37240C

GCP-30 Series
Genset Control

Application
Software Version 4.3xxx

Manual 37240C
Manual 37240C GCP-30 Series - Genset Control

WARNING
Read this entire manual and all other publications pertaining to the work to be performed before install-
ing, 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OUT-OF-DATE PUBLICATION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.

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Manual 37240C GCP-30 Series - Genset Control

Revision History

Rev. Date Editor Changes

NEW 04-09-23 TP Release
A 06-01-11 TP Minor corrections; addition of chapter 3
B 07-02-07 TP Minor corrections; extension of chapter 3
C 07-05-11 TP Minor corrections

Content

CHAPTER 1. GENERAL INFORMATION..........................................................................................4

CHAPTER 2. APPLICATIONS INTERFACES ....................................................................................5
Configuration via RS-232........................................................................................................................5
Conversion CAN to USB.........................................................................................................................7
Connection via GW4/RS-232 LDP........................................................................................................10
Connection via GW4/RS-422 LDP........................................................................................................13
Using a GSM Modem............................................................................................................................16
Using a Fixed-Network Modem.............................................................................................................22
Modbus Connection via GW 4 ..............................................................................................................27
Profibus Connection via GW 4..............................................................................................................29
CHAPTER 3. SPECIAL APPLICATIONS ........................................................................................31
Disable Emergency Power via Discrete Input.......................................................................................31
Analog Controller Output Value in Initial Position .................................................................................32
Start-Up Synchronization / Unexcited Start-Up ....................................................................................35

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Manual 37240C GCP-30 Series - Genset Control

Chapter 1.
General Information

Type English German

GCP-31/32 Series
GCP-31/32 Packages - Installation 37364 GR37364
GCP-31/32 Packages - Configuration 37365 GR37365
GCP-31/32 - Function/Operation 37238 GR37238
GCP-31/32 - Application this manual Ö 37240 GR37240
Option SB 37200 GR37200
Option SC06/SC07/SC08 37313 GR37313
Option SC09/SC10 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. Evalua-
tion 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, for configuration, for remote control, for data logging, for language upload, for alarm and user man-
agement and for management of the event recorder. This manual describes the use of the program.
LeoPC1 - Manual 37164 GR37164
PC program for visualization, for configuration, for remote control, for data logging, for language upload, for alarm and user man-
agement and for management 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: Manuals - Overview

Intended Use The unit must only be operated in the manner described by this manual. The prerequisite for a
proper and safe operation of the product is correct transportation, storage, and installation as well as careful op-
eration and maintenance.

NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens, and other details described, which do not exist on your unit, may be ignored.
The present manual has been prepared to demonstrate different applications of the unit. The descrip-
tion of the applications assumes that you are familiar with the unit and the described peripheral de-
vices and have read the manuals belonging to them. You can refer to the respective manuals for infor-
mation about operation and configuration of the unit and the peripheral devices.

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Manual 37240C GCP-30 Series - Genset Control

Chapter 2.
Applications Interfaces

Configuration via RS-232

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

RS-
RS-232 RS-
RS-232
COM1

Control Configuration wire Laptop

RJ45 socket edgewise with galvanic isolation (black box) with Windows operation system
DPC-
DPC-1 P/N 5417-
5417-557 98SE, NT, ME, 2000, XP
LeoPC1 3.1 or higher
configuration possible

Function

Woodward provides an interface cable and an application software to be able to configure the GCP comfortably
with a PC or laptop. The black box isolates the signals galvanically and must to be used absolutely. Otherwise,
possible potential shifts may damage the devices involved.

Different applications can be performed using the software LeoPC1. These applications include:
• Configuration
• Read out event logger
• Load language
• Transfer standard values to and from the harddrive

Preconditions

• GCP with RJ45 jack (software version 3.X and higher)

• DPC-1 interface set (DPC-1 P/N 5417-557)
• PC or laptop with Windows OS 98SE, NT, ME, 2000, XP and free Com port (USB to COM adapter
also possible)
• Application software LeoPC1 version 3.1 or higher
• Configuration file available (*.cfg, *.asm, *.opt,...)

© Woodward Page 5/38

Manual 37240C GCP-30 Series - Genset Control

Operation

In order to be able to configure, the following steps have to be performed at the GCP:

Enter code 1. Code level 2 has to be entered at the GCP.

0000
Direct para. 2. Direct configuration has to be enabled.
YES

If the GCP is equipped with a CAN bus (X1/X5), the configuration via RS-232 is only possible with stopped en-
gine. The reason for this is, that the unit changes to CAN bus automatically when detecting firing speed and, as a
result, the interface RS-232 (RJ45) will be cut off. In this case, the configuration screen "Direct para." is sup-
pressed. It has to be noted, that the code level expires when disconnecting the power supply at the GCP and with
that, the parameter "Direct para." returns to NO. It has to be set to YES again.

