Woodward GCP-30 Series User manual

37365A
Configuration
Software version starting from 4.3046
Manual 37365A
GCP-30 Series Packages
Genset Control

Manual 37365A GCP-30 Series Packages - Genset Control
Page 2/179 © Woodward
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before instal-
ling, 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 (overtempera-
ture, or overpressure, where applicable) shutdown device(s), that operates totally independently of the
prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other
type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic gov-
ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s),
or the controlled device(s) fail.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical,
or other operating limits may cause personal injury and/or property damage, including damage to the
equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within
the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,
and (ii) invalidate product certifications or listings.
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 dam-
age 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.
OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.
Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, 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 reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be
correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.
© Woodward
All Rights Reserved.

Manual 37365A GCP-30 Series Packages - Genset Control
© Woodward Page 3/179
Revision History
Rev. Date Editor Changes
NEW 06-01-11 TP Release
A 07-02-07 TP Minor corrections; linguistic review
Contents
NOTE
The functions described in this manual are included in the different packages of the GCP-30 series.
Some functions are only available in specific packages. Specific model numbers at the beginning of
the parameter/function text will indicate package specific parameters/functionality.
[GCP-32] This function is only found in GCP-32 controllers.
[GCP-31] This function is only found in GCP-31 controllers.
BPQ This function is only found in controllers with the BPQ Package (GCP-31/BPQ and GCP-
32/BPQ).
XPD This function is only found in controllers with the XPD Package (GCP-31/XPD and GCP-
32/XPD).
XPQ This function is only found in controllers with the XPQ Package (GCP-31/XPQ and GCP-
32/XPQ).
SB03 This function is only found in controllers with the SB03 Option (GCP-31/XPQ+SB03 and
GCP-32/XPQ+SB03).
SC10 This function is only found in controllers with the SC10 Option (GCP-31/XPQ+SC10 and
GCP-32/XPQ+SC10).
CHAPTER 1. GENERAL INFORMATION..........................................................................................7
Functional Overview.................................................................................................................................8
CHAPTER 2. FUNCTION...............................................................................................................9
Considerations To Be Taken: ..................................................................................................................9
Different Options............................................................................................................................9
Systems Without a Mains Circuit Breaker .....................................................................................9
Signals....................................................................................................................................................10
Discrete Inputs.............................................................................................................................10
Control Outputs............................................................................................................................12
CHAPTER 3. CONFIGURATION ...................................................................................................14
Basic Data..............................................................................................................................................15
Version Number (Software Version)............................................................................................15
Password .....................................................................................................................................15
Direct Configuration .....................................................................................................................16
Generator Number.......................................................................................................................17
Language Manager (XPD,XPQ) .................................................................................................17
Service Display ............................................................................................................................20
Event Logger (XPD,XPQ) .....................................................................................................................21
Possible Event Logger Entries.....................................................................................................21
Analog Inputs ...............................................................................................................................23

Manual 37365A GCP-30 Series Packages - Genset Control
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Measuring .............................................................................................................................................. 24
Rated Frequency......................................................................................................................... 24
Potential Transformers (Voltage Transformers).......................................................................... 24
Rated Voltage.............................................................................................................................. 26
Generator Current ....................................................................................................................... 27
Mains Current/Mains Power Measurement................................................................................. 28
LS 4 Mode (GCP-31: XPD,XPQ) ............................................................................................... 31
Measurement Units ..................................................................................................................... 31
Password Configuration .............................................................................................................. 32
Controller ............................................................................................................................................... 33
Analog Controller Outputs (BPQ,XPQ) ...................................................................................... 34
Real Power Controller, Set Point Values .................................................................................... 37
Table Of Set Point Values ........................................................................................................... 38
Frequency Controller................................................................................................................... 39
Voltage Controller........................................................................................................................ 43
Power Factor Controller .............................................................................................................. 47
Real Power Controller ................................................................................................................. 49
Load and/or var Sharing.............................................................................................................. 53
Automatic............................................................................................................................................... 57
Load Management ...................................................................................................................... 57
Stop Of The Engine At Mains Failure [GCP-31] ......................................................................... 66
Interface....................................................................................................................................... 67
Breaker .................................................................................................................................................. 68
Functional Description................................................................................................................. 68
Breaker Logic .............................................................................................................................. 74
Start/Stop Ramp, Open GCB With F2 Alarm .............................................................................. 81
GCB/MCB Pulse/Continuous Pulse ............................................................................................ 82
Open/Close GCB......................................................................................................................... 84
Synchronization........................................................................................................................... 85
Synchronization Time Monitoring................................................................................................ 86
Dead Bus Start ............................................................................................................................ 87
Breaker Monitoring ...................................................................................................................... 88
Mains Decoupling........................................................................................................................ 89
Emergency Power (AMF) (GCP-32;GCP-31: XPD, XPQ) ................................................................... 91
Emergency Power With Breaker Logic "PARALLEL" ................................................................. 92
Emergency Power With Breaker Logic "OPEN TRANSIT." ........................................................ 92
Emergency Power With Breaker Logic "CLOSED TRANSIT." ................................................... 93
Emergency Power With Breaker Logic "INTERCHANGE" ......................................................... 93
Emergency Power With Breaker Logic "EXTERNAL"................................................................. 93
Emergency power With MCB Malfunction................................................................................... 94
Emergency Power Operation; Parameters ................................................................................. 94
Protection............................................................................................................................................... 95
Generator Power Monitoring ....................................................................................................... 95
Mains Power Monitoring.............................................................................................................. 97
Generator Overload Monitoring................................................................................................... 98
Generator Reverse/Reduced Power Monitoring ......................................................................... 99
Unbalanced Load Monitoring .................................................................................................... 100
Independent Time-Overcurrent Monitoring ............................................................................... 101
Generator Frequency Monitoring .............................................................................................. 103
Engine Overspeed Monitoring................................................................................................... 103
Generator Voltage Monitoring ................................................................................................... 104
Mains Frequency Monitoring..................................................................................................... 105
Mains Voltage Monitoring.......................................................................................................... 106
Phase/Vector Shift Monitoring dϕ/dt ......................................................................................... 107
Mains Settling Time................................................................................................................... 108
Battery Voltage Monitoring ........................................................................................................ 109
Time Of Active Horn .................................................................................................................. 109

