Product Specification

03243C

GCP-20 Series
Genset Control Package
Mains & Generator
Protection & Control
• Complete engine,
generator, and mains
APPLICATIONS DESCRIPTION (continued) protection and
controller into one
The GCP-20 Series genset control is designed to provide Protection (all versions) ANSI #
unit
total control for stand-alone and multiple unit applications Mains
in isolated or mains parallel operation. • Over-/undervoltage (59/27) • AMF auto start/stop
• Over-/underfrequency (81O/U)
There are three GCP-20 Series Packages available for • Phase/vector shift (78) • True RMS sensing
various genset applications. The GCP-20 is designed for Generator
stand-by gensets. Open or closed transition power • Over-/undervoltage (59/27) • Synchronization for
transfers including logic for two circuit breakers. The • Over-/underfrequency (81O/U) one/two breakers
GCP-21 is designed for continuous parallel operation and • Overload/reverse power (32/32R)
has control logic for one circuit breaker. The GCP-22 has • Unbalanced load (46)
• Load management-
control logic for two circuit breakers that enable automatic • Independent time-overcurrent (50/51) automatic base
power transfers like open transition, closed transition and load/peak shaving,
softloading. GCP-20 (unique features) import/export power
Synchronizer for GCB and MCB control
Load management features include automatic base/peak • Automatic Mains Failure (AMF) operation
shaving, import/export control and emergency • Open transition (break-before-make) • Automatic start/stop
power/back up power generation. • Closed transition (make-before-break) sequencing
DESCRIPTION GCP-21/-22 (unique features) • Load/var sharing
Synchronizer for GCB
Features (all versions) • Real power/power fact. (cosphi) control • Counters for kWh,
• True RMS voltage (generator/busbar/mains) • Mains parallel operation engine starts,
• True RMS current (generator/mains) • Mains import/export power control operating hours,
• Start/stop logic for Diesel/Gas engines • Reduced power monitoring (32F) maintenance call
• Engine pre-glow or purge control • Load dependent start/stop
• Battery voltage monitoring • Load/var sharing (up to 8 units) • Freely configurable
• Speed control with overspeed monitoring discrete and analog
• kWh/oper.hours/start/maintenance counter GCP-22 (unique features)
Synchronizer for GCB and MCB alarm inputs
• Configurable trip/control set points
• Configurable delays for each protection • Automatic Mains Failure (AMF) operation • Freely configurable
• Speed input (magnetic/switching pickup, MPU) • Open transition (break-before-make)
relay and analog
• 14 configurable discrete alarm inputs • Closed transition (make-before-break)
• Softloading
outputs
• 4 configurable/programmable relays
• Two-line LC display
Special (Version dependent) • PC and front panel
• Push-buttons for direct control configurable
• 2 configurable analog outputs (0/4 to 20 mA)
• Multi-level password protection
• Generator real power setpoint via 0/4 to 20 mA • CAN bus
Controller (all versions) • Discrete raise/lower for n/f/V/P/Q *
communication
• Speed/frequency/voltage • Analog raise/lower for n/f/V/P/Q *
• Isolated operation • 3 conf. analog alarm inp. (0/4 to 20 mA, VDO) • CE marked
• CAN bus communication
• UL/cUL Listed
* n = speed; f = frequency; V = voltage;
P = real power; Q = reactive power
SPECIFICATIONS
Accuracy ..........................................................................................Class 1
Power supply.......................................................12/24 Vdc (9.5 to 32 Vdc)
Intrinsic consumption ..................................................................max. 15 W
Ambient temperature................................................................ -20 to 70 °C
Ambient humidity...................................................... 95 %, non-condensing
Voltage .................... Rated /Δ: [1] 66/115 Vac or [4] 230/400 Vac
Maximum value (Vmax): [1] 150 Vac or [4] 300 Vac
Rated voltage Vph-ground: [1] 150 Vac or [4] 300 Vac
Rated surge voltage: [1] 2.5 kV or [4] 4.0 kV
Measuring frequency................................................50/60 Hz (40 to 70 Hz)
Linear measuring range up to .......................................................1.3×Vrated
Input resistance..................................................... [1] 0.21 MΩ, [4] 0.7 MΩ
Max. power consumption per path ................................................ < 0.15 W
Current (rated value) ..................................................................... [5] ../5 A
Linear measuring range up to ...............................................IGen = 3.0×Irated
IMains = 1.5×Irated
Load .............................................................................................< 0.15 VA
Rated short-time current (1 s) .................................................... [5] 10×Irated
Discrete inputs .............................................................................. isolated
Input range .............................................................12/24 Vdc (4 to 40 Vdc)
Input resistance....................................................................approx. 6.7 kΩ
Analog inputs ....................................................................freely scaleable
Type ...............................................................................0/4 to 20 mA, VDO
Resolution ...........................................................................................10 Bit
Relay outputs ................................................................................ isolated
Contact material ............................................................................... AgCdO
Load (GP)......................................................................2.00 Aac@250 Vac
2.00 Adc@24 Vdc / 0.36 Adc@125 Vdc / 0.18 Adc@250 Vdc
Pilot duty (PD) ..............................................................................................
1.00 Adc@24 Vdc / 0.22 Adc@125 Vdc / 0.10 Adc@250 Vdc
Analog output................................................................................ isolated
Type ............................................................. 0/4 to 20 mA, freely scaleable
Resolution ....................................................8/12 Bit (depending on model)
Max. load 0/4 to 20 mA ..................................................................... 500 Ω
Insulating voltage .........................................................................3,000 Vdc
Housing......................................................Type APRANORM DIN 43 700
Dimensions .......................................................................144×96×118 mm
Front cutout ........................................................ 138 [+1.0] × 92 [+0.7] mm
Connection ................................................ screw/plug terminals depending
on connector 1.5 mm² or 2.5 mm²
Front.................................................................................insulating surface
Protection system.................................................. with correct installation
Front................................................. IP42
(sealed IP54; gasket kit = P/N 8923-1038)
Back ................................................. IP21
Weight ............................................ depending on version, approx. 1,000 g
Disturbance test (CE)..........tested according to applicable EN guidelines
Listings ................................................. UL/cUL listed (File No.: E231544)