Setting in LeoPC1

LeoPC1 will be installed according to the manual.

The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

The .cfg file with the contraction "Dir" in the file name is to be used for direct configuration via LeoPC1.

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Manual 37240C GCP-30 Series - Genset Control

Conversion CAN to USB

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

Conversion USB-CAN:
Up to 14 GCP-
GCP-30 can be
connected to the same
CAN bus

CAN USB

Max. 250m

IXXAT USB-to-CAN compact PC or Laptop with windows

GCP-30 terminals X1 to X5 P/N 8445-1023 98SE, NT, ME, 2000, XP
software LeoPC1 V3.1 or
higher
for configuration, visualization
and remote control

Function

A CAN/USB adapter can be used to configure and visualize the GCP comfortably with a PC or laptop. The
Woodward application software LeoPC1 supports the IXXAT adapter for this.

Different applications can be performed using the software LeoPC1. These applications include:
• Configuration
• Visualization with data logging
• Remote control (start and stop, transferring the set values for real power and generator power factor)
• Load language
• Transfer standard values to and from the harddrive

Preconditions

• GCP with CAN connection (X1/X5)

• IXXAT CAN / USB adapter (P/N 8445-1023; other adapters are not supported)
• PC or laptop with Windows OS 98SE, NT, ME, 2000, XP with USB port
• Application software LeoPC1 version 3.1 or higher
• Configuration file available (*.cfg, *.asm, *.opt,...)

For detailed information about the IXXAT product refer to the website www.ixxat.de

Connection

The connection for the IXXAT product can be taken from its data sheet. The CAN bus from the adapter is to be
connected to the terminals X4/X5. Make sure that the CAN bus is terminated correctly with two termination re-
sistors. Please note the following connection example:
CAN bus
CAN bus

CAN-L X5 CAN-L
CAN-H X4 CAN-H
GND X3 GND
CAN-L X2
Termination, approx. 120 Ohms
GCP CAN-H X1 USB to CAN

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Manual 37240C GCP-30 Series - Genset Control

Operation

In order to establish a connection between the GCP and LeoPC1, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the GCP.

0000
Direct para. 2. The direct configuration has to be disabled
if necessary.
No
Generator number The entry for the generator number determines
the CAN ID of the unit.
00

Once connected to the CAN bus, the USB to CAN adapter may serve up to 14 GCPs.

Settings in LeoPC1

LeoPC1 will be installed according to the manual. The IXXAT driver has to be installed after LeoPC1 has been
installed.
The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

The .cfg file with the contraction "_xUS" in the file name is to be used for access via CAN.
x stands for the number of parallel generators in the application here.
After LeoPC1 has been started and the configuration file has been called up, the driver has to be controlled. To
do this, proceed as follows:

NOTE
LeoPC1 version V2.x is not compatible for USB to CAN of IXXAT.
LeoPC1 software from version 3.1 is recommended since it includes the current driver VCI2.16 for the
USB to CAN of IXXAT in the installation.

If a VCI driver of IXXAT older than V2.16 is installed, we recommend to update to version V2.16 or
higher. To do this, proceed as described by IXXAT.

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Manual 37240C GCP-30 Series - Genset Control

In LeoPC1, select in the menu Devices -> Settings and then in the section Data communication IXXAT VCI2 -
CAN as Driver, and click Settings.

Set up the window CAN Settings like

shown on the left.

Check the CAN Settings again by se-

lecting Options and CAN-ID.

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Manual 37240C GCP-30 Series - Genset Control

Connection via GW4/RS-232 LDP

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

CAN RS-
RS-232
Max 250 m COM1

Control Gateway GW4B/RS232/LDP Laptop

with Windows operation system
terminals X1-
X1-X5 P/N 5448-
5448-910 98SE, NT, ME, 2000, XP
LeoPC1 3.1 or higher
configuration and remote control possible

Function

The GW 4 with RS-232 interface and LDP protocol can be used to configure and visualize the GCP comfortably
with a PC or laptop. The GW 4 serves as stationary solution with connection to a PC or industrial PC.

Different applications can be performed using the software LeoPC1. These applications include:
• Configuration
• Visualization with data recording
• Remote control (start and stop, transferring the set values for real power and generator power factor)
• Load language
• Transfer standard values to and from the harddrive

Preconditions for this example

• GCP with CAN connection (X1/X5)

• GW4B/RS232 LDP
• PC or laptop with Windows OS 98SE, NT, ME, 2000, XP and free Com port (USB to COM adapter
also possible)
• Application software LeoPC1 version 3.1 or higher
• Configuration file available (*.cfg, *.asm, *.opt,...)

