B C 8406-115 Utility Bus 480 V 240 V A 480 VLL Mains Disconnect A 40 B Mains/Bus Utility 240 V PT Input Breaker 41 B 240 V 480 V A Local Bus Connect Bus B 42 A+ Generator 240 V Breaker 43 A- 44 A 480 V 240 V B+ Gen PT 240 V B Inputs 45 B- C 46 C+ Generator C 240 V A B Bus 47 C- N VIS-147a 01-03-16 Voltage Input: Delta PT Ratio : 2:1 Voltage Ref: 480 Vac, L-L Figure 3-9b. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-115. 2. Follow Utility/Local Bus PT wiring. 22 Woodward Manual 26076 EGCP-2 Engine Generator Control Package A B C EGCP-2 Utility 8406-116 Bus A Mains Disconnect N 40 A Mains/Bus 69 V Utility PT input Breaker 41 N A Local Bus Connect N Bus 42 A+ 69 V Generator Breaker A 43 N N B+ 44 B Gen PT 69 V N Inputs 45 C N C+ N 46 Generator 69 V Bus A B 47 C N N Voltage Input: Wye VIS-148 01-03-16 PT Ratio : 4:1 Voltage Ref: 277 Vac, L-N Figure 3-10a. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-116. 2. Follow Utility/Local Bus PT wiring. Woodward 23 EGCP-2 Engine Generator Control Package Manual 26076 A B C EGCP-2 Utility 8406-115 Bus Mains Disconnect 40 A Mains/Bus Utility 277 V PT input Breaker 41 N Local Bus Connect Bus 42 A+ Generator 277 V Breaker 43 N B+ 44 Gen PT 277 V Inputs 45 N C+ 46 Generator 277 V Bus A 47 B C N N Voltage Input: Wye VIS-148a 01-03-29 PT Ratio : 1:1 Voltage Ref: 277 Vac, L-N Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs Please Note: 1. This drawing shows EGCP-2 part number 8406-115. 2. Follow Utility/Local Bus PT wiring. 24 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 3-11 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 125% 2500:5 the EGCP-2 will see 4 amps at 2000 generator amps Example 2: Generator rated for 150 amps per phase at 100% load, rated power factor. CT Ratio 100% 150:5 the EGCP-2 will see 5 amps at 150 generator amps 125% 188:5 the EGCP-2 will see 4 amps at 150 generator amps Current 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—PROTECTIVE RELAY TESTING 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 A PHASE CT 0-5 A (.050 OHMS) 89 (+) (-) 92 B PHASE CT (.050 OHMS) 91 (+) (-) 94 C PHASE CT (.050 OHMS) 93 (+) AB C VIS-049b 00-06-19 FIELD WIRING EGCP-2 Figure 3-11. Current Transfer Wiring Diagram for EGCP-2 Woodward 25 EGCP-2 Engine Generator Control Package Manual 26076 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 3-12 for wiring schematic. 4.99K (+) 70 1000pF MPU 4.99K 4.99K Magnetic Pickup Unit (-) 71 200 - 3K ohms impedance 1000pF VIS-051b 01-03-18 Figure 3-12. Wiring Diagram for MPU Input 26 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 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 (+) R 86 SW4-4 Process Import/Export Input 4-20 mA / 1-5 Vdc 250 (-) R 87 R Switch SW4-4: Open for 1-5 volt input @ 30K ohms Close for 4_20 mA @ 250 ohms VIS-149 00-08-15 Figure 3-13a. Wiring Diagram for Process Import/Export Input When connecting a KW transducer signal to multiple EGCP-2s, Woodward recommends converting the 4–12–20 mA signal to a 1–3–5 Vdc 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 250 ohm Transducer - 87 86 87 86 87 86 VIS-153 01-05-21 EGCP-2 EGCP-2 EGCP-2 Figure 3-13b. Connecting a KW Transducer Signal to Multiple EGCP-2s (switch 4-4 is in the OPEN position) Woodward 27 EGCP-2 Engine Generator Control Package Manual 26076 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 are optional and once connected-to can be configured to protect the engine by causing a system soft shutdown, hard shutdown, or alarm. To disable these inputs set all related Shutdown/Alarm settings to their “disabled” state. These inputs can be DIP switch configured to be compatible with 0–200 Ω sensors, 4–20 mA transducers, or 0–5 Vdc transducers. Depending on where a 0–200 Ω sensor’s linear range is, this input can also be DIP switch configured to vary sensor loading which will move the sensor output into the most linear part of its range. Refer to Figure 3-4 for DIP switch location and to Figure 3-14 for input wiring schematics. Temperature and Pressure Input Ratings Number of Channels: 2 Loop Voltage Source: Internal Input Impedance: Switch Dependant (refer to Figure 3-14) +12 Vdc 537.5 SW1-1 R 68 + SW 1-2 Oil Pressure R C SW1-3 SW1-4 Sensor Input R 249 100 100 69 - VIS-050a 00-08-24 Input 4-20mA 1-5 Volt 200 Ohm X - May be closed to insert 100 ohm shunt Sensor resistors required to make certain 0-200 SW1-1 Open Open Closed ohm transducers more linear. SW1-2 Closed Open Open DO NOT CLOSE FOR VOLTAGE OR SW1-3 Open Open X CURRENT INPUTS. SW1-4 Open Open X Figure 3-14a. Wiring Diagram for Pressure Inputs 28 Woodward Manual 26076 EGCP-2 Engine Generator Control Package +12 Vdc 537.5 SW2-1 R 66 + Coolant Temperature R C SW2-3 SW2-4 SW 2-2 Sensor Input R 249 100 100 67 - VIS-050b 01-01-31 Input 4-20mA 1-5 Volt 200 Ohm X - May be closed to insert 100 ohm shunt Sensor resistors required to make certain 0-200 SW2-1 Open Open Closed ohm transducers more linear. SW2-2 Closed Open Open DO NOT CLOSE FOR VOLTAGE OR SW2-3 Open Open X CURRENT INPUTS. SW2-4 Open Open X Figure 3-14b. Wiring Diagram for Temperature Inputs Woodward 29 EGCP-2 Engine Generator Control Package Manual 26076 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. Refer to Chapter 3, configuration menus, in manual 26086 for selection information. ±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. Refer to Chapter 3, configuration menus, in manual 26086 for selection information. The voltage bias output works with many automatic voltage regulators. Following is a list of manufacturers and types: Basler Caterpiller KATO Newage Leroy Somer SR4A VR3 360 MX321 SR8A DVR 760 MX341 SSE SSR DECS The EGCP-2 is not compatible with 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 ohms or more. Speed and Voltage Bias output Ratings Number of Channels: 2 Min Drive Impedance: 1000 Ω 30 Woodward Manual 26076 EGCP-2 Engine Generator Control Package (+) 500 Hz PWM 73 .5 to 4.5 VDC Speed Bias Output +/- 3VDC 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 3-15. Wiring Diagram for Speed Bias and Voltage Bias Outputs 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 Woodward 31 EGCP-2 Engine Generator Control Package Manual 26076 Discrete Input Ratings Number of Channels: 16 Input Type: Optically isolated Min Closed Sense Time: 40 ms Speed/Load Raise and Lower Inputs The functionality of the Speed/Load Raise and Lower inputs change based on the mode that the EGCP-2 control is in. 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. Refer to figure 8-23 for Speed/Load raise and lower contact functionality matrix. Voltage Raise and Lower Inputs The functionality of the Voltage Raise and Lower inputs change based on the mode that the EGCP-2 control is in. 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. The Configurable Alarm or Shutdown Inputs must be wired so they are closed when the alarm or shutdown condition is true. 32 Woodward Manual 26076 EGCP-2 Engine Generator Control Package +5 Vdc Typical Example of Discrete Input R (Auto/Manual Contact (DI#1) Input Shown) +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 3-16. 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 Woodward 33 EGCP-2 Engine Generator Control Package Manual 26076 Relay Output Ratings Number of Channels: 12 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. Mains EGCP-2 Breaker Close 7 + V Discrete 6 Output #1 5 Mains (utility) Breaker Close Coil VIS-154 01-06-01 Figure 3-17. 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. 34 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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—REMOVING POWER 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 5 VIS-154a 01-06-01 Figure 3-18. Example Using the NC Output to Control the Mains (Utility) Contactor (ENERGIZE TO OPEN) Discrete Output #2—Generator Breaker Close With the relay de-energized, this output has Normally Open (NO), terminals 8 and 9, and Normally Closed (NC), terminals 9 and 10, contacts to select from. The “Generator Breaker Close” relay output is utilized by the EGCP-2 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 When in the Breaker configuration, the EGCP-2 will ENERGIZE (momentary) 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. Woodward 35 EGCP-2 Engine Generator Control Package Manual 26076 Generator EGCP-2 Breaker Close 10 + V Discrete 9 Output #2 8 Generator Breaker Close Coil VIS-154b 01-06-01 Figure 3-19. 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. Generator EGCP-2 Contactor Close 10 + V Discrete 9 Output #2 8 Generator Contactor Open/Close Coil VIS-154c 01-06-01 Figure 3-20. Example Using the NO Contacts to Control the Generator’s Contactor (ENERGIZE TO CLOSE) 36 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 on terminals 15 and 16. 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 manual 26086 for information on acknowledging and committing alarms. Woodward 37 EGCP-2 Engine Generator Control Package Manual 26076 Discrete Output #7—Local Bus PT Connect The “Local Bus PT Connect” relay utilizes a set of Normally Open (NO) contacts on terminals 21 and 22. 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 and 3-8a and b 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 and 3-8a and b 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) With the relay de-energized, this output has Normally Open (NO), terminals 25 and 26, and Normally Closed (NC), terminals 26 and 27, contacts to select from. 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 When in the Breaker configuration, the EGCP-2 will ENERGIZE (momentary) to open the Mains (utility) Breaker. 38 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Mains EGCP-2 Breaker Trip 27 + V Discrete 26 Output #9 25 Mains Breaker Trip (Open) Coil VIS-154d 01-06-01 Figure 3-21. Example Using the NO Contacts to Control the Mains Breaker Trip (Open) Coil (ENERGIZE TO OPEN) Discrete Output #10—Generator Breaker Trip (Open) With the relay de-energized, this output has Normally Open (NO), terminals 28 and 29, and Normally Closed (NC), terminals 29 and 30, contacts to select from. 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 when the EGCP-2 is: 1. In the “AUTO” mode (Discrete Input #1) 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 the “AUTO” and Generator stable conditions are met. When operating in the Manual mode, it is required to externally control the Generators Breaker. The EGCP-2 will continuously be providing a Generator Breaker open command. This means the EGCP-2 will have no control over opening the generators breaker once it has been closed manually. See Chapter 8 for Manual operation details. Woodward 39 EGCP-2 Engine Generator Control Package Manual 26076 Generator EGCP-2 Breaker Trip 30 Generator Breaker + V Trip (Open) Coil Discrete 29 Output #10 28 VIS-154e 01-06-01 Figure 3-22. Example Using the NC Contacts to Control the Generator Breakers Open Coil (DE-ENERGIZE TO OPEN) EGCP-2 +V External Wiring Connections 9 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. External Wiring EGCP-2 +V Connection 9 Gen Breaker Close 8 Generator Contactor Close/Open Coil 29 Gen Breaker No Connection. Trip 30 VIS-142a 01-07-11 Generator Contactor Configuration Based Logic. Figure 3-23. Generator Breaker and Contactor Close and Open Logic 40 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 manual 26086 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. Woodward 41 EGCP-2 Engine Generator Control Package Manual 26076 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 42 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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) 60 Fault 2 Discrete Input (DI-12) + power supply (internal connection) 61 Fault 3 Discrete Input (DI-13) + power supply (internal connection) 62 Fault 4 Discrete Input (DI-14) + power supply (internal connection) 63 Fault 5 Discrete Input (DI-15) + power supply (internal connection) 64 Fault 6 Discrete Input (DI-16) + power supply (internal connection) 65 Switch Common Discrete Input – power supply (internal connection) NOTE: Approximately 5 mA current draw across each DI when CLOSED. Discrete Outputs Location Description Signal Output Rating 7 Mains Brkr Close NC Discrete Output (D01) (see Relay 6 Mains Brkr Close C (D01) Output Ratings) 5 Mains Brkr Close NO Discrete Output (D01) “ 10 Gen Brkr Close NC 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) Woodward 43 EGCP-2 Engine Generator Control Package Manual 26076 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 +5 Vdc common Internal Isolated Power Supply 79 +5 Vdc Internal Isolated Power Supply 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, that includes this converter. This cable is designed for point-to-point communications. 44 Woodward Manual 26076 EGCP-2 Engine Generator Control Package In a system with multiple (8 maximum) EGCP-2 controls, each control is interconnected to the others on the 422 network in a multidrop 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 EGCP-2 EGCP-2 EGCP-2 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 3-24. RS-422 Communications Switch configuration for multiple units utilizing RS-422 communication. Unit #1 Unit #2 Unit #8 SW3-1 Closed SW3-1Open SW3-1 Closed SW3-2 Closed SW3-2 Open SW3-2 Closed SW3-3 Closed SW3-3 Open SW3-3 Closed 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 dip switches must be closed on the end units on the network for proper communications. See the plant wiring diagram for switch locations. Failure to terminate the network properly will cause communication drop out errors. Woodward 45 EGCP-2 Engine Generator Control Package Manual 26076 +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 78 RS 422/485 (+) 84 Transceiver 422 TxD (- RS 422/485 ) Transceiver 85 80 VIS-108a RS-485 Termination RS-422 Termination 00-06-20 Figure 3-25. RS-485 and RS-422 Termination Diagrams For detailed wiring diagrams pertaining to the RS-422 network of the EGCP-2 controls, please consult the plant wiring diagram in this manual. 