Woodward E6 - replacement for EGS-01, EGS-02 and E3.

EGS-01 obsolute

EGS-01

EGS-01 is an electronic control system for a more accurate and flexible metering system for gas engine to keep the right emmissions and preformance.

The EGS 01 is a state-of-the-art control module for stationary gas engines. It can be used to control the gas flow in relation to the air flow of an engine, at any load and speed condition. The EGS 01 control is capable of keeping gas engine emissions constant over a longer period of time. And the EGS control is not sensitive to the quality of the gas or the gas pressure and temperature. This is accomplished by the patented gas quality closed loop (lean burn) algorithm or lambda sensor.

The EGS 01 control can be applied on in-line and V-type engines of any power output, naturally aspirated or turbocharged. The control can be easily programmed with the EGS monitoring program, and it covers the wide range of gas qualities, from landfill gas to propane. Even a significant change in gas quality during normal operation of the engine will be compensated for by the control.

The E6 main replace the EGS-01 with all his functionallaty. It can be exteneted now with ignition, knock, thermocouples and extra I/O.

E3-FA, E3-Rich and E3-TRIM obsolute

E3-FA E3-TRIM E3-RICH

E3 Full Authority (PCM128HD) replaced the EGS-01 with all his functionallaty. The E3 is now obsolute and replaced by the E6. It can be exteneted now with ignition, knock, thermocouples and extra I/O.

The E3 TRIM is replaced by the same E6-main and has the same software as the Full Autority. Only configuration is different.

The E3 RICH is replaced by the same E6-main, but has different software.

The E3-TRIM and E3-Rich had ignition with Smart Coils option, those will be replaced by the E6 2-stack, MAIN +EID.

EGS-02 (733) EGS-CAT or EGS-MHI

EGS-02 733 EGS-CAT EGS-MHI

EGS-02 Full Authority (733) replace the EGS-01 with all his functionallaty and has special functions for the Caterpillar and MHI engines. (NOx sensor, pre-chamber control).

The EGS-02(733) will be replaced by the E6. It can be exteneted now with ignition, knock, thermocouples and extra I/O.

LECM Large Engine Control Module - E6
LECM Large Engine Control Module - E6

Replacing the EGS01/02 Gas Engine Control with E6 Lean Control System

Woodward’s EGS-01 and EGS-02 controls are no longer in production, and have been replaced by the E6 Lean application. The EGS Conversion application replaces EGS-01/02 in Full-authority, Lambda >1, Mono-control systems.

The purpose of this application note is to provide guidance on retrofitting an EGS-01/02 installation or design with the E6 Lean. It is intended to supplement the EGS Control System Application Manual 26321 and the E3 Full Authority System manual 26538, which details control installation, operation, calibration, and troubleshooting of the (EGS-O2=E3).

Assumptions

  • 1. Customer has read the entire EGS Control System Application Manual 26321.
  • 2. Customer has read the entire E3 Full Authority System manual 26538.
  • 3. Customer has understood and complied with all of the warnings highlighted in the Manual 26321.
  • 4. Customer understands that they are strongly encouraged and expected to thoroughly develop and test specific EGS control schemes for their gas engine application under normal and extreme operating conditions.

Introduction

Woodward’s E6 Lean can be used as a functional replacement for the EGS-01/02/E3 FA FB control. The E6 Lean was designed to replace an EGS-01 or EGSO2 system with minimally changes to the existing wiring.

Differences Summary

Due to internal control design differences, the customer wiring to the control terminals is different. This application note illustrates the differences in wiring, sensors, communication interfaces, and Service Tool.