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Manual 37240C GCP-30 Series - Genset Control

Connection

This is an example for the connection of several GCPs with the GW 4.

The PC connection can be taken from the operation manual of the GW 4. Please note that a cable has to be tai-
lored for this.

Operation

In order to establish a connection between the GCP and LeoPC1, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the GCP.

0000
Direct para. 2. The direct configuration has to be disabled
if necessary.
No
Generator number The entry for the generator number determines
the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC09/10 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

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Manual 37240C GCP-30 Series - Genset Control

Settings in LeoPC1

LeoPC1 will be installed according to the manual.

The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

NOTE
If more than 8 GCP-30 are to be connected, the utilization of the USB/CAN adapter of IXXAT is recom-
mended.

The .cfg file with the contraction "_xUS" in the file name is to be used for access via CAN.
x stands for the number of parallel generators in the application here.
The driver Gateway - RS-232 is to be selected under Devices -> Settings -> Driver.

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Manual 37240C GCP-30 Series - Genset Control

Connection via GW4/RS-422 LDP

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

CAN RS-
RS-422 RS-
RS-232
Max 250 m Max 1000 m COM1

For example: Laptop

Control Gateway with Windows operation system
ADVANTECH
terminals X1-
X1-X5 GW4B/RS422+LDP 98SE, NT, ME, 2000, XP
ADAM-
ADAM-4520
P/N 8445-
8445-1015 LeoPC1 3.1 or higher
configuration and remote control possible

Function

The GW 4 with RS-422 interface and LDP protocol can be used to configure and visualize the GCP comfortably
with a PC or laptop. The GW 4 serves as stationary solution here with connection to a converter, which estab-
lishes a connection to a PC or industrial PC over a distance of 1000m. This example shows a solution for estab-
lishing a connection over large distances to a control station or visualization system.
Different applications can be performed using the software LeoPC1. These applications include:

• Configuration
• Visualization with data recording
• Remote control (start and stop, transferring the set values for real power and generator power factor)
• Transfer standard values to and from the harddrive

Preconditions for this example

• GCP with CAN connection (X1/X5)

• GW4B/RS422 LDP
• Converter RS-422 to RS-232, e.g. ADVANTECH ADAM-4520 (www.advantech.com)
• or ICSDataCom 485HF9: (www.icsdatacom.com)
• PC or laptop with Windows OS 98SE, NT, ME, 2000, XP and free Com port (USB to COM adapter
also possible)
• Application software LeoPC1 version 3.1 or higher
• Configuration file available (*.cfg, *.asm, *.opt,...)

© Woodward Page 13/38

Manual 37240C GCP-30 Series - Genset Control

Connection

This is an example for the connection of several GCPs with the GW 4.

Pin layout GW 4 / RS-422 to converter:

The specifications A, B, A’, B’, Tx+, Tx-, Rx+, and Rx- refer to the known converter types 485HF9 of
ICSDATACOM and ADAM-4520 of ADVANTECH.

Please note:

485HF9: RS-485 - RS4-22 Conversion has to be performed by re-soldering jumpers (manual)

ADAM-4520: RS-485 - RS-422 Conversion has to be performed by proper setting of the jumpers (manual)
Generally, please refer to the operation manual of the used converter.

Operation

In order to establish a connection between the GCP and LeoPC1, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the GCP.

0000
Direct para. 2. The direct configuration has to be disabled
if necessary.
No
Generator number The entry for the generator number determines
the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC09/10 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

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Manual 37240C GCP-30 Series - Genset Control

Settings in LeoPC1

LeoPC1 will be installed according to the manual.

The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

NOTE
This application is limited to 8 GCPs per interface at the moment. Please contact Woodward for bigger
plants.

The .cfg file with the contraction "_xUS" in the file name is to be used for access via CAN.
x stands for the number of parallel generators in the application here.
The driver Gateway - RS-232 is to be selected under Devices -> Settings -> Driver.

© Woodward Page 15/38

Manual 37240C GCP-30 Series - Genset Control

Using a GSM Modem

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

CAN RS-
RS-232
Max 250 m

Laptop
Control Gateway e.g. INSYS with Windows operation system
terminals X1-
X1-X5 GW4B/RS232+LDP GSM Modem 98SE, NT, ME, 2000, XP,
external modem
P/N 5448-
5448-910 with discrete input for dial up
LeoPC1 3.1 or higher
configuration and visualization

Function

It is possible to establish a cellular connection to the system using a GSM modem. This application is intended
for mobile use.
It is also interesting to trigger a call in case of an alarm with this application. The GSM modem provides a dis-
crete input for this, which can trigger e.g. a short message (SMS) (depending on the network provider, it can also
be possible to send a fax message).

