Woodward GCP-30 Series Installation Manual
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Woodward GCP-30 Series Installation Manual

Rental package genset control
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37366A
GCP-30 Series
Rental Package Genset Control
Installation
Software Version from V4.3046
Manual 37366A

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Summary of Contents for Woodward GCP-30 Series

  • Page 1 37366A GCP-30 Series Rental Package Genset Control Installation Software Version from V4.3046 Manual 37366A...
  • Page 2 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.

  • Page 3: Table Of Contents

    Manual 37366A GCP-30 Series - Rental Package Genset Control Revision History Rev. Date Editor Changes NEW 06-01-11 Release 07-02-07 Technical Data and CAN bus section updated; minor corrections Contents 1. G ..................6 HAPTER ENERAL NFORMATION 2. E ..............7 HAPTER LECTROSTATIC...
  • Page 4 Manual 37366A GCP-30 Series - Rental Package Genset Control Illustrations and Tables Illustrations Figure 3-1: Housing - Dimensions............................. 8 Figure 3-2: Housing - Control panel cut-out..........................9 Figure 3-3: Side view - without clamps ........................... 10 Figure 3-4: Side view - with clamps ............................10 Figure 4-1: Wiring diagram GCP-31/RPQ+SC09 Rental Package ..................
  • Page 5 Manual 37366A GCP-30 Series - Rental Package Genset Control Tables Table 1-1: Manual - Overview..............................6 Table 3-1: Housing - panel cut-out ............................9 Table 5-1: Conversion chart - wire size ........................... 14 Table 5-2: Terminal assignment - power supply........................14 Table 5-3: Terminal assignment - generator voltage measuring three-phase ................

  • Page 6: Chapter 1. General Information

    Manual 37366A GCP-30 Series - Rental Package Genset Control Chapter 1. General Information Type English German GCP-31/32 Series GCP-31/RPQ - Installation this manual 37366 GR37366 GCP-31/RPQ - Configuration 37367 GR37367 GCP-31/32 - Function/Operation 37238 GR37238 GCP-31/32 - Application 37240 GR37240...

  • Page 7: Chapter 2. Electrostatic Discharge Awareness

    WARNING To prevent damage to electronic components caused by improper handling, read and observe the pre- cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. © Woodward Page 7/41...

  • Page 8: Chapter 3. Housing

    Manual 37366A GCP-30 Series - Rental Package Genset Control Chapter 3. Housing Dimensions ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 32.0 mm 12.0 mm Configuration port 8.0 mm 136.0 mm 111.0 mm 2004-10-04 | GCP30 Dimensions g2ww-4504-ab.skf Figure 3-1: Housing - Dimensions Page 8/41 © Woodward...

  • Page 9: Panel Cut-Out

    Manual 37366A GCP-30 Series - Rental Package Genset Control Panel Cut-Out ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ h' h H Figure 3-2: Housing - Control panel cut-out Measure Description Tolerance Height Total 144 mm Panel cut-out 138 mm + 1.0 mm Housing dimension 136 mm...

  • Page 10: Side View

    Manual 37366A GCP-30 Series - Rental Package Genset Control Side view ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Cabinet Cabinet Front frame Front frame Housing Housing Mounting cones Mounting cones Mounting clamp Figure 3-3: Side view - without clamps Figure 3-4: Side view - with clamps Page 10/41 ©...

  • Page 11: Installation

    Manual 37366A GCP-30 Series - Rental Package Genset Control Installation ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ For installation into a door panel proceed as follows: Panel cut-out Cut out the panel according to the dimensions in Figure 3-1. Insert control into cut-out Move housing into panel Insert the control into the panel cut-out.

  • Page 12: Chapter 4. Wiring Diagrams - Overview

    Manual 37366A GCP-30 Series - Rental Package Genset Control Chapter 4. Wiring Diagrams - Overview WARNING A circuit breaker must be located near to the control and in a position easily accessible to the operator. This must also bear a sign identifying it as an isolating switch for the control.

  • Page 13: Gcp-31/Rpq+Sc09 Rental Package

    Manual 37366A GCP-30 Series - Rental Package Genset Control GCP-31/RPQ+SC09 Rental Package Operating Mode Automatic Operating Mode STOP Analog input 4 [T4] Mobile System Mode Pt100 [0 to 200°C] f/v Droop active Analog input 3 [T3] 0/4 to 20 mA...

  • Page 14: Chapter 5. Connectors - Details

    Manual 37366A GCP-30 Series - Rental Package Genset Control Chapter 5. Connectors - Details WARNING All technical data and ratings indicated in this chapter are not definite! Only the values indicated in Technical Data on page 37 are valid! The following chart may be used to convert square millimeters [mm²] to AWG and vice versa: mm²...

