Manual 26076 - Installation and Operatio

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WARNING—OUT-OF-DATE PUBLICATION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
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
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
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
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.
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
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
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
• 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
4
UTILITY
Watt Operator Control Panel

Transducer EGCP-2 Interfaces
Process
Input
Fault 1
Fault 2
Automatic
Utility Utility TB Aux
Process I/E
Test Engine
Speed Raise
Speed Lower
Breaker PC
Voltage Raise
Utility TB Open/Close PC Interface
Voltage Lower
Run With Load

RS-422
TO Other
Mains PT RS-485
EGCPs
Disconnect Port
EGCP-2 Engine Generator Control Package
Utility/Bus Input
EGCP
ALARM (VISUAL)
Local Bus Disconnect LAMP
GB Aux In ALARM (AUDIBLE)
Gen Breaker
Open/Close
Plant Load
Figure 2-1. EGCP-2 Interface Connections

Gen PT Inputs (3 phases)
HORN
Oil Pressure
Engine Preglow Gen CT inputs (3 phases)
Engine Crank
Fuel Shutoff Solenoid
Water Temperature MPU Speed Bias Voltage Bias
GEN
Generator Speed Voltage
Breaker Control Regulator
TO Other
Generators
Manual 26076
Woodward
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
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
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
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
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
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
Figure 2-3. Physical Outline with Dimensions of EGCP-2
Woodward 11
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
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
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
Figure 3-3. Wiring Diagram for EGCP-2
Woodward 15
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 -
3. 100 ohm dropping resistor Select. Dip Switch # 1 Dip Switch # 3
2. 123 ohm RS-422 Termination+
4. 100 ohm dropping resistor Select. 1 4
1. +5V RS-422
2 3
3 2 SW - 4
SW-2 4 1
Temperature Sensor Input Hardware RS - 485 Terminations
______________________________ Dip Switch # 2 Dip Switch # 4 ___________________________
1. 0-200 Sensor. 1 4 4. 4-20 mA Process Input
2 3
2. 4-20mA Input Select. 3 2 3. 123 ohm RS-485 Termination -
3. 100 ohm dropping resistor Select. 4 1 2. 123 ohm RS-485 Termination+
4. 100 ohm dropping resistor Select. 1. +5V RS-485
VIS-143 TB 5 TB 6 TB7 TB8 TB9
01-03-16
Figure 3-4. Dip Switch 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
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.”
A 42 +
A PHASE PT
43
-
B 44 +
B PHASE PT
45
-
C 46 +
C PHASE PT
47
-
VIS-054b EGCP-2
00-06-19
Figure 3-5. Three Wire Delta PT Connection for EGCP-2
Woodward 17
42 A +
A B
N
43
N
44 B +
N
N
45
N
C 46 C +
N
VIS-055a 47
00-10-17 N
EGCP-2
Figure 3-6. Four Wire WYE PT 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
Multiple Engine
NOTES: LOM's Applications EGCP-2
- *K1 SHOWN ENERGIZED
- *K2 SHOWN DE-ENERGIZED
- *K1 & K2 RELAYS ARE NOT (+V) 23 Mains PT
SUPPLIED BY WOODWARD Disconnect
- *K1 and K2 RELAYS SHOULD (Normally
BE CONNECTED AS NORMALLY Closed)
OPEN CONTACTS
24 (D08)
K1*
Mains PT
A K1-A
40 A
B or N K1-B
(B for Delta, N for Wye) Mains/Bus PT Input
A
Bus PT K2-A
41 B or N
B or N K2-B (B for Delta, N for Wye)
(B for Delta, N for Wye) K2*
21 Local Bus PT
Connect
(Normally
Open)
(+V) 22 (D07)
VIS-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
NOTES: Prime Power or

EGCP-2
- *K1 SHOWN ENERGIZED Single
- *K2 SHOWN DE-ENERGIZED (+V) 23 Mains PT
- *K1 & K2 RELAYS ARE NOT Engine LOMs Disconnect
SUPPLIED BY WOODWARD
Applications (Normally
- *K1 & K2 RELAYS SHOULD
BE CONNECTED AS NORMALLY
Closed)
OPEN CONTACTS 24 (D08)
K1*
Mains/Bus A
PT
K1-A
40 A
B or N K1-B
(B for Delta, N for Wye) Mains/Bus PT Input
K2-A
41 B or N
K2-B (B for Delta, N for Wye)
K2*
21 Local Bus PT
Connect
(Normally
Open)
VIS-146
(+V) 22 (D07)
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
Applications (Normally
Closed)
24 (D08)
NOTES:
- K2 SHOWN DE-ENERGIZED
- K2 RELAY IS NOT
SUPPLIED BY WOODWARD 40 A
K2*
Mains/Bus A K2-A
Mains/Bus PT Input
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
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
Utility
A B C 8406-116
Bus
480 VLL
480 V A 120 V
Mains Disconnect
A
B 40
Mains/Bus
Utility 120 V
Breaker PT Input
41
480 V A 120 V B
Local Bus Connect
Bus
B
42 A+
Generator 120 V
Breaker
43 A-
480 V A 120 V 44 B+ Gen PT
B 120 V
Inputs
C 45 B-
46 C+
Generator
Bus
A B C 120 V
47 C-
N VIS-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
Utility
A B C 8406-115
Bus
480 VLL
480 V A 240 V
Mains Disconnect
A
B 40
Mains/Bus
Utility 240 V
Breaker PT Input
41
480 V A 240 V B
Local Bus Connect
Bus
B
42 A+
Generator 240 V
Breaker
43 A-
480 V A 240 V 44 B+ Gen PT
B 240 V
Inputs
C 45 B-
46 C+
Generator
Bus
A B C 240 V
47 C-
N VIS-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:
22 Woodward
Utility A B C EGCP-2
Bus 8406-116
A
Mains Disconnect
N 40 A
69 V Mains/Bus
Utility PT input
Breaker
41 N
A
Local Bus Connect
Bus N
42 A+
69 V
Generator
Breaker
A 43 N
N
B 44 B+
69 V
Gen PT
Inputs
N
C 45 N
N 46 C+
Generator 69 V
Bus
A B C 47 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:
Woodward 23
Utility A B C EGCP-2
Bus 8406-115
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
44 B+
Gen PT
277 V
45 Inputs
N
46 C+
Generator
277 V
Bus
A B C 47 N
N
Voltage Input: Wye VIS-148a
PT Ratio : 1:1 01-03-29
Voltage Ref: 277 Vac, L-N