Manual 37365A GCP-30 Series Packages - Genset Control
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Discrete Inputs .....................................................................................................................................110
Alarm Inputs...............................................................................................................................111
Configuring The Text For The Discrete Inputs ..........................................................................112
Control Inputs.............................................................................................................................113
Terminal 6 Function ...................................................................................................................116
Analog Inputs (XPD,XPQ)...................................................................................................................119
Setting The Analog Inputs .........................................................................................................119
Outputs.................................................................................................................................................127
Analog Outputs (XPD, XPQ)......................................................................................................127
Relay Manager...........................................................................................................................128
Engine ..................................................................................................................................................129
Start/Stop Sequence 'Gas Engine' ............................................................................................130
Start/Stop Sequence 'Diesel Engine'.........................................................................................133
Cool Down .................................................................................................................................135
Delayed Engine Monitoring And Firing Speed...........................................................................136
Magnetic Pick-Up Input..............................................................................................................138
Counter / Real Time Clock...................................................................................................................139
Maintenance Call .......................................................................................................................139
Operating Hours Counter...........................................................................................................140
Start Counter..............................................................................................................................140
kWh Counter..............................................................................................................................141
Real Time Clock (XPD,XPQ) ....................................................................................................142
Current Slave Pointer ................................................................................................................143
CHAPTER 4. COMMISSIONING .................................................................................................144
APPENDIX A. ANALOG OUTPUT MANAGER (XPD,XPQ)...........................................................146
APPENDIX B. RELAY MANAGER ..............................................................................................149
APPENDIX C. INTERFACE PROTOCOL ......................................................................................153
Transmission Telegram .......................................................................................................................153
Receiving Telegram .............................................................................................................................162
CAN Bus Structure...............................................................................................................................163
Transmission Telegram .............................................................................................................163
Current Direction Message........................................................................................................163
Power Set Point Value Message ...............................................................................................164
CAN Bus Address Requirements ..............................................................................................164
APPENDIX D. LIST OF PARAMETERS .......................................................................................165
APPENDIX E. SERVICE OPTIONS .............................................................................................174
Product Service Options ......................................................................................................................174
Returning Equipment For Repair .........................................................................................................174
Packing A Control ......................................................................................................................175
Return Authorization Number RAN ...........................................................................................175
Replacement Parts...............................................................................................................................175
How To Contact Woodward .................................................................................................................176
Engineering Services ...........................................................................................................................177
Technical Assistance ...........................................................................................................................178