Different applications can be performed using the software LeoPC1. These applications include:
• Configuration
• Visualization with data logging
• Remote control (start and stop, transferring the set values for real power and generator power factor)
• Transfer standard values to and from the harddrive

Preconditions for this Example

• GCP with CAN interface (X1/X5)

• GW4B/RS232 LDP
• Wireless modem INSYS GSM 4.0 with antenna ([email protected])
• SIM card with data transfer enabled (to be enabled by the GSM provider)
• PC or notebook with Windows OS 98SE, NT, ME, 2000, XP with external analog modem
• Application software LeoPC1 version 3.1 or higher
• Configuration files available (*.cfg, *.asm, *.opt, ...)
• FAX/SMS receiver for receiving alarm messages

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Manual 37240C GCP-30 Series - Genset Control

Connection

The active call in case of an alarm can be triggered by energizing a relay with the relay manager:

GCP-30 GW 4/232 INSYS GSM

PIN
CAN-L
CAN-L X5 X5 CAN-L TxD Y5 2 RxD D-SUB
CAN-H 9 pins
CAN-H X4 X4 CAN-H CTS Y4 7 RTS female
GND
GND X3 X3 GND GND Y3 5 GND
CAN bus

CAN bus

RS-232

RS-232
X2 X2 RTS Y2 8 CTS
Termination R = approx. 120 Ohm Termination
X1 X1 RxD Y1 3 TxD

Alarm message Alarm input 1

Relay Manager 8 10

24Vdc

Operation

In order to establish a connection between the GCP and LeoPC1, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the

GCP.
0000
Direct para. 2. The direct configuration has to be
disabled if necessary.
No
Generator number The entry for the generator number de-
termines the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC09/10 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

© Woodward Page 17/38

Manual 37240C GCP-30 Series - Genset Control

Setting in LeoPC1

LeoPC1 will be installed according to the manual.

The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

The .cfg file with the contraction "_xUS" in the file name is to be used for access via modem.
x stands for the number of parallel generators in the application here.

Proceed now as follows:

In LeoPC1, select in the menu Devices -> Settings and then in the section Data communication Modem as
Driver, and click Settings.

In the Settings for modem dialog, se-

lect the COM port to which your mo-
dem is connected and click Options.

Make sure that the modem settings are

the same for LeoPC1 and the modem.

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Manual 37240C GCP-30 Series - Genset Control

Set up the window Settings for Mo-

dem like shown on the left.

Note: If a connection is to be estab-

lished using an exchange line, the fol-
lowing settings are recommended:
• Initialization
- ATH&F0 (for internal connec-
tions without exchange line)
- ATH (for external connections
with exchange line)
• Establish connection
- ATX1DT (for internal connec-
tions without exchange line)
- ATDT (for external connections
with exchange line)

If no PABX is used, the 0W can be

left out.

If you select connect, the field with

the phone number appears again.

NOTE
This application is limited to 8 GCPs per interface at the moment. Please contact Woodward for bigger
plants.

© Woodward Page 19/38

Manual 37240C GCP-30 Series - Genset Control

Settings at the GSM Modem

INSYS Microelectronics provides the application software HS-COMM to configure the GSM modem for the ap-
plication. Refer to the operation manual of the device for detailed information.
The following settings form an example for sending an alarm message as short message.
Descriptions of the individual parameters can be taken from the operation manual of the modem.

Settings using the configuration software

Make the following settings on the tab Basic Settings. These settings configure the modem to accept an incoming
call for remote configuration. The phone number and the text can be set as required.

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Manual 37240C GCP-30 Series - Genset Control

Make the following settings on the tab Alarm/Output 1. The phone number and the text can be set as required.

Make the following settings on the tab Alarm/Output 1. The phone number and the text can be set as required.

© Woodward Page 21/38

Manual 37240C GCP-30 Series - Genset Control

Using a Fixed-Network Modem

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

CAN RS-
RS-232
Max 250 m

Laptop
Control Gateway e.g. Phoenix with Windows operation system
terminals X1-
X1-X5 GW4B/RS232+LDP landline Modem 98SE, NT, ME, 2000, XP,
with discrete input for dial up external modem
P/N 5448-
5448-910
LeoPC1 3.1 or higher
configuration and visualization

Function

It is possible to establish a phone connection to the system using a modem. This application is intended for sta-
tionary use, where a steady remote control is required.
It is also interesting to trigger a call in case of an alarm with this application. The Phoenix modem provides a dis-
crete input for this, which can trigger e.g. a call or a fax message.