Figure 3-10b. PT Wiring Relationships for Generator, Bus, and Utility Inputs
Please Note:
24 Woodward
Current Transformer (CT) Inputs

Current Transformers (CTs) are utilized with the EGCP-2 control to allow high
level circuit currents to be stepped down to a safe level for the EGCP-2 input
circuitry. The EGCP-2 senses generator current via external current
transformers. Refer to Figure 3-11 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
Example 2:
Generator rated for 150 amps per phase at 100% load, rated power factor.
CT Ratio
Current Transformer Input Ratings

Number of Inputs: 3 Generator CTs
Nominal Current Ratings: 0–5 A rms
Maximum Current Rating: 7 A rms for 1 minute
Input Burden: 1.25 VA
Input Frequency Range: 40–70 Hz
CAUTION—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 (-)
0-5 A A PHASE CT
(.050 OHMS)
89 (+)
92 (-)
B PHASE CT
(.050 OHMS)
91 (+)
(-)
94
C PHASE CT
(.050 OHMS)
93 (+)
A B C
VIS-049b
00-06-19
FIELD WIRING EGCP-2
Figure 3-11. Current Transfer Wiring Diagram for EGCP-2
Woodward 25
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
Magnetic Pickup Unit (-) 4.99K

200 - 3K ohms impedance 71
1000pF
VIS-051b
01-03-18
Figure 3-12. Wiring Diagram for MPU Input
26 Woodward
Process Import/Export Input

The EGCP-2 control can be configured to control any process which is
determined or affected by generator load. The Process Import/Export input is
used by the EGCP-2 control to sense the process level being controlled. This
input can be DIP switch configured to accept either a 4–20 mA or 1–5 dc signal.
Refer to Figure 3-4 for DIP switch location.
Process Input Ratings

Loop Voltage Source: External (4–20 mA), External (1–5 Vdc)
Input Impedance: 249 Ω (4–20 mA), 30 000 Ω (1–5 Vdc)
(+) R
86
SW4-4
Process Import/Export Input
4-20 mA / 1-5 Vdc
250
(-)
R
87
Switch SW4-4: R
Open for 1-5 volt input @ 30K ohms
Close for 4_20 mA @ 250 ohms VIS-149
00-08-15
Figure 3-13a. 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 +
Transducer 250 ohm
-
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
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
Oil Pressure SW 1-2 C R

SW1-3 SW1-4
Sensor
Input
- 69
249 100 100 R
VIS-050a
00-08-24
Input 4-20mA 1-5 Volt 200 Ohm 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
+12 Vdc
537.5
SW2-1
R
+ 66
Coolant
Temperature SW 2-2 SW2-3 SW2-4 C R
Sensor
Input
- 67
249 100 100 R
VIS-050b
01-01-31
Input 4-20mA 1-5 Volt 200 Ohm 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
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

Min Drive Impedance: 1000 Ω
30 Woodward
(+)
500 Hz PWM
73
.5 to 4.5 VDC
+/- 3VDC Speed Bias Output
Software Switch Software Configurable for :
(-) +/- 3VDC
500 Hz PWM
74 5 to 4.5 VDC
75
(+)
+/-9VDC
37 Voltage Bias Output
+/- 3VDC
Software Configurable for:
+/- 1VDC +/- 1 Vdc
Software Switch +/- 3 Vdc
(-) +/- 9 Vdc
38
VIS-052a
00-04-19
39
Figure 3-15. 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
Discrete Input Ratings
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
+5 Vdc
Typical Example of Discrete Input

(Auto/Manual Contact (DI#1) Input Shown) R
+V
Note:
TB6-65 is the discrete input common for
all contact inputs
Auto/Manual
R
49
User Supplied Contact
VIS-053a
65 00--06-19
Discrete Input Common
Figure 3-16. 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
Relay Output Ratings
Relay Type: Sealed
Relay Response Time: 15 ms (operate and release)
Relay Life Expectancy: ≥50 000 operations @ rated load (8 A @ 250 Vac
COS ≥0.7) (8 A @ 24 Vdc τ ≥0.7 ms)
Replaceability: Relays are soldered to main board and are not field
replaceable
Max. Contact Ratings:
AC: 10 A, 250 Vac Resistive
249 W (1/3 hp), 125 Vac (7.2 A, 0.4–0.5 PF)
DC: 10 A, 30 Vdc Resistive
Relay Output Functions

Discrete Output #1—Mains Utility Breaker Close
With the relay de-energized, this output has Normally Open (NO), terminals 5
and 6, and Normally Closed (NC), terminals 6 and 7, contacts to select from.
The “Mains (utility) Breaker Close” relay output is utilized by the EGCP-2 to
command the Mains (utility) Breaker to close. This output is configured for use
with a BREAKER or a CONTACTOR in the Configuration menu under “CKT
Breaker Control”. Every EGCP-2 that has the capability of being a MASTER unit
must have this relay wired into the Mains (utility) Breaker close circuitry.
Breaker
When in the Breaker configuration, the EGCP-2 will ENERGIZE (momentary) to
close the Mains (utility) Breaker. The ENERGIZE time is determined by the “CB
Hold Time” in the Synchronizer menu. Discrete Output #9 is used to open the
mains breaker.
EGCP-2 Mains
Breaker
Close
7
+V
Discrete 6
Output #1
5 Mains (utility)
Breaker
VIS-154 Close Coil
01-06-01
Figure 3-17. 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
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
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

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
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 Generator
Breaker
Close
10
+V
Discrete 9
Output #2
8 Generator
Breaker
VIS-154b Close Coil
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.
EGCP-2 Generator
Contactor
Close
10
+V
Discrete 9
Output #2
8 Generator
Contactor
VIS-154c Open/Close Coil
01-06-01
Figure 3-20. Example Using the NO Contacts to Control the Generator’s

Contactor (ENERGIZE TO CLOSE)
36 Woodward
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
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)

