EGCP-1 Engine Generator Control Package: Installation (Set Builder) Manual

Installation (Set Builder) Manual
EGCP-1
Engine Generator Control Package
8406-020, 12 Vdc
8406-021, 24 Vdc
Manual 26048
WARNING
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.
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.
CAUTION
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.
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
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
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 1999
All Rights Reserved
Manual 26048 EGCP-1 Engine Generator Control Package
Contents
CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Introduction.............................................................................................................1
Declaration of Incorporation ...................................................................................1
Control Options.......................................................................................................1
Control Part Numbers.............................................................................................1
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS ............................... 2
CHAPTER 3. CONTROL OVERVIEW ............................................................... 3
Introduction.............................................................................................................3
Engine Control........................................................................................................3
Synchronizing .........................................................................................................3
Real (kW) Load Control..........................................................................................3
Reactive (KVAR) Control........................................................................................4
Automatic Generator Sequencing ..........................................................................4
Generator Protective Features ...............................................................................4
Engine Protective Features ....................................................................................4
PC Interface............................................................................................................4
Operator Interface ..................................................................................................5
Discrete Inputs and Outputs...................................................................................6
Hardware ................................................................................................................7
Physical Specifications ...........................................................................................7
AC Inputs ..............................................................................................................11
DC Inputs and Outputs .........................................................................................12
Discrete Inputs......................................................................................................13
Discrete Outputs...................................................................................................14
Communication Ports: RS-485 & RS-422 (1 each)..............................................15
Alarms and Shutdowns ........................................................................................20
CHAPTER 4. OPERATIONAL DESCRIPTION: SINGLE NO PARALLEL .............. 22
CHAPTER 5. OPERATIONAL DESCRIPTION: SINGLE UNIT PARALLEL ........... 24
CHAPTER 6. OPERATIONAL DESCRIPTION: MULTIPLE NO PARALLEL .......... 26
CHAPTER 7. OPERATIONAL DESCRIPTION: MULTIPLE PARALLEL ................ 28
CHAPTER 8. APPLICATION OVERVIEW ........................................................ 30
CHAPTER 9. EGCP-1 COMMUNICATIONS ................................................... 83
Overview...............................................................................................................83
Specifications .......................................................................................................84
Hardware Connections.........................................................................................84
Inter-control Communications (RS-485 Network) ................................................86
Modbus RTU Communications for the EGCP-1 Panel ........................................86
CHAPTER 10. SERVICE OPTIONS ............................................................... 93
Product Service Options.......................................................................................93
Returning Equipment for Repair...........................................................................94
Replacement Parts ...............................................................................................95
How to Contact Woodward...................................................................................95
Engineering Services ...........................................................................................96
Technical Assistance............................................................................................97
Woodward i
EGCP-1 Engine Generator Control Package Manual 26048
Illustrations and Tables
Figure 3-1. Keypad .................................................................................................5

Figure 3-2. Physical Outline with Dimensions of EGCP-1 .....................................8
Figure 3-3. Back View of EGCP-1 with Connector and Dip Switch ID Numbers. ..9
Figure 3-4. Wiring Diagram for EGCP-1...............................................................10
Figure 3-5. Wiring Diagram for Magnetic Pickups and Process Import/Export....11
Figure 3-6. Wiring Diagram for Sensors...............................................................12
Figure 3-7. Wiring Diagram for Speed Bias and Voltage Bias Outputs ...............13
Figure 3-8. Wiring Diagram for Typical Discrete I/O Connections .......................15
Figure 3-9. Current Transfer Wiring Diagram for EGCP-1...................................16
Figure 3-10. Three Wire Delta PT Connection for EGCP-1 ................................16
Figure 3-11a. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....17
Figure 3-11b. PT Wiring Relationships for Generator, Bus, and Utility Inputs.....17
Figure 3-11c. PT Wiring Relationships for Generator, Bus, and Utility Inputs .....18
Figure 3-12a. Main/Bus Switch Wiring .................................................................18
Figure 3-12b. Main/Bus Switch Wiring .................................................................19
Figure 3-13. Four Wire WYE PT Connection .......................................................19
Figure 8-1. Single No Parallel Application............................................................30
Figure 8-2a. Single No Parallel Overview Flow Diagram .....................................32
Figure 8-2b. Single No Parallel Overview Flow Diagram .....................................33
Figure 8-3. Single No Parallel Prime Power.........................................................34
Figure 8-4. Single Unit Parallel Application ..........................................................35
Figure 8-5a. Single Unit Parallel Overview Flow Diagram ...................................37
Figure 8-5b. Single Unit Parallel Overview Flow Diagram ...................................38
Figure 8-5c. Single Unit Parallel Overview Flow Diagram ...................................39
Figure 8-6. Multiple Unit No Parallel Application..................................................40
Figure 8-7a. Master Multiple Unit No Parallel Overview Flow Diagram ...............43
Figure 8-7b. Master Multiple Unit No Parallel Overview Flow Diagram ...............44
Figure 8-8a. Slave Multiple Unit No Parallel Overview Flow Diagram .................45
Figure 8-8b. Slave Multiple Unit No Parallel Overview Flow Diagram .................46
Figure 8-8c. Slave Multiple Unit No Parallel Overview Flow Diagram .................47
Figure 8-9. Multiple Unit No Parallel Prime Power Application ............................48
Figure 8-10 Multiple Unit Parallel Standby Power Application .............................49
Figure 8-11 Multiple Unit Parallel Peak Shaving Application ...............................50
Figure 8-12a. Master Multiple Parallel Process Control Flow Diagram ...............53
Figure 8-12b. Master Multiple Parallel Process Control Flow Diagram ...............54
Figure 8-12c. Master Multiple Parallel Process Control Flow Diagram ...............55
Figure 8-12d. Master Multiple Parallel Process Control Flow Diagram ...............56
Figure 8-12e. Master Multiple Parallel Process Control Flow Diagram ...............57
Figure 8-12f. Master Multiple Parallel Process Control Flow Diagram ................58
Figure 8-12g. Master Multiple Parallel Process Control Flow Diagram ...............59
Figure 8-12h. Master Multiple Parallel Process Control Flow Diagram ...............60
Figure 8-13a. Slave Multiple Parallel Process Control Flow Diagram .................61
Figure 8-13b. Slave Multiple Parallel Process Control Flow Diagram .................62
Figure 8-13c. Slave Multiple Parallel Process Control Flow Diagram..................63
Figure 8-13d. Slave Multiple Parallel Process Control Flow Diagram .................64
Figure 8-13e. Slave Multiple Parallel Process Control Flow Diagram .................65
Figure 8-13f. Slave Multiple Parallel Process Control Flow Diagram ..................66
Figure 8-13g. Slave Multiple Parallel Process Control Flow Diagram .................67
Figure 8-13h. Slave Multiple Parallel Process Control Flow Diagram .................68
Figure 8-13i. Slave Multiple Parallel Process Control Flow Diagram...................69
Figure 8-13j. Slave Multiple Parallel Process Control Flow Diagram...................70
Figure 8-13k. Slave Multiple Parallel Process Control Flow Diagram..................71
Figure 8-13l. Slave Multiple Parallel Process Control Flow Diagram...................72
Figure 8-14. Generator Start Sequence ...............................................................73
ii Woodward
Illustrations and Tables
Figure 8-15. Generator Stop Sequence ...............................................................74

Figure 8-16. Generator Breaker Close Sequence ...............................................75
Figure 8-19. Main Breaker Open Sequence ........................................................78
Figure 8-20. Mains Breaker Close Sequence ......................................................79
Figure 8-21. Mains Breaker Reclose Sequence ..................................................80
Figure 8-22. Mains Breaker Reclose Sequence ..................................................81
Figure 8-23. Speed Raise/Lower Switch Based Logic.........................................82
Figure 8-24. Voltage Raise/Lower Switch Based Logic .......................................82
Figure 9-1. RS-422 Communications...................................................................85
Figure 9-2. RS-485 and RS-422 Termination Diagrams.....................................85
Figure 9-3. RS-485 Inter-Control Communications..............................................86
Table 6-1. Modbus Addresses for the EGCP-1 Modbus RTU Protocol...............87
Table 6-2. Common Modbus Error Numbers .......................................................92
Table 6-3. Typical Modbus Communications Settings.........................................92
Woodward iii
iv Woodward
Chapter 1.
General Information
Introduction
This manual describes the Woodward EGPC-1 Engine Generator Control
Package, models 8406-020 (12 Vdc) and 8406-021 (24 Vdc).
Declaration of Incorporation
In accordance with the EMC Directive 89/336/EEC and its amendments, this
controlling device, manufactured by the Woodward Governor Company, is
applied solely as a component to be incorporated into an engine prime mover
system. Woodward Governor declares that this controlling device complies with
the requirements of EN50081-2 and EN50082-2 when put into service per the
installation and operating instructions outlined in the product manual.
NOTICE: This controlling device is intended to be put into service only upon
incorporation into an engine prime mover system that itself has met the
requirements of the above Directive and bears the CE mark.
Control Options
The EGPC-1 control requires the following power supply input voltages, with 6
watts as the nominal power consumption at rated voltage:
• 9–15 Vdc (12 Vdc nominal)
• 18–32 Vdc (24 Vdc nominal)
Control Part Numbers

Nominal PT Nominal CT
12 Vdc 24 Vdc Input Voltage Input Current
Part Number Supply Voltage Supply Voltage Range Range
8406-020 X 90–277 Vac rms 0–5 A rms
8406-021 X 90–277 Vac rms 0–5 A rms
Nominal AC Voltage as measured across + to – inputs for AC Mains/Bus and

Generator PT sensing.
Woodward 1
Chapter 2.
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.