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 3-25, 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. 46 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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). Unit #1 Unit #2 Unit #8 EGCP-2 EGCP-2 EGCP-2 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 3-26. RS-485 Inter-Control Communications Switch configuration for multiple units utilizing RS-485 communication. Unit #1 Unit #2 Unit #8 SW4-1 Closed SW4-1Open SW4-1 Closed SW4-2 Closed SW4-2 Open SW4-2 Closed SW4-3 Closed SW4-3 Open SW4-3 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. 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. Woodward 47 EGCP-2 Engine Generator Control Package Manual 26076 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, above. 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). 48 Woodward Manual 26076 EGCP-2 Engine Generator Control Package These parameters for loss of mains detection are as follows: 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). Woodward 49 EGCP-2 Engine Generator Control Package Manual 26076 Chapter 4. Operational Description: Single No Parallel G The most basic mode of operation for the EGCP-2 is Single Unit No Parallel. In this configuration the generator will never parallel with the mains. All operations requiring the generator to be on load will take place with the mains breaker open. The operations which place the generator on load are either a Loss of Mains detection, or an Auto and Run With Load Switch Input. Since the generator will never operate in parallel with the mains, all transitions between mains and generator power to the load are done in an open transition fashion. The key configuration points in the EGCP-2 software which need to be configured for Single Unit No Parallel operation are: Configuration Menu: Number of Units: Single Operating Mode: No Parallel Real Load Control Menu: Load Control Mode: Normal Transfer Switch Menu: Check Mains Breaker: Enabled if standby; Disabled if prime power If this is to be a standby power unit, which will close to the load on loss of mains, program the following setpoints as required by the system for reliable Loss of Mains Detection. Not all these setpoints have to be set for loss of mains detection, only those that pertain to detecting loss of mains for each particular application or system. If this is to be a prime power unit, which operates without any mains input to the load, program either Mains Frequency Low Limit Alarm, or Mains Voltage Low Limit Alarm for Loss Of Mains. This allows the unit to start any time it is given an auto input. 50 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Transfer Switch Menu: Mains Under/Over Voltage Alarm: Loss of Mains Mains Under/Over Freq. Alarm: Loss of Mains NOTE Loss of Mains may be substituted with Loss of Mains w/alarms if alarm indications during a loss of mains condition are desired. Switch Input Actions: Single Unit No Parallel (Standby Unit) Auto Switch Enables LOM Detection. Run with Load Switch Starts Unit. Auto Switch must be closed for generator and mains breaker operation. Test Switch Starts Engine; no other action taken. Process Switch No effect on operation. Auto and Run With Load Starts Generator Set. Generator set will be put on load (open transition with mains). Switch Input Actions: Single No Parallel Prime Power Auto Switch Will Start Unit and Closes Gen breaker to load. Run With Load Switch Starts Unit. Auto Switch must be closed for generator and mains breaker operation. Test Switch Starts Engine; no other action taken. Process Switch No effect in this mode. Woodward 51 EGCP-2 Engine Generator Control Package Manual 26076 The application overview section of the manual is intended for quick reference to basic wiring diagrams and operational concepts. Consult the Plant Wiring Diagram and Operational Description sections of the manual for more detail on the operating modes and wiring of the EGCP-2. NOTE These drawings show wiring for the breaker control options. See the plant wiring diagram in this manual for contactor wiring options. These drawings are for reference only. Do not use for construction. G52 LOAD U52 MAINS Number of Units = Single BUS GEN Mode of Load Transfer = PT PTs Local Mains No Parallel PT PT Disconnect Application: Standby Power Connect GEN CTs Mode Selector Switch See Switch Logic Diagram for Details Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery Gen Breaker Close Coil 4 NLT (No Load Test) or Manu l Test Gen Breaker +Battery Manual Run With Load (closed transition) Trip GTC Run W/LD Gen Breaker Trip Coil Mains Breaker +Battery Manual Voltage Raise MCC Close Mains Breaker Close Coil 1 +Battery Mains Breaker Voltage Lower Manual MTC Trip Mains Breaker Trip Coil Speed Raise +Battery Fuel 1 FUEL Solenoid Fuel shutoff solenoid Speed Lower +Battery Engine Manual G52a Gen CB Aux prglw Preglow Preglow relay U52a Mains CB Aux +Battery Engine Engine Crank Relay crank Crank Process I/E No Connection +Battery Visual Visual Alarm 2 Alarm Fault #1 . . . +Battery Audible 3 Fault #6 Alarm Audible Alarm Switch Common Single NoParallel Application VIS-061 3 00-04-19 1 Only required if the speed and voltage Faults #3 through #6 activate immediately, need to be adjusted when Test with programmable delays. or Manual is selected. 2 Use fault #1 or #2 input if using a Manual mode requires manual mains and generator breaker operation. 4 seperate device to sense Low Oil Manual mode will operate in KW and Voltage Droop. Pressure or High Water Temp. These Fault Inputs have 15 second delay timers on them after the engine reaches crank cutoutt speed. Figure 4-1. Single No Parallel Application 52 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Switch Based Logic (Single—No Parallel) X X OFF 1 X X X STARTS ENGINE * X 1 X X STARTS ENGINE * X 1 1 X X OPENS TB / STARTS ENGINE / CLOSES GB / CONTROLS IN ISOCH X X 1 X OPENS TB / STARTS ENGINE / CLOSES GB / CONTROLS IN ISOCH X X 1 X OPENS GB / CLOSES TB / SHUTS DOWN ENGINE * = When generator breaker is closed manually, unit will operate in Droop mode. 1 = Contact closed (Utility Power Stable) X = Contact open or closed (Utility Power Failed or Stable) TB = Utility Tie Breaker GB = Generator Breaker = Transition from Utility Stable to Utility Failed = Transition from Utility Failed to Utility Stable Woodward 53 TEST RUN w/ LOAD AUTO PROCESS UTILITY POWER EGCP-2 Engine Generator Control Package Manual 26076 Single Unit No Parallel Auto Input Test Input Run With Load Input Engine Loss of Mains No Start Engine Enabled? Sequence Start Sequence Generator Yes and Engine Unit will not close gen Alarms/ breaker (must be in AUTO Shutdowns Loss of Mains mode for breaker control) Active Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Close Mains Open Mains Breaker Sequence Breaker Sequence Yes Genset Start Sequence No No Mains Stable? Gen Stable? Yes Yes Close Gen Breaker Sequence Open Gen Breaker Sequence Isoch Load Control Close Mains Breaker Sequence No Mains Stable? Stop Genset Sequence Yes Open Gen Breaker Sequence Close Mains VIS-062 Breaker Sequence 00-04-20 Stop Genset Sequence Figure 4-2a. Single No Parallel Overview Flow Diagram 54 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Auto Input AND Run With Load Input Engine Start Sequence Loss of Mains No Enabled? Gen Stable? OR Loss No of Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No Close Gen Breaker >LOM Action Closed? Sequence Delay? No Yes Gen CB Aux Yes Run With Load Input Closed? Yes Isoch Load Control Closed? OR Loss Of Mains FLAG? No SET Loss of Mains FLAG No Close Mains Breaker Sequence Open Gen Breaker Sequence VIS-063 00-04-20 Close Mains Breaker Sequence Stop Genset Sequence Figure 4-2b. Single No Parallel Overview Flow Diagram Woodward 55 EGCP-2 Engine Generator Control Package Manual 26076 G52 LOAD No Mains Available (Prime Power Application) Number of Units = Single BUS GEN Mode of Load Transfer = PT PTs Local No Parallel Mains PT PT Disconne t Application: Prime Power Connect GEN CTs Mode Selector Switch See Switch Logic Diagram for Details Auto Gen Breaker +Battery Automatic Manual Close -Battery GCC Gen Breaker Close Coil 4 NLT (No Load Test) or Manual Test Gen Breake +Battery Manual Trip GTC Gen Breaker Trip Coil No Connection Run W/LD Mains Breaker No Connection Voltage Raise Close 1 Mains Breake Voltage Lower No Connection Trip Speed Raise +Battery Fuel 1 FUEL Solenoid Fuel shutoff solenoid Speed Lower +Battery G52a Engine Manual Gen CB Aux prglw Preglow Preglow relay Mains CB Aux +Battery No Connection Engine Engine Crank Relay crank Crank No Connection Process I/E +Battery Visual Visual Alarm 2 Alarm Fault #1 . . +Battery . 3 Audible Fault #6 Alarm Audible Alarm Switch Common Single No Parallel Prime Power Application VIS-064 1 Only required if the speed and voltage 3 Faults #3 through #6 activate immediately, 00-04-20 need to be adjusted when Test with programmable delays. or Manual is selected. 2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation. 4 seperate device to sense Low Oil Manual mode will operate in KW and Voltage Droop. Pressure or High Water Temp. These Fault Inputs have 15 second delay timers on them after the engine reaches crank cutoutt speed. Figure 4-3. Single No Parallel Prime Power 56 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Chapter 5. Operational Description: Single Unit Parallel G Single Unit Parallel operation of the EGCP-2 control enables the control’s ability to synchronize and close to the mains. When paralleling to the mains, the EGCP- 2 will operate in either a base load (constant generator KW), or process control modes, depending on which switch inputs are received at the control. The EGCP-2 will also operate in a Power Factor or VAR control mode while in parallel with the Mains if the VAR/PF control setpoint in the Reactive Load Control tuning menu is set for either PF control or KVAR control. The EGCP-2 may also be configured for soft transfer operation. Soft Transfer operation is enabled in the configuration menu item labeled “Load Control Mode”. Setting this item to “soft transfer” will enable the soft transfer capability of the control. Soft transfer refers to an operating mode in which the generator assumes load (either base load or process), and upon reaching a specific base load or process reference point, issues a command to open the mains breaker. This effectively transfers load from the mains to the generator in a smooth fashion. The key configuration points in the EGCP-2 software which need to be configured for Single Unit Parallel operation are: Configuration Menu: Number of Units: Single Operating Mode: Mains Parallel Real Load Control Menu: Load Control Mode: Normal or Soft Transfer (depending on application) Transfer Switch Menu: Check Mains Breaker: Enabled If this is to be a standby power unit, which will close to the load on loss of mains, program the following setpoints as required by the system for reliable Loss of Mains Detection. Not all these setpoints have to be set for loss of mains detection, only those that pertain to detecting loss of mains for each particular application or system. Woodward 57 EGCP-2 Engine Generator Control Package Manual 26076 Transfer Switch Menu: Mains Under/Over Voltage Alarm: Loss of Mains Mains Under/Over Freq. Alarm: Loss of Mains Load Surge: Loss of Mains* NOTE Loss of Mains may be substituted with Loss of Mains w/alarms if alarm indications during a loss of mains condition are desired. *Loss of Mains action is instant, and does not use the loss of mains action delay. All other Loss of Mains detection setpoints use the Loss of Mains action delay time before activating the generator set start sequence. Loss of mains action for a single parallel unit is identical to the single no parallel application. Upon sensing a loss of mains for the loss of mains action delay period, the EGCP-2 will open the mains breaker, start the generator set, wait for the gen stable time, and close the generator onto the dead bus, providing the load with power. Being a single unit parallel application, upon sensing return of the mains, and mains stable for the mains stable delay, the EGCP-2 will synchronize the generator set with the mains. After synchronizing to the mains, the EGCP-2 will parallel the generator with the mains, and softly unload the generator. Upon reaching the generator Unload Trip Point, the EGCP-2 will issue a generator breaker open command. This sequence softly transfers load from the generator back to the Mains. After the generator is unloaded, and its breaker is opened, it will shut down. There may be a cooldown period prior to shut down if the generator set has run at loads which exceed the Cooldown Limit KVA value. Switch Input Actions: Single Unit Parallel Auto Switch Enables LOM Detection. Run With Load Switch Starts Unit. Auto Switch must be closed for breaker operation. Test Switch When individually selected Starts Engine; no other action. Process Switch When individually selected No action. Auto and Run/Ld Synchronizes and Base Loads Unit with LOM detection enabled. Auto and Run/Ld and Process Synchronizes and Ramps to Process Control with LOM detection enabled. 