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
open the Mains (utility) Breaker.
38 Woodward
EGCP-2 Mains
Breaker
Trip
27
+V
Discrete 26
Output #9
25 Mains
Breaker
VIS-154d Trip (Open) Coil
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)

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
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

9
Connections
Gen Breaker Close
8
Generator Breaker
+V
Close Coil
29
Gen Breaker
Trip 30
Gen Breaker Trip will energize Generator Breaker
when in "Auto" and "Gen Trip Coil
Stable Delay" is met.
Generator Breaker Configuration Based Logic.
EGCP-2 +V External Wiring

Connection
9
Gen Breaker Close
8
Generator Contactor
Close/Open Coil
29
Gen Breaker
Trip No Connection.
30
VIS-142a
01-07-11
Generator Contactor Configuration Based Logic.
Figure 3-23. Generator Breaker and Contactor Close and Open Logic
40 Woodward
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
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
Discrete Inputs
Loc. Description Signal Input
49 Auto Discrete Input (DI-1) + power supply (internal connection)
50 Test Discrete Input (DI-2) + power supply (internal connection)
51 Run/Ld Discrete Input (DI-3) + power supply (internal connection)
52 Volt Raise Discrete Input (DI-4) + power supply (internal connection)
53 Volt Lower Discrete Input (DI-5) + power supply (internal connection)
54 Speed Raise Discrete Input (DI-6) + power supply (internal connection)
55 Speed Lower Discrete Input (DI-7) + power supply (internal connection)
56 Gen CB Aux Discrete Input (DI-8) + power supply (internal connection)
57 Mains CB Aux Discrete Input (DI-9) + power supply (internal connection)
58 Process Discrete Input (DI-10) + power supply (internal connection)
59 Fault 1 Discrete Input (DI-11) + power supply (internal connection)
65 Switch Common Discrete Input – power supply (internal connection)
NOTE: Approximately 5 mA current draw across each DI when CLOSED.
Discrete Outputs
Location Description Signal Output Rating
7 Mains Brkr Close NC Discrete Output (D01) (see Relay
6 Mains Brkr Close C (D01) Output Ratings)
5 Mains Brkr Close NO Discrete Output (D01) “
10 Gen Brkr Close NC Discrete Output (D02) “

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

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

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

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

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

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

29 Gen Brkr Trip C (DO10) “
28 Gen Brkr Trip NO Discrete Output (DO10)
33 Audible Alarm NC Discrete Output (DO11) “
32 Audible Alarm C Discrete Output (DO11) “
31 Audible Alarm NO Discrete Output (DO11)
Woodward 43
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
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

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.

SW3-1 Closed SW3-1Open SW3-1 Closed
SW3-2 Closed SW3-2 Open SW3-2 Closed
NOTES
When the RS-422 to RS-232 converter is greater than 30 meters from unit 1,
an isolating version will be required. Cable shields must also be AC coupled
to earth or connected to RS-422 to RS-232 converter chassis. This chassis
must be Isolated from earth and may be AC coupled to earth.
When unit 2 and/or unit 3 are more than 30 meters from unit 1, the cable
shield must be ac coupled to terminal 83. The capacitor must be 0.01 µF with
a working voltage of 1000 Vdc or greater.
The RS-422 Termination 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
+5 +5
Vdc Vdc
24 121. 24 24 121. 24
3 5 3 3 5 3
SW4-1 SW3-1
SW3- SW3-
SW4-2 SW4-3
2 3
422 RxD
485 (+)
(+) 81
76
422 RxD (-
)
82
485 (-
) Shiel
77 d
83
Shiel
d
422 TxD
RS 422/485 78
(+)
Transceiver 84
422 TxD (-
RS 422/485 )
Transceiver 85
80
VIS-108a
RS-485 Termination 00-06-20 RS-422 Termination
Figure 3-25. 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
The information on the RS-485 network is for communications between controls
only and must not be interfaced in any way with external devices. There is an
RS-422 port on the EGCP-2, which is used to monitor and control the units
remotely.
Example:
2 EGCP-2s—Both EGCP-2s must have the 485 network terminated.
3 or more EGCP-2s—The end controls must have the 485 network terminated
(see Figure 3-26).

78 78 78
485 485 485 485 485 485

(+) (-) (+) (-) (+) (-)
76 77 76 77 76 77
VIS-109a
00-06-20
Twisted shielded pair. Belden 3074F or equivalent
Figure 3-26. RS-485 Inter-Control Communications
Switch configuration for multiple units utilizing RS-485 communication.

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

The EGCP-2 has many alarm/shutdown setpoints which can be configured for
five different alarm/shutdown conditions. The five conditions are as follows:
Disabled
When an alarm setpoint is set for Disabled, the alarm condition will have no
external indicators to signal the event has occurred. No control actions occur as
a result of a disabled condition.
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
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
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
Chapter 4.
Operational Description:
Single No Parallel
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
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
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
GEN BUS
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
Auto Gen Breaker +Battery
Automatic Manual
Close GCC -Battery
NLT (No Load Test) or Manu l4 Gen Breaker Close Coil
Test Gen Breaker +Battery
Run With Load (closed transition) Trip Manual GTC
Run W/LD Gen Breaker Trip Coil
Mains Breaker Manual+Battery
Voltage Raise Close MCC
Mains Breaker Close Coil
1
Voltage Lower Mains Breaker +Battery
Manual
Trip MTC
Mains Breaker Trip Coil
Speed Raise
Fuel +Battery
1 FUEL
Solenoid Fuel shutoff solenoid
Speed Lower
Manual G52a Engine +Battery
Gen CB Aux Preglow prglw
Preglow relay
U52a Mains CB Aux Engine +Battery Engine Crank Relay
Crank crank
No Connection Process I/E
Visual +Battery Visual Alarm
2
Fault #1
.. Alarm
3 . Audible +Battery
Fault #6 Alarm
Audible Alarm
Switch Common
Single NoParallel Application
VIS-061
1 Only required if the speed and voltage 3 Faults #3 through #6 activate immediately, 00-04-19
need to be adjusted when Test with programmable delays.
or Manual is selected.
2 Use fault #1 or #2 input if using a 4 Manual mode requires manual mains and generator breaker operation.
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
Switch Based Logic

