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WOODWARD
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EGCP-3
Engine Generator
Control Package
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EGCP-3 Engine-Generator Control
• A fully integrated generator control and engine management package
– Automatic sequencing
– Gen-set synchronizing
– Real kW load control
– Reactive kVAR/PF control
– Local Display of Gen-Set Data
– Utility Monitoring and protection
– Engine control and protection
– Generator control and protection
– Automatic Peaking timers and Load Management control
– Automatic Transfer Switch functions
– Load Share with other EGCP-3 or DSLC
– Local display and keypad
4
Application Options
• LS – Load Share LS
– Single/Multiple unit isolated
– Multiple unit parallel to mains with MC
• MC – Master Controller
MC
– Mains tie breaker controller
5
Application Options LS
AVR AVR
EGCP-3 EGCP-3
LS Bus TIE LS
LON
Load Load
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Auto-Start Function LS
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Isolated Load Control
• Isochronous Load Sharing of up to 16 units
– Real and Reactive Load Sharing
• Droop Load Control Capability (as a backup)
• Automatic start/stop of units based on configurable bus
load levels
• Configurable Speed Bias Outputs
– Software Selectable:
• Woodward 3 Vdc
• DDEC 0.5-4.5 Vdc
• Cat PWM, 500 Hz, 5 Vpk
• Barber-Coleman Discrete Raise/Lower
• Waukesha 4-20 mA
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Real Power Load Control
• Integrating Base Load Control active when parallel to mains
– May also be activated during ISOC to control load on a single unit
• Process Control (Import/Export, Temperature/Pressure)
– Import/Export on MC uses PT and CT readings
– Temperature/Pressure on MC/LS uses analog inputs for control
• Base Load and Process References may be altered from the internal
configured setpoint
– Remote Raise/Lower commands (contact inputs)
– Remote reference level control via Analog Input or Modbus
• May force unload via contact input to the Unload Trip point
• Reset to default load command (contact input)
9
Reactive Load Control
• VAR or Power Factor Load Control in “Utility Parallel”
operation
• Power Factor Sharing in Load Share mode
• VAR/PF reference may be altered from the internally
configured setpoint
– Remote Raise/Lower commands (contact inputs)
– Remote VAR/PF reference level control via Analog Input or
Modbus
– Manual Voltage Control Capability
• Configurable Voltage Bias Signals
– 1, 3, 9 Vdc, 4-20mA, or Discrete Raise/Lower
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Synchronizing
• Phase Match or Slip Frequency Synchronization
• 3 Mode Automatic Operation or Manual
– Run (Auto Sync, Auto Close)
– Check (Auto Sync, Manual Close)
– Permissive (Sync Check)
– Manual Synchronization Capability
• Voltage Matching
• Dead Bus Closing
• Synch Timer
• Reclose Attempt/Timer
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Engine Monitoring & Protection
The EGCP3 is equipped for engine protection. This is a
function of the Cummins system on the Bourbon 254L
and 654M vessels. EPD has a setpoint for Overspeed. The
EGCP3 is not monitoring the engine for shutdowns.
Overspeed
– Alarm/Shutdown settings
EPD Alarm Setpoint 2050rpm
Alarm action: Hard Shutdown
VMS Alarm Setpoint 2003rpm
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Generator Ratings
The following setting are entered into the EGCP3 to define the generator for
GPA 254L Vessels. This information is entered in the “First Time Configuration”
Menu.