DIMENSIONS APPLICATIONS

Typical application for the GCP-22 (GCP-21

Side view Front view same but without MCB)

Direct configuration port Direct configuration

port
96

88

V~

Bottom view I~

116
8

Back view with on/off

connecting terminals
2-8
Load

48 25

90 92 Y1 Y5 X1 X5 120 128
V~ V~

93 104 60 75
136
144

50 54
on/off on/off

01 24 V~ V~

I~ I~
2004-12-01 | GCP20 Dimensions g3ww-4904-ab.skf

V/Q V/Q
G G
ϑ /n/Vbatt/.. ϑ /n/Vbatt/..
Start/Stop Start/Stop
n/f/P n/f/P
FEATURES OVERVIEW

GCP-20 Series GCP-20 GCP-21 GCP-22

Genset Control
Package LS LS LSB LSR LSX LS LSB LSR LSX
Control
Breaker control logic 2 1 1 1 1 2 2 2 2
Synchronization 9 9 9 9 9 9 9 9 9
Isolated single-unit operation 9 9 9 9 9 9 9 9 9
AMF (auto mains failure operation) 9 9 9 9 9
Stand-by operation 9 9 9 9 9
CHP (combined heat & power) operation 9 9 9 9 9 9 9 9
Peak load operation (auto start/stop) 9 9 9 9 9 9 9 9
Mains parallel operation 9 9 9 9 9 9 9 9
Open transition (break-before-make) 9 9 9 9 9
Closed transition (make-before-break) 9 9 9 9 9
Softloading 9#1 9#1 9#1 9#1 9 9 9 9
Accessories
Start/stop logic for Diesel/Gas engines 9 9 9 9 9 9 9 9 9
kWh counter 9 9 9 9 9 9 9 9 9
Operating hours/start/maintenance counter 9 9 9 9 9 9 9 9 9
Configuration via PC #2 9 9 9 9 9 9 9 9 9
Protection
Generator: voltage/frequency 9 9 9 9 9 9 9 9 9
Mains: volt./freq./phase shift 9 9 9 9 9 9 9 9
Generator: overload 9 9 9 9 9 9 9 9 9
Generator: reverse power 9 9 9 9 9 9 9 9 9
Generator: reduced power 9 9 9 9 9 9 9 9
Generator: unbalanced load 9 9 9 9 9 9 9 9 9
Generator: independent time-overcurrent (TOC) 9 9 9 9 9 9 9 9 9
Controller
Discrete raise/lower: n/f (speed/frequency) 9 9 9
Discrete raise/lower: V (voltage) 9 9 9 9 9
Discrete raise/lower: P (real power) 9 9
Discrete raise/lower: Q (reactive power) 9 9 9 9
Analog raise/lower: n/f (+/-3 Vdc) 9 9 9 9 9 9
Analog raise/lower: V (+/-5 Vdc) 9 9 9 9
Analog raise/lower: P (+/-3 Vdc) 9 9 9 9 9 9
Analog raise/lower: Q (+/-5 Vdc) 9 9 9 9
Mains import/export power (current measurement) 9 9 9 9 9 9 9 9
Load-dependent start/stop 9 9 9 9 9 9 9 9
Real power setpoint value: 0/4 to 20 mA [T3] 9 9
Load/var sharing 9 9 9 9 9 9 9 9
I/Os
Speed input (magnetic/switching Pickup) 9 9 9 9 9 9 9 9 9
Discrete alarm inputs (configurable) 14 14 14 14 14 14 14 14 14
Relay outputs (configurable) 4 4 4 4 4 4 4 4 4
Analog inputs (configurable) 4 #3 3 #4 4 #3 3 #4
Analog outp. 0/4 to 20 mA (configurable) 2 2
CAN bus communication #5 9 9 9 9 9 9 9 9
Listings/Approvals