58 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Auto and Run with Load and Test Synchronizes and Ramps to Base Load. If “Load Control Mode” is set for Soft Transfer in configuration menu, unit will open mains breaker when base load reference is reached. Auto and Run/Ld and Process and Test Synchronizes and Ramps to Process Control. Will open mains upon reaching Process Reference if software “Load Control Mode” in configuration menu is set for Soft Transfer. G52 LOAD GEN MAINS Number of Units = Single BUS Watt GEN Mode of Load Transfer = PT Xducer PTs Local Mains Parallel Mains PT PT Disconnect Application: Peak Shaving Set Connect GEN CTs Process Input 5 4-20mA or 1-5VDC Mode Selector Switch See Switch Logic Diagram for Details Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery Gen Breaker Close Coil 4 NLT (No Load Test) or Manual Test Gen Breaker +Battery Manual Run With Load (closed transition) Trip GTC Gen Breaker Trip Coil Run W/LD +Battery Mains Breaker Manual Voltage Raise MCC Close Mains Breaker Close Coil 1 +Battery Mains Breake Voltage Lower Manual MTC Trip Mains Breaker Trip Coil Speed Raise +Battery Fuel 1 FUEL Solenoid Speed Lower Fuel shutoff solenoid +Battery Engine G52a Manual prglw Gen CB Aux Preglow Preglow relay U52a Mains CB Aux +Battery Engine Engine Crank Relay crank Crank Process I/E +Battery Visual Visual Alarm 2 Alarm Fault #1 . . . +Battery Audible 3 Fault #6 Alarm Audible Alarm Switch Common Single Mains Parallel Application Peak Shaving Unit 3 VIS-065 1 Only required if the speed and voltage Faults #3 through #6 activate immediately, need to be adjusted when Test 01-03-30 with programmable delays. or Manual is selected. 2 Use fault #1 or #2 input if using a Manual mode requires manual mains and generator breaker operation. 4 seperate device to sense Low Oil Manual mode will operate in KW and Voltage Droop. Pressure or High Water Temp. Transducer input not required These Fault Inputs have 15 second 5 if Process Control Mode is delay timers on them after the Not used. engine reaches crank cutoutt speed. Figure 5-1. Single Unit Parallel Application Woodward 59 EGCP-2 Engine Generator Control Package Manual 26076 Switch Based Logic (Single—Parallel) X X OFF 1 X X X STARTS ENGINE * X 1 X X STARTS ENGINE * 1 X 1 READY TO START ENGINE UPON LOSS OF UTILITY POWER X 1 1 1 STARTS ENGINE / SYNCHRONIZES TO UTILITY / CONTROLS IN BASELOAD X 1 1 1 1 STARTS ENGINE / SYNCHRONIZES TO UTILITY / CONTROLS IN PROCESS 1 1 1 1 STARTS ENGINE / SYNCHS TO UTILITY / RAMPS TO BASELOAD / OPENS TB # 1 1 1 1 1 STARTS ENGINE / SYNCHS TO UTILITY / RAMPS TO PROCESS / OPENS TB # 1 X OPENS TB / STARTS ENGINE / CLOSES GB / CONTROLS IN ISOCH 1 X SYNCS TO UTILITY / OPENS GB / SHUTS DOWN ENGINE * = When generator breaker is closed manually, unit will operate in Droop mode. # = Soft Transfer Setting must be "Enabled" 1 = Contact closed (Utility Power Stable) X = Contact open or closed (Utility Power Failed or Stable) TB = Utility Tie Breaker GB = Generator Breaker = Transition from Utility Stable to Utility Failed = Transition from Utility Failed to Utility Stable 60 Woodward TEST RUN /w LOAD AUTO PROCESS UTILITY POWER Manual 26076 EGCP-2 Engine Generator Control Package Single Unit Mains Parallel Test Input Run With Load Auto Input Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Generator Unit will not close gen Yes and breaker (must be in AUTO Engine mode for breaker control) Alarms/ Shutdowns Loss of Mains Active Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Close Mains Open Mains Breaker Sequence Breaker Sequence Yes Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Close Mains Breaker Sequence Isoch Load Control Stop Genset Sequence No Mains Stable? Yes Close Mains Breaker Sequence VIS-066 00-04-20 Unload Ramp Stop Genset Open Gen Breaker Sequence Sequence Figure 5-2a. Single Unit Parallel Overview Flow Diagram Woodward 61 EGCP-2 Engine Generator Control Package Manual 26076 Auto Input AND Single Parallel Unit Run With Load Input Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Close Mains Breaker Sequence Unload Ramp SET Loss of Mains FLAG Open Gen Breaker Sequence VIS-067 00-04-20 Stop Genset Sequence Figure 5-2b. Single Unit Parallel Overview Flow Diagram 62 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Single Parallel Unit Run/Ld & Auto Loss of Mains No From Page 2 FLAG? Yes Open Mains Breaker Sequence Gen Breaker Yes Closed? No No Gen Stable? Yes Close Gen Breaker Sequence LOM Flag? Yes Isoch Load Control No Close Mains Breaker Sequence No Run/LD Yes Base Load Control Process Input? Input? No Yes Unload Ramp Process Load Control VIS-068 00-04-20 Open Gen Breaker Sequence Stop Genset Sequence Figure 5-2c. Single Unit Parallel Overview Flow Diagram Woodward 63 EGCP-2 Engine Generator Control Package Manual 26076 Chapter 6. Operating Mode: Multiple No Parallel G G G Multiple no parallel operation combines the generating capacity of multiple units to supply an isolated load. All operations of the generators on load in a multiple no parallel system are accomplished isolated from the mains. In a multiple unit system the EGCP-2 control operates in a Master/Slave type configuration. The master role is determined over the inter-control RS-485 network by the unit in Auto mode with the highest network priority (lowest numerical value). All other units on the same network, and in Auto mode are considered slave units, and follow the master commands for starting, and stopping. The Sequencing Status Screen can be viewed on any unit in auto to determine the master control on the network. The key configuration points in the EGCP-2 software which need to be configured for Multiple Unit No Parallel operation are: Configuration Menu: Number of Units: Multiple Operating Mode: No Parallel Real Load Control Menu: Load Control Mode: Normal Transfer Switch Menu: Check Mains Breaker: Enabled at units receiving Mains Breaker Aux. hard wired input in standby. Disabled if prime power application (there is no mains breaker to monitor). 64 Woodward Manual 26076 EGCP-2 Engine Generator Control Package IMPORTANT When operating as standby units there must be at least one unit on the network and in Auto with the mains breaker aux input wired, and the Check Mains Breaker setpoint Enabled at any given time. If these are to be standby power units, which will close to the load on loss of mains, program the following setpoints as required by the system for reliable Loss of Mains Detection. Not all these setpoints have to be set for loss of mains detection, only those that pertain to detecting loss of mains for each particular application or system. If these are to be a prime power units, which operate without any mains input to the load, program all units in the system for either Mains Frequency Low Limit Alarm, or Mains Voltage Low Limit Alarm for Loss Of Mains. This allows each unit to start any time it is given an auto input. In a multiple no parallel system automatic sequencing will be effective between all units in the auto mode with the “Automatic Sequencing” setpoint in the configuration menu set for “enabled”. If this setpoint is set for disabled, that unit will not be a part of the auto sequencing scheme. Transfer Switch Menu: Mains Under/Over Voltage Alarm: Loss of Mains Mains Under/Over Freq. Alarm: Loss of Mains NOTE Loss of Mains may be substituted with Loss of Mains w/alarms if alarm indications during a loss of mains condition are desired. Switch Input Actions: Multiple No Parallel Auto Switch Enables LOM detection. Enables Automatic Sequencing. Enables Dead Bus Closing. Run with Load Switch Starts Unit, but without Auto switch unit cannot close to dead bus. Process Switch When individually selected No effect in this mode. Test Switch When individually selected Starts Engine; no further action. Auto and Run with Load Isolates Mains. Loads Generators which are operating in Auto Mode (Enables Dead Bus Closing). Removal of Run with Load input causes open transition back to mains (so long as mains are in spec). Woodward 65 EGCP-2 Engine Generator Control Package Manual 26076 G52 LOAD U52 GEN MAINS Number of Units = Multiple BUS GEN Mode of Load Transfer = PT PTs Local No Parallel Mains PT PT Disconnect Application: Standby Power Connect GEN CTs Mode Selector Switch RS-485 LON To other Units See Switch Logic Diagram for Details Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery 4 Gen Breaker Close Coil NLT (No Load Test) or Manual Test Gen Breaker +Battery Manual Run With Load (closed transition) Trip GTC Gen Breaker Trip Co l Run W/LD Mains Breaker +Battery 4 Manual Voltage Raise Close MCC Mains Breaker Close Coil 1 +Battery Mains Breaker Voltage Lower 4 Manual MTC Trip Mains Breaker Trip Coil Speed Raise +Battery Fuel 1 FUEL Solenoid Speed Lower Fuel shutoff solenoid +Battery Engine G52a Manual Gen CB Aux prglw Preglow Preglow relay U52a 4 Mains CB Aux +Battery Engine Engine Crank Relay crank Crank Process I/E No Connection +Battery Visual Visual Alarm 2 Alarm Fault #1 . . +Battery . Audible 3 Fault #6 Alarm Aud ble Alarm Switch Common Multiple No Parallel Application VIS-069 1 3 Only required if the speed and voltage Faults #3 through #6 activate immediately, 00-04-20 need to be adjusted when Test with programmable delays. or Manual is selected. 2 Use fault #1 or #2 input if using a Manual mode requires manual mains and generator breaker operation. 4 seperate device to sense Low Oil Manual mode will operate in KW and Voltage Droop. Pressure or High Water Temp. These Fault Inputs have 15 second Only required if "Check Mains Breaker" setpoint delay timers on them after the is Enabled. Any unit which may operate as the master 4 engine reaches crank cutoutt must have these inputs. speed. Figure 6-1. Multiple Unit No Parallel Application 66 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Switch Based Logic (Multiple—No Parallel, Master Control’s Action) X X OFF 1 X X X STARTS MASTER ENGINE * X 1 X X STARTS MASTER ENGINE * 1 X 1 READY TO START ALL ENGINES UPON LOSS OF UTILITY POWER X 1 1 X 1 OPENS TB / STARTS ALL ENGINES / CLOSES GB / CONTROLS IN ISOCH # 1 X OPENS TB / STARTS ALL ENGINES / CLOSES GB / CONTROLS IN ISOCH # 1 X OPENS ALL UNIT GBs / CLOSES TB / SHUTS DOWN ALL UNITS * = When generator breaker is closed manually, unit will operate in Droop mode. # = Depending on plant load, slave units will be sequenced on or off the plant bus. 1 = Contact closed (Utility Power OK) X = Contact open or closed (Utility Power Failed or OK) TB = Utility Tie Breaker GB = Generator Breaker = Transition from Utility Stable to Utility Failed = Transition from Utility Failed to Utility Stable Switch Based Logic (Multiple—No Parallel, Slave Control’s Action) XOFF 1 X XSTARTS ENGINE * X 1 X STARTS ENGINE * 1 X FOLLOWS ALL MASTER'S COMMANDS * = When generator breaker is closed manually, unit will operate in Droop mode 1 = Contact closed X = Contact open or closed Woodward 67 TEST RUN /w LOAD AUTO PROCESS UTILITY POWER TEST RUN /w LOAD AUTO PROCESS EGCP-2 Engine Generator Control Package Manual 26076 MASTER Multiple Unit No Parallel Test Input Run With Load Auto Input Page 1 Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Unit will not perform Unit will not perform Yes auto reclose if mains auto reclose if mains breaker opens breaker opens Loss of Mains Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Close Mains Open Mains Breaker Sequence Breaker Sequence Set System RUN with LOAD FLAG Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Close Mains Breaker Sequence Isoch Load Control and Sequencing Remove System RUN with LOAD FLAG No Mains Stable? Stop Genset Yes Sequence Open Gen Breaker Sequence VIS-070 00-04-20 Close Mains Breaker Sequence Remove System RUN with LOAD FLAG Stop Genset Sequence Figure 6-2a. Master Multiple Unit No Parallel Overview Flow Diagram 68 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Auto Input AND MASTER Multiple Unit No Mains Parallel Run With Load Page 2 Input Set System Engine RUN with Start LOAD Sequence FLAG Loss of Mains No Enabled? Gen Stable? OR Loss of No Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Loss of Mains Closed? Yes Gen Stable? No Delay? FLAG? No Yes No Yes Gen CB Aux Closed? Yes Close Gen Breaker Sequence No SET Loss of Mains FLAG Close Mains Isoch Load Control Breaker Sequence Run With Load Input Yes with Sequencing Closed? OR Loss Of Mains FLAG? No Remove System RUN with LOAD FLAG Open Gen Breaker VIS-071 Sequence 00-04-20 Close Mains Breaker Sequence Stop Genset Sequence Figure 6-2b. Master Multiple Unit No Parallel Overview Flow Diagram Woodward 69 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit No Parallel Page 1 Run With Load Test Input Auto Input Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Unit will not perform Unit will not perform Yes auto reclose if mains auto reclose if mains breaker opens breaker opens Loss of Mains Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Close Mains Open Mains Breaker Sequence Breaker Sequence Yes Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Close Mains Breaker Sequence Isoch Load Control with auto sequencing Stop Genset Sequence No Mains Stable? Yes VIS-072 Open Gen Breaker 00-04-20 Sequence Close Mains Breaker Sequence Stop Genset Sequence Figure 6-3a. Slave Multiple Unit No Parallel Overview Flow Diagram 70 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit No Parallel Auto Input AND Page 2 Run With Load Input Engine Start Sequence Loss of Mains No Enabled? Gen Stable? OR Loss of No Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Loss of Mains Closed? Yes No Gen Stable? Delay? FLAG? No Yes No Yes Gen CB Aux Closed? Yes Close Gen Breaker Sequence No SET Loss of Mains FLAG Close Mains Breaker Sequence Run With Load Input Isoch Load Control Yes Closed? OR Loss Of Mains FLAG? No Open Gen Breaker Sequence Close Mains Breaker Sequence VIS-073 00-04-20 Stop Genset Sequence Figure 6-3b. Slave Multiple Unit No Parallel Overview Flow Diagram Woodward 71 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit No Parallel Auto Input AND Page 3 System Run With Load Flag Engine Start Sequence Loss of Mains No Enabled? Gen Stable? OR Loss of No Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Loss of Mains Closed? Yes Gen Stable? No Delay? FLAG? No Yes No Yes Gen CB Aux Closed? Yes Close Gen Breaker Sequence No SET Loss of Mains FLAG Close Mains Breaker Sequence Run With Load Input Isoch Load Control Closed? OR Loss Of Mains Yes with auto FLAG OR System Run with sequencing Load Flag? No Open Gen Breaker Sequence VIS-074 00-04-20 Close Mains Breaker Sequence Stop Genset Sequence Figure 6-3c. Slave Multiple Unit No