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Generator Protection - Voltage
3 Phase Generator Voltage Monitoring
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Generator Protection - Frequency
Generator Frequency Monitoring
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Generator Protection - Frequency
Generator 3 Phase Current Monitoring
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Generator Protection
• 3 Phase Generator Voltage Monitoring
– Over/Under Voltage Alarm & Pre-Alarm Settings
Over Voltage Pre-Alarm
– Over/Under Frequency Alarm & Pre-Alarm Settings
• 3 Phase Generator Current Monitoring
– Over Current Alarm & Pre-Alarm Settings
– Current Imbalance Alarm & Pre-Alarm Settings
• 3 Phase Generator Power Monitoring
– Reverse Power Alarm & Pre-Alarm Settings
– Over Power Alarm & Pre-Alarm Settings
– Reverse VAR Alarm & Pre-Alarm Settings (Loss of Excitation)
– Over VAR Alarm & Pre-Alarm Settings
• 3 Phase Paralleling Monitoring
– Negative Phase Sequence Voltage Alarm & Pre-Alarm Settings
– Negative Phase Sequence Current Alarm & Pre-Alarm Settings
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EGCP-3 Hardware Platform
11” 9.25”
13” 5.3”
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EGCP-3 Customer Interface
• Two, 20-character by 4-line LCD Displays
• One Membrane Keypad w/ Tactile Feedback
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EGCP-3 Hardware Profile
• The EGCP-3 control is based on Woodward’s modular Atlas
hardware platform for proven reliability and unsurpassed
adaptability
Power Supply
Board
PowerSense Board
Power Bus
PC104 Bus
SmartCore
Board
Displays and Keypad
Next Hardware
Section 20
Main “SmartCore” Board
• Main “SmartCore” Board
– 68332 application microprocessor (32-bit)
– 68302 communications microprocessor (32-bit)
• Magnetic Pick-up (or Proximity) Input for Speed Signal
• 4 Analog Inputs (configurable for 4-20mA or 1-5Vdc)
• 16 Discrete Inputs (24 Vdc nominal power)
– Isolated +24 Vdc supply output provided to power the
discrete inputs
• 4 Analog Output signals (4-20 mA)
• 3 Serial ports
– 2 x RS-232, RS-422 or RS-485, software configurable
– 1 x RS-232 only
• Real time clock with 10 year battery
• Flash upgradeable
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PowerSense Board
• PowerSense Board
– 3-Phase PT inputs for generator and bus
• 120/240/277 Vac (software selectable)
– 3-Phase CT Inputs for generator and bus
• 0-5 Amps (GPA254L uses 3200 / 5 CT’s)
– Embedded P for all generator waveforms
– Speed Bias Output (3 Vdc, 0-5 Vdc, 4-20 mA, or 500 Hz PWM)
– Voltage Bias Output (1, 3Vdc, 9 Vdc, or 4-20 mA)
– 1 LON Port (1.25 MBPS) – DSLC Compatible
• All listed I/O is independently isolated
• Factory flash upgradeable
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Communications
• HMI / PLC Interface Network
– Multi-Drop, Multi-Unit access
– Modbus RTU slave
– RS232 / 422 / 485 configurable
• HMI / PC Interface Network
– Multi-Drop, Multi-Unit access
– ServLink DDE client or Modbus RTU slave
– RS232 / 422 / 485 configurable
• Configuration Interface
– ServLink (to be used with WatchWindows)
– RS232
• Load Sharing Network
– Inter-control communications for Start/Stop, Process control, status
information, load share
– LON based
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EGCP-3 Local Configuration
• Right side display also used for configuration interface and
alarm log presentation
– Password needed for configuration and alarm reset
– Provides access to majority of setpoints
• 4 Levels of password
– Monitor (no password – access to status screens)
– Operator (configurable password – may reset alarms)
– Supervisor (configurable password – set peaking schedules,
day/day of week/time)
– Technician (configurable password – set all configuration items
except kw-hrs and engine hour accumulators)
– Factory (configurable password – full access)
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Service Tool
• Watch Window Standard
– Windows Based Service tool for troubleshooting, variable
monitoring and tuning
– Uses Servlink DDE interface
– Configuration Tool
– Upload/Download Tunables
• Watch Window Professional
– All above plus:
– Application Program Download
– Access to additional setpoints
– Debug capability
• No passwords required for configuration via Watch
Windows
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EGCP-3 Local HMI
STATUS CONFIG
SCROLL
I/O SYNC KW LOAD
ALARM CLEAR
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Operator Interface
• 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 Active Alarms and the
Alarm History Event log. If pressed once, the active alarms 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 active alarm list. The Alarm History Event log will store up to
100 events, as more events happen the oldest alarms will be
dropped off to make room for the newer events. These events will
be cleared on a reset of power.