Inputs Differences

Inputs EGS-01 EGS-02 E3 E6 Lean E6 Options
Power supply Nominal: 10–32 Vdc, minimum 7 Vdc Nominal: 8–32 Vdc, minimum 6 Vdc; 15 W nominal (not including driven loads) Nominal: 18–32 Vdc, minimum 12 Vdc for 30 seconds, 9 Vdc for 100ms
Speed Sensor VR or Active Sensor VR or Active Sensor VR or Active Sensor VR or Active Sensor
ALL ANALOG INPUTS Two-wire grounded or ungrounded One wire common return Some Analog Inputs may be used with a two-wire ungrounded (loop powered) transducer or an isolated (self-powered) transducer. Some One wire common return. AUX: 0-25 mA and/or 0-5 VDC
MAT PT-100 PWM or 4-20 mA Thermistor NTC Thermistor NTC AUX: Thermocouples and RTD
MAP 0–20 mA, 0–10 V or 0–5 V PWM or 0-20 mA 0–5 Vdc 0–5 Vdc
KW 0–20 mA, 0–10 V or 0–5 V 0–20 mA, J1939 with Easygen 0–5 Vdc, J1939 with Easygen 0–5 Vdc or 4-20 mA, J1939 (with Easygen)
CH4% 0–20 mA, 0–10 V or 0–5 V 0–20 mA 0–5 Vdc 0–5 Vdc or 4-20 mA, Modbus
Load Reference 0–20 mA, 0–10 V or 0–5 V 0–20 mA, J1939 with easYgen 0–5 Vdc, J1939 with easYgen 0–5 Vdc or 4-20 mA, J1939 (with easYgen)
Speed Bias 0–20 mA, 0–10 V or 0–5 V 0–20 mA, J1939 with easYgen 0–5 Vdc, J1939 with easYgen +/-2.5Vdc , 0–5 Vdc, 4-20 mA, PWM, J1939 (with easYgen)
Throttle Position Sensor 0–20 mA, 0–10 V or 0–5 V 0–5 Vdc 0–5 Vdc, J1939
Ignition Timing Input CAN/IC-92X only CAN/IC-92X only CAN/IC-92X only Internal to EID Ignition Only J1939
Detonation Protection CAN/FireFly™ only Internal to AUX Knock Only J1939
UEGO 0–2.5 V, 0–5 V Needs Converter box for 0–5 Vdc signal input (NGK UEGO) Bosch LSU 4.2 sensor directly or needs Converter box for 0–5 Vdc signal input (NGK UEGO) Bosch LSU 4.9 sensor directly or needs Converter box for 0–5 Vdc signal input (NGK UEGO)
Potentiometer Integrated into the control External 1 kΩ to 10 kΩ 3-wire pot External 1 kΩ to 10 kΩ 3-wire pot
Thermocouple Two (2) J or K type Cannot use thermocouple Cannot use thermocouple Eight (8) J or K type
ALL DISCRETE INPUTS 0–6 V = FALSE
4-32 V = TRUE
Sinking Close to J1-A24 to activate Based on Hardware Jumpers Sinking (E3)
> 9 Vdc = “OFF”
< 2 Vdc = “ON”
or Sourcing (EGSO1)
>9 Vdc=TRUE,
<2 VDC=FALSE
Circuit Breaker Aux Not available Connect to Gen circuit breaker aux, used for multiple dynamics Connect to Gen circuit breaker aux, used for multiple dynamics Connect to Gen circuit breaker aux, used for multiple dynamics
Mains Circuit Breaker Aux Close only when Gen & Mains is closed, used for activation of kW load control Connect to mains circuit breaker aux, used for multiple dynamics and activation of kW load control Connect to mains circuit breaker aux, used for multiple dynamics and activation of kW load control Connect to mains circuit breaker aux, used for multiple dynamics and activation of kW load control
Fuel On Activates control by opening throttle and TecJet™ Activates control by opening throttle and TecJet™ Activates control by opening throttle and TecJet™ Activates control by opening throttle and TecJet™
Raise/Lower Changes internal reference Changes internal reference Changes internal reference Changes internal reference
Rated/Idle Changes internal reference Changes internal reference Changes internal reference Changes internal reference
Fault Reset >10mA resets faults Sinking Close to J1-A24 to activate resets faults Standard DI resets faults
Sinking
> 9 Vdc = “No Reset”
< 2 Vdc = “RESET”

Outputs Differences

Outputs EGS-01 EGS-02 E3 E6 Lean E6 Options
Throttle Command PWM - Push-Pull, 0–24 Vdc, 1000 Hz PWM - Push-Pull, 0–5 Vdc, Frequency variable PWM - Push-Pull, 0–20 Vdc, 30–3000 Hz
Wastegate Output PWM - Push-Pull, 0–24 Vdc, 1000 Hz PWM - Push-Pull, 0–5 Vdc, Frequency variable PWM - Push-Pull, 0–20 Vdc, 30–3000 Hz
TecJet Power 6 A steady state, 10 A peak for 1 sec None None None
TecJet Keyswitch 10 mA max, activates the TecJet when the engine is rolling Use one of the speed switch outputs and an interposing relay Use one of the speed switch outputs and an interposing relay Use Master Power Relay Driver +20Vdc when active
Fault Outputs Form C, dry contacts Low side relay drivers Low side relay drivers
Major Alarm 15 Open from 14 when Engine Shutdown Condition is True
16 Close to 14 when Engine Shutdown Condition is True
Closes to Ground on Engine Shutdown Condition J1-006 De-energizes on Engine Shutdown Condition
Minor Alarm 52 Open from 51 when Engine Alarm Condition is True
53 Close to 51 when Engine Alarm Condition is True
De-energizes on Control Warning Condition J1-005 De-energizes on Control Warning Condition
CPU OK 55 Open from 54 when System Ready Condition is True
56 Close to 54 when System Ready Condition is True
De-energizes on Control Watchdog Condition J1-102 Energizes on Control when power supply input is in Range
Speed Switches None Individually configurable for speed limit activation Individually configurable for speed limit activation Individually configurable for speed limit activation
AUX Power 5 Vdc, 70 mA for sensor power 5 Vdc, 300 mA for sensor power 5 Vdc, 300 mA for sensor power
LED Indications Power, Fuel On, Alarm, Shutdown None None CPU, RS232, RS485, CAN1, CAN2, CAN3, Ethernet