Different applications can be performed using the software LeoPC1. These applications include:
• Configuration
• Visualization with data logging
• Remote control (start and stop, transferring the set values for real power and generator power factor)
• Transfer standard values to and from the harddrive

Preconditions for this Example

• GCP with CAN interface (X1/X5)

• GW4B/RS232 LDP
• Phoenix PSI data/fax modem/RS-232 (www.phoenixcontact.com)
• PC or notebook with Windows OS 98SE x, NT, ME, 2000, XP with external analog modem
• Application software LeoPC1 version 3.1 or higher
• Configuration files available (*.cfg, *.asm, *.opt, ...)
• FAX/SMS receiver for receiving alarm messages

Page 22/38 © Woodward

Manual 37240C GCP-30 Series - Genset Control

Connection

The active call in case of an alarm can be triggered by energizing a relay with the relay manager:

GCP-30 GW 4/232 Phoenix modem

PIN
CAN-L
CAN-L X5 X5 CAN-L TxD Y5 2 RxD D-SUB
CAN-H 9 pins
CAN-H X4 X4 CAN-H CTS Y4 7 RTS female
GND
GND X3 X3 GND GND Y3 5 GND
CAN bus

CAN bus

RS-232

RS-232
X2 X2 RTS Y2 8 CTS
Termination R = approx. 120 Ohm Termination
X1 X1 RxD Y1 3 TxD

Alarm message Alarm input 1

Relay Manager i+ i-

24Vdc

Operation

In order to establish a connection between the GCP and LeoPC1, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the

GCP.
0000
Direct para. 2. The direct configuration has to be
disabled if necessary.
No
Generator number The entry for the generator number de-
termines the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC09/10 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

© Woodward Page 23/38

Manual 37240C GCP-30 Series - Genset Control

Setting in LeoPC1

LeoPC1 will be installed according to the manual.

The configuration files of the device are copied to the PC. With this, the .cfg files are copied to the main path and
the other files are copied to the intended folders.

The .cfg file with the contraction "_xUS" in the file name is to be used for access via modem.
x stands for the number of parallel generators in the application here.

Proceed now as follows:

In LeoPC1, select in the menu Devices -> Settings and then in the section Data communication Modem as
Driver, and click Settings.

In the Settings for modem dialog, se-

lect the COM port to which your mo-
dem is connected and click Options.

Make sure that the modem settings are

the same for LeoPC1 and the modem.

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Manual 37240C GCP-30 Series - Genset Control

Set up the window Settings for Mo-

dem like shown on the left.

Note: If a connection is to be estab-

lished using an exchange line, the fol-
lowing settings are recommended:
• Initialization
- ATH&F0 (for internal connec-
tions without exchange line)
- ATH (for external connections
with exchange line)
• Establish connection
- ATX1DT (for internal connec-
tions without exchange line)
- ATDT (for external connections
with exchange line)

If no PABX is used, the 0W can be

left out.

If you select connect, the field with

the phone number appears again.

NOTE
This application is limited to 8 GCPs per interface at the moment. Please contact Woodward for bigger
plants.

© Woodward Page 25/38

Manual 37240C GCP-30 Series - Genset Control

Settings at the Phoenix Modem

The settings refer to an example for sending an alarm message via fax.
Descriptions of the individual parameters can be taken from the operation manual of the modem.

DIP Switches
All DIP switches are set to OFF (default state).

Settings using the configuration software

Phoenix provides an application software to configure the modem for the application. Refer to the operation
manual of the device for detailed information.
The following settings form an example for sending an alarm message via fax.
Descriptions of the individual parameters can be taken from the operation manual of the modem.

To configure the modem, proceed as follows.

Configure the COM port

The phone number and the text can be set as re-

quired.

These settings configure the modem to accept an in-

coming call for remote configuration.

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Manual 37240C GCP-30 Series - Genset Control

Modbus Connection via GW 4

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

RS-
RS-485
CAN
Max 250 m
RS-
RS-232

Gateway GW4B/RS485+MOD
Control P/N 5448-
5448-901 Modbus RTU Slave based PLC
terminals X1-
X1-X5 Gateway GW4B/RS232+MOD visualization and remote control possible
P/N 5448-
5448-895

Using GW 4/RS485 Modbus, a second unit of GW 4 can connected to communicate up to 14 GCP30.

Function

With this application, it is possible to communicate with the GCP(s) via the Modbus protocol. The GW 4 works
as RTU slave here.
While the RS-232 interface is used for the peer to peer connection, a field bus with several participants can also
be established with RS-485.

The bi-directional communication allows the following functions:

• Visualization of the process
• Remote control (start and stop, transferring the set values for real power and generator power factor)

Preconditions for this example

• GCP with CAN connection (X1/X5)

• GW4B/+MOD
• Automation device

Connection

The connection has to be taken from the GW 4 manual.