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Alarm / Event Log Screen
• The screen displays the Status Display Alarm Information
following information:
• Alarm Name.
• Hour and Minute of the
alarm occurrence. Loadshare (LS)
• Month and Day of the
Alarms: 8 Unit: 1 SPEED RANGE
alarm occurrence.
Bus - - Gen -- 03/01/14 15:42:56
Engine: OFF GEN BKR SHNT TRP ERR
State: OFF 03/01/14 15:41:11
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Operator Interface
• NAVIGATION and ADJUSTMENT KEYS:
The SCROLL KEY is used to move the cursor up, down , left and right. It also is used to
SCROLL increment and decrement values while in the configuration menus.
ESC
The ESCAPE KEY is used to move upwards (out of) the configuration menu levels.
ENTER
The ENTER KEY is used to move downwards (into) the configuration menu levels.
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Operator Interface
• STATUS and CONFIGURATION KEYS:
STATUS 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
i generator set operation. See the STATUS MENU buttons, below for details on the
various status keys. There are no adjustment values in the status
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.
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Configuration Screen
• The screen displays the
following information: Status Display Configuration Menus
• Configuration Menus.
Loadshare (LS)
Alarms: 8 Unit: 1 First Time Startup
Bus - - Gen -- Shutdowns and Alarms
Engine: OFF Engine Protection
State: OFF Gen Protection
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Operator Interface
• STATUS MENU KEYS:
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. Units that do not control engines (MC) will not provide status
information in this screen.
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System Status Screen One
• The screen displays some of the
following information:
• Number of active alarms. Loadshare – 2 Screens
• The network address. Master Control – 2 Screens
• The Mains Condition
• (- -) Mains Off Loadshare (LS)
• (++) Mains Active
• The Generator Condition Alarms: 0 Unit: 1 kW: 0 60.0 Hz
• (- -) Gen Off Bus ++ Gen ++ PF: 1.00LG
• (++) Gen Active Engine: OFF MW-hrs Run-Time
• Engine Operating State. State: OFF 30.23 5.23
• EGCP-3 Operating State.
• Load Control State. Master Control (MC)
• Total KW load on Gen.
Alarms: 0 Unit: 16 kW: 10.00 60.0 Hz
• Frequency of Gen.
Mains ++Bus ++ PF: 1.00LG
• Total Accumulated KW Hours.
Mode: OFF 15:43 Battery
• Total Accumulated Run Time.
State: OFF 11-Sept-2002 24.3V
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Engine Status Screen
• The screen displays some of
the following information:
• 24 Hour Clock Readout.
Loadshare – 2 Screens
• Date (MM-DD).
Master Control – 0 Screens
• Engine Control State. Loadshare (LS)
• Engine RPM.
16:49 14-Jan 2003 H2O Temp: 40.3 deg F
• Battery Voltage.
Engine: OFF Oil Press : 0.0 PSI
• Water Temperature in C or RPM : 0 Gen Breaker: OPEN
F. Battery Volts: 24.4V GEN: - -
• Oil Pressure In Bar or PSI.
• Gen Breaker Status.
Master Control (MC)
• The Generator Condition MASTER UNIT
• (- -) Gen Off
• (++) Gen Active
NO ENGINE STATUS
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Operator Interface
• STATUS MENU KEYS:
GEN
The GEN STATUS key shows three phase generator, bus or mains (depending on EGCP3
type) 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, communication and current system
configuration.