Manual 37365A GCP-30 Series Packages - Genset Control
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Illustrations And Tables
Illustrations
Figure 3-1: Control loop ........................................................................................................................................................... 34
Figure 3-2: Step response (Example)........................................................................................................................................ 34
Figure 3-3: Step responds - governor configuration ................................................................................................................. 36
Figure 3-4: CAN bus load/var sharing, diagram....................................................................................................................... 55
Figure 3-5: Breaker control logic 'Impulse' for MCB............................................................................................................... 82
Figure 3-6: Breaker control logic 'Impulse' for GCB................................................................................................................ 83
Figure 3-7: Breaker control logic 'Continuous'......................................................................................................................... 83
Figure 3-8: Characteristic of the time-overcurrent monitoring............................................................................................... 101
Figure 3-11: Sprinkler operation............................................................................................................................................. 118
Figure 3-12: VDO transmitter 323.425 (slope)....................................................................................................................... 124
Figure 3-13: Start-Stop sequence: Gas engine........................................................................................................................ 130
Figure 3-14: Wiring diagram for opening gas valves with the GCP-30 from V4.1001 .......................................................... 131
Figure 3-15: Start-stop sequence: Diesel engine..................................................................................................................... 133
Figure 3-16: Delayed engine monitoring................................................................................................................................ 136
Figure 4-1: Analog outputs - power factor scaling ................................................................................................................. 148
Tables
Table 1-1: Manual - Overview.................................................................................................................................................... 7
Table 1-2: Functional overview.................................................................................................................................................. 8
Table 3-1: Event recorder - Messages, part 1 ........................................................................................................................... 22
Table 3-2: Event recorder – Messages, part 2........................................................................................................................... 23
Table 3-3: Set point value table................................................................................................................................................ 38
Table 3-4: Limit values, permissible limits............................................................................................................................... 68
Table 3-5: Limit values generator, dead bus start..................................................................................................................... 71
Table 3-6: Limit values mains, dead bus start........................................................................................................................... 72
Table 3-7: Limit values, Emergency power.............................................................................................................................. 91
Table 3-9: Discrete alarm inputs - delay stages...................................................................................................................... 111
Table 3-10: Function - external operation mode selection...................................................................................................... 113

Manual 37365A GCP-30 Series Packages - Genset Control
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Chapter 1.
General Information
Type English German
GCP-31/32 Series
GCP-31/32 Packages - Installation 37364 GR37364
GCP-31/32 Packages - Configuration this manual 37365 GR37365
GCP-31/32 - Function/Operation 37238 GR37238
GCP-31/32 - Application 37240 GR37240
GCP-31/RPQ - Installation 37366 GR37366
GCP-31/RPQ - Configuration 37367 GR37367
Option SB - Caterpillar CCM coupling 37200 GR37200
Option SC09/SC10 - CAN bus coupling 37382 GR37382
Additional Manuals
IKD 1 - Manual 37135 GR37135
Discrete expansion board with 8 discrete inputs and 8 relay outputs that can be coupled via the CAN bus to the control unit. As-
sessment of the discrete inputs as well as control of the relay outputs is done via the control unit.
LeoPC1 - Manual 37146 GR37146
PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man-
agement of the event recorder. This manual describes the use of the program.
LeoPC1 - Manual 37164 GR37164
PC program for visualization, configuration, remote control, data logging, language upload, alarm and user management and man-
agement of the event recorder. This manual describes the programming of the program.
GW 4 - Manual 37133 GR37133
Gateway for transferring the CAN bus to any other interface or bus.
ST 3 - Manual 37112 GR37112
Control to govern the air fuel ratio of a gas engine. The ratio will be directly measured though a Lambda probe and controlled to a
configured value.
Table 1-1: Manual - Overview

Manual 37365A GCP-30 Series Packages - Genset Control
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Functional Overview
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Function Package
GCP-31 GCP-32
BPQ XPD XPQ XPQ+SB03
XPQ+SC10
BPQ XPD XPQ XPQ+SB03
XPQ+SC10
Common Functions
1×readiness for operation relay 
4/6×control relay (form A, make contact) 
7×freely configurable relay outputs (form A, make contact) 
2×three-position controller for n/f/V/P, power factor * -- -- -- -- -- -- -- --
2×three position controller for n/f/V/P, power factor via relay manager * -- -- 
2×analog controller outputs for n/f/V/P/Q and PWM output * -- -- 
up to 8×discrete control inputs 6 8 8 8 8 6 8 8 8 8
16×discrete alarm inputs 16 16 16 16 16 16 16 16 16 16
CAN bus interface 'guidance level' 
CAN bus interface to 2×IKD 1 and ST 3 -- -- -- -- -- -- -- -- 
CAN bus communications with mtu MDEC and Scania EMS/S6 -- -- -- -- -- -- -- -- 
CAN bus communications with SAE J1939 -- -- -- -- -- -- -- -- 
RS-232 communications via Caterpillar CCM with ECM & EMCP-II -- -- -- -- -- -- -- --
7×analog inputs -- -- 
1×Magnetic Pick-Up input 
2×analog outputs + external operation mode selection by term. 127/128 -- -- 
Password system 
Configuration via DPC possible (direct configuration) 
Event recorder with real-time clock -- -- 
Language manager for LCD texts 
Running hours, maintenance, start, and kWh counter 
Control/Synchronization
Synchronization of 1 breaker with V and f correction * 
Synchronization of 2 breakers with V and f correction * -- -- -- -- -- 
Closing to a dead/voltage free busbar (dead bus start) 
Voltage control 
Power factor control 
Speed/frequency control 
Generator real power control & import/export real power control 
Real power & var sharing 
Analog set point value for real power -- -- 
Analog mains interchange (import/export) real power measuring -- -- 
"Open transition" & "closed transition" breaker logic -- -- -- -- -- 
"Soft loading "breaker logic -- -- -- -- -- 
"Parallel operation" breaker logic 
"External" breaker logic 
Remote control via CAN bus interface 
Protective Functions
Over-/undervoltage monitoring, generator VGe
n
>/< 
Over-/undervoltage monitoring, mains VMains>/< 
Over-/underfrequency monitoring f>/< 
dϕ/dt vector/phase jump monitoring dϕ/dt 
Reverse/reduce power monitoring +/-PGe
n
< 
Overload monitoring PGe
n
> 
Unbalanced load monitoring ΔPGe
n
> 
Independent time-overcurrent monitoring I> / I>> 
Battery voltage monitoring VBa
t
< 
* n = speed / f = frequency / V = voltage / P = real power / Q = reactive power
Table 1-2: Functional overview