(Single—No Parallel)
UTILITY POWER
RUN w/ LOAD
PROCESS
AUTO
TEST
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
Single Unit No Parallel Auto Input

Test Input Run With Load
Input
Engine Loss of Mains

Start Engine No
Enabled?
Sequence Start
Sequence
Generator
Yes
and
Engine Unit will not close gen
Alarms/ breaker (must be in AUTO
Shutdowns mode for breaker control) Loss of Mains
Active Detection Active
Mains CB AUX Loss of Mains for

Yes No
Closed? >LOM Action
Delay?
No
Yes
Close Mains
Breaker Sequence Open Mains
Breaker Sequence
Yes
Genset Start
Sequence
No Mains Stable? No 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
Auto Input AND

Run With Load
Input
Engine
Start
Sequence
No Loss of Mains
Enabled?
No Gen Stable? OR Loss
of Mains FLAG?
Yes
Yes
Loss of Mains
Detection Active
Open Mains
Breaker Sequence
Mains CB AUX Loss of Mains for

Yes No Close Gen Breaker
>LOM Action
Closed? Sequence
Delay?
No
Yes
Gen CB Aux
Yes
Closed? Run With Load Input
Yes Isoch Load Control
Closed? OR Loss Of
Mains FLAG?
No SET Loss of Mains

FLAG
No
Close Mains
Breaker Sequence
Open Gen Breaker
VIS-063 Sequence
00-04-20
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 4-2b. Single No Parallel Overview Flow Diagram
Woodward 55
G52 LOAD
No Mains Available (Prime Power Application)

Number of Units =
Single
GEN BUS
Mode of Load Transfer = PTs PT
Local
No Parallel PT
Mains
PT Disconne t
Application: Prime Power GEN Connect
CTs

Automatic Manual
Close GCC -Battery
NLT (No Load Test) or Manual 4 Gen Breaker Close Coil
Test Gen Breake +Battery
Trip Manual GTC
No Connection Gen Breaker Trip Coil
Run W/LD
Mains Breaker
Voltage Raise No Connection
Close
1
Voltage Lower Mains Breake
No Connection
Trip
Speed Raise +Battery
Fuel
1 FUEL
Solenoid
Speed Lower Fuel shutoff solenoid
G52a Engine +Battery

Manual
Gen CB Aux Preglow prglw Preglow relay
No Connection Mains CB Aux Engine +Battery Engine Crank Relay

Crank crank
2 Alarm
..
Fault #1
3 . Audible +Battery
Fault #6 Alarm
Audible Alarm
Switch Common
Single No Parallel Prime Power Application
VIS-064
2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation.
4
speed.
Figure 4-3. Single No Parallel Prime Power
56 Woodward
Chapter 5.
Operational Description:
Single Unit Parallel
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.

configured for Single Unit Parallel operation are:
Configuration Menu:
Number of Units: Single
Operating Mode: Mains Parallel

Load Control Mode: Normal or Soft Transfer (depending on
application)

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
Woodward 57
Load Surge: Loss of Mains*
NOTE
*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
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
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
GEN BUS Watt
Mode of Load Transfer = PTs PT Xducer
Mains Parallel Local Mains
PT PT Disconnect
Application: Peak Shaving Set GEN Connect
CTs Process Input
5 4-20mA or 1-5VDC
Auto Automatic Gen Breaker +Battery
Close Manual GCC -Battery
NLT (No Load Test) or Manual4
Gen Breaker Close Coil
Mains Breaker +Battery

Voltage Raise Manual MCC
Close Mains Breaker Close Coil
1
Voltage Lower Mains Breake +Battery
Manual MTC
Trip Mains Breaker Trip Coil
1 Fuel
Solenoid FUEL

Preglow relay
U52a Mains CB Aux Engine +Battery Engine Crank Relay
Crank crank
Process I/E
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm Audible Alarm
Switch Common
Single Mains Parallel Application

Peak Shaving Unit
1 Only required if the speed and voltage 3 Faults #3 through #6 activate immediately, VIS-065
need to be adjusted when Test with programmable delays. 01-03-30
These Fault Inputs have 15 second Transducer input not required
5 if Process Control Mode is
engine reaches crank cutoutt Not used.
speed.
Figure 5-1. Single Unit Parallel Application
Woodward 59
Switch Based Logic

(Single—Parallel)
UTILITY POWER
RUN /w LOAD
PROCESS
AUTO
TEST
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
# = Soft Transfer Setting must be "Enabled"
1 = Contact closed (Utility Power Stable)
X = Contact open or closed (Utility Power Failed or Stable)
60 Woodward
Single Unit Mains Parallel

Test Input Run With Load Auto Input
Input
Engine
Start Engine
Sequence Start Loss of Mains
Sequence No
Enabled?
Generator Unit will not close gen Yes

and breaker (must be in AUTO
Engine mode for breaker control)
Alarms/
Shutdowns Loss of Mains
Loss of Mains for

Mains CB AUX
Yes No >LOM Action
Closed?
Delay?
No
Yes
Close Mains
Breaker Sequence
Yes
Genset Start
Sequence
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
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

VIS-067 Sequence
00-04-20
Stop Genset
Sequence
Figure 5-2b. Single Unit Parallel Overview Flow Diagram
62 Woodward
Single Parallel Unit
Run/Ld & Auto Loss of Mains

No
From Page 2 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
VIS-068
00-04-20
Open Gen Breaker
Sequence
Stop Genset
Sequence
Figure 5-2c. Single Unit Parallel Overview Flow Diagram
Woodward 63
Chapter 6.
Operating Mode:
Multiple No Parallel
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.

configured for Multiple Unit No Parallel operation are:
Configuration Menu:
Number of Units: Multiple
Operating Mode: No Parallel

Load Control Mode: Normal

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
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
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.