Parallel Overview Flow Diagram 72 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Chapter 7. Operating Mode: Multiple Parallel G G G The Multiple Parallel operating mode of the EGCP-2 is the most complex. In this mode, multiple generator sets have the capability to operate as: Standby Units upon loss of mains detection; Peak Shaving Units; Load Demand Reduction Units, and Soft Transfer Units. Since the operating mode implies mains parallel, the generators are allowed to synchronize with the mains under various operating conditions such as: Loss of Mains re-transfer to the mains, Base Load Control, Process Control, Soft Transfer return to Mains (softly unloads generators and restores mains power feed to the load), Soft Transfer from the Mains to the generators (softly loads the generators against the mains before opening the mains breaker). In a multiple parallel system, automatic sequencing will be effective between all units in the auto mode with the “Automatic Sequencing” setpoint in the configuration menu set for “enabled”. If this setpoint is set for disabled, that unit will not be a part of the auto sequencing scheme. The key configuration points in the EGCP-2 software which need to be configured Multiple Unit Parallel operation are: Configuration Menu: Number of Units: Multiple Operating Mode: Parallel Real Load Control Menu: Load Control Mode: Normal or Soft Transfer (depending on application) Transfer Switch Menu: Check Mains Breaker: Enabled at units receiving the Mains Breaker Aux . hard wired input. Disabled in units not receiving the Mains Breaker Aux. hard wire input. Woodward 73 EGCP-2 Engine Generator Control Package Manual 26076 IMPORTANT There must be at least one unit on the network and in Auto with the mains breaker aux hard wired input, and configured for “Check Mains Breaker” setpoint “enabled” at any given time. If these are to be standby power units, which will close to the load on loss of mains, program the following setpoints as required by the system for reliable Loss of Mains Detection. Not all these setpoints have to be set for loss of mains detection, only those that pertain to detecting loss of mains for each particular application or system. Transfer Switch Menu: Mains Under/Over Voltage Alarm: Loss of Mains Mains Under/Over Freq. Alarm: Loss of Mains NOTE Loss of Mains may be substituted with Loss of Mains w/alarms if alarm indications during a loss of mains condition are desired. Switch Input Actions: Multiple Parallel Auto Enables LOM Detection and Dead Bus Closing. Enables Auto Sequencing. Run With Load StartsUnit. Auto Switch must be closed for breaker operation. Process When individually selected No action as a single input. Test When individually selected Starts Engine. Auto and Run With Load and Test (Base load Soft Transfer Mode Selected) Starts all Units in Auto Mode. Units synchronize and parallel with Mains. Units Ramp to Base Load control Reference. Upon reaching Base Load Reference, Master opens Mains Breaker. Removing Run with Load input softly transfers load back to mains. Auto and Run With Load and Process and Test (Process Soft Transfer Mode Selected) Starts all Units in Auto Mode. Units synchronize and parallel with Mains. Units Ramp to Process control Reference. Upon reaching Process Reference, Master opens Mains Breaker. Removing Run with Load input softly transfers load back to mains. 74 Woodward Manual 26076 EGCP-2 Engine Generator Control Package G52 LOAD GEN No Mains Available (Prime Power Application) Number of Units = Multiple BUS GEN Mode of Load Transfer = PT PTs Local No Parallel Mains PT PT Disconnect Application: Prime Power Connect GEN CTs Mode Selector Switch RS-485 LON To other Units See Switch Logic Diagram for Details Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery Gen Breaker Close Coil 4 NLT (No Load Test) or Manual Test Gen Breaker +Battery Manual Trip GTC Run With Load Gen Breaker Trip Co l Run W/LD Mains Breaker No Connection Voltage Raise Close Mains Breaker Voltage Lower No Connection Trip Speed Raise +Battery Fuel 1 FUEL Solenoid Speed Lower Fuel shutoff solenoid +Battery Engine Manual G52a Gen CB Aux prglw Preglow Preglow relay Mains CB Aux +Battery No Connection Engine Engine Crank Relay crank Crank No Connection Process I/E +Battery Visual Visual Alarm 2 Alarm Fault #1 . . . +Battery Audible 3 Fault #6 Alarm Aud ble Alarm Switch Common Multiple No Parallel Prime Power Application VIS-075 1 Only required if the speed and voltage 3 Faults #3 through #6 activate immediately, 00-04-20 need to be adjusted when Test with programmable delays. or Manual is selected. 2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation. 4 seperate device to sense Low Oil Manual mode will operate in KW and Voltage Droop. Pressure or High Water Temp. These Fault Inputs have 15 second delay timers on them after the engine reaches crank cutoutt speed. Figure 7-1. Multiple Unit No Parallel Prime Power Application Woodward 75 EGCP-2 Engine Generator Control Package Manual 26076 G52 LOAD U52 GEN MAINS Number of Units = Multiple BUS Watt GEN Mode of Load Transfer = PT Xducer PTs Local Mains Parallel Mains PT PT Disconnect Application: Standby Power and Connect GEN Peak Shaving Set CTs Process Input 5 4-20mA or 1-5VDC Mode Selector Switch RS-485 LON To other Units See Switch Logic Diagram for Details Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery Gen Breaker Close Coil 4 NLT (No Load Test) or Manual Test Gen Breaker +Battery Manual Run With Load (closed transition) Trip GTC Gen Breaker Trip Coil Run W/LD +Battery Mains Breaker 6 Manual Voltage Raise MCC Close Mains Breaker Close Coil 1 +Battery Mains Breaker Voltage Lower 6 Manual MTC Trip Mains Breaker Trip Coil Speed Raise +Battery Fuel 1 FUEL Solenoid Speed Lower Fuel shutoff solenoid +Battery Engine Manual G52a Gen CB Aux prglw Preglow Preglow relay U52a 6 Mains CB Aux +Battery Engine Engine Crank Relay crank Crank Process I/E +Battery Visual Visual Alarm 2 Alarm Fault #1 . . . +Battery 3 Audible Fault #6 Alarm Audible Alarm Switch Common Multiple Mains Parallel Application 1 Only required if the speed and voltage Manual mode requires manual mains and generator breaker operation. 4 need to be adjusted when Test Manual mode will operate in KW and Voltage Droop. VIS-076 or Manual is selected. 00-04-20 Transducer input not required 2 Use fault #1 or #2 input if using a 5 if Process Control Mode is seperate device to sense Low Oil Not used. Pressure or High Water Temp. These Fault Inputs have 15 second Only required if "Check Mains Breaker" setpoint delay timers on them after the is Enabled. Any unit which may operate as the master engine reaches crank cutoutt 6 must have these inputs. speed. 3 Faults #3 through #6 activate immediately, with programmable delays. Figure 7-2. Multiple Unit Parallel Standby Power Application 76 Woodward Manual 26076 EGCP-2 Engine Generator Control Package G52 LOAD GEN MAINS Number of Units = Multiple BUS Watt GEN Mode of Load Transfer = PT Xducer PTs Local Mains Parallel Mains PT PT Disconnect Application:Peak Shaving Set Connect GEN CTs Process Input 5 4-20mA or 1-5VDC Mode Selector Switch RS-485 LON See Switch Logic Diagram for Details To other Uni s Gen Breaker Auto +Battery Automatic Manual Close GCC -Battery Gen Breaker Close Coil 4 NLT (No Load Test) or Manual Test Gen Breaker +Battery Manual Trip Run With Load (closed transition) GTC Gen Breaker Trip Coil Run W/LD Mains Breaker +Battery Close Voltage Raise MCC Mains Breaker Close Coil 1 Mains Breaker +Battery Voltage Lower Manual Trip MTC Mains Breaker Trip Coil Speed Raise +Battery Fuel 1 FUEL Solenoid Speed Lower Fuel shutoff solenoid +Battery Engine Manual G52a Gen CB Aux prglw Preglow Preglow relay U52a 6 +Battery Mains CB Aux Engine Engine Crank Relay crank Crank Process I/E +Battery Visual Visual Alarm 2 Alarm Fault #1 . . . +Battery Audible 3 Fault #6 Alarm Audible Alarm Switch Common Multiple Mains Parallel Application Manual mode requires manual mains and generator breaker operation. 1 Only required if the speed and voltage 4 Manual mode will operate in KW and Voltage Droop. need to be adjusted when Test VIS-077 or Manual is selected. Transducer input not required 01-03-30 2 Use fault #1 or #2 input if using a 5 if Process Control Mode is seperate device to sense Low Oil Not used. Pressure or High Water Temp. These Fault Inputs have 15 second delay timers on them after he Only required if "Check Mains Breaker" setpoint engine reaches crank cutoutt is Enabled. Any unit which may operate as the master 6 speed. must have these inputs. 3 Faults #3 through #6 activate immediately, with programmable delays. Figure 7-3. Multiple Unit Parallel Peak Shaving Application Woodward 77 EGCP-2 Engine Generator Control Package Manual 26076 Switch Based Logic (Multiple—Parallel, Master Control’s Action) X X OFF 1 X X X STARTS ALL ENGINES * X 1 X X STARTS ALL ENGINES * 1 X 1 READY TO START ALL ENGINES UPON LOSS OF UTILITY POWER X 1 1 1 STARTS ALL ENGINES / ALL UNITS SYNC TO UTILITY / CONTROL IN BASELOAD X 1 1 1 1 STARTS ALL ENGINES / ALL UNITS SYNC TO UTILITY / CONTROL IN PROCESS # 1 1 1 1 STARTS ALL ENGINES / UNITS SYNC TO UTILITY / RAMP TO BASELOAD / OPENS TB ** 1 1 1 1 1 STARTS ALL ENGINES / UNITS SYNC TO UTILITY / RAMPS TO PROCESS / OPENS TB ** 1 X OPENS TB / STARTS ENGINES / UNITS CLOSE GBs TO BUS / CONTROLS IN ISOCH # 1 X SYNCS BUS TO UTILITY / UNLOADS ALL ENGINES / SHUTS DOWN ALL ENGINES * = When generator breaker is closed manually, unit will operate in Droop mode. ** = Soft Transfer Setting must be "Enabled" # = Depending on process demand, slave units will be sequenced on or off the plant bus. 1 = Contact closed (Utility Power OK) X = Contact open or closed (Utility Power Failed or OK) TB = Utility Tie Breaker GB = Generator Breaker = Transition from Utility Stable to Utility Failed = Transition from Utility Failed to Utility Stable Switch Based Logic (Multiple—Parallel, Slave Control’s Action) X OFF 1 X X STARTS ENGINE * X 1 X STARTS ENGINE * 1 X FOLLOWS ALL MASTER'S COMMANDS * = When generator breaker is closed manually, unit will operate in Droop mode 1 = Contact closed X = Contact open or closed 78 Woodward TEST E RUN /w LOAD AUTO PROCESS UTILITY POWER TEST T RUN /w LOAD AUTO PROCESS Manual 26076 EGCP-2 Engine Generator Control Package MASTER Multiple Unit Utility Parallel Test Input Run With Load Auto Input Page 1 Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Generator Unit will not close gen Yes and breaker (must be in AUTO Engine mode for breaker control) Alarms/ Shutdowns Loss of Mains Active Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Mains Breaker Open Mains Reclose Sequence Breaker Sequence Yes Set System RUN with Load Flag and Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Close Mains Breaker Sequence Isoch Load Control with sequencing Remove System Run with Load Flag and Stop Genset Sequence No Mains Stable? Yes VIS-078 Close Mains 00-04-20 Breaker Sequence Remove System Run with Load Flag and Unload Ramp Stop Genset Open Gen Breaker Sequence Sequence Figure 7-4a. Master Multiple Parallel Process Control Flow Diagram Woodward 79 EGCP-2 Engine Generator Control Package Manual 26076 MASTER Multiple Unit Utility Parallel Auto Input AND Page 2 Run With Load Input Set System Run with LOM Sequence Shown On Load Flag and Engine Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No No Yes Mains Breaker Reclose Sequence Remove System Run with Load Flag and SET Loss of Mains Unload Ramp FLAG Open Gen Breaker Sequence VIS-079 00-04-20 Stop Genset Sequence Figure 7-4b. Master Multiple Parallel Process Control Flow Diagram 80 Woodward Manual 26076 EGCP-2 Engine Generator Control Package MASTER Multiple Unit Utility Parallel Page 3 Loss of Mains From Pages 2,4,5 and 7 No FLAG? Yes Set System Run with Load Flag and Open Mains Breaker Sequence Gen Breaker Yes Closed? No Gen Stable? No Yes Close Gen Breaker Sequence Isoch Load Control Yes LOM Flag? and auto sequencing No Close Mains Breaker Sequence VIS-080 00-04-24 No Run/LD Yes Base Load Control Process Input? Input? No Yes Remove System Run with Load Flag and Unload Ramp Set Master Process Flag and System Process Load Control with auto sequencing. Open Gen Breaker Sequence Stop Genset Sequence Figure 7-4c. Master Multiple Parallel Process Control Flow Diagram Woodward 81 EGCP-2 Engine Generator Control Package Manual 26076 MASTER Multiple Unit Utility Parallel Page 4 Auto Input AND Run With Load Input AND Set System Run with Process Load Flag and LOM Sequence Shown On Engine Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Set System Mains Breaker Process Flag and Reclose Sequence Process Input Yes System Process Closed? Load Control with Remove system auto sequencing run with load flag SET Loss of Mains and Unload Ramp No FLAG Open Gen Breaker Sequence VIS-081 00-04-24 Stop Genset Sequence Figure 7-4d. Master Multiple Parallel Process Control Flow Diagram 82 Woodward Manual 26076 EGCP-2 Engine Generator Control Package MASTER Multiple Unit Utility Parallel Page 5 Auto Input AND Run With Load Input AND Test Set System Run with LOM Sequence Shown On Load Flag and Page #3 Engine Start Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Mains Breaker Reclose Sequence Soft Transfer Mode Test Input Closed? Yes Enabled Remove System Run with Load Flag SET Loss of Mains and Unload Ramp No FLAG Load Control Mode To Page Setpoint = Yes #6 SOFT TRANFER? Open Gen Breaker Sequence No VIS-082 Stop Genset 00-04-24 Sequence Figure 7-4e. Master Multiple Parallel Process Control Flow Diagram Woodward 83 EGCP-2 Engine Generator Control Package Manual 26076 MASTER Multiple Unit Utility Parallel Page 6 From Gen KW = Baseload Yes No Page #5 Reference Setpoint? Yes Mains Breaker Open Sequence Isoch Load Control with auto sequencing Run with Load and Test Run with Load Switch No Test Switch Opened? No No Base Load Control Switch Closed? Opened? Yes Yes Yes Remove System Run with Load Mains Breaker Flage