Manual 37365A GCP-30 Series Packages - Genset Control
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Chapter 2.
Function
Considerations To Be Taken:
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Different Options
Depending how a control unit is configured, different parameters will be displayed and only the relevant parame-
ters will be able to be accessed:
•Various inputs and outputs will be present or deleted, corresponding to the control configuration (depending
on the ordered package). Please refer to the wiring diagram and the notes regarding the packages contained in
these. The control inputs and outputs will vary by the specific package ordered. Refer to the wiring diagram
and notes that correspond to them.
•Specific display screens correspond to specific types of interfaces.
Systems Without a Mains Circuit Breaker
If a control with 2-circuit-breaker logic [GCP-32] or 1-circuit-breaker logic [GCP-31] is installed for use with
one circuit breaker, the following shall apply:
•If the control unit is to be operated in an isolated or an isolated parallel application (the MCB is opened), the
following terminals must be energized/de-energized:
- "Reply: MCB is open" / "Isolated operation" (terminal 54): energized (logical "1")
- "Enable MCB" (terminal 53): de-energized (logical "0")
- Condition: Parameter 137 "Emergency power" must be configured as "OFF".
•If the control unit is to be operated in a mains parallel application (the MCB always is closed if the generator
operates in mains parallel), the following terminals must be energized/de-energized:
- "Reply: MCB is open" / "Isolated operation" (terminal 54): de-energized (logical "0")
- "Enable MCB" (terminal 53): energized (logical "1")
•If the control unit is to be operated in an isolated parallel as well as a mains parallel application (the MCB can
be opened or closed), the following terminals must be energized/de-energized:
- "Reply: GCB is open" (terminal 4): de-energized (logical "0")
- "Reply: MCB is open" (terminal 54): de-energized (logical "0")
- "Enable MCB" (terminal 53): energized (logical "1")
Case A - The MCB must remain closed (except during an emergency power operation): Terminal 53 must be
energized.
Case B - The MCB can be opened (except during an emergency power operation): If a mains parallel opera-
tion is to be initiated, terminal 53 must be energized to initiate synchronization of the MCB. During the syn-
chronization of the MCB (GCP-31: This is performed by an LS-4 or external control) the generator frequency
is increased to a level slightly higher than the mains frequency (df max/2). A message is shown in the LC dis-
play that the unit is synchronizing. If the system is to be disconnected from the mains and operated in an isl-
and mode, terminal 53 must be de-energized.