To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION
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.
2 Woodward
Chapter 3.
Control Overview
Introduction
The EGCP-1 is a microprocessor based complete generator load control and
engine management package designed for use with a Woodward speed control
and a separate voltage regulator. The control's functions include:
Engine Control
• Engine Pre-glow
• Fuel Solenoid Control
• Engine Starter Control
• KVA Controlled Cool-down Timer
• Oil Pressure Monitoring
• Water Temperature Monitoring
• Battery Voltage Monitoring
• Speed Monitoring with Overspeed Protection
Synchronizing
• Digital signal processing to eliminate problems induced in systems with high
harmonic content causing multiple zero crossing of voltage wave forms.
• Adjustable maximum phase window, voltage window, and dwell times—
windows as small as 2º phase error and 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
• Externally adjustable Base Load or Process Reference Levels with
independent ramp rates
• kW droop provided for manual load control.
Woodward 3
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-1 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 detection
• Speed/Frequency Mismatch
• Load Surge
Engine Protective Features

• High/Low Coolant Temperature
• High/Low Oil Pressure
• Overspeed
• Start Failure
PC Interface
• Easy Download of setpoints to FLASH memory
• 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 trademark of Modicon, Inc.
4 Woodward
Operator Interface
The EGCP-1 Operator Interface is designed for simplicity and redundancy of
function in all operating modes. The backlit LCD screens with contrast
adjustment are used to display various operating and status information to the
operator, as well as for reading tuning setpoints. The back light on the LCD
screens automatically shuts off after a five minute period of non -use to reduce
power consumption. Pressing any key on the front key pad will turn the light back
on.
The screens provide six lines of Status Information, and two lines of Setpoint
tuning information. These screens allow the user to monitor and tune related
parameters at the same time.
Figure 3-1. Keypad
An imbedded 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.
There are seven rectangular keys on the operator interface and two “teardrop”
keys. The keys have the following functions:
A larm R eset C om m it E scape

R esets A larm s E nters Setpoints E scapes S etpoints
C lears A larm Ind. E nters M enus E scapes M enus
Woodward 5
Up Key Down Key Left Key Right Key

Moves Cursor Moves Cursor Moves Cursor Moves Cursor
Increments Val. Decrements Val.
R ig h t H a n d T e a rd ro p K e y s
U pper K ey
S e le c ts S ta tu s M e n u
T w o P re sse s S e le c ts C o n tro l O v e rv ie w S c re e n
(F ro m a n y M e n u )
L ow er K ey
S e le c ts T u n in g M e n u
S e le c ts S e tp o in t E n try
Discrete Inputs and Outputs

The discrete inputs and outputs of the EGCP-1 control are used to interface
external commands to specific control actions and operations, and to control
external devices.
The Discrete inputs are designed to be tied back into a switch common on the
EGCP-1 when closed. Each switch input will sink 5 mA of current at 12 Vdc
(8406-020) or 24 Vdc (8406-021) when closed.
Here is a list of the discrete inputs available to the EGCP-1 control.
ID # Description
1. Automatic Switch
2. Test Switch
3. Run with Load Switch
4. Volts Raise
5. Volts Lower
6. Speed Raise
7. Speed Lower
8. Gen Circuit Breaker Aux Contact
9. Mains Circuit Breaker Aux Contact
10. Process Switch
11-16. Configurable Alarm/Shutdown Inputs
The discrete outputs of the EGCP-1 consist of double pole relays (normally open,
normally closed). These relays are rated for 10 amps at 120 VAC, 8 amps at 277
VAC resistive.
6 Woodward
ID# Description
1. Mains 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. Mains PT Disconnect
9. Mains Breaker Trip
10. Gen Breaker Trip
11. Audible Alarm
12. Not Used (indicates key press on keypad)
The identification numbers associated with the discrete inputs and outputs are
used in the discrete I/O status screen of the EGCP-1.
Hardware
The EGCP-1 is integrated control package. All control hardware is contained in
one compact enclosure.
Figure 3-2 is a physical outline with dimensions of the EGCP-1. This outline is for
reference only and should not be used for construction of mounting panels, etc.
Physical Specifications
Temperature Range
–40 to +70 °C operating.
Relative Humidity 95% non-condensing, at 30 to 60 °C.
EMI/ESD
Conforms to EN 55011:1991 (CISPR11:1990) Group 1, Class B and to prEN
50082-2-2:1994
Associated Standards
ENV 50140, ENV 50141, ENV 50142, EN 61000-4-2, IEC 801-4, IEC 801-5, IEC
1000-4-1 and BS EN 61010-1:1993
On the back of the EGCP-1 there are 4 quick connector points. They are used to
connect external wiring into the EGCP-1. The connectors are located as shown
in Figure 3-3.
Woodward 7
Figure 3-2. Physical Outline with Dimensions of EGCP-1
8 Woodward
Also on the back of the EGCP-1 are 3 dip switches. These dip switches are used
to set network terminations and input signal conditioning for the EGCP-1. They
are identified as shown in Figure 3-3 as well.
J1 J2
EXPLANATION OF SWITCHES
SW-1
8 water temp shunt resistor (100 ohms) when ON.
7 water temp shunt resistor (100 ohms) when ON
6 oil pressure shunt resistor (100 ohms) when ON
5 oil pressure shunt resistor (100 ohms) when ON
4 not used.
3 not used
2 not used.
1 not used.
on off
8
7
6 CONTRAST ADJ. SW-2
5
4
8 process I/E: ON = 4-20 mA @250 ohms; OFF = 1-5 VDC @ 30Kohms
3
7 not used.
2
1
J5 6 not used.
5 voltage bias output scaling +/- 1 VDC +/- 3 VDC +/- 9 VDC
SW-1
4 voltage bias output scaling
SW2-5 ON SW2-4 ON SW2-4 ON
SW2-1 ON SW2-3 ON
SW2-2 ON
SW-3
8 RS-485 Termination +
7 RS-485 Termination -
on off 6 not used.
8
7
5 not used.
6 4 RS-485 +5VDCpull up.
5
3 RS-422 Termination RxD -
4
3
2 RS-422+5VDC pull up.
2 1 RS-422 Termination RxD +
J8 on
8
off
1
7
SW-2
6
5
4
3
2
1
SW-3
Figure 3-3. Back View of EGCP-1 with Connector and Dip Switch ID Numbers.
Connector location and pin/socket numbers are identified by connector number-

pin number throughout this manual. Example: J8-5 is connector J8
(communications port) pin 5.
Dip switch locations are identified by switch location-switch number throughout

this manual. Example: Switch SW1-5 would be Switch location #1, switch
number 5.
Woodward 9
Wiring Diagram for EGCP-1

Connector Connector Connector
J5 J1 J2
+ 12 -
+ 17 9
Speed bias output Mains breaker close (DO1) n. o.
12 Vdc or 24 Vdc - 13 18
- 8 n. c.
Shield termination 4
- 1 27
MPU speed input
+ 2 8
+ 20 n. o.
Mains/Bus A phase PT Generator Breaker Close (DO2)
+
- 24 5 17
Coolant temperature sensor n. c.
- 26
+ 19 6
Generator A phase PT Oil pressure sensor
- 23
+ 9 7
Engine Preglow (DO3) n. o.
Auto / manual (DI1)
+ 18 16 16
n. c.
Generator B phase PT Test engine (DI2)
22 10 25
-
Run with load (DI3) 34
+ 17 11
Fuel Solenoid (DO4) n. o.
Generator C phase PT Voltage raise (DI4)
21 12 35
- n. c.
Voltage lower (DI5) 36
Generator A phase CT + 9 24
Speed raise (DI6)
Generator B phase CT + 5 19 6
Engine Crank (DO5) n. o.
Speed lower (DI7)
Generator C phase CT + 1 20 15
Generator CB aux (DI8) n. c.
10 15 24
CT Neutral -
Mains CB aux (DI9) 31
+ 2 22
Process import/export Visual Alarm (DO6) n. o.
Process I/E (DI10)
(4-20 mA/1-5 Vdc) 6 18 32
- n. c.
Fault 1(DI11) 33
+ 3 14
Voltage bias output Fault 2 (DI12)
7 23 5
- n. o.
Fault 3 (DI11) Local Bus PT Connect (DO7)
8 13
No Connect 11 n. c.
Fault 4 (DI12)
7 23
No Connect 13
Fault 5 (DI11) 4
14 4
No Connect n. o.
Fault 6 (DI12)
3 14
No Connect 15 Mains PT Disconnect (DO8) n. c.
21 22
No Connect 16
1
Mains Breaker Trip (DO9) n. o.
10
n. c.
Connector
3
J8
2
+ 1 n. o.
RS-485 Network Generator Breaker Trip (DO10)
- 2 11
Connector J5 is 24-pin male Trim Trio type n. c.
(male connector on PC board) Shield termination 7 12
+ 3 28
Connector J1 is 24-pin female Trim Trio type RS-422 RxD Audible Alarm (DO11) n. o.
(female connector on PC board) 29
- 6 n. c.
+ 8 30
Connector J2 is 36-pin female Trim Trio type RS-422 TxD
(female connector on PC board) - 9 No Connect 19
4 No Connect 20
No Connect
Connector J8 is 9-pin male Trim Trio type
(male connector on PC board) No Connect 5 No Connect 21
Figure 3-4. Wiring Diagram for EGCP-1
10 Woodward
AC Inputs
The EGCP-1 receives AC inputs from the generator, bus, mains and engine.
They are as follows:
Location Description Signal Burden

J5-19 Generator PT phase A + AC Voltage 200 kΩ
J5-23 Generator PT phase A – AC Voltage A+ to A–
J5-18 Generator PT phase B + AC Voltage 200 kΩ