NOTE
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
No effect in this mode.
Test Switch
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
G52 LOAD U52

GEN MAINS
Number of Units =
Multiple
GEN BUS
Mode of Load Transfer = PTs PT
No Parallel Local
Mains
PT
Application: Standby Power PT Disconnect
GEN Connect
CTs

RS-485 LON
See Switch Logic Diagram for Details To other Units
Automatic Manual
Close GCC -Battery
Run With Load (closed transition) Trip Manual
GTC
Run W/LD Gen Breaker Trip Co l
4 Mains Breaker +Battery

Voltage Raise Manual MCC
Close Mains Breaker Close Coil
1
Voltage Lower 4 Mains Breaker +Battery
Manual MTC
Fuel
1 FUEL
Solenoid

Preglow relay
U52a Mains CB Aux 4 Engine +Battery Engine Crank Relay
Crank crank
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm
Aud ble Alarm
Switch Common
Multiple No Parallel Application
VIS-069
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 4 must have these inputs.
speed.
Figure 6-1. Multiple Unit No Parallel Application
66 Woodward
Switch Based Logic

(Multiple—No Parallel, Master Control’s Action)
UTILITY POWER
RUN /w LOAD
PROCESS
AUTO
TEST
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
# = 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)
Switch Based Logic

(Multiple—No Parallel, Slave Control’s Action)
RUN /w LOAD
PROCESS
AUTO
TEST
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
Woodward 67
MASTER Multiple Unit No Parallel

Page 1
Input
Engine
Start Engine
Sequence No
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
Breaker Sequence
Set System RUN

with LOAD FLAG
Genset Start
Sequence
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
Sequence Yes
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
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?
No
Gen Stable? OR Loss of
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
FLAG
Close Mains
Breaker Sequence Run With Load Input Isoch Load Control
Closed? OR Loss Of Yes with Sequencing
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
SLAVE Multiple Unit No Parallel
Page 1
Input
Engine
Start Engine
Sequence No
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
Breaker Sequence
Yes
Genset Start
Sequence
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

Auto Input AND
Page 2
Run With Load
Input
Engine
Start
Sequence
Loss of Mains
No
Enabled?
No
Mains FLAG?
Yes
Yes
Loss of Mains
Detection Active
Open Mains
Breaker Sequence
Loss of Mains for

Mains CB AUX
Delay? FLAG?
No
No Yes
Yes
Gen CB Aux
Closed?
Sequence
FLAG
Close Mains
Closed? OR Loss Of Yes
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
Auto Input AND

System Run Page 3
With Load Flag
Engine Start
Sequence
Loss of Mains
No
Enabled?
No
Mains FLAG?
Yes
Yes
Loss of Mains
Detection Active
Open Mains
Breaker Sequence
Loss of Mains for

Mains CB AUX
Delay? FLAG?
No
Yes
No
Yes
Gen CB Aux
Closed?
Sequence
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
Chapter 7.
Operating Mode:
Multiple Parallel
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.

configured Multiple Unit Parallel operation are:
Configuration Menu:
Number of Units: Multiple
Operating Mode: Parallel

Load Control Mode: Normal or Soft Transfer (depending on
application)

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
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

NOTE
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
No action as a single input.
Test
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
G52 LOAD
GEN
No Mains Available (Prime Power Application)

Number of Units =
Multiple
GEN BUS
Mode of Load Transfer = PT
PTs Local
No Parallel Mains
PT
Application: Prime Power PT Disconnect
GEN Connect
CTs

RS-485 LON
Automatic Manual
Close GCC -Battery
Trip Manual
Run With Load GTC
Run W/LD Gen Breaker Trip Co l
Mains Breaker
Voltage Raise No Connection
Close
Voltage Lower Mains Breaker

No Connection
Trip
Fuel
1 FUEL
Solenoid

Preglow relay
No Connection Mains CB Aux Engine +Battery Engine Crank Relay
Crank crank
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm
Aud ble Alarm
Switch Common
Multiple No Parallel Prime Power Application
VIS-075
2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation.
4
speed.
Figure 7-1. Multiple Unit No Parallel Prime Power Application
Woodward 75
G52 LOAD U52

GEN MAINS
Number of Units =
Multiple
GEN BUS Watt
Mains Parallel Local
Mains
PT
Application: Standby Power and PT Disconnect
GEN Connect
Peak Shaving Set CTs Process Input
5 4-20mA or 1-5VDC
RS-485 LON
Automatic Manual
Close GCC -Battery
Run With Load (closed transition) Trip Manual
GTC

6 Manual
Voltage Raise Close Mains Breaker Close Coil
MCC
1
Voltage Lower 6 Mains Breaker +Battery
Manual MTC
Fuel
1 FUEL
Solenoid

Preglow relay
U52a Mains CB Aux 6 +Battery
Engine Engine Crank Relay
Crank crank
Process I/E
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm
Audible Alarm
Switch Common
Multiple Mains Parallel Application
1 Only required if the speed and voltage 4 Manual mode requires manual mains and generator breaker operation.
need to be adjusted when Test Manual mode will operate in KW and Voltage Droop. VIS-076
Transducer input not required 00-04-20
2 Use fault #1 or #2 input if using a 5 if Process Control Mode is
seperate device to sense Low Oil Not used.
delay timers on them after the Only required if "Check Mains Breaker" setpoint
engine reaches crank cutoutt is Enabled. Any unit which may operate as the master
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
G52 LOAD
GEN MAINS
Number of Units =
Multiple
GEN BUS Watt
Mains Parallel Local Mains
PT PT Disconnect
Application:Peak Shaving Set GEN Connect
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
Automatic Close Manual
4 Gen Breaker Close Coil GCC -Battery
NLT (No Load Test) or Manual
Gen Breaker Trip Coil
Run W/LD
Voltage Raise Close MCC
Mains Breaker Close Coil
1
Voltage Lower Mains Breaker +Battery
Trip Manual MTC
Mains Breaker Trip Coil
1 Fuel
Solenoid FUEL

Preglow relay
U52a Mains CB Aux 6 Engine +Battery
Engine Crank Relay
Crank crank
Process I/E
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm Audible Alarm
Switch Common
Multiple Mains Parallel Application
1 Only required if the speed and voltage 4 Manual mode requires manual mains and generator breaker operation.
need to be adjusted when Test Manual mode will operate in KW and Voltage Droop.
or Manual is selected. VIS-077
2 Use fault #1 or #2 input if using a Transducer input not required 01-03-30
5 if Process Control Mode is
seperate device to sense Low Oil
Pressure or High Water Temp. Not used.
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
speed. 6 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
Switch Based Logic

(Multiple—Parallel, Master Control’s Action)
UTILITY POWER
RUN /w LOAD
PROCESS
AUTO
TEST
E
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
** = 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)
Switch Based Logic

(Multiple—Parallel, Slave Control’s Action)
RUN /w LOAD
PROCESS
AUTO
TEST
T
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
MASTER Multiple Unit Utility Parallel

Test Input Run With Load Page 1 Auto Input
Input
Engine
Start Engine
Sequence No
Enabled?