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Signals
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Discrete Inputs
NOTE
Emergency power and critical operation modes will be carried out while the GCP-30 is in TEST or AU-
TOMATIC mode regardless if the discrete inputs for "Automatic 1" and/or "Automatic 2" are enabled.
This is dependent upon if Parameter 137 (Emergency power) has been configured as ON and if Para-
meter 211 (Terminal 6) is configured for a critical/sprinkler mode.
NOTE
If terminals 3 and 5 are enabled simultaneously, terminal 3 has precedence over terminal 5 and the ge-
nerator will operate in accordance with how "Automatic 1" is configured.
Automatic 1 (Start/Stop the engine) Terminals 3/7
Enabling this input while the control is in the AUTOMATIC operation mode will result in the GCP-
30 controlling the real power in accordance with how "P controller: set point 1" is configured and
may be used to initiate the engine start/stop sequence.
Energize........ If the AUTOMATIC operation mode has been enabled the real power is controlled in
the manner configured in "P controller: set point 1" (Parameter 35) while in parallel
with the mains. If "P controller: set point 1" is configured for baseload (C), import (I),
or export (E) the engine will start when terminal 3 is energized and a mains parallel
operation will be performed following the synchronization of the GCB. If the genera-
tor is not connected to the mains, the generator will start, perform a dead bus closure,
and assume the load. Additional generators will synchronize and share the load propor-
tionally.
If the controller is in the AUTOMATIC operation mode and "P controller: set point 1"
(Parameter 35) is configured for 000kW and "Loadd.start/stop at ter.3" (Parameter 95)
is configured OFF, the engine will start and the GCB will synchronize. The load may
be increased or decreased by raising or lowering the load set point manually. The load
for the control is changed by pressing the SETPOINT button until the "P set 1" screen
is displayed and increasing or decreasing the load set point to the desired value by
pressing either the Setpoint raise or lower buttons.
De-energize .. The generator will unload, the GCB will open, and the engine will perform a cool
down and stop unless an emergency power or critical/sprinkler mode operation is ac-
tive. The generator will shutdown after the emergency power or critical/sprinkler mode
operation has terminated.

Manual 37365A GCP-30 Series Packages - Genset Control
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Automatic 2 (Start/Stop the engine) Terminals 5/7
Enabling this input while the control is in the AUTOMATIC operation mode will result in the GCP-
30 controlling the real power in accordance with how " P controller: set point 2" is configured and
may be used to initiate the engine start/stop sequence.
Energize........If the AUTOMATIC operation mode has been enabled the real power is controlled in
the manner configured in "P controller: set point 2" (Parameter 36) while in parallel
with the mains. If "P controller: set point 2" is configured for baseload (C), import (I),
or export (E) the engine will start when terminal 5 is energized and a mains parallel
operation will be performed following the synchronization of the GCB. If the genera-
tor is not connected to the mains, the generator will start, perform a dead bus closure,
and assume the load. Additional generators will synchronize and share the load propor-
tionally.
If the controller is in the AUTOMATIC operation mode and "P controller: set point 2"
(Parameter 36) is configured for 000kW and "Loadd.start/stop at ter.5" (Parameter 96)
is configured OFF, the engine will start and the GCB will synchronize. The load may
be increased or decreased by raising or lowering the load set point manually. The load
for the control is changed by pressing the SETPOINT button until the "P set 2" screen
is displayed and increasing or decreasing the load set point to the desired value by
pressing either the Setpoint raise or lower buttons.
De-energize...The generator will unload, the GCB will open, and the engine will perform a cool
down and stop unless an emergency power or critical/sprinkler mode operation is ac-
tive. The generator will shutdown after the emergency power or critical/sprinkler mode
operation has terminated.
If a set point value is specified externally (e.g. via an 0/4 to 20 mA analog input or a bi-directional in-
terface), the external set point value is the discrete input enabled by energizing terminal 5 (refer to
Table 3-3: Set point value table).
MultifunctionTerminals 6/7
Terminal 6 may be configured to perform one of several functions. Parameter 211 lists the available
functions.
Note: When the Critical (Sprinkler) mode is configured, the input operates on negative logic. The
Critical (Sprinkler) mode is disabled when terminal 6 is energized and enabled when terminal 6 is de-
energized.
Reply: GCB is open Terminals 4/7
When this input is energized, the controller recognizes that the GCB is open (the "GCB ON" LED is
not illuminated).
[GCP-32] Reply: MCB is open Terminals 54/7
When this input is energized, the controller recognizes that the MCB is open (the "MCB ON" LED is
not illuminated).
[GCP-31] Isolated operating / reply external breaker Terminals 54/7
When this input is energized, the controller recognizes that the genset is operating isolated from the
mains (the "Mains parallel" LED is not illuminated). This discrete input determines if the controller
performs frequency control (terminal 54 = energized) or real power control (terminal 54 = de-
energized) after the GCB has been closed.
Enable MCB Terminals 53/7
Energized......The MCB has been enabled and a mains parallel operation will be performed. The
GCP-31 uses the LS-4 or an external controller to operate the MCB.
De-energized.The MCB is disabled and cannot be closed. The controller will operate as an isolated
or mains parallel operation dependent upon the state of the input "Reply MCB is
open".