J5-22 Generator PT phase B – AC Voltage B+ to B–
J5-17 Generator PT phase C + AC Voltage 200 kΩ

J5-21 Generator PT phase C – AC Voltage C+ to C–
J5-9 Generator CT phase A Current AC Current 0.067 Ω

J5-5 Generator CT phase B Current AC Current 0.067 Ω
J5-1 Generator CT Phase C Current AC Current 0.067 Ω
J5-10 Generator CT Neutral AC Current Common
J5-20 Mains/Bus PT + AC Voltage 200 kΩ

J5-24 Mains/Bus PT – AC Voltage + to –
J1-2 Magnetic Pickup + AC Frequency 15 kΩ

J1-1 Magnetic Pickup – AC Frequency + to –
(+) 4.99K
J1-1
1000pF
MPU 4.99K
(-)
4.99K
Magnetic Pickup Unit J1-2
200 - 3K ohms impedance
500 - 8000 Hz 1000pF
2 - 25 VRMS
(+)
R
J5-6
SW2-
Process Import/Export (PIE) 8
4-20 mA / 1-5 Vdc
250
(-)
R
J5-2
Switch SW2-8
Open for 1-5 volt input @ 30K ohms
Close for 4_20 mA @ 250 ohms
Figure 3-5. Wiring Diagram for Magnetic Pickups and Process Import/Export
Woodward 11
DC Inputs and Outputs

Location Description Signal I/O
J5-12 + power supply 9–15 Vdc (12 Vdc unit) Isolated
18–32 Vdc (24 Vdc unit) Input
J5-8 – power supply 6 W typical,
20 W max.
J5-2 + Process Signal 4–20 mA Isolated Input

J5-6 – Process Signal or 1–5 Vdc 249 (4–20 mA)
30 k (1–5 Vdc)
J1-17 + Speed Bias ±3 Vdc

J1-13 – Speed Bias 10 mA Maximum
J5-3 + Voltage Bias ±1, 3, or 9 Vdc Isolated Output

J5-7 – Voltage Bias 10mA Maximum
J1-9 Pressure Sensor + 0–200 sensor Internal Voltage Source

J1-6 Pressure Sensor – Internal Source Common
J1-5 Temp Sensor + 0–200 sensor Internal Voltage Source

J1-6 Temp Sensor – Internal Source Common
+12 Vdc
537.5
R
J1-9
Oil Pressure
Sensor 1000pF SW1- SW1- C R
0-200 Ohm 5 6
100 100 R
J1-6
+12 Vdc
537.5
R
J1-5
Water
Temperature 1000pF SW1- SW1- C R
Sensor 8 7
0-200 Ohm
100 100 R
J1-6
Switches SW1-5 through SW1-8

may be closed to insert shunt
resistors required to make certain
transducers more linear.
Figure 3-6. Wiring Diagram for Sensors
12 Woodward
(+)
J1-17
Speed Bias Output

+/- 3 Vdc
Isolated to 1000V
(-)
J1-13
Switch Configurations
(Switches off unless indicated)
+/- 1 Vdc - On- (5)
+/- 3 Vdc - On- (1), (4)
+/- 9 Vdc - On- (2), (3), (4)

(+)
J5-3 Voltage Bias Output

Configurable Output Range
+/- 1 Vdc
+/- 3 Vdc
(-) +/- 9 Vdc
Isolated to 1500V
J5-7
SW2- SW2- SW2- SW2- SW2-
1 2 3 4 5
+V
J5-7
Figure 3-7. Wiring Diagram for Speed Bias and Voltage Bias Outputs
Discrete Inputs
Location Description Signal Input
J1-16 Auto Discrete Input (DI-1) + power supply (internal connection)
J1-10 Test Discrete Input (DI-2) + power supply (internal connection)
J1-11 Run/Ld Discrete Input (DI-3) + power supply (internal connection)
J1-12 Volt Raise Discrete Input (DI-4) + power supply (internal connection)
J1-24 Volt Lower Discrete Input (DI-5) + power supply (internal connection)
J1-19 Speed Raise Discrete Input (DI-6) + power supply (internal connection)
J1-20 Speed Lower Discrete Input (DI-7) + power supply (internal connection)
J1-15 Gen CB Aux Discrete Input (DI-8) + power supply (internal connection)
J1-22 Mains CB Aux Discrete Input (DI-9) + power supply (internal connection)
J1-18 Process Discrete Input (DI-10) + power supply (internal connection)
J1-14 Fault 1 Discrete Input (DI-11) + power supply (internal connection)
J1-21 Switch Common Discrete Input – power supply (internal connection)
NOTE
Approximately 5 mA current draw across each DI when CLOSED.
Woodward 13
Discrete Outputs
Location Description Signal Output Rating
J2-27 Mains Brkr Close NC Discrete Output (D01) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-18 Mains Brkr Close C Discrete Output (D01)
J2-9 Mains Brkr Close NO Discrete Output (D01) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-26 Gen Brkr Close NC Discrete Output (D02) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-17 Gen Brkr Close C Discrete Output (D02)
J2-8 Gen Brkr Close NO Discrete Output (D02) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-25 Engine Preglow NC Discrete Output (DO3) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-16 Engine Preglow C Discrete Output (DO3)
J2-7 Engine Preglow NO Discrete Output (DO3) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-36 Fuel Solenoid NC Discrete Output (DO4) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-35 Fuel Solenoid C Discrete Output (DO4)
J2-34 Fuel Solenoid NO Discrete Output (DO4) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-25 Crank Engine NC Discrete Output (DO5) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-15 Crank Engine C Discrete Output (DO5)
J2-6 Crank Engine NO Discrete Output (DO5) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-33 Visual Alarm NC Discrete Output (DO6) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-32 Visual Alarm C Discrete Output (DO6)
J2-31 Visual Alarm NO Discrete Output (DO6) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-23 Bus PT Connect NC Discrete Output (DO7) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-13 Bus PT Connect C Discrete Output (DO7)
J2-5 Bus PT Connect NO Discrete Output (DO7) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-22 Mains PT Disconnect NC Discrete Output (DO8) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-14 Mains PT Disconnect C Discrete Output (DO8)
J2-4 Mains PT Disconnect NO Discrete Output (DO8) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-3 Mains Brkr Trip NC Discrete Output (DO9) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-10 Mains Brkr Trip C Discrete Output (DO9)
J2-1 Mains Brkr Trip NO Discrete Output (DO9) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-12 Gen Brkr Trip NC Discrete Output (DO10) 10 A @ 120 Vac,

6 A @ 277 Vac Res.
J2-11 Gen Brkr Trip C Discrete Output (DO10)
J2-2 Gen Brkr Trip NO Discrete Output (DO10) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
14 Woodward
Location Description Signal Output Rating
J2-30 Audible Alarm NC Discrete Output (DO11) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-29 Audible Alarm C Discrete Output (DO11)
J2-28 Audible Alarm NO Discrete Output (DO11) 10 A @ 120 Vac,
6 A @ 277 Vac Res.
J2-21 Not Used

J2-20 Not Used
J2-19 Not Used
K1 - K11
J2-27
Mains
Breaker
Discrete I/O K2 J2-18 Close
+5 Vdc J2-9
R Typical Example of Discrete Output

+V
(Mains Breaker Close shown)
Typical Example of Discrete Input Relay Rating (Resistive):
(Auto/Manual Contact Input Shown) 10 Amps @120 VAC
Note: 6 Amps @ 277 VAC
J1-21 is the discrete input common for all
contact inputs
Auto/Manual
R
J1-16
User Supplied Contact
J1-21
Discrete Input Common
Figure 3-8. Wiring Diagram for Typical Discrete I/O Connections
Communication Ports: RS-485 & RS-422 (1 each)

Location Description Signal
J8-2 – 485 Communication Inter-control Communications
J8-1 + 485 Communication Inter-control Communications
J8-4 +5 Vdc Internal Isolated Power Supply
J8-5 +5 Vdc common Internal Isolated Power Supply
J8-3 422 Communication RX+ PC interface
J8-6 422 Communication RX– PC interface
J8-8 422 Communication TX+ PC interface
J8-9 422 Communication TX– PC interface
Woodward 15
Current Transformer Wiring Diagram
J-5 Connector Pins

0-5 A
9
.067 ohms
5
.067 ohms
A B C 1
.067 ohms
10
FIELD WIRING EGCP-1
G
Figure 3-9. Current Transfer Wiring Diagram for EGCP-1
EGCP-1 THREE WIRE DELTA PT CONNECTION

(A-B-C ROTATION) Voltage Input Setpoint = DELTA
Voltage Reference Setpoint = Vrms L-L
J-5 Connector Pins
19 +
C A PHASE PT
23
-
18 +
A B B PHASE PT
22
-
17 +
21
C PHASE PT
-
G FIELD WIRING EGCP-1
EQUIVALENT CIRCUIT DIAGRAM

C C
C+ B-
EGCP-1 Inputs
Generator or PT Secondary C- B+
A B A A+ A-
B
Figure 3-10. Three Wire Delta PT Connection for EGCP-1
16 Woodward
4160 VL-L 120 VL-L
u
t 4160 VL-L 120 VL-L
i
l
4160 V L-L C-
277 VL-N
PT Ratio : 4:1 C+
Voltage Config: Delta B-
Voltage Ref: 480 Gen PT inputs
B+
A-
480 VL-L : 120 VL - L
A B C A+
N
277 VOLTS L-N
Figure 3-11a. PT Wiring Relationships for Generator, Bus, and Utility Inputs
480 VL-L 120 VL-L
u Mains/Bus PT Input
t
480 VL-L 120 VL-L
i
l
480 V L-L C-
277 VL-N
PT Ratio : 4:1 C+
B+
A-
A B C A+
N
277 VOLTS L-N

PT wiring relationships for generator, bus and utility inputs
Figure 3-11b. PT Wiring Relationships for Generator, Bus, and Utility Inputs
Woodward 17
480 VL-L 120 VL-L
u
t 480 VL-L 120 VL-L
i
l
480 V L-L C-
277 VL-N
PT Ratio : 4:1 C+
B+
A-
A B C A+
N
277 VOLTS L-N
Figure 3-11c. PT Wiring Relationships for Generator, Bus, and Utility Inputs
EGCP-1 Mains/Bus Switch Wiring Voltage Input Setpoint = DELTA
2 wire Delta Connection Shown Voltage Reference Setpoint = Vrms L-L
14 K1 NOTE: K1 and K2 are Single Pole, Double throw (Form C) Relays.