and Unload Close Sequence Ramp Base Load Control Open Gen Breaker Sequence Stop Genset VIS-083 00-04-24 Sequence Figure 7-4f. Master Multiple Parallel Process Control Flow Diagram 84 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Auto Input AND MASTER Multiple Unit Utility Parallel Run With Load Input Page 7 AND Process input AND Test Input Set System Run with Load LOM Sequence Shown On Flag and Engine Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Set System Mains Breaker Process Flag and Reclose Sequence Process Input Yes Process Load Closed? Control with auto Remove System sequencing Run with Load Flag SET Loss of Mains and Unload Ramp No FLAG Soft Transfer Mode Test Input Closed? Yes Open Gen Breaker Enabled Sequence Load Control Mode To Page Setpoint Yes #8 Stop Genset SOFT TRANFER? VIS-084 Sequence 00-04-24 No Figure 7-4g. Master Multiple Parallel Process Control Flow Diagram Woodward 85 EGCP-2 Engine Generator Control Package Manual 26076 MASTER Multiple Unit Utility Parallel From Process mA input = Yes No Page 8 Page #7 Process Reference? Yes Mains Breaker Open Sequence Isoch Load Control with auto sequencing Run with Load and Run with Load Switch Process Load Process and Test Switch No Test Switch Opened? No No Process Switch Opened? No Opened? Control Closed? Yes Yes Yes Yes Remove System Process Flag and Base Load Control Remove System Mains Breaker Run with Load Flag Close Sequence and Unload Ramp Set System Process Flag and Process Load Control with auto sequencing Open Gen Breaker Sequence VIS-085 Stop Genset 00-04-24 Sequence Figure 7-4h. Master Multiple Parallel Process Control Flow Diagram 86 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit Mains Parallel Page1 Run With Load Test Input Auto Input Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Generator Unit will not close gen Yes and breaker (must be in AUTO Engine mode for breaker control) Alarms/ Shutdowns Loss of Mains Active Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Mains Breaker Open Mains Reclose Sequence Breaker Sequence Yes Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Master Close Mains Breaker Sequence Isoch Load Control with sequencing Stop Genset Sequence No Mains Stable? Yes Master Close Mains Breaker Sequence Unload Ramp VIS-086 00-04-24 Stop Genset Open Gen Breaker Sequence Sequence Figure 7-5a. Slave Multiple Parallel Process Control Flow Diagram Woodward 87 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit No Parallel Page 2 Auto Input AND Run With Load Input Engine Start Sequence Loss of Mains No Enabled? Gen Stable? OR Loss of No Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Loss of Mains Closed? Gen Stable? Yes No Delay? FLAG? No Yes No Yes Gen CB Aux Closed? Yes Close Gen Breaker Sequence No SET Loss of Mains FLAG Close Mains Breaker Sequence Run With Load Input Isoch Load Control Yes Closed? OR Loss Of Mains FLAG? No Open Gen Breaker Sequence Close Mains Breaker Sequence VIS-087 00-04-24 Stop Genset Sequence Figure 7-5b. Slave Multiple Parallel Process Control Flow Diagram 88 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit No Parallel Auto Input AND Page 3 System Run With Load Flag Engine Start Sequence Loss of Mains No Enabled? Gen Stable? OR Loss of No Mains FLAG? Yes Yes Loss of Mains Detection Active Open Mains Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Loss of Mains Closed? Yes Gen Stable? No Delay? FLAG? No Yes No Yes Gen CB Aux Closed? Yes Close Gen Breaker Sequence No SET Loss of Mains FLAG Close Mains Breaker Sequence Run With Load Input Closed? Isoch Load Control OR Loss Of Mains FLAG OR Yes with auto System Run with Load Flag? sequencing No Open Gen Breaker Sequence Close Mains Breaker Sequence VIS-088 00-04-24 Stop Genset Sequence Figure 7-5c. Slave Multiple Parallel Process Control Flow Diagram Woodward 89 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit Mains Parallel Page1 Test Input Run With Load Auto Input Input Engine Engine Start Start Sequence Loss of Mains No Sequence Enabled? Generator Unit will not close gen Yes and breaker (must be in AUTO Engine mode for breaker control) Alarms/ Shutdowns Loss of Mains Active Detection Active Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? No Yes Mains Breaker Open Mains Reclose Sequence Breaker Sequence Yes Genset Start Sequence No Mains Stable? No Gen Stable? Yes Yes Close Gen Breaker Sequence Master Close Mains Breaker Sequence Isoch Load Control with sequencing Stop Genset Sequence No Mains Stable? Yes Master Close Mains Breaker Sequence Unload Ramp VIS-089 00-04-24 Stop Genset Open Gen Breaker Sequence Sequence Figure 7-5d. Slave Multiple Parallel Process Control Flow Diagram 90 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit Mains Parallel Auto Input AND Page 2 Run With Load Input Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Base Load Control Yes Closed? No Yes No Mains Breaker Reclose Sequence Unload Ramp SET Loss of Mains FLAG Open Gen Breaker Sequence Stop Genset VIS-090 00-04-24 Sequence Figure 7-5e. Slave Multiple Parallel Process Control Flow Diagram Woodward 91 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit Mains Parallel Page 3 Loss of Mains From Pages 2,4,5,7,9 No FLAG? Yes Open Mains Breaker Sequence Gen Breaker Yes Closed? No Gen Stable? No Yes Close Gen Breaker Sequence LOM Flag? Yes Isoch Load Control No Close Mains Breaker Sequence No Run/LD Yes Base Load Control Process Input? Input? No Yes Unload Ramp Process Load Control Open Gen Breaker Sequence VIS-091 00-04-24 Stop Genset Sequence Figure 7-5f. Slave Multiple Parallel Process Control Flow Diagram 92 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit Mains Parallel Page 4 Auto Input AND Run With Load Input AND Process Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Mains Breaker Reclose Sequence Process Input Process Load Yes Closed? Control Unload Ramp SET Loss of Mains No FLAG Open Gen Breaker Sequence VIS-092 00-04-24 Stop Genset Sequence Figure 7-5g. Slave Multiple Parallel Process Control Flow Diagram Woodward 93 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit Mains Parallel Page 5 Auto Input AND Run With Load Input AND Test Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Mains Breaker Reclose Sequence Soft Transfer Mode Test Input Closed? Yes Enabled Unload Ramp SET Loss of Mains No FLAG Load Control Mode To Page Setpoint = Yes #6 SOFT TRANFER? Open Gen Breaker Sequence No VIS-093 00-04-24 Stop Genset Sequence Figure 7-5h. Slave Multiple Parallel Process Control Flow Diagram 94 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Mul iple Unit Mains Parallel Page 6 Gen KW = Baseload From Yes No Page #5 Refernece Setpoint? Yes Mains Breaker Open Sequence Isoch Load Control Run with Load and Test Run with Load Switch No Test Switch Opened? No No Base Load Control Switch Closed? Opened? Yes Yes Yes Mains Breaker Unload Ramp Close Sequence Base Load Control Open Gen Breaker Sequence Stop Genset VIS-094 Sequence 00-04-24 Figure 7-5j. Slave Multiple Parallel Process Control Flow Diagram Woodward 95 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit Mains Parallel Auto Input AND Page 7 Run With Load Input AND Process input AND Test Input Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Loss of Mains for Mains CB AUX Yes No >LOM Action Closed? Delay? Run With Load Input Yes Base Load Control Closed? No Yes No Mains Breaker Reclose Sequence Process Input Process Load Yes Closed? Control Unload Ramp SET Loss of Mains No FLAG Soft Transfer Mode Test Input Closed? Yes Open Gen Breaker Enabled Sequence Load Control Mode To Page Setpoint = Yes #8 Stop Genset SOFT TRANFER? Sequence VIS-095 00-04-24 No Figure 7-5k. Slave Multiple Parallel Process Control Flow Diagram 96 Woodward Manual 26076 EGCP-2 Engine Generator Control Package SLAVE Multiple Unit Mains Parallel Page 8 From Process mA input Yes No Page #7 Process Reference? Yes Mains Breaker Open Sequence Isoch Load Control Run with Load and Run with Load Switch Process Load Process and Test Switch No Test Switch Opened? No No Process Switch Opened? No Opened? Control Closed? Yes Yes Yes Yes Base Load Control Mains Breaker Unload Ramp Close Sequence Process Load Control Open Gen Breaker Sequence VIS-096 Stop Genset Sequence 00-04-24 Figure 7-5l. Slave Multiple Parallel Process Control Flow Diagram Woodward 97 EGCP-2 Engine Generator Control Package Manual 26076 SLAVE Multiple Unit Mains Parallel Auto Input AND Page 9 System Run With Load Flag Engine LOM Sequence Shown On Start Page #3 Sequence Loss of Mains No Enabled? No Gen Stable? Yes Yes Loss of Mains Detection Active Close Gen Breaker Sequence Mains CB AUX Yes No Loss of Mains for System Closed? Run with Load >LOM Action Base Load Mains Breaker Master Process No Yes Flag OR Run With Yes Delay? Control Closed? Flag? Load Input Closed? No Yes No Yes No Mains Breaker Base Load Control Reclose With Master Sequence System Load Isoch Load Reference Control Unload Ramp (Process Control) SET Loss of Mains FLAG Open Gen Breaker Sequence VIS-097 00-04-24 Stop Genset Sequence Figure 7-5m. Slave Multiple Parallel Process Control Flow Diagram 98 Woodward Manual 26076 EGCP-2 Engine Generator Control Package The following flow diagrams are specific sequences referred to in the preceding overview flow diagrams: Generator Start Sequence Test Input OR Run With Load Input OR (Auto & Run with load flag from Master) OR (Auto Input & LOM) Initialze Timers, Counters Set Crank Fail Crank Attempt Counter > Yes Alarm Flag Crank Attempt Setpoint ? No Energize Preglow Output Preglow Timer No Expired? Yes Energize Fuel Solenoid Output Energize Crank Output MPU => Crank Timer No No Crank Cutout Speed Expired? ? Yes Yes Set ENGINE RUNNING FLAG = TRUE Increment Crank Attempt Counter Remove Preglow Command Remove Crank Command Remove Fuel Solenoid Command Remove Preglow Command Remove Crank Command Start Crank Retry VIS-098 Delay Timer 00-04-24 Figure 7-6. Generator Start Sequence Woodward 99 EGCP-2 Engine Generator Control Package Manual 26076 Generator Stop Sequence Test Input turned OFF AND Run With Load Input turned OFF AND (Auto & Run with load flag from Master) turned OFF AND (Auto Input & No LOM) Initialze Timers, Counters Begin Cooldown Timer KVA Level During Run > Yes Cooldown Level Setpoint ? Decrement cooldown No timer De-Energize Fuel Solenoid Output Cooldown Timer Depleted? Engine State MPU Input = 0? =Spindown VIS-099 Engine State 00-04-24 = Off Figure 7-7. Generator Stop Sequence 100 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Sync Timeout Gen Breaker Close Sequence No Time Expired? Single No Mains Parallel Unit Yes Close Gen Breaker FLAG = TRUE Force Sync Mode = OFF Initialize Timers, Counters Set Sync Reclose Alarm Close Attempts < Force Sync No Close Attempts Setpoint? Mode = OFF Switch PT input to Set Sync Bus Sensing Reclose Alarm Sync Timeout No Time Expired? Dead Bus? YES No (Bus PT Input < 40VAC) Force Sync Mode = OFF YES Dead Bus Closing No Set Sync ENABLED? Reclose Alarm YES Energize Breaker Close Command No Breaker Logic? YES Energize Breaker Close Command Energize Breaker Open Command Gen Breaker Hold Gen CB Aux No Timer Expired? Input? YES YES De-Energize Breaker Close Gen Breaker Hold No Command No Timer Expired? YES Sync Successful Breaker Logic? No Set Mode Flag = IN SYNC YES De-Energize Breaker Open Command VIS-100 Increment Close 00-04-25 Attempts Reset Close Timer Start Reclose Delay Timer Figure 7-8. Generator Breaker Close Sequence (Single No Mains Parallel) Woodward 101 EGCP-2 Engine Generator Control Package Manual 26076 Gen Breaker Close Sequence Sync Timeout No Time Expired? Single Mains Parallel Unit YES Force Sync Close Gen Breaker FLAG = TRUE Mode = OFF Initialize Timers, Counters Set Sync Reclose Alarm Close Attempts < Force Sync No Close Attempts Setpoint? Mode = OFF Sync Mode = Run? YES Set Sync Switch PT input to Adjust Speed Reclose Alarm Bus Sensing NO Bias Sync Mode =Permissive? Mains CB Aux = TRUE? NO Voltage Matching Enabled? Dead Bus? (Bus PT Input < 40VAC) No Adjust Volt Bias YES Dead Bus Closing No ENABLED? Phase <= Phase Window? YES Energize Breaker Close Command No Breaker Logic? Voltage Error <= Voltage Window? YES Energize Breaker Close Command Sync Mode = Check? Energize Breaker Open Command Gen CB Aux Gen Breaker Hold No No Input? Timer Expired? YES YES De-Energize Breaker Close Gen Breaker Hold No Command Timer Expired? YES Sync Successful Breaker Logic? No Set Mode Flag = IN SYNC YES De-Energize Breaker Open Command VIS-101 00-04-25 Increment Close Attempts Reset Close Timer Start Reclose Delay Timer Figure 7-9. Generator Breaker Close Sequence (Single Mains Parallel) 102 Woodward Manual 26076 EGCP-2 Engine Generator Control Package NO Sync Timeout Time Expired? Gen Breaker Close Sequence Multiple No Mains Parallel Unit YES Force Sync Mode = OFF Close Gen Breaker FLAG = TRUE Set Sync Initialize Timers, Reclose Alarm Counters Force Sync Close Attempts < NO Mode = OFF Close Attempts Setpoint? YES YES Set Sync Sync Mode = Run? Switch PT input to Reclose Alarm Bus Sensing Adjust Speed Bias NO YES YES Mains Breaker OPEN Sync Mode =Permissive? and Live (>40VAC) Bus? NO Voltage Matching NO Enabled? NO YES Dead Bus? NO (Bus PT Input < 40VAC) Adjust Volt Bias YES NO Dead Bus Closing ENABLED? NO Phase <= Phase YES Window? NO Dead Bus Token YES Granted? Voltage Error NO YES <= Voltage Window? YES Check Mode? YES YES Sync Mode = Check? NO Energize Breaker NO NO Close Command Breaker Logic? YES Energize Breaker Close Command Energize Breaker Open Command NO Gen Breaker Hold NO Gen CB Aux Timer Expired? Input? YES YES De-Energize Breaker Close NO Command Gen Breaker Hold Timer Expired? YES NO Breaker Logic? Sync Successful Set Mode Flag = IN SYNC YES De-Energize Breaker Open Command Increment Close Attempts VIS-102 Reset Close Timer 00-04-26 Start Reclose Delay Timer Figure 7-10. Generator Breaker Close Sequence (Multiple No Mains Parallel) Woodward 103 EGCP-2 Engine Generator Control