EGCP-3 Installation Manual 26122
Environmental Specifications
Please refer to Technical Specifications in Appendix C and inside the back cover
of this manual for environmental characteristics. When installed on a generator
package, the EGCP-3 should be mounted in a suitable enclosure where the
entire enclosure is isolated from engine and generator vibrations above 30 Hz.
Electrical Connections
Most inputs and outputs to the EGCP-3 are made through “CageClamp” terminal
blocks.
For noise suppression, it is recommend that all low-current wires be separated
from all high-current wire.
See Appendix A for additional information on connector wiring.
Most of the EGCP-3 control’s terminal blocks are designed for removal by hand.
After EGCP-3 input power is disconnected, the pluggable terminal blocks can be
removed one at a time by pulling them straight out. Be careful not to pull the plug
out at an angle, as this will fracture the end terminal.
Each Terminal block has a label (PS, PSEN, SCOR) to indicate which board it is
used with, and terminal numbering to indicate which terminal block on that board
to plug into. The board assemblies also are marked with a label to match with
terminal block labels.
The pluggable terminal blocks are screwless CageClamp-style blocks. The
spring clamp can be opened with a standard 2.5 mm (3/32 inch) flat bladed
screwdriver (see Figure 2-2). The EGCP-3 pluggable terminal blocks accept wire
28 to 18 AWG (0.08 to 0.8 mm²). One 18 AWG (0.8 mm²) wire, or two 20 AWG
(0.5 mm²) wires, or three 22 AWG (0.3 mm²) wires can be easily installed in each
terminal. Wires for the pluggable I/O terminals should be stripped 8 mm (0.3
inch).
Method #1 Method #2
Free Hand (holds spring open) Bench (opens spring
while force is applied)
Figure 2-2. Wiring of Pluggable Spring Clamp Terminals
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Manual 26122 EGCP-3 Installation
The EGCP-3 fixed terminal blocks used for the power supply input accept wires
from 28 to 18 AWG (0.08 to 0.8 mm²). One 18 AWG (0.8 mm²) wire, or two 20
AWG (0.5 mm²) wires, or three 22 AWG (0.3 mm²) wires can be easily installed
in each terminal. Wires for the fixed mounted power terminals should be stripped
5 mm (0.2 inch).
Figure 2-3. Wiring of Fixed Terminal
NOTE
Do not tin (solder) the wires that terminate at the EGCP-3 terminal blocks.
The spring-loaded CageClamp terminal blocks are designed to flatten
stranded wire, and if those strands are tinned together, the connection loses
surface area and is degraded.
All ac wiring for voltages and currents is done with fixed screw barrier blocks
rather than pluggable terminal blocks. The fixed screw barrier blocks accept
wires terminated into terminal lugs for #6 screws.
Figure 2-4. Fixed Ring Terminals
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EGCP-3 Installation Manual 26122
Grounding for Protection Against Electrical Shock
Protective Earth (PE) must be connected to the termination point on the backside
of the unit next to the label with the symbol (or 1 of 3 other like
termination points without label) to reduce the risk of electric shock. This
connection will be made using a thread-forming screw (M4 x 6 mm). The
conductor providing the connection must have a properly sized ring lug and wire
larger than or equal to 3.3 mm² (12 AWG).
Recommended Grounding Practices
Providing the proper ground for the EGCP-3 is important. Improper connection of
the EGCP-3 chassis to the ground plane may lead to stray currents between the
reference point for the ac signal sources (current and voltage transformers), and
the reference point for the sensing inputs on the EGCP-3. Differences in potential
between these two points results in equalizing current flow which then produces
unacceptably high common mode voltages. Common mode voltages may result
in improper readings for the sensed ac inputs, or even damage to the EGCP-3 in
extreme cases. To minimize this problem, it is necessary to provide a low
resistance path between the ac signal reference point, and the chassis of the
EGCP-3. Typically this point is the designated ground for the generator set and
related instrument transformers.
Generator
Ground Bonding Conductor
VIS-144
00-8-23
EGCP-3 chassis ground
lug connection point (4)
TB 1 TB 2 TB 3 TB 4
Back of EGCP-3
TB 5 TB 6 TB7 TB8 TB9
Figure 2-5. Recommended Single Point Grounding Scheme
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Manual 26122 EGCP-3 Installation
Shields and Grounding
An individual shield termination is provided at the terminal block for each of the
signals requiring shielding. These include all sensor wiring and ac signal inputs.
Relay outputs, contact inputs, ac power inputs, and power supply wiring does not
normally require shielding, but can be shielded if desired. All shielded cable must
be a twisted conductor pair. Do not attempt to tin (solder) the braided shield. All
signal lines should be shielded to prevent picking up stray signals from adjacent
equipment. Wire exposed beyond the shield should be as short as possible, not
exceeding 50 mm (2 inches). The other end of the shields must be left open and
insulated from any other conductor.
The EGCP-3 is designed for shield termination to earth ground at the EGCP-3. If
intervening terminal blocks are used in routing a signal, the shield should be
continued through the terminal block. If shield grounding is desired at the
terminal block, it should be ac coupled to earth. All other shield terminations
except at the EGCP-3 should be ac coupled to earth through a capacitor. A 1000
pF, 500 V capacitor is sufficient. The intent is to provide a low impedance path to
earth for the shield at frequencies of 150 kHz and up. Multiple direct connections
of a shield to earth risk high levels of current to flow within the shield. See
Woodward application note 50532, Interference Control in Electronic Governing
Systems, for more information.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below.
1. Strip outer insulation from both ends, exposing the braided or spiral wrapped
shield. Do not cut the shield.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type, twist
it to prevent fraying.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
5. Connect wiring and shield as shown in plant wiring diagram.
For noise suppression reasons, it is recommend that all low-current wires be
separated from all high-current wires. Input power ground terminal should also
be wired to earth ground. Installations with severe electromagnetic interference
(EMI) may require additional shielding precautions, such as wire run in conduit or
double shielding. Contact Woodward for more information.
Shields can be grounded at both ends (EGCP-3 and load) if the cable length is
sufficiently short (within a cabinet) to prevent ground loop current in the shield.
Cabinet Installations: If the EGCP-3 is installed in a cabinet, shielded I/O can be
terminated directly to the cabinet (earth ground) at the entry to the cabinet, as
well as at the EGCP-3.
Isolation
Figure 2-6 shows how the I/O is isolated with regard the main system power
supply and other I/O types. Each input wiring diagram also shows how an input
type is isolated in more detail.
Figure 2-6 uses numerals to indicate isolation grouping. Power and Ground
isolation groups are indicated with a P# and G#. Every instance of the same P#
and G# indicates that the item is part of the same group and not isolated from the
other members of the same group. For example, all analog inputs, analog
outputs, and CPUs use P9 for power and G9 for ground.
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