Relay contacts must be rated for line voltage
Mains PT Disconnect (D08)
and input load current.
22 Relay Control Voltage (+V)

NOTE: Relay Contacts for D07 and D08 are rated for
10 Amps at 120 VAC, 6 Amps at 277 VAC, resistive load.
5 K2 NOTE: All relay contacts shown in this drawing are in a
de-energized state.
Local Bus PT Connect (D07)
This is the typical state of the mains/bus PT sensing relays.
(Sensing the Mains PT input)
Equivalent Wiring Diagram
K1
C
+ 20
Mains PT (A to B Phase)
A B Line voltage input 90-277 VAC rms 50/60 Hz.
Mains/Bus PT input (A to B phase)
190 kohms resistive load.
K2
C - 24
Bus PT ( A to B Phase)
A B NOTE: Mains and Bus input voltage and configuration
( WYE or Delta) must be identical for proper amplitude and
phase angle readings.
Figure 3-12a. Main/Bus Switch Wiring
18 Woodward
EGCP-1 Mains/Bus Switch Wiring Voltage Input Setpoint = DELTA
2 wire WYE Connection Shown Voltage Reference Setpoint = Vrms L-L
14 K1 NOTE: K1 and K2 are Single Pole, Double Throw (Form C) Relays.

Relay contacts must be rated for line voltage
Mains PT Disconnect (D08)
and input load current.

NOTE: Relay Contacts for D07 and D08 are rated for
10 Amps at 120 VAC, 6 Amps at 277 VAC, resistive load.
5 K2 NOTE: All relay contacts shown in this drawing are in a
de-energized state.
Local Bus PT Connect (D07)
This is the typical state of the mains/bus PT sensing relays.
(Sensing the Mains PT input)
Equivalent Wiring Diagram
K1
A C
+ 20
Mains PT (A to B Phase)
Line voltage input 90-277 VAC rms 50/60 Hz.
Mains/Bus PT input (A to B phase)
B K2
190 kohms resistive load.
- 24
A C
Bus PT ( A to B Phase)
NOTE: Mains and Bus input voltage and configuration
( WYE or Delta) must be identical for proper amplitude and
B phase angle readings.
Figure 3-12b. Main/Bus Switch Wiring
EGCP-1 FOUR WIRE WYE PT CONNECTION

Voltage Input Setpoint = WYE
J-5 Connector Pins Voltage Reference = Vrms L-N
19 +
A A PHASE PT
C
23
-
18 +
B PHASE PT
22
-
B 17 +
21
C PHASE PT
G FIELD WIRING
-
EGCP-1
EQUIVALENT CIRCUIT DIAGRAM

A C
A C A+
C+
A-
Generator or PT Secondary C-
B-
EGCP-1 Inputs
B B+
Figure 3-13. Four Wire WYE PT Connection
Woodward 19
Alarms and Shutdowns

The EGCP-1 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-1 to flash continuously until the alarm condition is
acknowledged. No control actions occur as a result of a warning condition.
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-1
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-1 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-1 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-1 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.
20 Woodward
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).
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 21
Chapter 4.
Operational Description:
Single No Parallel
The most basic mode of operation for the EGCP-1 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-1 software which need to be

configured for Single Unit No Parallel operation are:
Configuration Menu:
Number of Units:
Single
Load Control Mode:

Normal
Operating Mode:
No Parallel
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.
Shutdown/Alarm Menu:
Mains Under/Over Voltage Alarm:
Loss of Mains
Mains Under/Over Freq. Alarm:

Loss of Mains
22 Woodward
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 engine and transfers load to the generator (opens mains breaker)..
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 breaker operation.
Test Switch
Starts Engine; no other action taken.
Process Switch
No effect in this mode.
Woodward 23
Chapter 5.
Single Unit Parallel
Single Unit Parallel operation of the EGCP-1 control enables the control’s ability
to synchronize and close to the mains. When paralleling to the mains, the EGCP-
1 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-1 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-1 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.
The 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
Load Control Mode: Normal or Soft Transfer (depending on application)
Operating Mode: Mains Parallel
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
Loss of Mains
Mains Under/Over Freq. Alarm

Loss of Mains
Load Surge:
Loss of Mains*
24 Woodward
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-1 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-1 will synchronize the
generator set with the mains. After synchronizing to the mains, the EGCP-1 will
parallel the generator with the mains, and softly unload the generator. Upon
reaching the generator Unload Trip Point, the EGCP-1 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 Rams to Process Control with LOM detection enabled.
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.
Woodward 25
Chapter 6.
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-1 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. See the Generator Sequencing Functions
Chapter in this manual for more detail on automatic sequencing.

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

Normal
Operating Mode:
No Parallel

Enabled at units receiving Mains Breaker Aux. hard wired input in standby.
Disabled if prime power application (there is no mains breaker to monitor).
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.
26 Woodward
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.
Loss of Mains

Loss of Mains
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 27
Chapter 7.
Multiple Parallel
The Multiple Parallel operating mode of the EGCP-1 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
Load Control Mode:

Normal or Soft Transfer (depending on application)
Operating Mode:
Parallel

Enabled at units receiving the Mains Breaker Aux . hard wired input.
Disabled in units not receiving the Mains Breaker Aux. hard wire input.
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.
28 Woodward
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
Loss of Mains

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 (Baseload 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.
Woodward 29
Chapter 8.
Application Overview
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-1.
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

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

See Switch Logic Diagram for Details
Auto Gen Breaker +Battery
Automatic Manual
Close GCC -Battery
NLT (No Load Test) or Manual 4 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 +Battery

Voltage Raise Manual MCC
Close Mains Breaker Close Coil
1
Voltage Lower Mains Breaker +Battery
Manual MTC
Trip Mains Breaker Trip Coil
Speed Raise +Battery
Fuel
1 FUEL
Solenoid
Speed Lower Fuel shutoff solenoid
Manual G52a Engine +Battery

Gen CB Aux Preglow prglw
Preglow relay
U52a Mains CB Aux +Battery
Engine Engine Crank Relay
Crank crank
No Connection Process I/E
Visual +Battery Visual Alarm
2 Alarm
.
Fault #1
..
3 Audible +Battery
Fault #6 Alarm
Audible Alarm
Switch Common
Single NoParallel Application
1 Only required if the speed and voltage 3 Faults #3 through #6 activate immediately,
need to be adjusted when Test with programmable delays.
or Manual is selected.
2 Use fault #1 or #2 input if using a 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 8-1. Single No Parallel Application
30 Woodward
SWITCH BASED LOGIC

(SINGLE - NO PARALLEL)
T R A P U
E U U R T
S N T O I
T \ O C L
w E I
L S T
O S Y
A
D P
O
W
E
R
X X OFF
1 X X X STARTS ENGINE *
X 1 X X STARTS ENGINE *
X 11 X X OPENS TB \ STARTS ENGINE \ CLOSES GB \ CONTROLS IN ISOCH
X X1 X OPENS TB \ STARTS ENGINE \ CLOSES GB \ CONTROLS IN ISOCH
X X1 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 31
Single Unit No Parallel

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

Mains CB AUX
Yes No >LOM Action
Closed?
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
Stop Genset No Mains Stable?

Sequence
Yes
Open Gen Breaker

Sequence
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 8-2a. Single No Parallel Overview Flow Diagram
32 Woodward
Auto Input AND

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

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

FLAG
No
Close Mains
Breaker Sequence
Open Gen Breaker
Sequence
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 8-2b. Single No Parallel Overview Flow Diagram
Woodward 33
G52 LOAD
GEN
No Mains Available (Prime Power Application)

Number of Units =
Single
GEN BUS
No Parallel Local
Mains
PT
PT Disconnect
Application: Prime Power GEN Connect
CTs

Automatic Manual
Close GCC -Battery
Trip Manual
GTC
No Connection Run W/LD Gen Breaker Trip Coil
Mains Breaker
Voltage Raise No Connection
Close
1
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
Audible Alarm
Switch Common
Single No Parallel Prime Power Application
2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation.
4
speed.
Figure 8-3. Single No Parallel Prime Power
34 Woodward
G52 LOAD
GEN MAINS
Number of Units =
Single
GEN BUS Watt
Mode of Load Transfer = PTs PT Xducer
Mains Parallel Local
Mains
PT
Application: Peak Shaving Set PT Disconnect
GEN Connect
CTs Process Input
5 4-20mA or 1-5VDC
Automatic Manual
Close GCC -Battery
Run With Load (closed transition) Trip Manual GTC
Mains Breaker No Connection

Voltage Raise Close
1
Voltage Lower Mains Breaker No Connection
Trip
Fuel
1 FUEL
Solenoid

Preglow relay
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
These Fault Inputs have 15 second Transducer input not required
5 if Process Control Mode is
engine reaches crank cutoutt Not used.
speed.
Figure 8-4. Single Unit Parallel Application
Woodward 35
SWITCH BASED LOGIC