  • Page 15: Measuring Inputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Measuring Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CAUTION The usage of the voltage and current measuring inputs for three-phase or single-phase measuring de- pends on the configuration of the parameter "Single phase" (refer to configuration manual 37367, Pa- rameter chapter, Measuring section).

  • Page 16: Figure 5-3: Measuring Inputs - Voltage - Busbar Three-Phase

    Manual 37366A GCP-30 Series - Rental Package Genset Control Busbar Busbar voltage Figure 5-3: Measuring inputs - Voltage - Busbar three-phase Terminal Measurement Description 400 Vac or Busbar voltage L1 2.5 mm² ../100 Vac Busbar voltage L2 2.5 mm² Table 5-4: Terminal assignment - busbar voltage measuring three-phase...

  • Page 17: Current Three-Phase

    Manual 37366A GCP-30 Series - Rental Package Genset Control Current Three-Phase WARNING Before disconnecting the secondary terminals of the current transformer or the connections of the cur- rent transformer at the control, ensure that the transformer is short-circuited. NOTE Current transformers are generally to be grounded on one side of the secondary.

  • Page 18: Figure 5-6: Measuring Inputs - Current - Mains - Via Transformer

    Manual 37366A GCP-30 Series - Rental Package Genset Control Mains (Mains Current Measuring Via Transformer) s1 (k) Mains current ../1A or ../5 A s2 (l) Figure 5-6: Measuring inputs - Current - Mains - via transformer Terminal Measurement Description Transformer Mains current L1, transformer terminal s2 (l) 2.5 mm²...

  • Page 19: Voltage Single-Phase

    Manual 37366A GCP-30 Series - Rental Package Genset Control Voltage Single-Phase Generator Generator voltage Figure 5-8: Measuring inputs - Voltage - Generator single-phase Terminal Measurement Description Generator voltage L1 2.5 mm² Generator voltage L2 (connected with neutral) 2.5 mm² 400 Vac Generator voltage L3 (connected with neutral) 2.5 mm²...

  • Page 20: Current Single-Phase

    Manual 37366A GCP-30 Series - Rental Package Genset Control Mains Mains voltage Figure 5-10: Measuring inputs - Voltage - Mains single-phase Terminal Measurement Description Mains voltage L1 2.5 mm² Mains voltage L2 (connected with neutral) 2.5 mm² 400 Vac Mains voltage L3 (connected with neutral) 2.5 mm²...

  • Page 21: Figure 5-12: Measuring Inputs - Current - Mains - Via Transformer Single-Phase

    Manual 37366A GCP-30 Series - Rental Package Genset Control Mains (Mains Current Measuring Via Transformer) s1 (k) Mains current ../1A or ../5 A s2 (l) Figure 5-12: Measuring inputs - Current - Mains - via transformer single-phase Terminal Measurement Description...

  • Page 22: Discrete Inputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Discrete Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CAUTION Please note that the operating voltages recommended for the discrete inputs range from 4 to 40Vdc. The voltage potential may be applied with either a positive or negative polarity without causing damage.
  • Page 23 Manual 37366A GCP-30 Series - Rental Package Genset Control Terminal Associated Description common (according to DIN 40 719 Part 3, 5.8.3) Digital input [D04] 2.5 mm² - Alarm input Digital input [D05] - Alarm input or 2.5 mm² - Firing speed reached ("alternator", "oil pressure")

  • Page 24: Operating Modes Of The Rental Package Rpq+Sc09

    Manual 37366A GCP-30 Series - Rental Package Genset Control NOTE The operating mode selection via DI is only possible if the digital input 6 (terminal 63, block operation mode selector) is energized. For detailed information, refer to the Configuration Manual (37367) under "Block operation mode selector switch via terminal 63".
  • Page 25 Manual 37366A GCP-30 Series - Rental Package Genset Control Switch Position OFF The GCP will be de-energized in this operating mode. No actions are initiated by the unit anymore. If you switch to position OFF while the genset is running, the GCB opens and the genset stops immediately (it is assumed that this is provided by the customer).
  • Page 26 Manual 37366A GCP-30 Series - Rental Package Genset Control The following is valid for free operating mode selection at the GCP: STOP: Genset stops with cool down or remains stopped. If necessary, the load will be taken off of the genset and the GCB will be opened.

  • Page 27: Phase Rotation Monitoring Busbar

    Manual 37366A GCP-30 Series - Rental Package Genset Control Switch Position Emergency Power Start The GCP operating modes are enabled: STOP: Genset stops with cool down or remains stopped. If necessary, the load will be taken off of the genset and the GCB will be opened.