Package Manual 26076 Mains Breaker Open Sequence Open Mains Breaker Flag NO Sync Timeout Time Expired? YES Initialize Timers Set Sync Reclose Alarm Note: Sync Timeout Alarm ONLY. Unit will continue to try opening Check Mains NO Mains Breaker until the Breaker = Mains CB Aux input goes open. ENABLED? Sync Timeout will Indicate failure to Open Mains within specified time. YES NO AUTO input? YES NO Breaker Logic Energize Mains Breaker Close ? Command YES Energize Mains Breaker Open Command Mains CB Aux Input Open ? VIS-103 00-04-26 Mains Breaker Open = TRUE Figure 7-11. Main Breaker Open Sequence 104 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Parallel Mains Breaker Close Diagram Close Mains Breaker Flag Initialize Timers, Counters NO Check Mains Breaker = Enabled? YES NO Unit in Auto? YES YES Breaker Close Attempts > Logic? Close Attempts Setpoint? YES NO De-Energize Mains Energize Mains Breaker Close YES NO Phase <= NO Breaker Close Generator Sync Mode = Command Phase Window PERMISSIVE? CB Aux? NO YES YES Adjust Speed NO Mains Monitor Bias Synchro OFF, Stable? Mains Reclose Alarm PT YES NO NO Voltage <= Sync Mode = Monitor Bus Voltage Window? PERMISSIVE? PT Note: To Clear Mains Reclose Failure, Cycle Run W/ Load Input YES YES NO from OFF to ON to OFF. Voltage Matching Dead NO = ENABLED? Bus? YES YES Adjust Volt YES Sync Bias Check? NO De-Energize YES Mains Breaker Sync Mode = NO Breaker Close CHECK? Command Logic NO YES YES In Phase De-Energize Mains Window for Breaker Open => Dwell Time? Command Energize Mains NO Breaker Close Command NO Decrement Hold Mains CB Timer Hold Timer Aux? YES Expired? NO YES Decrement Hold Sync Timer Successful Start Reclose YES Hold Timer Delay Expired? NO Decrement Delay VIS-104 NO Reclose Delay 00-04-26 Timer Expired? YES Increment Close Attempts Figure 7-12. Mains Breaker Close Sequence (Mains Parallel) Woodward 105 EGCP-2 Engine Generator Control Package Manual 26076 Close Mains Parallel Mains Breaker Re-close Diagram Breaker Flag (occurs if mains opens due to external function) Initialize Timers, Counters Check Mains NO Breaker Setpoint =Enabled? YES YES Unit in Test? NO YES Unit in Run? NO NO Unit in Auto? YES YES Breaker Close Attempts > Close Attempts Setpoin Logic? ? YES NO Energize Mains De-Energize NO NO YES Breaker Mains YES Phase <= Sync Mode = Breaker Close Generator CB Master Unit? Close Phase Window PERMISSIVE? Command Aux? NO YES YES Adjust System Speed NO Mains Bias Monitor Stable? Synchro OFF, Mains Reclose Alarm PT YES NO NO Voltage < Sync Mode = Monitor Bus Voltage PERMISSIVE? PT Window? Note: To Clear Mains Reclose Failure, YES YES Cycle Run W/ Load Input Follow Master Voltage NO Matching NO Dead Speed from OFF to ON to OFF. = ENABLED? and Voltage Bus? Bias YES YES Adjust System YES Volt Bias Sync Check? NO De-Energize YES Mains Breaker Sync Mode = Breaker Close CHECK? Command Logic NO NO YES De-Energize Mains YES Breaker Open In Phase Window for Command => Dwell Time? NO Energize Mains Breaker Close Command NO Decrement Hold Mains CB Timer Hold Timer Aux? YES Expired? NO YES Decrement Hold Sync Timer Successful YES Start Reclose Hold Timer Delay Expired? NO Decrement Delay VIS-105 NO Reclose Delay 00-04-26 Timer Expired? YES Increment Close Attempts Figure 7-13. Mains Breaker Reclose Sequence (Mains Parallel) 106 Woodward Manual 26076 EGCP-2 Engine Generator Control Package No Parallel Mains Breaker Re-Close Sequence Close Mains Breaker Flag Initialize Timers, Counters YES Unit in Test? NO YES Unit in Run? NO NO Unit in Auto? YES YES Close Attempts > Breaker Logic? Close Attempts Setpoint ? NO YES Energize Mains De-Energize Mains YES Set Gen Breaker Breaker Close Breaker Close Generator CB Aux? Command Open Flag NO NO Mains Stable? Monitor Synchro OFF, Mains PT Reclose Alarm YES Note: To Clear Mains Reclose Failure, Monitor Bus PT Cycle Run W/ Load Input from OFF to ON to OFF. NO Dead Bus? YES YES Sync Check? NO De-Energize NO Mains Breaker Breaker Logic Close Command YES Energize Mains Breaker Open Command Energize Mains Breaker Close Command NO Decrement Hold Timer Hold Timer Mains CB Aux? Expired? YES NO YES VIS-106 Decrement Hold Timer 00-04-26 Sync Successful YES Hold Timer Start Reclose Delay Expired? NO Decrement Delay NO Reclose Delay Timer Expired? YES Increment Close Attempts Figure 7-14. Mains Breaker Reclose Sequence (No Parallel) Woodward 107 EGCP-2 Engine Generator Control Package Manual 26076 Switch Based Logic (Speed Raise/Lower Contact Functionality) X X SPEED BIAS RAISE & LOWER * 1 X DISABLED 1 1 BASELOAD SETPOINT RAISE & LOWER * 1 1 1 PROCESS SETPOINT RAISE & LOWER * 1 = Breaker/Contact closed X = Breaker/Contact open or closed * = If both the Raise & Lower contacts are closed at the same time all functionality is disabled. Figure 7-15. Speed Raise/Lower Switch Based Logic Switch Based Logic (Voltage Raise/Lower Contact Functionality) X VOLTAGE BIAS RAISE & LOWER * 1 DISABLED 1 1 UNIT VAR/PF SETPOINT RAISE & LOWER* 1 = Breaker/Contact closed X = Breaker/Contact open or closed * = If both the Raise & Lower contacts are closed at the same time all functionality is disabled. Figure 7-16. Voltage Raise/Lower Switch Based Logic 108 Woodward GEN BRKR GEN BRKR TIE BRKR TIEBREAKER PROCESS Manual 26076 EGCP-2 Engine Generator Control Package Chapter 8. Manual Operation Manual (Droop) operation Manual operation is obtained by selecting the Test or Run with Load discrete inputs, with the EGCP-2 in either: 1. Configured Droop a. In “Real Load Control” menu i. “Load Control Mode” is set for KW Droop b. The EGCP-2 is operated with Discrete Input # 8, Generator Breaker Aux Contact, being closed when connected to a load or the mains (utility). 2. Manual Droop a. In “Real Load Control” menu i. “Load Control Mode” is set for Normal or Soft Transfer b. The EGCP-2 is operated with Discrete Input # 8, Generator Breaker Aux Contact, being kept open when connected to a load or the mains (utility). Discrete Input #1, Automatic mode, cannot be closed for Manual operation. Manual Operation – Configured Droop 1. TEST, Discrete Input #2, or RUN with LOAD, Discrete input #3, is selected a. The EGCP-2 goes through the start sequence. b. The operator can manually raise and lower the speed and voltage. c. The generator breaker (G52) can be manually closed. i. Discrete Output #10, “Generator Breaker Trip (open)”, will stay in the Trip position. The user must wire around the Trip command in order to manually close the breaker. d. The EGCP-2 can be in a single or multiple unit / Mains Parallel e. Mains is Stable f. Mains Breaker is closed g. Unit operates in KW Droop i. Adjust Load with Speed Raise and Lower inputs ii. Adjust Power Factor with Voltage Raise and Lower inputs h. Unload Generator i. Open Generator Breaker Externally (Manually) j. Open Test or Run with Load input k. Engine will “cool down” and then shutdown 2. Shutdowns and Alarms a. The EGCP-2 does NOT control the Generator Breaker when in a Manual operating mode. This means that during a Soft or Hard shutdown sequence, the EGCP-2 cannot open the Generator Breaker (G52). b. A Soft or Hard shutdown command will react the same. Woodward 109 EGCP-2 Engine Generator Control Package Manual 26076 3. Operating Information a. The Generator Breaker can be manually closed before the “Generator Stable Delay” time is reached. b. If the Test or Run with Load input is opened BEFORE the generator breaker is closed, the engine will shutdown. c. If the Test or Run with Load input is opened AFTER the generator breaker is closed – Nothing Changes i. Engine mode stays in RUN ii. Operating State is Manual iii. Load Control State is KW Droop iv. The operator can still adjust the Load and PF using the speed and voltage raise and lower inputs d. When the Generator Breaker is opened, the speed and voltage bias will be reset to there “0” bias points. e. If the AUTO input is closed, with the Test input or no input the “Operating State” changes to AUTO. The “Load Control State” remains in KW Droop f. If the AUTO input is closed with the Run with Load input the “Operating State” changes to AUTO. The “Load Control State” remains in KW Droop i. The “Generator Breaker Trip (open)” output will energize and be in the “close” position. If the manual override of the generator breaker trip (open) is now removed, the EGCP-2 will control the opening of the generator breaker. This allows the soft and hard shutdowns in the EGCP-2 to be fully functional. Manual Operation – Manual Droop 1. TEST, Discrete Input #2, or RUN with LOAD, Discrete Input #3, is selected a. The EGCP-2 goes through the start sequence b. The operator can manually raise and lower the speed and voltage c. The generator breaker (G52) can be manually closed i. Discrete Output #10, “Generator Breaker Trip (open)”, will stay in the Trip position. The user must wire around the Trip command in order to manually close the breaker. d. The EGCP-2 can be in a single or multiple unit / Mains Parallel e. Mains is stable f. Mains Breaker is closed g. Unit operates in KW Droop i. Adjust Load with Speed Raise and Lower inputs ii. Adjust Power Factor with Voltage Raise and Lower inputs h. Unload Generator i. Open Generator Breaker Externally (Manually) j. Open Test or Run with Load input k. Engine will “cool down” and then shutdown 110 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 2. Shutdowns and Alarms a. The EGCP-2 does NOT control the Generator Breaker when in a Manual operating mode. This means that during a Soft or Hard shutdown sequence, the EGCP-2 cannot open the Generator Breaker (G52). b. A Soft or Hard shutdown command will react the same. 3. Operating Information a. The Generator Breaker can be manually closed before the “Generator Stable Delay” time is reached. b. If the Test or RUN with LOAD input is opened BEFORE the generator breaker is closed, the engine will shutdown. c. If the TEST or RUN with LOAD input is opened AFTER the generator breaker is closed - the EGCP2 i. Engine State changes from “Run” to “Cool Down” or “Shutdown” 1.) This resets the “Speed Bias” and ‘Voltage Bias” to there “0” bias points. 2.) Depending on where the “0” speed bias was set, the generator set could start to Load or Unload. 3.) When the Engine State goes to “Shutdown” i.) The Fuel Solenoid output will de-energize and the engine will be in a Reverse Power state. At this point the EGCP2 cannot open the generator breaker. ii. Operating State will remain in Manual iii. Load Control State is KW Droop iv. The operator should open the generator breaker if in this state. d. If the AUTO input is closed with the TEST input already closed i. The Operating State changes to AUTO ii. The Load Control State remains KW Droop iii. The operator can still adjust the Load and PF using the speed and voltage raise and lower inputs. e. If the AUTO input is closed with the RUN with LOAD input already closed i. The Operating State changes to AUTO ii. The Load Control State remains KW Droop iii. The EGCP-2 will Synchronize and give Breaker Close commands until a Synch Reclose Alarm is gotten. The “Generator Breaker Trip (open)” output will be in the Trip position. Woodward 111 EGCP-2 Engine Generator Control Package Manual 26076 Chapter 9. EGCP-2 Communications Overview This Chapter is the MODBUS addresses for the following part numbers. EGCP-2 Software 8406-115 5418-002 NEW, A, & B 8406-116 5418-002 NEW, A, & B To view the software version in the EGCP-2: 1. Select Config key on front panel 2. The right side of the display will say Security Code 3. Select Enter key on front panel 4. The software version will be displayed on the bottom of the right side of the display The EGCP-2 panel RS-422 port protocol may be selected for Modbus RTU or ServLink protocol, which uses an open protocol used by many third party software manufacturers, or UPLOAD SETPOINTS, which allows a setpoint transfer to and from the EGCP-2. To select which protocol will be used, enter the configuration menu of the EGCP- 2 panel using the proper software password, and scroll to the menu item labeled: 422 Protocol. The selections under this menu item are: 1. Modbus 2. Upload Setpoints 3. ServLink NOTE Whenever the 422 Protocol setpoint is changed, the EGCP-2 panel must be powered down, then powered up again, to reset to the proper protocol. If ServLink is chosen for the protocol selection, the EGCP-2 panel will communicate in the ServLink protocol. Woodward Governor Company’s ServLink communications protocol is a proprietary DDE interface to the EGCP-2 Control. This interface allows access to readout and setpoint variables in the unit. ServLink software must be purchased from Woodward, or its distributors, and resident on the host computer in order to access the EGCP-2 data over the RS-422 communication port. For more information about Woodward products, which use ServLink, contact your local Woodward Distributor. If Modbus is chosen, the EGCP-2 panel will communicate in MODBUS RTU protocol, and make its information available according to the address list as shown in Table 9-2. Also, the Modbus Address, Modbus Time-out, and Modbus Reset menu items become functional when the 422 Protocol is set to Modbus. 112 Woodward Manual 26076 EGCP-2 Engine Generator Control Package NOTE If Upload Setpoints is chosen, the EGCP-2 panel will switch to a communications mode where it is waiting to see characters on the 422 serial ports that set it to transfer the contents of the setpoint file to the PC. This task is run on the PC using the Download_D.exe DOS program. The Download_D.exe program is available for download on Woodward’s Internet web page. 1) Go to www.woodward.com/software. 