(SINGLE - PARALLEL)
R U
T U A P T
E N U R I
S \ T O L
T w O C I
L E T
O S Y
A S
D P
O
W
E
R
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)
36 Woodward
Single Unit Mains Parallel

Input
Engine
Start Engine
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
Active 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
Stop Genset
Sequence
No Mains Stable?
Yes
Close Mains
Breaker Sequence
Unload Ramp
Stop Genset Open Gen Breaker

Sequence Sequence
Figure 8-5a. Single Unit Parallel Overview Flow Diagram
Woodward 37
Auto Input AND Single Parallel Unit

Run With Load
Input
Engine LOM Sequence Shown On
Start Page #3
Sequence
Loss of Mains
No
Enabled?
No Gen Stable?
Yes
Yes
Loss of Mains
Detection Active
Close Gen
Breaker Sequence
Loss of Mains for

Mains CB AUX
Yes No >LOM Action
Closed?
Delay? Run With Load Input
Yes Base Load Control
Closed?
No
Yes No
Close Mains
Breaker Sequence
Unload Ramp
SET Loss of Mains
FLAG
Open Gen Breaker

Sequence
Stop Genset
Sequence
Figure 8-5b. Single Unit Parallel Overview Flow Diagram
38 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
Open Gen Breaker

Sequence
Stop Genset
Sequence
Figure 8-5c. Single Unit Parallel Overview Flow Diagram
Woodward 39
G52 LOAD U52

GEN MAINS
Number of Units =
Multiple
GEN BUS
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
GTC
4 Mains Breaker +Battery

Voltage Raise Manual MCC
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
Audible Alarm
Switch Common
Multiple No Parallel Application
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 8-6. Multiple Unit No Parallel Application
40 Woodward
SWITCH BASED LOGIC

(MULTIPLE - NO PARALLEL, MASTER CONTROL'S ACTIO
T R A P U
E U U R T
S N T O I
T \ O C L
w E I
L S T
O S Y
A
D P
O
W
E
R
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)
Woodward 41
SWITCH BASED LOGIC

(MULTIPLE - NO PARALLEL, SLAVE CONTROL'S ACTION)
T R A P
E U U R
S N T O
T \ O C
w E
L S
O S
A
D
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
42 Woodward
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
Close Mains
Breaker Sequence
Remove System
RUN with LOAD
FLAG
Stop Genset
Sequence
Figure 8-7a. Master Multiple Unit No Parallel Overview Flow Diagram
Woodward 43
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

Sequence
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 8-7b. Master Multiple Unit No Parallel Overview Flow Diagram
44 Woodward
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
Open Gen Breaker

Sequence
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 8-8a. Slave Multiple Unit No Parallel Overview Flow Diagram
Woodward 45

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
Stop Genset
Sequence
Figure 8-8b. Slave Multiple Unit No Parallel Overview Flow Diagram
46 Woodward

Auto Input AND Page 3
System Run
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
Close Mains
Breaker Sequence
Stop Genset
Sequence
Figure 8-8c. Slave Multiple Unit No Parallel Overview Flow Diagram
Woodward 47
G52 LOAD
GEN
No Mains Available (Prime Power Application)

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

RS-485 LON
Automatic Manual
Close GCC -Battery
Trip Manual GTC
Run With Load Run W/LD Gen Breaker Trip Coil
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
Audible Alarm
Switch Common
Multiple No Parallel Prime Power Application
2 Use fault #1 or #2 input if using a Manual mode requires manual generator breaker operation.
4
speed.
Figure 8-9. Multiple Unit No Parallel Prime Power Application
48 Woodward
G52 LOAD U52

GEN MAINS
Number of Units =
Multiple
GEN BUS Watt
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
Mains Breaker +Battery

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

Preglow relay
U52a Mains CB Aux 6 +Battery
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.
2 Transducer input not required
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 8-10 Multiple Unit Parallel Standby Power Application
Woodward 49
G52 LOAD
GEN MAINS
Number of Units =
Multiple
GEN BUS Watt
Mains
PT
Application:Peak Shaving Set PT Disconnect
GEN Connect
CTs Process Input
5 4-20mA or 1-5VDC
RS-485 LON
Automatic Manual
Close GCC -Battery
GTC
Mains Breaker No Connection

Voltage Raise Close
1
Voltage Lower Mains Breaker No Connection
Trip
Fuel
1 FUEL
Solenoid

Preglow relay
U52a Mains CB Aux 6 +Battery
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.
2 Transducer input not required
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
speed. 6 must have these inputs.
3 Faults #3 through #6 activate immediately,
with programmable delays.
Figure 8-11 Multiple Unit Parallel Peak Shaving Application
50 Woodward
SWITCH BASED LOGIC

(MULTIPLE - PARALLEL, MASTER CONTROL'S ACTION)
RA P U
T UU R T
E NT O I
S \ O C L
T w E I
L S T
O S Y
A
D P
O
W
E
R
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 11 1 STARTS ALL ENGINES \ ALL UNITS SYNC TO UTILITY \ CONTROL IN BASELOAD
X 11 1 1 STARTS ALL ENGINES \ ALL UNITS SYNC TO UTILITY \ CONTROL IN PROCESS #
1 11 1 STARTS ALL ENGINES \ UNITS SYNC TO UTILITY \ RAMP TO BASELOAD \ OPENS TB **
1 11 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)
Woodward 51
SWITCH BASED LOGIC

(MULTIPLE - PARALLEL, SLAVE CONTROL'S ACTION)
T R A P
E U U R
S N T O
T \ O C
w E
L S
O S
A
D
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
52 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
Close Mains
Breaker Sequence
Remove System
Run with Load Flag
and
Unload Ramp

Sequence Sequence
Figure 8-12a. Master Multiple Parallel Process Control Flow Diagram
Woodward 53
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
SET Loss of Mains Flag and
FLAG Unload Ramp
Open Gen Breaker

Sequence
Stop Genset
Sequence
Figure 8-12b. Master Multiple Parallel Process Control Flow Diagram
54 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
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 8-12c. Master Multiple Parallel Process Control Flow Diagram
Woodward 55

Page 4
Auto Input AND
Run With Load
Input AND
Process Set System Run with
Load Flag and LOM Sequence Shown On
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
Stop Genset
Sequence
Figure 8-12d. Master Multiple Parallel Process Control Flow Diagram
56 Woodward

Page 5
Auto Input AND

Run With Load
Input AND Test
Set System Run with
Load Flag and LOM Sequence Shown On
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
Stop Genset
Sequence
Figure 8-12e. Master Multiple Parallel Process Control Flow Diagram
Woodward 57

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
Stop Genset
Sequence
Figure 8-12f. Master Multiple Parallel Process Control Flow Diagram
58 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?
Sequence
No
Figure 8-12g. Master Multiple Parallel Process Control Flow Diagram
Woodward 59

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
Stop Genset
Sequence
Figure 8-12h. Master Multiple Parallel Process Control Flow Diagram
60 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

Sequence Sequence
Figure 8-13a. Slave Multiple Parallel Process Control Flow Diagram
Woodward 61

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
Stop Genset
Sequence
Figure 8-13b. Slave Multiple Parallel Process Control Flow Diagram
62 Woodward

Auto Input AND Page 3
System Run 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 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
Stop Genset
Sequence
Figure 8-13c. Slave Multiple Parallel Process Control Flow Diagram
Woodward 63

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

Sequence Sequence
Figure 8-13d. Slave Multiple Parallel Process Control Flow Diagram
64 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
Stop Genset
Sequence
Figure 8-13e. Slave Multiple Parallel Process Control Flow Diagram
Woodward 65

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
Stop Genset
Sequence
Figure 8-13f. Slave Multiple Parallel Process Control Flow Diagram
66 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
Stop Genset
Sequence
Figure 8-13g. Slave Multiple Parallel Process Control Flow Diagram
Woodward 67

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
Stop Genset
Sequence
Figure 8-13h. Slave Multiple Parallel Process Control Flow Diagram
68 Woodward

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
Sequence
Figure 8-13i. Slave Multiple Parallel Process Control Flow Diagram
Woodward 69

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
No
Figure 8-13j. Slave Multiple Parallel Process Control Flow Diagram
70 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
Stop Genset
Sequence
Figure 8-13k. Slave Multiple Parallel Process Control Flow Diagram
Woodward 71

Page 9
System Run With
Load Flag
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? System Run with Load
Delay? Base Load Control Master Process Flag? No
Flag OR Run With Load Yes Mains Breaker Closed? Yes
Input Closed?
No
Yes
Yes No
No
Mains Breaker Base Load Control
Reclose Sequence With Master
System Load
Isoch Load Control Reference
Unload Ramp (Process Control)
SET Loss of Mains
FLAG
Open Gen Breaker

Sequence
Stop Genset
Sequence
Figure 8-13l. Slave Multiple Parallel Process Control Flow Diagram
72 Woodward
The following flow diagrams are specific sequences referred to in the preceding
overview flow diagrams:
Generator Start Sequenc

Test Input OR
Run With Load Input OR
(Auto & Run with load flag from Master) OR
(Auto Input & LOM)
Initialze
Timers,
Counters
Set Crank FailYES Crank Attempt Counter >

Alarm Flag 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

Delay Timer
Figure 8-14. Generator Start Sequence
Woodward 73
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 TimerYES KVA Level During Run >

Cooldown Level Setpoint
?
NO
Decrement cooldown
timer De-Energize Fuel
Solenoid Output
Cooldown Timer Depleted? Engine State

MPU Input = 0? =Spindown
Engine State
= Off
Figure 8-15. Generator Stop Sequence
74 Woodward
Gen Breaker Close Sequence

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

Mode = OFF Close Attempts Setpoint?
YES
Set Sync
Reclose Alarm Switch PT input to
Bus Sensing
Sync Timeout NO
Time Expired?
NO Dead Bus? YES

(Bus PT Input < 40VAC)
Force Sync
Mode = OFF
YES
Set Sync
NO Dead Bus Closing Reclose Alarm
ENABLED?
YES
Energize Breaker NO
Close Command Breaker Logic?
YES
Energize Breaker
Close Command
Energize Breaker
Open Command
Gen CB Aux NO Gen Breaker Hold NO

Input? Timer Expired?
YES YES
De-Energize
NO Gen Breaker Hold
Breaker Close
Command
Timer Expired?
YES
Sync Successful
Breaker Logic? NO
Set Mode Flag
= IN SYNC
YES
De-Energize
Breaker Open
Command
Increment Close
Attempts
Reset Close
Timer
Start Reclose
Delay Timer
Figure 8-16. Generator Breaker Close Sequence

(Single No Mains Parallel)
Woodward 75
Sync Timeout NO
Time Expired?
YES
Single Mains Parallel Unit
Force Sync
Mode = OFF
Close Gen Breaker

Set Sync FLAG = TRUE
Reclose Alarm
Initialize Timers,
Counters

YES Sync Mode = Run?