Alarms/
Loss of Mains for

Mains CB AUX
Yes No >LOM Action
Closed?
Delay?
No
Yes
Mains Breaker
Reclose Sequence Open Mains
Breaker Sequence
Yes
Set System RUN

with Load Flag and
Genset Start
Sequence
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
00-04-20
Close Mains
Breaker Sequence
Remove System
Run with Load Flag
and
Unload Ramp

Sequence Sequence
Figure 7-4a. Master Multiple Parallel Process Control Flow Diagram
Woodward 79
Auto Input AND MASTER Multiple Unit Utility Parallel

Run With Load Page 2
Input Set System Run with
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?
Closed?
No
Yes No
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

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

LOM Flag? Yes and auto
sequencing
No
Close Mains
Breaker Sequence
VIS-080
00-04-24
No
Run/LD
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

Page 4
Auto Input AND
Run With Load
Input AND
Process Set System Run with
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?
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

Page 5
Auto Input AND

Run With Load
Input AND Test
Set System Run with
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?
Closed?
No
Yes No
Mains Breaker
Reclose Sequence Soft Transfer Mode
Test Input Closed? Yes
Enabled
Remove System
Run with Load Flag
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

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
Mains Breaker Run with Load
Close Sequence Flage and Unload
Ramp
Base Load Control

Open Gen Breaker
Sequence
VIS-083 Stop Genset

00-04-24 Sequence
Figure 7-4f. Master Multiple Parallel Process Control Flow Diagram
84 Woodward
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?
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
FLAG
Soft Transfer Mode

Open Gen Breaker Test Input Closed? Yes
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

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
SLAVE Multiple Unit Mains Parallel
Test Input Run With Load Page1 Auto Input
Input
Engine
Start Engine
Sequence No
Enabled?

Alarms/
Loss of Mains for

Mains CB AUX
Yes No >LOM Action
Closed?
Delay?
No
Yes
Mains Breaker
Breaker Sequence
Yes
Genset Start
Sequence
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

Sequence Sequence
Figure 7-5a. Slave Multiple Parallel Process Control Flow Diagram
Woodward 87

Page 2
Auto Input AND
Run With Load
Input
Engine
Start
Sequence
Loss of Mains
No
Enabled?
No
Mains FLAG?
Yes
Yes
Loss of Mains
Detection Active
Open Mains
Breaker Sequence
Loss of Mains for

Mains CB AUX
Delay? FLAG?
No
Yes
No
Yes
Gen CB Aux
Closed?
Sequence
FLAG
Close Mains
Closed? OR Loss Of Yes
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
Auto Input AND

System Run With Page 3
Load Flag
Engine Start
Sequence
Loss of Mains
No
Enabled?
No
Mains FLAG?
Yes
Yes
Loss of Mains
Detection Active
Open Mains
Breaker Sequence
Loss of Mains for

Mains CB AUX
Delay? FLAG?
No
Yes
No
Yes
Gen CB Aux
Closed?
Sequence
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
Test Input Run With Load Page1 Auto Input
Input
Engine
Start Engine
Sequence No
Enabled?

Alarms/
Loss of Mains for

Mains CB AUX
Yes No >LOM Action
Closed?
Delay?
No
Yes
Mains Breaker
Breaker Sequence
Yes
Genset Start
Sequence
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

Sequence Sequence
Figure 7-5d. Slave Multiple Parallel Process Control Flow Diagram
90 Woodward
Auto Input AND SLAVE Multiple Unit Mains Parallel

Page 2
Run With Load
Input
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?
Closed?
No
Yes No
Mains Breaker
Reclose Sequence
Unload Ramp
SET Loss of Mains
FLAG
Open Gen Breaker

Sequence
VIS-090 Stop Genset

00-04-24 Sequence
Figure 7-5e. Slave Multiple Parallel Process Control Flow Diagram
Woodward 91

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
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

Page 4
Auto Input AND

Run With Load
Input AND
Process
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?
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

Page 5
Auto Input AND

Run With Load
Input AND Test
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?
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
SLAVE Mul iple Unit Mains Parallel

Page 6
From Gen KW = Baseload

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

Page 7
Run With Load Input
AND Process input AND
Test Input
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?
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

Open Gen Breaker Test Input Closed? Yes
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

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

00-04-24 Sequence
Figure 7-5l. Slave Multiple Parallel Process Control Flow Diagram
Woodward 97

Page 9
System Run With
Load Flag
Start Page #3
Sequence
No Loss of Mains
Enabled?
No Gen Stable?
Yes
Yes
Loss of Mains
Detection Active
Close Gen
Breaker
Sequence
Yes Mains CB AUX No Loss of Mains for System

Closed? >LOM Action Run with Load Mains Breaker Base Load Master Process
Yes No
Delay? Flag OR Run With Yes Closed? Control Flag?
Load
Input Closed?
No
Yes
Yes No
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
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 >

Alarm Flag Yes Crank Attempt Setpoint
?
No
Energize Preglow Output
Preglow Timer No
Expired?
Yes
Energize Fuel Solenoid Output

Energize Crank Output
MPU =>
No Crank Timer No Crank Cutout Speed
Expired? ?
Yes Yes
Increment Crank Set ENGINE RUNNING FLAG = TRUE

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
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
timer No
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
Sync Timeout
Time Expired? No Gen Breaker Close Sequence
Single No Mains Parallel Unit
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 ENABLED? Set Sync
Reclose Alarm
YES
Energize Breaker
Close Command No Breaker Logic?
YES
Energize Breaker
Close Command
Energize Breaker
Open Command
Gen CB Aux Gen Breaker Hold No

Input? Timer Expired?
YES YES
De-Energize
Gen Breaker Hold Breaker Close
No Timer Expired? No Command
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
Gen Breaker Close Sequence

Sync Timeout
Time Expired? No Single Mains Parallel Unit
YES
Force Sync Close Gen Breaker
Mode = OFF FLAG = TRUE
Initialize Timers,
Counters
Set Sync
Reclose Alarm
Force Sync Close Attempts <

Mode = OFF No Close Attempts Setpoint?
YES Sync Mode = Run?

