WOODWARD EGCP-3 Engine Generator Control Package LS (Load Sharing)

General Information 

Introduction

This manual describes the Woodward EGCP-3 Engine Generator Control Package, Load Sharing (LS) model, part number 8406-113. It provides description, operation, tuning, and troubleshooting information for EGCP-3 digital controls. The details on installation, wiring, communication, Regulatory Notes and Warnings are in the EGCP-3 Installation Manual 26122. The EGCP-3 LS is intended for power generator applications where multiple control/generators will supply an isolated bus, or operate in parallel with a Mains (Utility) bus. The EGCP-3 can perform engine start/stop sequencing. For isolated load operation, the control will operate in isochronous speed control. For a multiple engine bus, up to 16 generators can share load, operate in BaseLoad, or process control modes.

The generator should be equipped with a sync check relay, circuit breaker, and other fast-acting protective relays as required by local codes and practices to protect against damage to the generator with possible personal injury, loss of life, or property damage.

The overspeed shutdown device, sync check relay, circuit breaker, and other fast-acting protective relays must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.

Protective Earth (PE) must be connected to the termination point on the backside of the unit next to the label with the  symbol (or 1 of 3 other like termination points without label) to reduce the risk of electric shock. 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 4 mm² (12 AWG).

HIGH VOLTAGE—The calibration and checkout procedure should only be performed by authorized personnel knowledgeable of the risks posed by live electrical equipment.

The installation must include the following: 

  The power supply mains should be properly fused according to the installation instructions and the appropriate wiring requirements. 

  A switch or circuit breaker must be included in the building installation in close proximity to the equipment and within easy reach of the operator, and must be clearly marked as the disconnecting device for the equipment. The switch or circuit breaker will only remove power to the unit—hazardous voltages may still be connected to other terminals on the unit.

Application and Functions

The EGCP-3 control is a microprocessor-based generator load control designed for use with a separate speed control and an automatic voltage regulator to provide synchronizing, paralleling, loading and unloading. All transitions between EGCP-3 functions are coordinated to provide smooth operation.

EGCP-3 LS Functions:

Display/Keypad Interface for local setup/monitoring

Engine Start/Stop Sequence Control

Monitor of Generator and Bus power

Unit sequencing and individual unit protection

Engine Protection and Monitoring

Synchronizer with speed, phase, voltage matching, token passing for dead bus closure, and multiple unit synchronizing

KW Control with automatic generator loading and unloading for bumpless load transfer

Droop, BaseLoad, Isochronous, and Isochronous load sharing control capability

Frequency and voltage trimming in Isochronous mode

Communication bus between Master Control and other LS units

Master/Slave Process control for cogeneration, import/export, pressure control, or other processes

KVAR/PF Control and bus /PF sharing

Individual generator stable timing

Built in diagnostics

Generator and Bus Protective Relaying

Generator Power & Energy Metering

Modbus® * and ServLink communications for remote HMI/PLC connections

HMI/Front Panel Display

The EGCP-3 has a keypad and two 4-line display panels on the front cabinet mounted chassis. The display can be used to configure and set up the control for site specific requirements. The display is also used in normal operating service to monitor operation and view alarm data. All functions performed and parameters monitored by the front panel are also available through the three serial ports. These ports can be configured to use Woodward Watch Window software, an external HMI and Modbus communication, or ServLink DDE software.

Engine Control

The EGCP-3 control performs stop and start logic for both gas and diesel reciprocating engines. The starting logic includes: pre-glow capability, separate enabling for ignition, fuel pump/FSOV logic, and a configurable pause at idle. The engine stop function includes: controlled cooldown, soft shutdown logic and emergency stop logic. The start and stop logic includes closing and opening of generator breaker. Typical protections such as over speed, coolant temperature, oil pressure, and battery voltage are also provided. Configurable digital and analog fault inputs are provided for use with temperature, pressure, or level switches. All the faults may be disabled when not needed. In addition to automatic modes, Manual start and stop for the engine is possible. The circuit breaker can be closed manually to load the generator in the selected load control mode (Process, Droop, BaseLoad, Isochronous) when manual control is desired.