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

Mains CB Aux = TRUE? NO
Voltage Matching
Enabled?
NO Dead Bus?
Adjust Volt
Bias
YES
NO Dead Bus Closing

ENABLED?
Phase <= Phase Window?

YES
Energize Breaker NO
Voltage Error
YES <= Voltage Window?
Energize Breaker
Close Command
Energize Breaker Sync Mode = Check?

Open Command

YES YES
De-Energize
NO Gen Breaker Hold
Breaker Close
Command
Timer Expired?
YES
Sync Successful
Breaker Logic? NO
Set Mode Flag
= IN SYNC
YES
De-Energize
Breaker Open
Command
Increment Close
Attempts
Reset Close
Timer
Start Reclose
Delay Timer

(Single Mains Parallel)
76 Woodward
Sync Timeout NO
Time Expired?
YES
Multiple No Mains Parallel Unit
Force Sync
Mode = OFF
Set Sync Close Gen Breaker

Reclose Alarm FLAG = TRUE
Initialize Timers,
Counters

YES
YES Sync Mode = Run?
Set Sync
Reclose Alarm Switch PT input to Adjust Speed
Bus Sensing
NO Bias
YES
Sync Mode =Permissive?
Mains Breaker OPEN YES
and Live (>40VAC)
Voltage Matching NO
Bus?
NO Enabled?
NO
YES
NO Dead Bus?
Adjust Volt
Bias
YES
NO Dead Bus Closing

ENABLED?
NO
YES Phase <= Phase Window?
Dead Bus Token NO YES

Granted?
Voltage Error NO
YES
<= Voltage Window?
YES
Check Mode? YES
NO YES
Sync Mode = Check?
Energize Breaker NO
NO
YES
Energize Breaker
Close Command
Energize Breaker
Open Command

YES YES
De-Energize
NO Gen Breaker Hold
Breaker Close
Command
Timer Expired?
YES
Sync Successful
Breaker Logic? NO
Set Mode Flag
= IN SYNC
YES
De-Energize
Breaker Open
Command
Increment Close
Attempts
Reset Close
Timer
Start Reclose
Delay Timer

(Multiple No Mains Parallel)
Woodward 77
Mains Breaker Open Sequence
Open Mains
Breaker Flag
Sync Timeout NO
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 ?
Mains Breaker Open

= TRUE
Figure 8-19. Main Breaker Open Sequence
78 Woodward
Parallel Mains Breaker Close Diagram

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

Breaker Logic? Close Attempts Setpoint
?
YES NO
Energize Mains
Sync Mode =NO
De-Energize Mains
Breaker Close Breaker Close YES Phase <= NO
Generator CB Aux? Phase Window?
Command PERMISSIVE?
NO YES YES Adjust Speed
NO Mains Stable? Bias
Monitor
Synchro OFF,
Mains PT
Reclose Alarm
YES
Note: To Clear Mains Reclose Failure, Voltage <= NO Sync Mode =NO
Monitor Bus PT
Voltage Window? PERMISSIVE?
Cycle Run W/ Load Input
from OFF to ON to OFF. YES YES
NO
Voltage Matching NO
Dead Bus?
= ENABLED?
YES
YES
Adjust Volt
Sync Check?
YES Bias
NO
De-Energize Sync Mode = YES
Breaker Logic
NO Mains Breaker CHECK?
Close 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 Timer Hold Timer
Mains CB Aux?
Expired?
YES
NO YES
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 8-20. Mains Breaker Close Sequence

(Mains Parallel)
Woodward 79
Parallel Mains Breaker Re-close Diagram

Close Mains
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

?
YES NO
Energize Mains De-Energize Mains
YES YES Phase <= NO Sync Mode =NO
Breaker Close
Command
Breaker Close Generator CB Aux? Master Unit? Phase Window? PERMISSIVE?
NO YES YES Adjust System Speed
NO Mains Stable? Bias
Monitor
Synchro OFF,
Mains PT
Reclose Alarm
YES
Note: To Clear Mains Reclose Failure, Voltage <= NO Sync Mode =NO
Monitor Bus PT
Voltage Window? PERMISSIVE?
from OFF to ON to OFF. YES YES
Follow Master Speed Voltage Matching NO
Dead Bus? NO and Voltage Bias = ENABLED?
YES
YES
Adjust System Volt
Sync Check?
YES Bias
NO
De-Energize Sync Mode = YES
Breaker Logic
NO Mains Breaker CHECK?
Close Command
NO
YES
De-Energize Mains YES
Breaker Open In Phase Window for
Command
=> Dwell Time?
Energize Mains NO
Breaker Close
Command
NO
Mains CB Aux?
Expired?
YES
NO YES
Sync Successful

Expired?
NO
Decrement Delay
NO Reclose Delay
Timer Expired?
YES
Increment Close
Attempts
Figure 8-21. Mains Breaker Reclose Sequence

(Mains Parallel)
80 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 NO
Energize Mains De-Energize Mains
Breaker Close Breaker Close YES Set Gen Breaker
Generator CB Aux?
Command Open Flag
NO
NO Mains Stable?
Synchro OFF, Monitor
Reclose Alarm Mains PT
YES
Note: To Clear Mains Reclose Failure, Monitor Bus PT
from OFF to ON to OFF.
Dead Bus? NO
YES
Sync Check?
YES
NO
De-Energize
NO Mains Breaker
Breaker Logic
Close Command
YES
Energize Mains
Breaker Open
Command
Energize Mains
Breaker Close
Command
NO
Mains CB Aux?
Expired?
YES
NO YES
Sync Successful

Expired?
NO
Decrement Delay
NO Reclose Delay
Timer Expired?
YES
Increment Close
Attempts
Figure 8-22. Mains Breaker Reclose Sequence

(No Parallel)
Woodward 81
SWITCH BASED LOGIC

(SPEED RAISE\LOWER CONTACT FUNCTIONALITY)
G T P
E I R
N E O
C
B B
R R D
K K I
R R
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 8-23. Speed Raise/Lower Switch Based Logic
SWITCH BASED LOGIC

(VOLTAGE RAISE\LOWER CONTACT FUNCTIONALITY)
G T
E I
N E
B
B R
R K
K R
R
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 8-24. Voltage Raise/Lower Switch Based Logic
82 Woodward
Chapter 9.
EGCP-1 Communications
Overview
The EGCP-1 panel RS-422 port protocol may be selected for Modbus RTU
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-1.
To select which protocol will be used, enter the configuration menu of the EGCP-
1 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
2) Servlink
NOTE
Whenever the 422 Protocol setpoint is changed, the EGCP-1 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-1 panel will
communicate in the Servlink protocol. Woodward Governor Company’s Servlink
communications protocol is a proprietary DDE interface to the EGCP-1 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-1 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-1 panel will communicate in MODBUS RTU

protocol, and make its information available according to the address list as
shown in Table 6-1. Also, the Modbus Address, Modbus Time-out, and
Modbus Reset menu items become functional when the 422 Protocol is set to
Modbus.
NOTE
If Upload Setpoints is chosen, the EGCP-1 panel will switch to a
communications mode where it is waiting to see characters on the 422 serial
port that set it to transfer the contents of the setpoint file to the PC. This
task is run on the PC using the download.com DOS program. The
download.com program is available for download on Woodward’s Internet
web page located at: www.woodward.com. Follow the “EGCP-1 software
download” links to access the file.
Woodward 83
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-1 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-
1 control(s) RS-422 network.
The laptop or desktop computer which will be used with the EGCP-1 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-1 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-1 control network. This conversion is
accomplished by an external conversion module which takes the 9-pin RS-232
serial port input from the computer, and changes it to a 25-pin RS-422 protocol
for the EGCP-1. These converters can be found in most computer or electronics
stores, and are called RS-232 to RS-422 Converters. Below is a diagram of a
typical cable used between the computer and the EGCP-1 with the converter
installed on it.
In a system with multiple (8 maximum) EGCP-1 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.
84 Woodward
Unit #1 Unit #2 Unit #8
EGCP-1 EGCP-1 EGCP-1

J8-7 J8-7 J8-7
J8-5 J8-5 J8-5
422Rx 422Rx 422Tx 422Tx 422Rx 422Rx 422Tx 422Tx 422Rx 422Rx 422Tx 422Tx
(+) (-) (+) (-) (+) (-) (+) (-) (+) (-) (+) (-)
J8-3 J8-6 J8-8 J8-9 J8-3 J8-6 J8-8 J8-9 J8-3 J8-6 J8-8 J8-9
Twisted shielded pair. Belden 3074F or equivalent
Note:
422Rx(-) A complete cable/converter
assembly is available as
422Rx(+) Woodward p.n.
5416-870
422Tx(-)
422Tx(+)
IBM compatible computer