© Woodward Page 27/38

Manual 37240C GCP-30 Series - Genset Control

Operation

In order to establish a connection between the GCP and the PLC, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the

GCP.
0000
Direct para. 2. The direct configuration has to be
disabled if necessary.
No
Generator number The entry for the generator number de-
termines the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC06/07 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

NOTE
This application is limited to 8 GCPs per interface at the moment. If more than 8 generators are to be
read out, a second GW 4 has to be used. An RS-485 hardware is recommended at the GW 4 in this
case. With this, both GW 4s can be read out with one interface of the automation device.
The interface control (start/stop and reset) for more than 8 units can not be performed at the moment
because of technical reasons. Please request newer software revisions.

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Manual 37240C GCP-30 Series - Genset Control

Profibus Connection via GW 4

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

up to 8 GCPs can
be connected to the
same CAN Bus

ProfibusDP
CAN
Max 250 m

Control Gateway
terminals X1-
X1-X5 GW4B/PROFIBUS+DPSLAVE ProfibusDP based PLC
visualization and remote control possible
P/N 5448-
5448-902

Using GW 4/Profibus-DP, a second unit of GW 4 can connected to communicate up to 14 GCP30.

Function

With this application, it is possible to communicate with the GCP(s) via the Profibus DP interface. The GW 4
works as slave here.

The bi-directional communication allows the following functions:

• Visualization of the process
• Remote control (start and stop, transferring the set values for real power and generator power factor)

Preconditions for this example

• GCP with CAN connection (X1/X5)

• GW 4B/Profibus+DPSLAVE
• Automation device

Connection

The connection has to be taken from the GW 4 manual.

© Woodward Page 29/38

Manual 37240C GCP-30 Series - Genset Control

Operation

In order to establish a connection between the GCP and the PLC, the correct entry of the generator number at the
GCP has to be observed:

Enter code 1. Code level 2 has to be entered at the

GCP.
0000
Direct para. 2. The direct configuration has to be
disabled if necessary.
No
Generator number The entry for the generator number de-
termines the CAN ID of the unit.
00

Once connected to the CAN bus, the GW 4 may serve up to 8 GCPs. If the unit includes the options SC09/10 or
SB03, only 4 GCPs can be connected if the ECM data is to be visualized as well. Then, the GW 4 has to be con-
figured to extended blocks.

NOTE
This application is limited to 8 GCPs per interface at the moment. If more than 8 generators are to be
read out, a second GW 4 has to be used. An RS-485 hardware is recommended at the GW 4 in this
case. With this, both GW 4s can be read out with one interface of the automation device.
The interface control (start/stop and reset) for more than 8 units can not be performed at the moment
because of technical reasons. Please request newer software revisions.

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Manual 37240C GCP-30 Series - Genset Control

Chapter 3.
Special Applications

Disable Emergency Power via Discrete Input

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

NOTE
This functionality is implemented in all GCP-30s with software version 4.3010 or later.

This function allows to disable an emergency operation with discrete input 11 (terminal 68). If the discrete input
has been configured as control input, an emergency operation may be terminated by energizing this discrete in-
put. Energizing the discrete input has the same effect as the configuration of the parameter "Emergency power"
to OFF.

Emergency OFF Prevent an emergency power operation via terminal 68 ON/OFF

by Ter.68 OFF
OFF.............. This terminal is used as an alarm input.
ON................ This terminal is used as control input.
• High signal If this terminal utilizes a HIGH signal (energized), an
emergency power operation is prevented or termi-
nated. The unit operates as if Parameter "Emergency
power" is disabled.
• Low signal If this terminal utilizes a LOW signal (de-energized),
the setting of Parameter "Emergency power" is taken
over.

If the parameter "Emergency OFF by Ter.68" is configured ON, an emergency operation may be prevented by
energizing the discrete input at terminal 68.
If an emergency operation has already been initiated before energizing the discrete input at terminal 68, the em-
regency operation may also be terminated by energizing the discrete input at terminal 68.

Exception: If the breaker logic Parallel, Closed transition, or Interchange is selected and the discrete input at
terminal 53 is energized, an emergency operation with already closed GCB may not be terminated by energizing
the discrete input at terminal 68.

Explanation: When energizing the discrete input at terminal 53 (Enable MCB), a synchronization of the MCB
will be achieved before terminating the emergency operation. But this cannot be performed because no mains
power is present.

Solution: If an emergency operation with already closed GCB is to be terminated, a "GCB open" signal must be
generated externally together with energizing the discrete input at terminal 68. If the GCB is opened then and the
discrete input at terminal 68 is still activated, the GCP will not try to close the GCB anymore.

© Woodward Page 31/38

Manual 37240C GCP-30 Series - Genset Control

Analog Controller Output Value in Initial Position

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

NOTE
This functionality is only valid for GCP-30 Packages which are equipped with analog controllers.