  • Page 28: Analog Inputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Analog Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ WARNING The analog inputs of the GCP are not isolated. When utilizing an isolation monitor, use of two-pole, iso- lated transmitters is recommended. The analog inputs for active transmitters (0 to 20 mA, 0 to 10V) should only be operated with two-pole, isolated transmitters.

  • Page 29: Mpu

    Manual 37366A GCP-30 Series - Rental Package Genset Control ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ sw./ind. 24 V swiching/inductive < 1.0 V Figure 5-15: MPU Terminal Description switching/inductive 2.5 mm² 2.5 mm² (Magnetic Pickup Unit) 2.5 mm² Table 5-16: MPU - terminal assignment Specification of the input circuit for inductive speed sensors Ambient temperature: 25 °C...

  • Page 30: Relay Outputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Relay Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Controller Outputs max. 250 V AC Command: close GCB Command: close MCB Command: open MCB Enable GCB Figure 5-17: Relay outputs - Controller outputs - CB activation Description Make cont.

  • Page 31: Analog Outputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Analog Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Analog output Figure 5-19: Analog outputs Description Analog output [A1] - 0/4 to 20 mA 1.5 mm² Analog output [A2] - 0/4 to 20 mA 1.5 mm² Table 5-20: Analog outputs - terminal assignment ©...

  • Page 32: Controller Outputs

    Manual 37366A GCP-30 Series - Rental Package Genset Control Controller Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Multi Functional Controller Outputs Configuration and an external jumper can change the multifunction controller outputs. Versions - Three-position controller via relay manager - Control of n/f/P: Parameter "...

  • Page 33: Figure 5-21: Analog Controller Output N/F/P - Wiring And External Jumper Setting

    Manual 37366A GCP-30 Series - Rental Package Genset Control - Setting: ANALOG or PWM (Analog controller) - Frequency-/Power controller Speed / power controller Speed / power controller Speed / power controller Figure 5-21: Analog controller output n/f/P - Wiring and external jumper setting...

  • Page 34: Interface

    Manual 37366A GCP-30 Series - Rental Package Genset Control Interface ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Interface Wiring Figure 5-23: Interface - Terminals Terminal Description CAN bus CAN-H CAN-L CAN-H CAN-L guidance level CAN bus CAN-H CAN-L CAN-H CAN-L machine level * may be used to connect to the CAN bus and/or to connect the termination resistor.

  • Page 35: Can Bus Topology

    Incorrect baud rate (too high) for length of CAN bus The CAN bus cable is co-routed with power cables Woodward recommends the use of twisted-pair cables for the CAN bus (i.e.: Lappkabel Unitronic LIYCY (TP) 2×2×0.25, UNITRONIC-Bus LD 2×2×0.22). Maximum CAN Bus Length The maximum length of the communication bus wiring is dependent on the configured Baud rate.

  • Page 36: Dpc - Direct Configuration Interface

    Manual 37366A GCP-30 Series - Rental Package Genset Control DPC - Direct Configuration Interface NOTE To configure via the configuration interface (direct configuration), you need the configuration cable (part number 5417-557), the program LeoPC1 (delivered with the cable), and the corresponding con- figuration files.

  • Page 37: Chapter 6. Technical Data

    Manual 37366A GCP-30 Series - Rental Package Genset Control Chapter 6. Technical Data Nameplate ----------------------------------------------------------------------------------------------------- Serial number (numerical) Date of production (YYMM) Serial number (Barcode) Item number Item revision number Details Technical data Type Description (long) Type Description (short) UL sign...
  • Page 38 Anleitung 37366A GCP-30 Series - Rental Package Genset Control Discrete inputs ---------------------------------------------------------------------------------------isolated Input range (V )........Rated voltage 12/24 Vdc (6 32 Vdc) Cont, digital input Input resistance .....................approx. 6.8 kΩ Relay outputs ---------------------------------------------------------------------------------potential free Contact material ......................AgCdO General purpose (GP) (V Cont, relay output AC..........2.00 Aac@250 Vac...
  • Page 39 Anleitung 37366A GCP-30 Series - Rental Package Genset Control Interface -------------------------------------------------------------------------------------------------------- Service interface Version ........................RS-232 Signal level ........................5 V Level conversion and insulation by using DPC (P/N 5417-557) CAN bus interface isolated Insulation voltage ....................1,500 Vdc Version ........................CAN bus Internal line termination ..................

  • Page 40: Chapter 7. Accuracy

    Anleitung 37366A GCP-30 Series - Rental Package Genset Control Chapter 7. Accuracy Measuring values Display and ranges Accuracy Notes Frequency Generator 15.0 to 85.0 Hz Busbar 15.0 to 85.0 Hz Mains 40.0 to 85.0 Hz Voltage Generator 0 to 400 V...
  • Page 41 Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/power Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address/phone/fax/e-mail information for all locations is available on our website (www.woodward.com).

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