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Generator Status Screen
• The screen displays some
of the following
information:
Loadshare – 8 Screens
Master Control – 8 Screens
• Three Phase KVA
• Three Phase KW
Loadshare (LS)
• Three Phase KVAR
GEN 34.644kVA BUS 34.644kVA
• Volts per each Phase
483.23 VLL 27.434kW 483.23 VLL 27.434kW
• Amps per each Phase 278.99 VLN 21.156kVR 278.99 VLN 21.156kVR
• PF for each Phase 41.392 A PF:0.79LG 41.392 A PF:0.79LG
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Input / Output (I/O) Screen
• The screen displays some
of the following
information:
Loadshare – 3 Screens
Master Control – 3 Screens
• Discrete Inputs 1 – 16.
(X=closed)
Loadshare (LS)
• Discrete Outputs 1 – 12.
(X=energized) DISCRETE I/O Volt Bias : 0.0%
1234567890123456 Speed Bias : 100.0%
• Voltage Bias Percentage.
X X IN Load Ref: - - -
• Speed Bias Percentage. XXX- - - - OUT LD Mode: ISOCH
• System Status Master Control (MC)
• Analog In/Out Status PF Cmd: 0.13
DISCRETE I/O
1234567890123456 Load Cmd: 20.2
X X IN Load Ref: 33.2%
XXX- - - - OUT LD Mode: BASELOAD
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(I/O) Screen – EPD Inputs
DI 1 – Emergency Stop DI 9 – Speed Lower
DI 2 – Auto Mode DI 10 – LON Failure
DI 3 – Test (Not Used) DI 11 – Engine Fault (Cummings Fault)
DI 4 – Run W/ Load DI 12 – Bus Tie Closed
DI 5 – CB Aux (Closed FB) DI 13 – Spare Input
DI 6 – Voltage Raise DI 14 – Spare Input
DI 7 – Voltage Lower DI 15 – Spare Input
DI 8 – Speed Raise DI 16 – Spare Input
Loadshare (LS)
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(I/O) Screen – EPD Outputs
DO 1 – CB Close DO 7 – Starter
DO 2 – CB Open DO 8 – Spare Output
DO 3 – Run Rated DO 9 – Spare
DO 4 – Fault Shutdown (to Cummings) DO 10 – LON Failure
DO 5 – Fuel Solenoid DO 11 – Spare Output
DO 6 – Spare Output DO 12 – Spare Output
Loadshare (LS)
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Operator Interface
• STATUS MENU KEYS:
SYNC
The SYNC STATUS key shows status information regarding current breaker
synchronization.
KW LOAD
The KW LOAD STATUS key, when pressed, shows the status information for the Real load
control of the EGCP-3.
PF / KVAR
The PF/KVAR STATUS key, when pressed, shows the status information for the Reactive
load control of the EGCP-3.
40
Synchronizer Status Screen
• The screen displays some of the
following information:
• Slip Frequency In Hertz. Loadshare – 2 Screens
• Phase Angle in degrees. Master Control – 2 Screens
• Voltage Differential in
Percent. Loadshare (LS)
• Dead Bus Status. Synchro: RUN/AUTO
Slip Phase Volts
• Synchronizer State. 0.12 Hz 20.43deg 0.23% VB: 23.4% SB:-10.2%
• Voltage Bias Output in ++ -- ++ Gen Avg: 482.34 VLL
Percent. Bus Dead? True Bus Avg: 480.21 VLL
• Speed Bias Output in
Percent.
Master Control (MC)
• Bus Voltages. Slip Phase Volts Synchro: RUN/AUTO
0.12 Hz 20.43Hz 0.23% VB: 23.4% SB:-10.2%
++ -- ++ Bus Avg: 482.34 VLL
Main Dead? False Main Avg: 480.21 VLL
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KW Load Status Screen
• The screen displays some of the
following information:
• Loads on buses
Loadshare – 1 Screen
• Load References
Master Control – 4 Screens
• Calculated System Load.