Set Sync Switch PT input to Adjust Speed
Reclose Alarm Bus Sensing NO Bias
Sync Mode =Permissive?

Mains CB Aux = TRUE?
Voltage Matching NO
Enabled?
Dead Bus?
No (Bus PT Input < 40VAC) Adjust Volt
Bias
YES
No Dead Bus Closing

ENABLED? Phase <=
YES Phase Window?
Energize Breaker
Close Command No Breaker Logic?
Voltage Error
YES <= Voltage Window?
Energize Breaker
Close Command
Sync Mode = Check?

Energize Breaker
Open Command
Gen CB Aux
Input? No Gen Breaker Hold
Timer Expired? No
YES YES
De-Energize
Breaker Close
No Gen Breaker Hold
Timer Expired?
Command
YES
Sync Successful
Set Mode Flag Breaker Logic? No
= IN SYNC
YES
De-Energize
Breaker Open
Command
VIS-101
00-04-25
Increment Close
Attempts
Reset Close
Timer
Start Reclose
Delay Timer

(Single Mains Parallel)
102 Woodward
NO
Sync Timeout
Time Expired? Gen Breaker Close Sequence
YES Multiple No Mains Parallel Unit
Force Sync
Mode = OFF
Close Gen Breaker
FLAG = TRUE
Set Sync Initialize Timers,

Reclose Alarm Counters
Force Sync NO Close Attempts <

Mode = OFF Close Attempts Setpoint?
YES YES
Set Sync Switch PT input to Sync Mode = Run?
Reclose Alarm Bus Sensing Adjust Speed
NO Bias
Mains Breaker OPEN YES YES

Sync Mode =Permissive?
and Live (>40VAC)
Bus? NO
Voltage Matching
NO
NO Enabled?
YES
NO Dead Bus?
(Bus PT Input < 40VAC) Adjust Volt
Bias
YES
NO Dead Bus Closing

ENABLED?
Phase <= Phase NO
YES Window?
NO
Dead Bus Token YES
Granted?
Voltage Error NO
YES <= Voltage Window?
YES
Check Mode? YES
YES
NO Sync Mode = Check?
Energize Breaker NO
Close Command Breaker Logic? NO
YES
Energize Breaker
Close Command
Energize Breaker
Open Command
NO
NO Gen Breaker Hold
Gen CB Aux Timer Expired?
Input?
YES
YES
De-Energize
Breaker Close
NO Gen Breaker Hold Command
Timer Expired?
YES NO
Sync Successful Breaker Logic?
Set Mode Flag
= IN SYNC
YES
De-Energize
Breaker Open
Command
Increment Close
Attempts
VIS-102 Reset Close
00-04-26 Timer
Start Reclose
Delay Timer

(Multiple No Mains Parallel)
Woodward 103
Mains Breaker Open Sequence
Open Mains
NO Breaker Flag
Sync Timeout
Time Expired?
YES
Initialize Timers
Set Sync
Reclose Alarm
Note: Sync Timeout Alarm ONLY.

Unit will continue to try opening
Mains Breaker until the Check Mains NO
Mains CB Aux input goes open. Breaker =
Sync Timeout will Indicate failure to ENABLED?
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
Parallel Mains Breaker Close Diagram

Close Mains
Breaker Flag
Initialize Timers,
Counters
NO Check Mains
Breaker =
Enabled?
YES
NO
Unit in Auto?
YES
Breaker YES Close Attempts >

Logic? Close Attempts
Setpoint?
YES
NO
Energize Mains De-Energize Mains
Breaker Close
Command Breaker Close Generator YES Phase <= NO Sync Mode = NO
Phase Window PERMISSIVE?
CB Aux?
NO YES
YES Adjust
NO Mains Speed
Monitor Bias
Synchro OFF, Stable? Mains
Reclose Alarm
PT
YES NO
Voltage <=
NO
Sync Mode =
Monitor Bus Voltage Window? PERMISSIVE?
Note: To Clear Mains Reclose Failure, PT
Cycle Run W/ Load Input YES
YES
from OFF to ON to OFF. Voltage Matching
NO
Dead NO = ENABLED?
Bus?
YES
YES
Adjust Volt
Sync YES
Bias
Check?
NO
De-Energize YES
Breaker NO Mains Breaker
Close
Sync Mode =
CHECK?
Logic Command
YES NO
YES In Phase
De-Energize Mains
Breaker Open Window for
Command => Dwell Time?
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

Delay Hold Timer
Expired?
Decrement NO
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
Close Mains Parallel Mains Breaker Re-close Diagram

Breaker Flag
(occurs if mains opens due to external function)
Initialize Timers,
Counters
NO Check Mains
Breaker
Setpoint =Enabled?
YES
YES
Unit in Test?
NO
YES
Unit in Run?
NO
NO
Unit in Auto?
YES
Breaker YES Close Attempts >

Logic? Close Attempts Setpoin
?
YES
NO
Energize Mains De-Energize
Breaker Mains YES YES Phase <= NO Sync Mode = NO
Close Breaker Close Generator CB Master Unit? Phase Window PERMISSIVE?
Command Aux?
NO
YES YES Adjust System
Speed
NO Mains Bias
Stable? Monitor
Synchro OFF, Mains
Reclose Alarm PT
YES
Monitor Bus Voltage < NO Sync Mode = NO
Voltage PERMISSIVE?
PT Window?
Note: To Clear Mains Reclose Failure, YES