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Discrete inputs Terminals 34 to 36/33 and 61 to 73/60
These freely programmable alarm inputs may be configured with user defined text, alarm classes, time
delays, whether alarm monitoring should be delayed by the engine speed, and if the contacts are N.O.
or N.C. contacts.
Control Outputs
Ready for operation Terminals 18/19
This relay output is used to ensure that the internal functions of the controller are operating properly.
If this relay is bypassed or disabled, proper functionality of the control cannot be guaranteed. This re-
lay should be used in conjunction with an alarm that ensures proper actions are initiated upon activa-
tion of this relay output (i.e. GCB opening, engine shutdown). It is recommended that this contact be
put in series with an emergency stop function.
Preheating (Diesel engine) pre-assigned to terminals 37/38
When this relay is enabled, the diesel engine's glow plugs are energized (refer to the "Diesel Engine"
section). This function only occurs if the control has been configured for diesel engine start/stop log-
ic.
Ignition "ON" (Gas engine) pre-assigned to terminals 37/38
When this relay is enabled, the ignition of the gas engine is energized (refer to the "Gas Engine" sec-
tion). This function only occurs if the control has been configured for gas engine start/stop logic.
Fuel relay / gas valve Terminals 43/44
a) Diesel engine: fuel relay (Parameter 269)
a.1) Open to stop
A start/run command will initiate the start sequence for the diesel engine and close the contacts for
this relay energizing the fuel solenoid relay. This relay will disable (contacts open) when a stop
command is issued or the engine speed drops below the configured firing speed (Parameter 272).
Refer to the "Diesel Engine" section.
a.2) Close to stop
A start/run command will initiate the start sequence for the diesel engine and open the contacts for
this relay. This relay will enable (contacts close) when a stop command is issued or the engine
speed drops below the configured firing speed (Parameter 272). Refer to the "Diesel Engine" sec-
tion.
b) Gas engine: gas valve
A start/run command will initiate the start sequence for the gas engine and close the contacts for
this relay energizing the gas valve relay. This relay will disable (contacts open) when a stop com-
mand is issued or the engine speed drops below the configured firing speed (Parameter 272). Refer
to the "Gas Engine" section.
Starter Terminals 45/46
The starter relay is enabled when a start command is issued. The starter relay output is de-energized
when firing speed (Parameter 272) has been achieved, the configured crank time (Parameter 259 or
Parameter 265) has expired, or the STOP mode is enabled.

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Centralized alarm pre-assigned to terminals 47/48
This relay is enabled when a centralized alarm is issued. An external horn, buzzer, or beacon may be
operated by this relay output during a fault condition. Pressing the "RESET" button will reset the re-
lay. The relay will re-energize if another alarm condition is detected. The centralized alarm is issued
for fault classes F1 through F3.
Command: close GCB Terminals 14/15
The "Command: close GCB" relay issues the signal for the GCB to close. This relay may be confi-
gured for a momentary pulse to operate an external holding coil for the GCB or for a continuous cur-
rent (Parameter 114).
If the relay is configured for a momentary pulse, the relay will energize for the time configured in
"Synchronize time pulse" (Parameter 119).
If the relay is configured for a constant current, the relay will energize and remain energized when the
discrete input "Reply: GCB is open" de-energizes and the generator and busbar voltages are identical.
If an F2 alarm condition is detected, the generator load is reduced and the GCB is opened when the
measured power is less than 3% of rated or the time configured for "Add on/off max. time" (Para-
meter 112) expires, which ever occurs first. If an F3 alarm condition is detected, this relay de-
energizes immediately.
Command: open GCB Terminals 41/42
The "Command: open GCB" relay issues the signal to open the GCB. After the open command has
been issued this relay is de-energized.
[GCP-32] Command: close MCB Terminals 16/17
The "Command: close MCB" relay issues the signal for the MCB to close. This relay is a momentary
pulse and must be used with an external holding coil for the MCB.
[GCP-32] Command: open MCB Terminals 39/40
The "Command: open MCB" relay issues the signal to open the MCB. After the open command has
been issued this relay is de-energized.
Relay Manager Terminals 74 to 83, 37/38, 47/48
The "Relay Manager" (Parameter 250) permits specific logical functions to be assigned to specific re-
lay outputs.
Default values:
•·Relay 1 to 5 = relay number (e.g. relay 1 = alarm class F1, relay 2 = alarm class F2, etc.)
•·Relay 6 = Ignition / preheating
•·Relay 7 = Centralized alarm
Refer to Appendix B for a description of the Relay Manager functions.

