Category: Woodward

HARDWARE SPECIFICATIONS

Size:

Operator Interface Panel:

Power Supply Voltage:

Control Part Numbers:

Connectors:

Voltage Measuring Input Range:

Current Measuring Inputs:

Temperature Range:

Humidity:

Enclosure Rating:

Vibration:

Mechanical Shock:

Regulatory Compliance (pending):

281.8mm (11.1”) High x 358.1mm (14.1”) Wide x 134.0mm (5.275”) Deep

8 (20 Character) lines plus membrane keypad

24 Vdc system (18–32 Vdc nominal; 9–40 Vdc maximum)

DR: 8406-103

LS: 8406-113

MC: 8406-114

Terminal blocks are screwless CageClamp style blocks. PT and CT inputs

are fixed screw terminals.

70–300 Vac

5 Aac RMS nominal, 7 Aac RMS maximum –20 to +70 °C operating; –30 to +80 °C storage

95% at +60 °C non-condensing

Meets IP56 (IEC) and Type 4 (NEMA) requirements from the front panel and

properly installed in an equivalent enclosure

Suitable for engine skid or control cabinet

Random Test: 10–2000 Hz at 0.04 G²/Hz and 8.2 Grms PSD

30 g peak, 11 ms duration, non-operating

UL508; CSA Hazardous Locations Class I, Division 2. Groups A–D

IEC Zone 2 European Group IIC

EEC EMC Directive; EEC Low-Voltage Directive

Marine LR

RINA, ABS, and GL classifications

EGCP-3 Applications

• Single Unit—No Utility Parallel

• Single Unit—Utility Parallel

• Multiple Unit—No Utility Parallel

• Multiple Unit—Utility Parallel

• Multiple Unit—Multiple Utility Feeds Parallel

Generator Protective Features

• Over/Under Voltage (27.59)

• Over/Under Frequency (81O,81U)

• Directional (Forward/Reverse) Power (32)*

• Negative Phase Sequence Overcurrent (46)

• Negative Phase Sequence Overvoltage (47)

• Phase Overcurrent (51)*

• Directional VAR

• Phase Current Differential Imbalance (87)*

• Speed/Frequency Mismatch

• Load Surge

Utility Protective Features

• Over/Under Voltage (27.59)

• Over/Under Frequency (81O,81U)

• Directional (Forward/Reverse) Power (32)*

• Negative Phase Sequence Overcurrent (46)

• Negative Phase Sequence Overvoltage (47)

• Phase Overcurrent (51)*

• Voltage Restrained Phase Overcurrent (51V)*

• Directional VAR

• Phase Current Differential Imbalance (87)*

• Loss of Mains/Loss of Mains with Alarm

*—Inverse Time Protections implemented are according to IEEE C37.112 “Very Inverse” curves

Automatic Unit Sequencing

• Automatically starts and stops gen-sets based on plant bus demand

• Automatic generator set loading and unloading for bumpless transfer

• Configurable plant bus demand startstop levels and timers

• Configurable generator priority sequencing

Communications

• Modbus® RTU or DDE communications via RS232 (1 each) and RS-232/422/485 (2 each) serial ports

• Echelon® TP/XF-1250 network

• CAN 2.0b Network (OEM option only)

Reactive kVAR Control

• VAR (PF) sharing on isolated busses using percentage based reactive load sharing

• Voltage bias signal to AVR configurable for discrete raise/lower,4–20 mA, ±1. ±3. or ±9 Vdc

• Power factor or VAR control when base loaded

• Externally adjustable VAR or PF setpoint levels

• Manual voltage control capability

• Configurable load/unload ramp rates

Synchronizing

• Phase match or slip frequency synchronization with voltage matching

• Full three-phase sensing on both busses

• Manual synchronization capability

• Adjustable phase window, voltage window, reclose attempts, reclose timing

• Safe dead bus closing logic internal to the control

• Synch check (25)

• Breakers or contactors

Reactive kVAR Control

• VAR (PF) sharing on isolated busses using percentage based reactive load sharing

• Voltage bias signal to AVR configurable for discrete raise/lower,4–20 mA, ±1. ±3. or ±9 Vdc

• Power factor or VAR control when base loaded

• Externally adjustable VAR or PF setpoint levels

• Manual voltage control capability

• Configurable load/unload ramp rates

Synchronizing

• Phase match or slip frequency synchronization with voltage matching

• Full three-phase sensing on both busses

• Manual synchronization capability

• Adjustable phase window, voltage window, reclose attempts, reclose timing

• Safe dead bus closing logic internal to the control

• Synch check (25)

• Breakers or contactors

Automatic Unit Sequencing

• Automatically starts and stops gen-sets based on plant bus demand

• Automatic generator set loading and unloading for bumpless transfer

• Configurable plant bus demand startstop levels and timers

• Configurable generator priority sequencing

Communications

• Modbus® RTU or DDE communications via RS232 (1 each) and RS-232/422/485 (2 each) serial ports

• Echelon® TP/XF-1250 network

• CAN 2.0b Network (OEM option only)

Custom OEM Configurations

Among the many EGCP-3 control functions are:

Engine Control/Protection

• Configurable start sequencing

• kVA-controlled cool-down timer

• Oil pressure monitoring (idle/rated)