YES
Cycle Run W/ Load Input Follow Master Voltage
Matching NO
Dead NO Speed
from OFF to ON to OFF. and Voltage
= ENABLED?
Bus?
Bias
YES
YES
Adjust System
Sync YES Volt Bias
Check?
NO
De-Energize
Mains Breaker YES
Breaker Sync Mode =
Close CHECK?
Logic NO Command
NO
YES
De-Energize Mains YES
Breaker Open In Phase Window for
Command => Dwell Time?
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?
Decrement NO
Delay
NO Reclose Delay VIS-105

Timer Expired? 00-04-26
YES
Increment Close
Attempts
Figure 7-13. Mains Breaker Reclose Sequence

(Mains Parallel)
106 Woodward
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
?
YES NO
Energize Mains De-Energize Mains YES
Breaker Close Breaker Close Generator CB Aux? Set Gen Breaker
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.
Dead Bus? NO
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
00-04-26 Decrement Hold Timer
Sync Successful
Start Reclose Delay YES Hold Timer

Expired?
NO
Decrement Delay
NO Reclose Delay
Timer Expired?
YES
Increment Close
Attempts
Figure 7-14. Mains Breaker Reclose Sequence

(No Parallel)
Woodward 107
Switch Based Logic

(Speed Raise/Lower Contact Functionality)
GEN BRKR
PROCESS
TIE BRKR
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)
GEN BRKR
TIEBREAKER
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
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
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
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
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
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
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
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
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
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)
00015 BW Not Used
00016 BW Commit All Alarms

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
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)
10034 BR SYNC TIMEOUT Status
10035 BR SYNC RECLOSE Status
10036 BR CRANK_FAIL Status
10037 BR VOLTAGE_RANGE Status
10038 BR OVERSPEED Status
10039 BR OVERCURRENT Status
10040 BR REVERSE POWER Status
10041 BR LOSS OF EXCITATION Status
10042 BR SPEED_FREQ_MISMATCH Status
10043 BR H2O_HIGH_LIMIT Status
10044 BR H2O_LOW_LIMIT Status
10045 BR OIL PRESS HIGH LIMIT Status
10046 BR OIL PRESS LOW LIMIT Status
10047 BR BATT VOLT LOW LIMIT Status
10048 BR BATT VOLT HIGH LIMIT Status
10049 BR GEN_VOLT_LOW_LIMIT Status
10050 BR GEN_VOLT_HIGH_LIMIT Status
10051 BR GEN_FREQ_HIGH_LIMIT Status
10052 BR GEN FREQ LOW LIMIT Status
10053 BR LOAD HIGH LIMIT Status
10054 BR LOAD LOW LIMIT Status
10055 BR PROCESS_HIGH_LIMIT Status
10056 BR PROCESS_LOW_LIMIT Status
10057 BR REMOTE_FAULT1 Status
10058 BR REMOTE FAULT2 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.

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
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
30045 AR REMOTE_FAULT3 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
30070 AR Address of Master Unit.
30071 AR Not Used
30072 AR Engine State.
30073 AR Synchroscope Phase Angle

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
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
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
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.
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
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
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
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward 125
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
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
Appendix B.
Speed Bias Connections
EGCP-2 EPG
Speed Bias Output
SPEED
CONTROL
+ 73
- 74
EGCP-2 To EPG Speed Control Wiring and

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

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

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

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

VIS-127a
00-06-20

Common FLO-TECH Speed Control Part Numbers:

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

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

VIS-128a
00-06-20

Common Pro-ACT Speed Control Part Numbers:

9905-462, 9905-463
Woodward 129
EGCP-2 CSC
+ 73 11 +
- 74 12 -
EGCP-2 To CSC Speed Control Wiring and

VIS-129a
00-06-20

EGCP-2 2301A LSSC

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

Settings
VIS-130a
00-06-20

NOTE: 2301A LSSC must have terminal 14 powered for

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

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

Settings
VIS-131a
00-06-20

Common 701 and 701A Speed Control Part Numbers:

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

Settings
VIS-132a
00-06-20

Common 721 Speed Control Part Numbers:

9905-291, 9907-206, 9907-207
Woodward 131
EGCP-2 723 or 723 Plus

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

Settings
VIS-133a
00-06-20

Common 723 or 723 Plus Speed Control Part Numbers:

9907-031, 8280-412
132 Woodward
Woodward 133
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

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Installation (Set Builder) Manual

8406-115, 150–300 Vac PT Input, 9–32 Vdc

Manual 26076 (Revision F)

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

Revisions—Text changes are indicated by a black line alongside the text.

APPENDIX A. CONNECTOR INFORMATION .................................................126

Illustrations and Tables

Figure 2-1. EGCP-2 Interface Connections ...........................................................4

Illustrations and Tables

Illustrations and Tables

Table 9-1. Examples of Modbus Control Mode Switching Logic....................... 114

WARNING—TRAINED PERSONNEL/HIGH VOLTAGE

North American Compliance:

General Installation and Operation Notes and Warnings

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

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

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

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

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

Control Electrical Ratings

Real (kW) Load Control

Reactive (KVAR) Control

Automatic Generator Sequencing

Generator Protective Features

Engine Protective Features

Watt Operator Control Panel

Run With Load

Figure 2-1. EGCP-2 Interface Connections

Water Temperature MPU Speed Bias Voltage Bias

Figure 2-2. Operator Interface

ALARM/EVENT LOG KEYS:

The ALARM/EVENT key is used to access the Event

The ALARM CLEAR key is used to acknowledge and

If the Alarm mode is Visual or Warning –

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

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

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

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

STATUS and CONFIGURATION KEYS:

STATUS MENU KEYS:

The SYSTEM STATUS key, when pressed displays the system

The ENGINE STATUS key , when pressed displays status

The GEN STATUS key shows three phase generator

The SYNC STATUS key shows status information regarding the

The KW LOAD STATUS key, when pressed, shows the

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

The SEQUENCE STATUS key provides sequencing

The ATS STATUS key, when pressed, displays the status

• 8928-301—EGCP-2 connector kit. Contains all of the mating terminal blocks

Figure 2-3. Physical Outline with Dimensions of EGCP-2

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

Grounding for Protection Against Electric Shock

Recommended Grounding Practices

Ground Bonding Conductor

TB 5 TB 6 TB7 TB8 TB9

Figure 3-2. Recommended Single Point Grounding Scheme