The analog value, which is output from the GCP-30 in initial controller position depends on the setting of various
parameters. The following examples show this behavior.

Parameters

F/P contr.output f controller: output range refer to parameter description for settings
----------------
If the parameter "F/P contr.type" has been configured to "ANALOG", this parame-
ter must be configured to the appropriate type of analog controller. The range of the
analog output is configured here. To switch from a current to a voltage or PWM
output a jumper must be added to terminals 8/9.

Initial state f controller: initial frequency 0 to 100 %

Frequency 000%
Analog controller output setting with disabled controller. The set value in percent
refers to the range between minimum and maximum value of the output signal.

Stepper sign.frq f controller: minimum value 0 to 100%

(min.) 000%
This parameter permits the operator to clamp or limit the lower analog output
value.

Stepper sign.frq f controller: maximum value 0 to 100%

(max.) 000%
This parameter permits the operator to clamp or limit the upper analog output
value.

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Manual 37240C GCP-30 Series - Genset Control

Example Configurations

Example 1
Settings:

• f controller: output range 0 to 20mA (0 to 10V)

• Jumper between terminals 8 and 9 yes
• Initial state frequency 50%
• f controller: minimum value 20%
• f controller: maximum value 60%

Controller output:

• f controller: minimum value 20% from 0 to 10V = 2V

• f controller: maximum value 60% from 0 to 10V = 6V
• Initial state frequency 50% from 2V to 6V = 4V

Controller range
(0%) (50%) (100%)
V 2 4 6
|.........|.........|.........|.........|.........|.........|.........|.........|.........|.........|
0 5 10
(0%) (50%) (100%)
Total range

Example 2
Settings:

• f controller: output range +/- 20mA (+/- 10V)

• Jumper between terminals 8 and 9 no
• Initial state frequency 25%
• f controller: minimum value 40%
• f controller: maximum value 80%

Controller output:

• f controller: minimum value 40% from - 20mA to + 20mA = - 4mA

• f controller: maximum value 80% from - 20mA to + 20mA = +12mA
• Initial state frequency 25% from - 4mA to + 12mA = 0mA

Controller range
(0%) (25%) (100%)
mA -4 0 12
|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|...|
-20 0 20
(0%) (50%) (100%)
Total range

© Woodward Page 33/38

Manual 37240C GCP-30 Series - Genset Control

Example 3
Settings:

• f controller: output range 20 to 0mA (10 to 0V)

• Jumper between terminals 8 and 9 yes
• Initial state frequency 75%
• f controller: minimum value 30%
• f controller: maximum value 70%

Controller output:

• f controller: minimum value 30% from 10 to 0V = 7V

• f controller: maximum value 70% from 10 to 0V = 3V
• Initial state frequency 75% from 7V to 3V = 4V

Controller range
(0%) (75%) (100%)
V 7 4 3
|.........|.........|.........|.........|.........|.........|.........|.........|.........|.........|
10 5 0
(0%) (50%) (100%)
Total range

Example 4
Settings:

• f controller: output range 0.5V to 4.5V

• Jumper between terminals 8 and 9 yes
• Initial state frequency 60%
• f controller: minimum value 10%
• f controller: maximum value 90%

Controller output:

• f controller: minimum value 10% from 10 to 0V = 0.9V

• f controller: maximum value 90% from 10 to 0V = 4.1V
• Initial state frequency 60% from 0.9V to 4.1V = 2.82V

Controller range
(0%) (60%) (100%)
V 0.9 2.82 4.1
|.........|.........|.........|.........|.........|.........|.........|.........|
0.5 2.5 4.5
(0%) (50%) (100%)
Total range

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Manual 37240C GCP-30 Series - Genset Control

Start-Up Synchronization / Unexcited Start-Up

≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡

It may be necessary for systems with high consumer load to couple multiple gensets for emergency power opera-
tion. The start-up synchronization allows to couple the gensets much more quickly than the classical synchroni-
zation.
However, the gensets must be unexcited before they are paralleled.

The GCP-30 has no automatic start-up synchronization, because the proceeding depends on the respective appli-
cation.
The following description explains, which standard functions of the GCP-30 may be used to realize a start-up
synchronization.

A separate busbar for the gensets must be present for an operation with start-up synchronization. In addition, a
generator group breaker (GGB) for disconnecting the generator busbar and consumer load busbar is required.
Moreover, an MPU or an external speed governor with connection to terminal 62 (Firing speed reached) at the
GCP-30 must be present.

The process of the start-up synchronization must be controlled externally (e.g. via a PLC).
The PLC may read states like e.g. engine is running, from the GCP-30 via the CAN bus or relay manager output
and process this data.