(Load Sharing Only). Loadshare (LS)
• Load Control State. Gen Load : 240.24kW Proc Actual : 0.000%
• Process Reference in mA. Load Ref : 245.65kW Process Ref: 0.000%
%Rating: 75.4% LD Mode : ISOCH
• Load modes and states
System Load: 77.1% State: AT REFERENCE
• Demand values
• Demand and TOD start Master Control (MC)
information
Mains Load : 230.67kW Proc Actual : 0.000%
• Load shed information Load Ref : 229.34kW Process Ref: 0.000%
Demand: 185.56kVA LD Mode : BASELOAD
Max Demand: 500.20kVA State: AT REFERENCE
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PF / KVAR Status Screen
• The screen displays the
following information:
Loadshare – 1 Screens
• PF or VAR Mode. Master Control – 1 Screens
• PF or VAR State
Loadshare (LS)
• PF Reference.
Mode : Manual GEN BUS
• VAR Reference
State : Manual 0.91LAG 0.00 LAG
• PF/VAR on different PF Ref : 0.90LAG 30.23 kVAR 0.000kVAR
buses VAR Ref: --- Vbias: 14.21%
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Operator Interface
• STATUS MENU KEYS:
SEQUENCE
The SEQUENCE STATUS key provides sequencing information for multiple unit systems
(LS and MC). Single unit systems (DR) 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. Loadshare systems (LS) will not provide status information in
this screen.
44
Alarm / Event Log Screen
• The screen displays the Status Display Alarm Information
following information:
• Alarm Name.
• Hour and Minute of the
alarm occurrence. Loadshare (LS)
• Month and Day of the
Alarms: 8 Unit: 1 SPEED RANGE
alarm occurrence.
Bus - - Gen -- 03/01/14 15:42:56
Engine: OFF GEN BKR SHNT TRP ERR
State: OFF 03/01/14 15:41:11
45
LON Communications
• LON is the communications protocol used by the EGCP-3 to communicate load
control, sequencing, system configuration
• Diagnostic Features (Lon Messaging – Err Num):
– Same node number detected on Network (1-16)
– Multiple sequencing algorithms detected (261)
• Using Watch Windows Lon Messaging menu troubleshooting of the
communications can be performed
– Master in control
– Start Ready
– Start Nodes
– Online Capacity
– Total Demand
46
Software Tools
STATUS CONFIG
SCROLL
I/O SYNC KW LOAD
ALARM CLEAR
47
Servlink Communication
• Servlink
– Watchwindow
– Microsoft Excel
– Remote Communications via modem
Local Modem
Remote Computer
48
ServLink Software
• ServLink is a proprietary serial communications protocol
developed by Woodward for the specific purpose of
communicating from PC’s to Woodward controls
• The EGCP-3, EGCP-2, 723Plus, In-Pulse Plus, and MicroNet
controls support the ServLink protocol
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ServLink Main Screen
• Create the Network Definition File using ServLink software.
Choose File and then New.
50
Opening Communications To A Control
• Before communications can begin between the server and a
control, you must first create a network definition file.
• To create a network definition file choose New ... under the file
menu.
• Before the file can be created the server will prompt you to set the
network options.
• You must specify the port the control is connected to, the baud
rate, the mode of communications, and the parity and stop bits.
• Once all the network options are set click OK to begin the network
scan.
• If the mode is set to be Master/Salve, it may take several minutes to
complete the network scan.
• Once the symbol tables are read, the network definition file will be
complete and can be saved for future retrieval.
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Communication Screen
• Set the Port to Com 1, Mode to Point to Point, and Baud Rate to 115200.
Choose OK.
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Communication With Control
• Communication should begin, and the Network
Definition File will be created.
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No Communication
• If no communication occurs, Red Scanners will appear and an
error message will show.
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Network Definition File
• When the Network Definition File has been created, it will show a
window that looks like this, with the name of the control as
indicated.
Name Of Control
55
Watch Window
• After the Net file is made we can open Watch Windows
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