2) In the box, select EGCP-2 Tools for all EGCP-2 related software available at present time. Modbus RTU Communications for the EGCP-2 Panel The Modbus ID configuration menu item is adjustable from 1 to 247. This address identifies the Modbus Slave to the Modbus Master using this address. The Modbus address chosen for any particular EGCP-2 panel should be unique from any other devices on the Modbus network. NOTE The Network Address of the EGCP-2 panel is not linked to the Modbus ID in any way. Modbus Time-out is located in the Sequencing and Comms configuration menu. This item is the time, in seconds, which the EGCP-2 panel will wait before either receiving a valid message from the Modbus master, or indicating a Modbus failure. The EGCP-2 panel indicates a Modbus failure in the bottom two lines of the Modbus Timeout and Modbus Reset Sequencing and Comms configuration menu items. This display shows Link failure (failure to receive a valid message from the master) as true/false, and an error number, which is associated with the type of failure. For example LF-XF 0 is the indication of a healthy Modbus connection with a Link failure of False and a failure number of 0. The Link failure is a latching-type indication, and requires the Modbus Reset menu item to be toggled from True to False in order to reset. See Table 9-3 for a list of common error numbers that may be seen in the Load Control Monitor Display. The Modbus Reset is located in Sequencing and Comms configuration menu. It is used to reset any failures indicated on the Modbus serial communications, and also to restart the Modbus Time-out timer from zero seconds. The Modbus Reset should be left at FALSE, and only turned to TRUE to provide a reset action on the Modbus. Once the reset is accomplished, the Modbus Reset must be taken back to False once again. The Modbus communications used by the EGCP-2 panel operate at 9600 baud, with 8 data bits, 1 stop bit, NO parity, and NO flow control. The protocol used is Modbus RTU (Master/Slave). Woodward 113 EGCP-2 Engine Generator Control Package Manual 26076 Reply Time-out, Delay, and Number of Retries for the Modbus Master must be configured to meet the requirements of the entire Modbus network and the devices communicating on that network. See Table 9-4 for more information on typical settings. Modbus Information Addresses 00001–00016 Boolean Writes The Boolean write variables can be used for remote control of the EGCP-2 over Modbus. Fourteen variables are available to mimic the fourteen discrete input switches. The Gen CB Aux input and Mains CB Aux input are not included in the Modbus addresses. They must be hard wired to the control. If remote control is desired the control must first be placed in the “Modbus Control Mode”. The Auto, Test, and Run With Load inputs are used to determine whether the control is in the Modbus control or Hardware control mode. To activate the Modbus mode all three of the addresses 00001, 00002, and 00003 must be set. It is not required that these Modbus inputs be different than the actual hardware inputs, but all three must be set before any remote control can take place. For example, if the Auto, Test, and Run With Load inputs were all open, the user could send a False command to the addresses 00001, 00002, and 00003 and the control would switch from the Hardware control mode to Modbus control, but no action would take place. Table 9-1 shows some examples of how this switching takes place. Table 9-1. Examples of Modbus Control Mode Switching Logic Starting Auto Test Run WL Auto Test Run WL Mode Input 1 Input 2 Input 3 00001 00002 00003 Hardware Open Open Open Set to False Set to False Set to False All three Modbus commands were sent so the Control mode changes from Hardware Result to Modbus. No action is taken because the control remains in the OFF mode. Hardware Open Open Open Set to False Set to True Set to False All three Modbus commands were sent so the Control mode changes from Hardware to Modbus. The Test input is set to True so the control will go into the TEST mode and the engine will start. If the Modbus commands were sent one at a time in the Result order of Auto, Test, Run WL, it would be after the Run WL input was sent that the engine would start, because it was the third one required, not after the Test input was set True. Modbus Open Open Open Set to True False False Modbus control has already been established. None of the discrete inputs change, so Result the unit is placed in the AUTO mode. Modbus Open Open to Open True False False close Modbus control was established in the AUTO mode, and the Test hardware input was Result closed. This will switch the control into the Hardware control mode. The unit would go in to the TEST mode and would start. Modbus Open to Open Open True False False close Modbus control has already been established. The Auto hardware input was closed. Since the hardware now matches the Modbus, no action is taken. The control Result remains in the Modbus mode until the switch configuration is made different from the Modbus inputs. 114 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Once Modbus control has been established, the Modbus inputs can be viewed on the I/O Status screen. There is no indication that the control has seen three successful Modbus input messages. The four momentary switch inputs to the EGCP-2 (Voltage Raise/Lower, Speed Raise/Lower) are internally (EGCP-2 software) timed to open after a one second ON time. This means that if the EGCP-2 receives an ON command via Modbus for any of these four switches, the unit will turn the switch ON for one second, and then turn the input OFF. If the Modbus update for the ON command occurs again within the one-second period, the EGCP-2 will continue holding the switch ON until one second after the last active Modbus On update is received. Addresses 10001–10071 Boolean Read The Boolean Read variables are True/False inputs that show the positions of the hardware, the alarm status, and some system status readings. Boolean Read one (10001) will be true whenever the control is switching between the Mains and Bus PT’s via the PT disconnect relays. For the engine and generator alarms, variables 34 through 62 (10034–10062), these will only go true after the delay time has been satisfied and will remain true until the alarm is cleared from the alarm log. If the corresponding alarm is set to the Disable level, it will not be seen in the Modbus variable. Boolean Read 71 (10071), PF indication will be True to indicate a leading voltage and False to indicate a lagging voltage. Addresses 30001–30073 Analog Read The Analog Read variables are numeric representations showing the measured values of the control inputs, the alarm level type, and the mode of operation for certain functions of the control. These values use a signed integer format that does not support decimal places. In order to view the decimal places on certain variables the value is multiplied by a scaling variable. For analog reads 20 through 48 (30020–30048), the engine and generator alarm types, the alarm type is defined as follows: 0 = Disabled 1 = Warning 2 = Visual Alarm 3 = Audible Alarm 4 = Soft Shutdown 5 = Hard Shutdown For analog reads 49 through 53 (30049–30053), the Loss Of Mains Alarms, the alarm type is defined as follows: 0 = Disabled 1 = Warning 2 = Loss of Mains 3 = Loss of Mains with Alarms Woodward 115 EGCP-2 Engine Generator Control Package Manual 26076 For the analog read 67, the Load Control Mode, the mode is defined as follows: 0 = Off 1 = Droop (Generator frequency will decrease as load is increased) 2 = Isochronous (On load, not in parallel with the Mains) 3 = Baseload (In parallel with the Mains, at a fixed kW setpoint) 4 = Process (In parallel with the Mains, controlling the process input) For the analog read 68, the Synchronizer Mode, the mode is defined as follows: 0 = Off 1 = ATS (Auto Transfer State. Trying to open the Mains breaker 2 = Parallel (Trying to close Mains breaker) 3 = In Sync (Gen breaker or Mains breaker was synchronized successfully.) 4 = ATS Return (Trying to Open Gen breaker) 5 = Parallel Mains (Trying to Close Mains breaker) 6 = Gen Close Timer (Gen breaker close issued, waiting for feed back to show closed) 7 = Mains Close Timer (Mains breaker close issued, waiting for feed back to show closed) 8 = Gen Sync Timer (checking for successful synchronization of the generator) 9 = Mains Sync Timer (checking for successful synchronization of the Mains breaker) For the analog read 71 (30071), the Address of the Master Unit, is only valid on controls that are in the Auto mode. Units not in Auto are not communicating with the master and cannot be relied upon. For the analog read 72 (30072), the Engine state the state is defined as follows: 1 = Off 2 = Preglow 3 = Crank 4 = Run 5 = Cooldown (engine has ran above the Cooldown setpoint and will wait before stopping) 6 = Spindown (fuel solenoid is open but engine speed is still sensed as the engine coasts down) 7 = Restart (previous start attempt has failed, so trying again.) For the analog read 73 (30073), the Synchroscope Phase Angle, will give a value between –180 and 180 degrees. Zero degrees would be in phase, negative measurements occur when in the right half of the synchroscope, and positive measurements occur when in the left half of the synchroscope. For example, if the synchroscope were showing a rotation in the clockwise direction for a generator that was slightly faster than the bus the sequence of angles would be 0, -30, -60, -90, -120, -150, 180, 150, 120, 90, 60, 30, 0… Address 40001 Analogs Write The Analog Write variable can be used to change the priority of the EGCP-2 over Modbus. To change the priority the unit must be in the AUTO mode. When multiple units are in Auto the following rules apply to changing the priority. 116 Woodward Manual 26076 EGCP-2 Engine Generator Control Package When decreasing (incrementing value) a unit's priority, every active unit (in multiple unit configuration and auto mode) on the same network with a higher priority (lower value) than the unit, which is currently having its priority, changed, will increase (decrement value) priority when the priority change is committed. And inverse to this: When increasing (decrementing value) a unit's priority, every active unit (in multiple unit configuration and auto mode) on the same network with a lower priority (higher value) than the unit, which is currently having its priority, changed, will decrease (increment value) priority when the priority change is committed. A delay occurs after a priority change of master units to allow proper record sorting for all units on the network. Table 9-2. Modbus Addresses for the RTU Protocol Address Data Type/Scaling Description 00001 BW Change Input #1 (Auto) 00002 BW Change Input #2 (Test) 00003 BW Change Input #3 (Run With Load) 00004 BW Change Input #4 (Voltage Raise) 00005 BW Change Input #5 (Voltage Lower) 00006 BW Change Input #6 (Speed Raise) 00007 BW Change Input #7 (Speed Lower) 00008 BW Change Input #10 (Process I/E) 00009 BW Change Input #11 (Fault #1) 00010 BW Change Input #12 (Fault #2) 00011 BW Change Input #13 (Fault #3) 00012 BW Change Input #14 (Fault #4) 00013 BW Change Input #15 (Fault #5) 00014 BW Change Input #16 (Fault #6) 00015 BW Not Used 00016 BW Commit All Alarms Address Data Type/Scaling Description 10001 BR Bus/Mains PT Switch in Transition 10002 BR Mains Stable Indication 10003 BR Bus Stable Indication 10004 BR Alarm Status 10005 BR Loss of Mains Status 10006 BR Relay #1 (Mains Brk Close) Status 10007 BR Relay #2 (Gen Brk Close) Status 10008 BR Relay #3 (Engine Preglow) Status 10009 BR Relay #4 (Fuel Solenoid) Status 10010 BR Relay #5 (Engine Crank) Status 10011 BR Relay #6 (Visual Alarm) Status 10012 BR Relay #7 (Bus PT Connect) Status 10013 BR Relay #8 (Mains PT Disconnect) Status 10014 BR Relay #9 (Mains Brk Trip) Status 10015 BR Relay #10(Gen Brk Trip) Status 10016 BR Relay #11(Audible Alarm) Status 10017 BR Relay #12 (Idle/Rated) Status 10018 BR Input #1 Status (Auto) 10019 BR Input #2 Status (Test) 10020 BR Input #3 Status (Run with Load) 10021 BR Input #4 Status (Voltage Raise) 10022 BR Input #5 Status (Voltage Lower) 10023 BR Input #6 Status (Speed Raise) 10024 BR Input #7 Status (Speed Lower) Woodward 117 EGCP-2 Engine Generator Control Package Manual 26076 Address Data Type/Scaling Description 10025 BR Input #8 Status (Gen CB Aux.) 10026 BR Input #9 Status (Mains CB Aux.) 10027 BR Input #10 Status (Process I/E) 10028 BR Input #11 Status (Fault #1) 10029 BR Input #12 Status (Fault #2) 10030 BR Input #13 Status (Fault #3) 10031 BR Input #14 Status (Fault #4) 10032 BR Input #15 Status (Fault #5) 10033 BR Input #16 Status (Fault #6) 10034 BR SYNCTIMEOUT Status 10035 BR SYNCRECLOSE Status 10036 BR CRANK_FAIL Status 10037 BR VOLTAGE_RANGE Status 10038 BR OVERSPEED Status 10039 BR OVERCURRENT Status 10040 BR REVERSEPOWER Status 10041 BR LOSSOFEXCITATION Status 10042 BR SPEED_FREQ_MISMATCH Status 10043 BR H2O_HIGH_LIMIT Status 10044 BR H2O_LOW_LIMIT Status 10045 BR OILPRESSHIGHLIMIT Status 10046 BR OILPRESSLOW LIMIT Status 10047 BR BATTVOLTLOW LIMIT Status 10048 BR BATTVOLTHIGHLIMIT Status 10049 BR GEN_VOLT_LOW_LIMIT Status 10050 BR GEN_VOLT_HIGH_LIMIT Status 10051 BR GEN_FREQ_HIGH_LIMIT Status 10052 BR GENFREQLOW LIMIT Status 10053 BR LOADHIGHLIMIT Status 10054 BR LOADLOW LIMIT Status 10055 BR PROCESS_HIGH_LIMIT Status 10056 BR PROCESS_LOW_LIMIT Status 10057 BR REMOTE_FAULT1 Status 10058 BR REMOTEFAULT2 Status 10059 BR REMOTEFAULT3 Status 10060 BR REMOTEFAULT4 Status 10061 BR REMOTE_FAULT5 Status 10062 BR REMOTE_FAULT6 Status 10063 BR Not Used 10064 BR Not Used 10065 BR Not Used 10066 BR Not Used 10067 BR Not Used 10068 BR Not Used 10069 BR Not Used 10070 BR Not Used 10071 BR PF Leading/Lagging Indicator NOTE: Analog inputs are signed integer data. Address Data Type/Scaling Description 30001 AR X10 Battery Voltage 30002 AR X10 Engine Oil Pressure 30003 AR Engine Coolant Temperature 30004 AR Engine Run Time 30005 AR Engine KW/Hours 30006 AR Engine RPM 30007 AR Phase A Volts 30008 AR Phase B Volts 30009 AR Phase C Volts 118 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Address Data Type/Scaling Description 30010 AR Total KW 30011 AR Total KVA 30012 AR X100 Generator