Mains

Breaker command MCB

Load
Breaker command generator
group breaker

Breaker command GCB Breaker command GCB Breaker command GCB

AVR G AVR G AVR G

Excitation Excitation Excitation
Engine

Engine

Engine
Start Start Start
Relay manager information

Relay manager information

Relay manager information

Reply GCB (Term. 4)

Reply GCB (Term. 4)

Reply GCB (Term. 4)

Idle Mode (Term. 70)

Idle Mode (Term. 70)

Idle Mode (Term. 70)

Start (Term. 3/5)

Start (Term. 3/5)

Start (Term. 3/5)

CAN BUS

PLC

© Woodward Page 35/38

Manual 37240C GCP-30 Series - Genset Control

Usable Standard Functions of the GCP-30

RelayManager Functions

The following information, which is provided by the GCP-30 via the relay manager, may be important for the
master control in association with the start-up synchronization :

• Parameter No. 4 Firing speed reached (engine runs)

• Parameter No. 88 Generator voltage and frequency are NOT available
• Parameter No. 89 Busbar voltage and frequency are NOT available
• Parameter No. 91 Pickup has nominal speed (rated speed +/- 6%)
• Parameter No. 96 Delayed engine monitoring time exceeded
• Parameter No.133 Idle mode active

NOTE
All above mentioned information is also available on the guidance bus (CAN bus terminals X1 to X5).

Parameter Enable 'idle mode' via terminal 70

Parameter 1 Enable idle mode via terminal 70 ON/OFF

Idle Mode
by term.70 ON OFF ..............This terminal is used as an alarm input.
ON ................This terminal is used as control input. The relay programmed with
the relay manager function 133 reacts together with the logical status
of terminal 70 according to the configured NO/NC logic and invert-
ing the relay output. This relay must be wired to the "idle input" of
the speed governor normally.
• High signal Energizing the terminal 70 discrete input enables the
idle mode. The message "Idle Mode" is displayed in
all operational modes (except STOP mode) when a
start request is initiated and during the postrun time
so long as there are no other message with a higher
display priority (i.e. preglow). The generator under-
voltage and underfrequency protections are disabled
while in the idle mode and the warning limit value
for the oil pressure VDO input is suppressed. These
protections are enabled after terminal 70 is de-
energized and the monitored frequency is measured
within 1 Hz of the rated generator frequency or after
60 seconds passes, which ever occurs first.
• Low signal The idle mode is disabled and the protections become
active again (see above description).

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Manual 37240C GCP-30 Series - Genset Control

Realization

There are different methods for the start-up synchronization. Two proceedings are described in the following:

Method 1
The generator circuit breakers (GCB) will be closed by an external signal (e.g. via PLC).
Together with the start request for the GCP-30, terminal 70 (idle mode) and terminal 4 must be energized. Ter-
minal 70 prevents, that the GCP-30 trips with generator underfrequency or generator undervoltage. Energizing
terminal 4 simulates an opened GCB for the GCP-30. Otherwise, the GCP-30 would attempt to open the GCB or
no start process would be performed.
The generator excitation will be activated by an external signal (e.g. via PLC) for all gensets, which are in opera-
tion (firing speed reached).
If generator frequency and voltage are within the permissible limits, terminal 70 and terminal 4 may be de-
energized again.
The mains circuit breaker (MCB) may either be opened by the PLC or the GCP-30 (pre-condition: Emergency
power = ON).
The closure of the generator group breaker (GGB) must be performed by an external signal (e.g. via PLC) again.

NOTE
If it is not possible to start a genset successfully, its GCB must be opened. A later synchronization to
the busbar is possible.

Method 2
Together with the start request for the GCP-30, terminal 70 (idle mode) and terminal 4 must be energized. Ter-
minal 70 prevents, that the GCP-30 trips with generator underfrequency or generator undervoltage. Energizing
terminal 4 simulates an opened GCB for the GCP-30. Otherwise, the GCP-30 would attempt to open the GCB or
no start process would be performed.
If the gensets are started (firing speed reached), the generator circuit breakers (GCB) will be closed by an exter-
nal signal (e.g. via PLC).
The generator excitation will be activated for all gensets, which are in operation (firing speed reached).
If generator frequency and voltage are within the permissible limits, terminal 70 and terminal 4 may be de-
energized again.
The mains circuit breaker (MCB) may either be opened by the PLC or the GCP-30 (pre-condition: Emergency
power = ON).
The closure of the generator group breaker (GGB) must be performed by an external signal (e.g. via PLC) again.

© Woodward Page 37/38

 We appreciate your comments about the content of our publications.
Please send comments to: [email protected]
Please include the manual number from the front cover of this publication.

Woodward
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Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100
[email protected]

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for all locations is available on our website (www.woodward.com).

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