Pentium based w / Windows '9X or NT 4.0
Figure 9-1. RS-422 Communications
NOTE
The RS-422 Termination dip switches should 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 may cause
communication drop out errors.
+5 Vdc +5 Vdc
243 121.5 243 243 121.5 243
SW3-4 SW3-2
SW3- SW3- SW3- SW3-

8 7 1 3
422 RxD (+)

485 (+) J8-3
J8-1
422 RxD (-)
J8-6
485 (-)
J8-2 Shield
J8-7
Shield
J8-7 422 TxD (+)
RS 422/485
Transceiver J8-8
RS 422/485 422 TxD (-)

Transceiver J8-9
RS-485 Termination RS-422 Termination J8-5
Figure 9-2. RS-485 and RS-422 Termination Diagrams
For detailed wiring diagrams pertaining to the RS-422 network of the EGCP-1
controls, please consult the plant wiring diagram in this manual.
Woodward 85
Inter-control Communications (RS-485 Network)

The EGCP-1 uses a proprietary communication structure to share information
between multiple EGCP-1 controls in a system. This communication structure
allows accurate load sharing, status, and command messages to be exchanged
between up to 8 units. The network uses RS-485 protocol over a standard
twisted shielded pair to link the units in the system together. The end units of the
network must have the proper network termination switches selected at Switch
Location 3. Switches 4, 7, and 8 must be on to ensure robust inter-control
communications, and prevent reflected data from propagating on the network.
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-1 which is used to monitor and control the units
remotely.
Unit #1 Unit #2 Unit #8
EGCP-1 EGCP-1 EGCP-1

J8-7 J8-7 J8-7
485 485 485 485 485 485

(+) (-) (+) (-) (+) (-)
J8-1 J8-2 J8-1 J8-2 J8-1 J8-2
Twisted shielded pair. Belden 3074F or equivalent
Figure 9-3. RS-485 Inter-Control Communications
Modbus RTU Communications for the EGCP-1 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-1 panel should be unique
from any other devices on the Modbus network.
NOTE
The Network Address of the EGCP-1 panel is not linked to the Modbus ID in
any way.
Modbus Time-out is located in the shutdown and alarms configuration menu.

This item is the time, in seconds, that the EGCP-1 panel will wait before either
receiving a valid message from the Modbus master, or indicating a Modbus
failure. The EGCP-1 panel indicates a Modbus failure in the Load Control
Monitor status menu, and is displayed in the upper right corner of the lower LCD
display. 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 6-2 for a list of common
error numbers which may be seen in the Load Control Monitor Display.
86 Woodward
The Modbus Reset is located in the shutdown and alarms 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-1 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).
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 6-3 for more information on
typical settings.
Table 6-1. Modbus Addresses for the EGCP-1 Modbus RTU Protocol
NOTE
Input #1 (Auto), Input #2 (Test), and Input #3 (Run With Load) must be sent
as a group so that the receiving slave sees all three addresses in the same
message. Logic within the EGCP-1 requires these three inputs be received
from Modbus in order to switch from monitoring the hardware inputs for
these switches to the Modbus inputs for these switches. The switch does
not have to change state from hardware to Modbus. It is the reception of
these three inputs over Modbus which causes the transition from hardware
to Modbus monitoring. Any transition of any of the three hardware inputs
will reset the monitoring of these three switches back to the hardware, until
a new Modbus message is received containing all three BW addresses.
Address Data Type/Scaling Description

1 BW Change Input #1 (Auto)
2 BW Change Input #2 (Test)
3 BW Change Input #3 (Run With Load)
4 BW Change Input #4 (Voltage Raise)
5 BW Change Input #5 (Voltage Lower)
6 BW Change Input #6 (Speed Raise)
7 BW Change Input #7 (Speed Lower)
8 BW Change Input #10 (Process I/E)
9 BW Change Input #11 (Fault #1)
15 BW Not Used
16 BW Commit All Alarms
10001 DI Bus PT Switch Stable

10002 DI Mains Stable Indication
10003 DI Bus Stable Indication
10004 DI Alarm Status
10005 DI Loss of Mains Status
10006 DI Relay #1 (Mains Brkr Close) Status
10007 DI Relay #2 (Gen Brkr Close) Status
10008 DI Relay #3 (Engine Preglow) Status
10009 DI Relay #4 (Fuel Solenoid) Status
10010 DI Relay #5 (Engine Crank) Status
Woodward 87
10011 DI Relay #6 (Visual Alarm) Status
10012 DI Relay #7 ( Bus PT Connect) Status
10013 DI Relay #8 (Mains PT Disconnect) Status
10014 DI Relay #9 (Mains Brkr Trip) Status
10015 DI Relay #10(Gen Brkr Trip) Status
10016 DI Relay #11(Audible Alarm) Status
10017 DI Relay #12 (Not Used) Status
10018 DI Input #1 Status (Auto)
10019 DI Input #2 Status (Test)
10020 DI Input #3 Status (Run with Load)
10021 DI Input #4 Status (Voltage Raise)
10022 DI Input #5 Status (Voltage Lower)
10023 DI Input #6 Status (Speed Raise)
10024 DI Input #7 Status (Speed Lower)
10025 DI Input #8 Status (Gen CB Aux.)
10026 DI Input #9 Status (Mains CB Aux.)
10027 DI Input #10 Status (Process I/E)
10028 DI Input #11 Status (Fault #1)
10034 DI SYNC_TIMEOUT Status
10035 DI SYNC_RECLOSE Status
10036 DI CRANK_FAIL Status
10037 DI VOLTAGE_RANGE Status
10038 DI OVERSPEED Status
10039 DI OVERCURRENT Status
10040 DI REVERSE_POWER Status
10041 DI LOSS_OF_EXCITATION Status
10042 DI SPEED_FREQ_MISMATCH Status
10043 DI H2O_HIGH_LIMIT Status
10044 DI H2O_LOW_LIMIT Status
10045 DI OIL_PRESS_HIGH_LIMIT Status
10046 DI OIL_PRESS_LOW_LIMIT Status
10047 DI BATT_VOLT_LOW_LIMIT Status
10048 DI BATT_VOLT_HIGH_LIMIT Status
10049 DI GEN_VOLT_LOW_LIMIT Status
10050 DI GEN_VOLT_HIGH_LIMIT Status
10051 DI GEN_FREQ_HIGH_LIMIT Status
10052 DI GEN_FREQ_LOW_LIMIT Status
10053 DI LOAD_HIGH_LIMIT Status
10054 DI LOAD_LOW_LIMIT Status
10055 DI PROCESS_HIGH_LIMIT Status
10056 DI PROCESS_LOW_LIMIT Status
10057 DI REMOTE_FAULT1 Status
10063 DI LOAD_SURGE Status
10064 DI MAINS_VOLT_LOW_LIMIT Status
10065 DI MAINS_VOLT_HIGH_LIMIT Status
10066 DI MAINS_FREQ_HIGH_LIMIT Status
10067 DI MAINS_FREQ_LOW_LIMIT Status
10068 DI External LOM Status
10069 DI Generator Output Stable
88 Woodward
10070 DI Voltage Sense Configuration
10071 DI PF Leading/Lagging Indicator
NOTE
LOM Alarm Actions (Load Surge, Mains Voltage, Mains Frequency)
The Loss of Mains (LOM) Alarms, when configured for any state except for Disabled,
will indicate a “True” state when the alarm condition is true. The alarm states are
considered to be true as follows:
Load Surge: Any instantaneous change in generator load equal to or greater than the
Load Surge setpoint. No Time Delay.
Mains Voltage High/Low Limit: Any change in the Mains Voltage equal to or greater
than the high limit setpoint, or less than or equal to the low limit setpoint. The alarm
condition will register true only if the high/low limit is exceeded for at least the LOM
action delay time.
Mains Frequency High/Low Limit: Any change in the Mains Frequency equal to or
greater than the high limit setpoint, or less than or equal to the low limit setpoint. The
alarm condition will register true only if the high/low limit is exceeded for at least the
LOM action delay time.
Due to the asynchronous nature of the triggering of the alarm state, and the
Modbus polling time, a software latch on the alarm indication is used. This latch
does not affect the actual indication of the alarm condition on the 6000 control panel.
The latch is active only on the Modbus messaging between the 6000 panel and the
Modbus communications. The latch is set by the occurrence of any of the LOM Alarm
actions, and is only reset if the alarm condition no longer exists, and the pre-existing
alarm condition has been actively read once by the Modbus master. This means that
short duration LOM alarm events, such as Load Surge, will always show true for one
Modbus poll cycle after the occurrence of the alarm. If the alarm condition no longer
exists after this poll cycle, the Modbus alarm indication will reset to false as the
alarm condition is no longer true.
Momentary Switches (Voltage Raise/Lower, Speed Raise/Lower)
The four momentary switch inputs to the EGCP-1 are internally (EGCP-1 software)
timed to open after a one second ON time.
This means that if the EGCP-1 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-1 will continue holding the switch ON until one second
after the last active Modbus On update is received.
NOTE: ANALOG INPUTS ARE SIGNED DATA.