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Chapter 3.
Configuration
Configuration may be performed via the front panel keys or using a PC and the LeoPC1 program via the serial
interface. LeoPC1 version 3.1 or higher is required to perform this. Configuration via a CAN bus converter is al-
so possible. The following communication protocols require the following baud rates:
•Direct configuration (RS-232) = 9,600 Baud (8 Bit, no parity, 1 Stop bit)
•CAN bus (CiA) (RS-485) = 125 kBaud
CAUTION
A PC with configuration software with the following revision number or higher is required to configure
this control (applies to firmware versions 4.3xxx or higher):
LeoPC1 from 3.1
GCP controllers with Option SC10 cannot be completely configured through the face panel. Therefore,
it is recommended to have LeoPC1 and the correct configuration files available when commissioning.
Due to functional enhancements of the GCP-30 control series, it is necessary (beginning with firmware version
4.3xxx) to use a newer version of the configuration software LeoPC1. This requires that LeoPC1 version 3.1 or
higher be used. If your current LeoPC1 software is an earlier version, the latest version can be ordered from our
technical sales or can be downloaded from our homepage at http://www.woodward.com/software.
Older project files may still be used with the updated version of LeoPC1 after installation has been completed.
These files should be transferred to the appropriate file locations within the updated version of LeoPC1.
WARNING
Please note that configuration only should be performed while the system is not operating.
NOTE
Prior to configuring a control unit, familiarize yourself with the parameters listed in this manual.
You can advance through the individual parameter screens if you are in configuration mode (simultaneously
pressing of "Digit↑" and "Cursor→" push buttons permits access to the configuration mode) by using the "Se-
lect" button. If you press and hold the "Select" push button, the scroll function will be activated, allowing for the
parameter screens to be advanced through more rapidly. The control unit will permit the operator to reverse up to
four previous screens (exception: it is not possible to reverse from the first parameter to the last parameter or to
backup through the service screens). To perform the reverse function through the parameter screens, the "Select"
and "Cursor→" push buttons must be pressed and released simultaneously. The control unit will revert to auto-
matic mode if an entry isn’t performed, a change made, or any other action performed for 90 seconds.
NOTE
Two hardware versions are described in this manual. The differences between these versions are 120
Vac and 480 Vac voltage-measuring inputs. Configuration screens and permissible limits of these units
will differ as well. These models are differentiated by numerals in the applicable text. The 120 Vac
model is identified by a [1] and the 480 Vac is identified by a [4] in front of the text that applies to the
unit.

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Basic Data
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Version Number (Software Version)
Parameter 1
Software version
Vx.xxxx
Software version
This screen displays the software version loaded into the control (the last two xx
are for software revisions which do not affect the function of the unit).
Password
The unit is equipped with a three-level code and configuration hierarchy, which allows different user access to
the control. A distinction is made between:
Code level CS0 (User Level) Factory password = none
This code level allows for monitoring of the system and does not permit access to the parameters. Configuration
is blocked.
Code level CS1 (Basis Service Level) Factory password = "0 0 0 1"
This code level entitles the user to change selected parameters, like setting Bar/PSI, °C/°F, and clock adjustment.
Changing a password is not permitted at this level. This password expires two hours after entering the password
and the user is returned to the CS0 level.
Code level CS2 (Commissioning Level) Factory password = "0 0 0 2"
Allows direct access to all parameters (displaying and changing). In addition, the user may also set the password
for levels CS1 and CS2. This password expires two hours after entering the password and the user is returned to
the CS0 level.
NOTE
Once the code level is entered, access to the configuration menus will be allowed for two hours or until
another password is entered into the control. If a user needs to exit a code level, then code level CS0
should be entered. This will block any configuration of the control.
Specific code levels may also be accessed using the LeoPC1 program.
Parameter 2
Enter code
0000
Enter code number 0000 to 9999
Upon enabling the configuration mode, the user is required to enter an access code
number, which identifies the various users. The displayed number 0000 is a ran-
domly generated number. If the random number is confirmed by pressing the "Se-
lect" button without being changed, the current level of access maintained. Upon
entering either a level 1 or level 2 access code, the corresponding level of access is
granted. If an incorrect access code is entered the control unit changes to code level
0 and all access is blocked until a code level 1 or 2 access code is entered.