Power Factor 30013 AR Phase A kVAR 30014 AR Phase B kVAR 30015 AR Phase C kVAR 30016 AR Total kVAR 30017 AR X10 Bus Output Frequency 30018 AR X10 Generator Output Frequency 30019 AR Network Address 30020 AR SYNC_TIMEOUT Alarm Type 30021 AR SYNC_RECLOSE Alarm Type 30022 AR CRANK_FAIL Alarm Type 30023 AR VOLTAGE RANGE Alarm Type 30024 AR OVERSPEED Alarm Type 30025 AR OVERCURRENT Alarm Type 30026 AR REVERSE POWER Alarm Type 30027 AR LOSS_OF_EXCITATION Alarm Type 30028 AR SPEED_FREQ_MISMATCH Alarm Type 30029 AR H2O_HIGH_LIMIT Alarm Type 30030 AR H2O LOW LIMIT Alarm Type 30031 AR OIL PRESS HIGH LIMIT Alarm Type 30032 AR OIL PRESS LOW LIMIT Alarm Type 30033 AR BATT_VOLT_LOW_LIMIT Alarm Type 30034 AR BATT_VOLT_HIGH_LIMIT Alarm Type 30035 AR GEN_VOLT_LOW_LIMIT Alarm Type 30036 AR GEN VOLT HIGH LIMIT Alarm Type 30037 AR GEN FREQ HIGH LIMIT Alarm Type 30038 AR GEN FREQ LOW LIMIT Alarm Type 30039 AR LOAD_HIGH_LIMIT Alarm Type 30040 AR LOAD_LOW_LIMIT Alarm Type 30041 AR PROCESS_HIGH_LIMIT Alarm Type 30042 AR PROCESS LOW LIMIT Alarm Type 30043 AR REMOTE FAULT1 Alarm Type 30044 AR REMOTE FAULT2 Alarm Type 30045 AR REMOTE_FAULT3 Alarm Type 30046 AR REMOTE_FAULT4 Alarm Type 30047 AR REMOTE_FAULT5 Alarm Type 30048 AR REMOTE FAULT6 Alarm Type 30049 AR LOAD SURGE Alarm Type 30050 AR MAINS VOLT LOW LIMIT Alarm Type 30051 AR MAINS_VOLT_HIGH_LIMIT Alarm Type 30052 AR MAINS_FREQ_HIGH_LIMIT Alarm Type 30053 AR MAINS_FREQ_LOW_LIMIT Alarm Type 30054 AR Generator Phase A/Neutral Volts 30055 AR Generator Phase B/Neutral Volts 30056 AR Generator Phase C/Neutral Volts 30057 AR Mains/Bus Phase A/Neutral Volts 30058 AR Phase A current 30059 AR Phase B current 30060 AR Phase C current 30061 AR Phase A KVA 30062 AR Phase B KVA 30063 AR Phase C KVA 30064 AR Voltage Bias Analog Output (0-100%) 30065 AR Speed Bias Analog Output (0-100%) 30066 AR Load Control Mode 30067 AR Synchronizer Mode 30068 AR Number of Unacknowledged Alarms 30069 AR Unit Network Priority Woodward 119 EGCP-2 Engine Generator Control Package Manual 26076 Address Data Type/Scaling Description 30070 AR Address of Master Unit. 30071 AR Not Used 30072 AR Engine State. 30073 AR Synchroscope Phase Angle Address Data Type/Scaling Description 40001 AW 1 to 8 Priority Change Address Table 9-3. Common Modbus Error Numbers CODE Name Meaning 00 NO ERROR No Modbus communication faults detected. 01 Illegal Function The function received is not an allowable action for the addressed slave. 02 Illegal Data Address The address referenced in the data field is not an allowable address for the addressed slave. 03 Illegal Data Value The amount of data requested from the slave was too large for the slave to return in a single response. 09 Checksum Error There was an error in the message checksum. This can indicate link quality problems and/or noise on the line. 10 Garbled Message The slave received data, however it is too short to be a valid Modbus message/command. 12 Buffer Overflow Input buffer overflow. This indicates that the length of the received message from the master has exceeded the input buffer capacity of the EGCP-2. Reduce message sizes to correct. 20 Unsolicited Response Unsolicited message received by the slave. Table 9-4. Typical Modbus Communications Settings Poll Time Number of Retries Retry Delay Timeout 1.0 seconds 3 1.0 second* 10 seconds 1 second is the minimum recommended retries delay time. Setting the retry delay to less than one second may cause the control to fail to boot up properly upon a power cycle. NOTE Communications settings will vary based on the Modbus system configuration. These settings are the recommended typical settings for a multiple unit EGCP-2 system connected to Modbus master. 120 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Chapter 10. Service Options Product Service Options If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward product, the following options are available: • Consult the troubleshooting guide in the manual. • Contact the manufacturer or packager of your system. • Contact the Woodward Full Service Distributor serving your area. • Contact Woodward technical assistance (see “How to Contact Woodward” later in this chapter) and discuss your problem. In many cases, your problem can be resolved over the phone. If not, you can select which course of action to pursue based on the available services listed in this chapter. OEM and Packager Support: Many Woodward controls and control devices are installed into the equipment system and programmed by an Original Equipment Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the programming is password-protected by the OEM or packager, and they are the best source for product service and support. Warranty service for Woodward products shipped with an equipment system should also be handled through the OEM or Packager. Please review your equipment system documentation for details. Woodward Business Partner Support: Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls, as described here: • A Full Service Distributor has the primary responsibility for sales, service, system integration solutions, technical desk support, and aftermarket marketing of standard Woodward products within a specific geographic area and market segment. • An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission. • A Recognized Engine Retrofitter (RER) is an independent company that does retrofits and upgrades on reciprocating gas engines and dual-fuel conversions, and can provide the full line of Woodward systems and components for the retrofits and overhauls, emission compliance upgrades, long term service contracts, emergency repairs, etc. • A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. A current list of Woodward Business Partners is available at www.woodward.com/support. Woodward 121 EGCP-2 Engine Generator Control Package Manual 26076 Woodward Factory Servicing Options The following factory options for servicing Woodward products are available through your local Full-Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is originally shipped from Woodward or a service is performed: • Replacement/Exchange (24-hour service) • Flat Rate Repair • Flat Rate Remanufacture 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 a flat-rate program and includes the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option allows you to call your Full-Service Distributor 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 Full-Service Distributor. Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is shipped. If the core (field unit) is returned within 60 days, a credit for the core charge will be issued. Flat Rate Repair: Flat Rate Repair is available for the majority of 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. 122 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Returning Equipment for Repair If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-Service Distributor in advance to obtain Return Authorization and shipping instructions. When shipping the item(s), attach a tag with the following information: • return number; • 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. 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. CAUTION—ELECTROSTATIC DISCHARGE 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. Replacement Parts When ordering replacement parts for controls, include the following information: • the part number(s) (XXXX-XXXX) that is on the enclosure nameplate; • the unit serial number, which is also on the nameplate. Woodward 123 EGCP-2 Engine Generator Control Package Manual 26076 Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. • Technical Support • Product Training • Field Service Technical Support is available from your equipment system supplier, your local Full-Service Distributor, or from many of Woodward’s worldwide locations, depending upon the product and application. This service can assist you with technical questions or problem solving during the normal business hours of the Woodward location you contact. Emergency assistance is also available during non- business hours by phoning Woodward and stating the urgency of your problem. Product Training is available as standard classes at many of our worldwide locations. 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. Field Service engineering on-site support is available, depending on the product and location, from many of our worldwide locations or from one of our Full- Service 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 information on these services, please contact us via telephone, email us, or use our website and reference www.woodward.com/support, and then Customer Support. How to Contact Woodward For assistance, call one of the following 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. Electrical Power Systems Engine Systems Turbine Systems Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 China ------------ +86 (512) 6762 6727 China ------------ +86 (512) 6762 6727 China ------------ +86 (512) 6762 6727 Germany: Germany: Kempen --- +49 (0) 21 52 14 51 Stuttgart ----- +49 (711) 78954-0 Stuttgart ----- +49 (711) 78954-0 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Korea --------------- +82 (51) 636-7080 Korea --------------- +82 (51) 636-7080 Korea --------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111 Poland -------------- +48 12 618 92 00 United States ----- +1 (970) 482-5811 United States ----- +1 (970) 482-5811 United States ----- +1 (970) 482-5811 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward’s website (www.woodward.com/support) for the name of your nearest Woodward distributor or service facility. For the most current product support and contact information, please refer to the latest version of publication 51337 at www.woodward.com/publications. 124 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 Control/Governor Information Please list all Woodward governors, actuators, and electronic controls in your system: Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number If you have an electronic or programmable control, please have the adjustment setting positions or the menu settings written down and with you at the time of the call. Woodward 125 EGCP-2 Engine Generator Control Package Manual 26076 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. 126 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 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 Woodward 127 EGCP-2 Engine Generator Control Package Manual 26076 Appendix B. Speed Bias Connections EPG EGCP-2 SPEED Speed Bias Output CONTROL + 73 - 74 EGCP-2 To EPG Speed Control Wiring and Configuration Settings VIS-125a 00-06-20 Speed Bias Output Type = +/- 3VDC EGCP-2 2301A Speed Bias Output Speed Control + 73 15 + - 74 17 - EGCP-2 To 2301A Speed Control Wiring and Configuration Settings 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, 9907-014 128 Woodward Manual 26076 EGCP-2 Engine Generator Control Package EGCP-2 FLO-TECH Speed Bias Output Speed Control + 73 11 + 74 - 12 - EGCP-2 To FLO-TECH Speed Control Wiring and Configuration Settings VIS-127a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common FLO-TECH Speed Control Part Numbers: 8290-195, 8290-196 EGCP-2 Pro-ACT I & II Speed Bias Output Speed Control + 73 12 + - 74 13 - EGCP-2 To Pro-ACT Speed Control Wiring and Configuration Settings VIS-128a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common Pro-ACT Speed Control Part Numbers: 9905-462, 9905-463 Woodward 129 EGCP-2 Engine Generator Control Package Manual 26076 EGCP-2 CSC Speed Bias Output Speed Control + 73 11 + 74 - 12 - EGCP-2 To CSC Speed Control Wiring and Configuration Settings VIS-129a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC 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 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC NOTE: 2301A LSSC must have terminal 14 powered for the load sharing line inputs (10 and 11) to be active. 130 Woodward Manual 26076 EGCP-2 Engine Generator Control Package 701 or 701A EGCP-2 Speed Speed Bias Output Control + 73 21 + 74 - 22 - EGCP-2 To 701 and 701A Wiring and Configuration Settings VIS-131a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common 701 and 701A Speed Control Part Numbers: 8280-102, 8280-193, 9905-211 721 EGCP-2 Speed Speed Bias Output Control + 73 21 + - 74 22 - EGCP-2 To 701 and 701A Wiring and Configuration Settings VIS-132a 00-06-20 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common 721 Speed Control Part Numbers: 9905-291, 9907-206, 9907-207 Woodward 131 EGCP-2 Engine Generator Control Package Manual 26076 723 or 723 Plus EGCP-2 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 Speed Bias Output Type = +/- 3VDC 0% Speed Bias Output = 0 VDC Common 723 or 723 Plus Speed Control Part Numbers: 9907-031, 8280-412 132 Woodward Manual 26076 EGCP-2 Engine Generator Control Package Woodward 133 EGCP-2 Engine Generator Control Package Manual 26076 134 Woodward EGCP-2 Control Specifications Woodward Part Numbers: 8406-115 EGCP-2 Engine Generator Control, 150–300 Vac PT input 8406-116 EGCP-2 Engine Generator Control, 50–150 Vac PT input Power Supply Rating 9–32 Vdc (SELV) Maximum input voltage range Power Consumption Less than or equal 13 W nominal, 20 W maximum Input Supply Voltage Input Supply Current 12 V (nominal) 1.08 A 24 V (nominal) 542 mA 32 V 406 mA PT input 50–150 Vac, 8406-116 150–300 Vac, 8406-115 CT input 0–5 A rms Generator Frequency Range 40–70 Hz Magnetic Pickup 100–15 000 Hz Discrete Inputs (8) 5 mA source current when CLOSED to Switch Common (65) Process input 4–20 mA, 1–5 Vdc Temperature and pressure inputs 0–200 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. We appreciate your comments about the content of our publications. Send comments to: icinfo@woodward.com Please include the manual number from the front cover of this publication. 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 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website. 2008/9/Fort Collins