30001 AI X10 Battery Voltage
30002 AI X10 Engine Oil Pressure
30003 AI Engine Coolant Temperature
30004 AI Engine Run Time
30005 AI Engine KW/Hours
30006 AI Engine RPM
30007 AI Phase A Volts
30008 AI Phase B Volts
30009 AI Phase C Volts
30010 AI Total KW
30011 AI Total KVA
30012 AI X100 Generator Power Factor
30013 AI Phase A kVAR
30014 AI Phase B kVAR
30015 AI Phase C kVAR
30016 AI Total kVAR
30017 AI X10 Bus Output Frequency
30018 AI X10 Generator Output Frequency
30019 AI Network Address
30020 AI SYNC_TIMEOUT Action
30021 AI SYNC_RECLOSE Action
Woodward 89
30022 AI CRANK_FAIL Action
30023 AI VOLTAGE_RANGE Action
30024 AI OVERSPEED Action
30025 AI OVERCURRENT Action
30026 AI REVERSE_POWER Action
30027 AI LOSS_OF_EXCITATION Action
30028 AI SPEED_FREQ_MISMATCH Action
30029 AI H2O_HIGH_LIMIT Action
30030 AI H2O_LOW_LIMIT Action
30031 AI OIL_PRESS_HIGH_LIMIT Action
30032 AI OIL_PRESS_LOW_LIMIT Action
30033 AI BATT_VOLT_LOW_LIMIT Action
30034 AI BATT_VOLT_HIGH_LIMIT Action
30035 AI GEN_VOLT_LOW_LIMIT Action
30036 AI GEN_VOLT_HIGH_LIMIT Action
30037 AI GEN_FREQ_HIGH_LIMIT Action
30038 AI GEN_FREQ_LOW_LIMIT Action
30039 AI LOAD_HIGH_LIMIT Action
30040 AI LOAD_LOW_LIMIT Action
30041 AI PROCESS_HIGH_LIMIT Action
30042 AI PROCESS_LOW_LIMIT Action
30043 AI REMOTE_FAULT1 Action
30049 AI LOAD_SURGE Action
30050 AI MAINS_VOLT_LOW_LIMIT Action
30051 AI MAINS_VOLT_HIGH_LIMIT Action
30052 AI MAINS_FREQ_HIGH_LIMIT Action
30053 AI MAINS_FREQ_LOW_LIMIT Action
30054 AI External LOM Action
30055 AI Generator Phase A/Neutral Volts
30056 AI Generator Phase B/Neutral Volts
30057 AI Generator Phase C/Neutral Volts
30058 AI Mains/Bus Phase A/Neutral Volts
30059 AI Phase A current
30060 AI Phase B current
30061 AI Phase C current
30062 AI Phase A KVA
30063 AI Phase B KVA
30064 AI Phase C KVA
30065 AI Voltage Bias Analog Output (0-100%)
30066 AI Speed Bias Analog Output (0-100%)
30067 AI Load Control Mode
30068 AI Synchronizer Mode
30069 AI Number of Unacknowledged Alarms
30070 AI Unit Network Priority
30071 AI Master Unit. See Note on Master Unit.
30072 AI Engine State. See Note on Engine State.
30073 AI Synchroscope. See Note on Phase Angle.
90 Woodward
NOTES ON AI MESSAGES:
Typical Conditions: Open/False = 0, Closed/True = 1.
Alarm Actions Defined As Follows: 0 = Disabled, 1 = Warning, 2 = Visual Alarm, 3 =
Audible Alarm, 4 = Soft Shutdown, 5 = Hard Shutdown.
NOTE! External LOM is not used at this time.
Loss Of Mains Actions Defined As Follows: 0 = Disabled, 1 = Warning, 2 = Loss of
Mains, 3 = Loss of Mains With Alarms.
PF Leading/Lagging Indication Defined As Follows: 0 = Lagging, 1 = Leading.
Voltage Sense Configuration Defined As Follows: 0 = Line to Neutral, 1 = Line to
Line.
Load Control Modes Defined As Follows: 0 = Off, 1 = Droop, 2 = Isochronous, 3 =
Baseload, 4 = Process.
Droop = Droop Load Control Setpoint Selected and Generator on load.
Isochronous = Normal or Soft Transfer Load Control Setpoint Selected, and Gen on
load, but not in parallel with mains.
Baseload = Normal or Soft Transfer Load Control Setpoint Selected, and Gen on
load, and in parallel with mains.
Process = Same as Baseload, but Process Discrete Input is Active.
Synchronizer Control Modes Defined As Follows: 0 = Off, 1 = ATS, 2 = Parallel, 3 = In
Synch, 4 = ATS Return, 5 = Parallel Mains, 6 = Gen Close Timer, 7 = Mains Close
Timer, 8 = Gen Synch Timer, 9 = Main Synch Timer.
ATS = Auto Transfer State. Trying to Open Mains Breaker.
Parallel = Trying to Close Gen Breaker.
Parallel Mains = Trying to Close Mains Breaker
ATS Return = Trying to Open Gen Breaker.
In Sync = Gen Breaker/Mains Breaker Closed Successfully, and held for synch timer.
Gen Close Timer = Gen Breaker Close Issued. Checking for good closure.
Mains Close Timer = Mains Breaker Close Issued. Checking for good closure.
Gen Synch Timer = Checking for successful synchronization of generator.
Main Synch Timer = Checking for successful synchronization of mains.
Master Unit: Master Unit value is the Network Address of the Master Unit. Units not in
Auto cannot display active Master information, and should not be relied upon for this
information.
Engine State: The Current Engine State is represented by the following integer
values:
1=Off, 2=Preglow, 3=Crank, 4=Run, 5=Cooldown, 6=Spindown, 7=Restart
Phase Angle: The Phase Angle reading is a value from 0 (phase matched at 12:00 on
a synchroscope) to ±180 degrees. Negative degree measurements occur in the right
half of the synchroscope, while positive degree measurements occur in the left half
of the synchroscope. Therefore, a generator with a positive slip frequency (clockwise
synchroscope rotation) would display a sequence of numbers such as 0, –30, –60, –
90,
–120, –150, –180, 150, 120, 90, 60, 30, 0....

40001 AW 1 to 8 Priority Change Address
Changing Priority:
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.
Woodward 91
Table 6-2. 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 Data was received by the slave, 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-1. Reduce
message sizes to correct.
20 Unsolicited Response Unsolicited message received by the
slave.
Table 6-3. Typical Modbus Communications Settings
NOTE
Communications settings will vary based on the Modbus system
configuration. These settings are the recommended typical settings for a
multiple unit EGCP-1 system connected to Modbus master.
Poll Time Number of Retries Retry Delay Timeout

1.0 seconds 3 1.0 second* 10 seconds
1second is the minimum recommended retry 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.
92 Woodward
Chapter 10.
Service Options
Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.
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 also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call 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 Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).
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 to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.
Woodward 93
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.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• 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.
CAUTION
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.
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.
94 Woodward
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
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.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058
For assistance outside North America, call one of the following international
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.
Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
Woodward 95
Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—[email protected]
Website—www.woodward.com
Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard

classes). 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. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.
Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized 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 field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.
96 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 97
We appreciate your comments about the content of our publications.
Send comments to: [email protected]
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.
04/11/F

EGCP-1 Engine Generator Control Package: Installation (Set Builder) Manual

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Installation (Set Builder) Manual

Electronic controls contain static-sensitive parts. Observe the following

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Illustrations and Tables

Figure 3-1. Keypad .................................................................................................5

Illustrations and Tables

Figure 8-15. Generator Stop Sequence ...............................................................74

Control Part Numbers

Nominal AC Voltage as measured across + to – inputs for AC Mains/Bus and

All electronic equipment is static-sensitive, some components more than others.

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

Real (kW) Load Control

Reactive (KVAR) Control

Automatic Generator Sequencing

Generator Protective Features

Engine Protective Features

Figure 3-1. Keypad

A larm R eset C om m it E scape

Up Key Down Key Left Key Right Key

Discrete Inputs and Outputs

Here is a list of the discrete inputs available to the EGCP-1 control.

Figure 3-2. Physical Outline with Dimensions of EGCP-1

Connector location and pin/socket numbers are identified by connector number-

Dip switch locations are identified by switch location-switch number throughout

Wiring Diagram for EGCP-1

Figure 3-4. Wiring Diagram for EGCP-1

Location Description Signal Burden

J5-18 Generator PT phase B + AC Voltage 200 kΩ

J5-17 Generator PT phase C + AC Voltage 200 kΩ

J5-9 Generator CT phase A Current AC Current 0.067 Ω

J5-20 Mains/Bus PT + AC Voltage 200 kΩ

J1-2 Magnetic Pickup + AC Frequency 15 kΩ

DC Inputs and Outputs

J5-2 + Process Signal 4–20 mA Isolated Input

J1-17 + Speed Bias ±3 Vdc

J5-3 + Voltage Bias ±1, 3, or 9 Vdc Isolated Output

J1-9 Pressure Sensor + 0–200 sensor Internal Voltage Source

J1-5 Temp Sensor + 0–200 sensor Internal Voltage Source

Switches SW1-5 through SW1-8

Speed Bias Output

+/- 1 Vdc - On- (5)

+/- 3 Vdc - On- (1), (4)

+/- 9 Vdc - On- (2), (3), (4)

J5-3 Voltage Bias Output

J2-26 Gen Brkr Close NC Discrete Output (D02) 10 A @ 120 Vac,

J2-25 Engine Preglow NC Discrete Output (DO3) 10 A @ 120 Vac,

J2-36 Fuel Solenoid NC Discrete Output (DO4) 10 A @ 120 Vac,

J2-25 Crank Engine NC Discrete Output (DO5) 10 A @ 120 Vac,

J2-33 Visual Alarm NC Discrete Output (DO6) 10 A @ 120 Vac,

J2-23 Bus PT Connect NC Discrete Output (DO7) 10 A @ 120 Vac,

J2-22 Mains PT Disconnect NC Discrete Output (DO8) 10 A @ 120 Vac,

J2-3 Mains Brkr Trip NC Discrete Output (DO9) 10 A @ 120 Vac,

J2-12 Gen Brkr Trip NC Discrete Output (DO10) 10 A @ 120 Vac,

J2-21 Not Used