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Direct Configuration
NOTE
A direct configuration cable DPC (P/N 5417-557), the LeoPC1 program (supplied with the cable), and the
corresponding configuration files are required to perform direct configuration. After the program has
been installed, consult the online help for a description of the PC program and its setup.
Configuration files may be downloaded from the Woodward homepage at:
http://www.woodward.com/software/ConfigFiles/
The unit part number and revision number will be required to locate the appropriate configuration files.
Remote configuration: For remote configuration, the level CS2 password of must be entered via the parameter
"Enter code", otherwise, the values can only be read but not written. Configuring via the communication bus has
no effect on the unit display screen. This means that the control unit remains in code level 0and configuration is
only permitted via the communication bus. The control may remain idle for 2 hours before configuration via the
communication bus is disabled. The password must be re-entered to re-enable configuration via the communica-
tion bus again. The password must also be entered prior to loading a language file. If the code for level 2 is en-
tered on the unit itself, configuration via the communication bus is automatically enabled.
WARNING
If Parameter 3 "Direct para." is configured to "YES", communication via the interface terminals X1 to X5
is disabled. If the interface communication is to be re-established after the unit is configured, Para-
meter 3 must be configured to "NO"!
The GCP-30 will automatically disable the direct configuration port (Parameter 3 is automatically
switched from YES to NO) when the unit detects that firing speed has been achieved (Parameter 272).
Additional configuration may be performed while the generator is running through the display panel or
via a CAN bus converter (i.e. IXXAT USB to CAN 1 converter). The direct configuration port is disabled
and the communication interface is re-enabled upon detection firing speed as a safety precaution. This
is done to prevent a simultaneous closing of GCBs to the de-energized bus bar in the event conditions
for a multiple unit start-up (i.e. emergency power situation) are detected.
Parameter 3
Direct para.
YES
Direct configuration YES/NO
YES ..............The direct configuration port is enabled, and CAN bus communica-
tions via X1 to X5 terminals are disabled. The following conditions
must be met in order to carry out configuration via the configuration
port:
- A connection must be established via the direct configuration cable
between the control and the PC
- The baud rate of the LeoPC1 program must be set to 9,600 Baud
- The corresponding configuration file for the controller must be
used (file name: "xxxx-xxxx-yyy-zz.asm").
NO................The direct configuration port is disabled and CAN bus communica-
tions via X1 to X5 terminals are enabled.

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Generator Number
Parameter 4
Generator number
0
Generator number (controller CAN bus address) 1 to 14
If a power plant is composed of multiple generators with controllers, the controllers
must be coupled via a CAN bus. Each controller must be assigned a unique CAN
bus address to differentiate the units. Generator address number 1 should be as-
signed even if the power plant is composed of only a single generator and control-
ler. The address assigned in this parameter corresponds to the control number used
in the LeoPC1 program.
Language Manager (XPD,XPQ)
The following steps must be accomplished in order to load a different language into the control:
1.) A communication link between your PC and the control unit must be established via the direct configura-
tion cable (DPC). To do this insert the serial cable into the COM port of your PC and the RJ45 plug into the
communication port of the control unit (communication via the CAN bus or a GW 4 is also possible).
2.) Enter the CS 2 level password into the control (Parameter 2).
3.) If the direct configuration cable (DPC) is to be utilized, Parameter 3 "Direct para." must be configured as
"YES". If a GW 4 or the CAN bus is to be utilized for configuration, Parameter 3 "Direct para." must be
configured as "NO".
4.) If a language is to be loaded via the CAN bus, enter the desired CAN bus address (1 to 14) into the "Gene-
rator number" screen (Parameter 4), so that LeoPC1 is able to communicate with the correct control unit.
5.) Scroll the configuration screen on the controller to "Language" (Parameter 5) and select either the primary
language for the control unit by selecting "first" or the secondary language by selecting "second".
6.) Start the program LeoPC1, and log into the program by selecting "System" from the tool bar and "User lo-
gin…" from the drop down menu or clicking on the key icon.
7.) Enter the user name and password and click the "OK" button. The default user ID is "system" and the de-
fault password is "system".

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8.) Open the applicable *.cfg file for the application by selecting "File" from the tool bar and "open" from the
drop down menu. Select the proper *.cfg file from the window that appears.
9.) To start communication between the control unit and LeoPC1 select "Communication" from the tool bar
and "Connect" from the drop down menu or click on the up and down arrow icon.
10.) Select "Devices" from the tool bar and "Parameterize…" from the drop down menu or click on the letter P
icon.

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11.) A window will appear with all the tunable parameters in it. Move the cursor over the numbers for the pass-
word and double click.
12.) Enter the password for code level CS 2 (Parameter 2).
13.) Close the parameterization window.
14.) Select "Devices" from the tool bar and "Load language…" from the drop down menu or click on the letter L
icon.

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15.) Load the desired language file using the button "Load LNG file ..."
16.) Select the desired language and click the "Transfer language" button.
17.) If an additional language is to be loaded into the control unit, return to step 5 and change the language se-
lection from the currently active language to the inactive language and acknowledge the change with the
"Select" button. This is cannot be accomplished via LeoPC1. Repeat the sequence of step use to load the
previous language.
Parameter 5
Language
-----
Language first / second
first...............All texts are displayed in the primary language.
second...........All texts are displayed in the secondary language.
Service Display
Refer to manual 37238 for a description of these screens.