Woodward EGCP-3 8406-113 Digital Generator Control

Description

Key Technical Specifications

Product Introduction & Supply Chain Strategy

The Woodward EGCP-3 (Part Number 8406-113) is a digital engine-generator control package engineered for complex multi-unit paralleling power generation systems. Designed to handle automatic sequencing, speed governing, voltage regulation, synchrocheck, and digital KW/KVAR load sharing, the 8406-113 provides complete engine protection and utility tie management across standby and prime power installations.

Because the EGCP-3 series has moved into legacy status with limited OEM manufacturing availability, stocking the 8406-113 as New Surplus is a vital risk-mitigation strategy for mission-critical power systems. A failure in an active paralleling controller halts automatic emergency power transfer for entire critical infrastructure facilities. Sourcing New Surplus inventory eliminates the severe multi-week lead times required for full switchgear re-engineering while completely avoiding the premature relay wear and capacitor degradation inherent to refurbished controllers.

Installation & Configuration Guide

Stage 1: Pre-Installation (Prep & Safety)

1. Lock-Out/Tag-Out (LOTO): De-energize all 24 VDC control power feeds, AC voltage sensing lines from the bus and generator, and current transformer (CT) shorting blocks before servicing.
2. CT Shorting Safety: Ensure all current transformer secondaries are shorted at the terminal block before disconnecting CT wiring leads to prevent high-voltage hazards.
3. Documentation: Record all current DIP switch positions, communication network addresses, and take clear photos of all rear terminal harness landings on the existing unit.

Stage 2: Removal

1. Unplug the multi-pin terminal block connectors for control power, discrete inputs, relay outputs, and analog control lines.
2. Disconnect the RS-485 and CANbus communication cables.
3. Loosen the panel mounting bracket hardware surrounding the EGCP-3 housing and carefully extract the unit from the front cutout.

Stage 3: Installation (Clone & Seat)

1. Slide the new EGCP-3 8406-113 into the standard panel cutout and tighten the mounting clamps evenly to preserve the front panel IP seal.
2. Set rear DIP switches and terminating resistor jumpers to match the outgoing unit’s network topology.
3. Re-plug all terminal block connectors into their designated backplane sockets, verifying terminal numbers against the electrical schematic. Un-short the CT blocks once connections are verified.

Stage 4: Power-On & Testing

1. Apply 24 VDC control power and observe the boot sequence. Verify that the unit powers up to the main display screen without triggering internal system fault indicators.
2. Connect a PC running Woodward ServLink or Watch Window software to verify or upload the exact .cfg parameter file from your facility’s software backup.
3. Perform a manual engine start test to verify speed and voltage bias signals before closing generator breakers into a live bus.

Firmware/Software Versions & Upgrade Notes

• Configuration Software: Requires Woodward Watch Window or ServLink software tools for full parameter backup, upload, and tuning adjustments.
• Hardware Variant Matching: Ensure the replacement part number matches 8406-113 exactly. While EGCP-3 controllers share similar housings, different part numbers specify distinct internal hardware options (e.g., CT ratings, analog output ranges, or communication hardware packages).
• Parameter Backups: Custom site parameters (governor gains, protection setpoints, load-share ramps) are saved in non-volatile EEPROM memory. Always extract and save an unedited backup file from your old unit before removing it from service.

EGCP-3 8406-113

EGCP-3 8406-113

Frequently Asked Questions (FAQ)

1. Is this Woodward 8406-113 controller brand new, or has it been used/refurbished?

This unit is guaranteed 100% Original New Surplus. It has never been mounted in a control panel, wired into an active switchboard, or energized in a operational power plant. It remains preserved in original factory packaging and has undergone visual and physical pin verification.

2. Why should I purchase a New Surplus 8406-113 instead of taking a chance on a refurbished unit?

Refurbished generator controllers from active industrial or marine environments often suffer from unseen component fatigue, such as degraded electrolytic filter capacitors, aged LCD backlights, and worn output relay contacts. A failure in a refurbished paralleling controller can cause out-of-phase breaker closure, resulting in catastrophic alternator or engine damage. New Surplus guarantees original factory manufacturing standards and full operating life.

3. Will this unit drop directly into my existing switchgear panel?

Yes, replacing an existing part number 8406-113 with this unit provides a 100% direct mechanical and electrical drop-in replacement. Panel cutouts, terminal assignments, and connector plug layouts are completely identical. You only need to upload your site-specific parameter file after mounting.

4. What happens if I do not have a software parameter backup from my old unit?

If a saved digital parameter file is unavailable, you must manually record all setpoints (voltage thresholds, frequency limits, PID governor gain settings, load sharing parameters) from the front display screen of the existing unit prior to replacement, then enter them into the new unit via the front keypad or ServLink software.

5. What warranty is provided with this controller?

We support this New Surplus Woodward 8406-113 controller with a full 1-year functional warranty. Every unit is inspected for physical pin condition and power-on readiness prior to shipment.