• Coolant temperature monitoring

• Battery voltage monitoring

• Speed monitoring with overspeed protection

Real kW Load Control

• True RMS power calculations

• Load bias signal to engine speed control, configurable for ±3 Vdc, 0–5

Vdc, 500 Hz PWM, 4–20 mA, discrete raise/lower

• Configurable loadunload ramp rates

• Isochronous load-sharing of up to 16 EGCP-3 units using percentage based load sharing

• Built-in import/export control

• Soft utility transfer function

• Externally adjustable load or process references

DESCRIPTION

EGCP-3 is available in standard configurations including:

DR—Distributed Resource:

• Single unit isolated

• Single unit parallel to mains

• Single unit ATS

LS—Load Share:

• Multiple unit isolated

• Multiple unit parallel to mains

MC—Master Controller:

• Mains tie breaker control

• Inter-bus tie breaker control

Features

• Complete generator system control package

• Automatic load demand sequencing of multiple units

• Three-phase synchronization

• Comprehensive system protection –engine, utility, and generator

• Revenue-grade power and energy metering

• Digital display of engine, generator, and system data

• Real kW and reactive kVAR load sharing and control

• Additional on board and distributed I/O available

• Easily adapts to exact application needs with GAP™ programming tools

• Advanced network communications

• DSLC™ compatible

• Built-in diagnosticsWoodward EGCP-3

APPLICATIONS

EGCP-3 is a powerful microprocessor based generator system control and

management package designed for the most demanding power generation applications.

EGCP-3 combines engine, generator, power system, switchgear, and utility monitoring,

protection, and control functions in a single, compact, and cost-effective package.

Perfect for medium- and large-sized generation systems, the EGCP-3 is designed 

for use in stand-alone, peaking, or utility paralleled systems.

Up to 16 EGCP-3 controls can be networked together to provide total system

control, including multiple utility and  inter-bus tie breakers.

DESCRIPTION

EGCP-3 is available in standard configurations including:

DR—Distributed Resource:

• Single unit isolated

• Single unit parallel to mains

• Single unit ATS

LS—Load Share:

• Multiple unit isolated

• Multiple unit parallel to mains

MC—Master Controller:

• Mains tie breaker control

• Inter-bus tie breaker control

Using the sequencing functionality of the EGCP‐3. the control is configured to

start an additional unit two seconds after the load on the master unit exceeds 75%.

When the load reduces to below 30%, the slave unit is removed from the system after 60 seconds.

The controls needs to be able to trade master/slave relationships,

so a switch is used to place one control in Auto and Run w/ Load (Master)

and the second unit in Auto (Slave). Both controls have the option to operate in either

mode—so if sequencing needs to be avoided, the operator can place both

controls in Auto and Run w/ Load, and both units will share the entire electrical load.

The closed transition to shore power was solved by sending a remote fault input to the EGCP‐3 when the

shore power breaker is closed onto the system. When coming into port, ship’s power is reduced before

synchronizing to shore power. This means that only one unit is online with low load. When shore power is

connected, the operator adjusts a switch from “Generators” to “Shore” power. Instigating this switch turns

on the SPM‐D and allows the unit to begin sending digital signals to the EGCP‐3 LS to synchronize the

ship’s power to shore power.

When the breaker is closed, the aux feedback is sent to a remote input on the EGCP‐3 that opens the

generator breaker and shuts the generator down. The system is then completely supplied by shore power.

When the ship switches back to Generators, the remote input is cleared and the unit coming online

synchronizes to the shore power, closes its breaker, and the shore power breaker is immediately opened.

The system is then on Generator power.

Application

The ship’s chief engineer required several modes of operation in order to

optimize the performance of the yacht’s electrical system.

During normal operation, the load on the ship can be supplied by one genset, but when seas are

rough and the ship’s stabilizers are running, there is a need for additional generation.

In this mode of operation, both gensets must run continuously.

Also, the ship needs to be connected to shore power when in port.

In order to eliminate a blackout on the ship during the power transfer,

and to reduce the amount of load generated to the shore power,

a scheme was developed to provide an automatic closed transition using a Woodward SPM‐D.

Using the sequencing functionality of the EGCP‐3. the control is configured to

start an additional unit two seconds after the load on the master unit exceeds 75%.

When the load reduces to below 30%, the slave unit is removed from the system after 60 seconds.

The controls needs to be able to trade master/slave relationships,

so a switch is used to place one control in Auto and Run w/ Load (Master)

and the second unit in Auto (Slave). Both controls have the option to operate in either

mode—so if sequencing needs to be avoided, the operator can place both

controls in Auto and Run w/ Load, and both units will share the entire electrical load.

Electrical System

The Sea Jewel’s two Cat 3304 gensets are rated for 80 kW each. Each genset is

controlled by a Woodward EGCP‐3 LS and can connect to the ship electrical load via

its generator breaker. The load can also be supplied by shore power when in port.

To synchronize the boat to shore power, a Woodward SPM‐D delivers

synchronization signals to the two EGCP‐3 LS units and closes the breaker when

phase and frequency are matched.

Conclusions

The commissioning of the Sea Jewel was a success, and operation of an EGCP‐3 and SPM‐D illustrated the

adaptability of Woodward controls to any application. By applying the EGCP‐3 LS units to the control of

the Cat gensets and the SPM‐D for synchronizing the shore power, the Sea Jewel now has a reliable

system to begin their chartering business this summer. Woodward would like to thank Sea Jewel Ltd and

Governor Control Systems fortheir time and energy on this project and congratulates them on a great

control system.