CE marked 9 9 9 9 9 9 9 9 9
UL/cUL listed 9 9 9 9 9 9 9 9 9
Product number P/N
100 Vac, ../5 A 8440-1581 8440-1586 8440-1541 8440-1346 8440-1587 8440-1590 8440-1103 8440-1052 8440-1591
400 Vac, ../5 A 5448-918 5448-916 8440-1014 5448-915 8440-1013 5448-914 8440-1012 5448-913 8440-1011
#1 In isolated parallel operation with min. 2 gensets in parallel
#2 Cable incl. software necessary (DPC)
#3 [T1]= VDO 0 to 5/10 bar; 0 to 180 Ohm; [T2] = VDO 40 to 120°C; 0 to 380 Ohm; [T3] & [T4] = 0/4 to 20 mA; freely scaleable
#4 [T1]= VDO 0 to 5/10 bar; 0 to 180 Ohm; [T2] = VDO 40 to 120°C; 0 to 380 Ohm; [T4] = 0/4 to 20 mA; freely scaleable
#5 Remote monitoring, control, configuration (GW 4 could be used for several interfaces)
 WIRING DIAGRAM (GCP-22; refer to manual for GCP-20 and GCP-21)
International
Woodward
PO Box 1519

0 1 2 3 5 6 7 33 34 35 36 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 18 19 43 44 45 46 37 38 47 48 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104

LSR / LSX Packages
The PC configuration plug
Fort Collins CO, USA is located on the side of the unit. Analog input 4 [T4]

quasi-continuous controller with analog outputs

This is where the DPC cable 0/4 to 20 mA
80522-1519 must be plugged in.
1000 East Drake Road
Fort Collins CO 80525 Analog input 3 [T3]
Ph: +1 (970) 482-5811

120 121 122 123

LSX Package
11 12 13
GND GND External setpoint value (LSX Package only)

+/-5 V DC

Analog output
0/4 to 20 mA
Fax: +1 (970) 498-3058

manager
VA IA
Analog output

Control room
0/4 to 20 mA
GND
Europe

PLC
PC
Analog input 2 [T2]
IA
Woodward Governor Company VDO, 0 to 380 Ohm (40 to 120 °C)

8 9 10
GND

+/-3 V DC
Leonhard-Reglerbau GmbH VA
Handwerkstrasse 29
Analog input 1 [T1]
70565 Stuttgart, Germany VDO, 0 to 180 Ohm
Ph: +49 (0) 711 789 54-0 (0 to 5/10 bar or 0 to 27/145 psi)
GATEWAY
GW 4

Fax: +49 (0) 711 789 54-100

GND

50 51 52 27 28 39 40 16 17 53 54 23 24 41 42 14 15 4 25 26 29 30 31 32 20 21 22 11 12 13 8 9 10 X1 X2 X3 X4 X5
Distributors & Service CAN-L Pickup

Woodward has an international CAN-H switching/inductive

network of distributors and GND

CAN bus interface
Guidance level Standard =
service facilities. For your Relay 4 Centralized alarm

nearest representative, call the Termination

Fort Collins plant or see the Relay 3

Standard =
Ignition / preglow
Worldwide Directory on our lower SPEED / POWER
Drive

(three-position controller)
website. higher
LSB/LSR/LSX altern.: Starter
Analog controller output
up to 8 additional gensets
(each via one GCP-20)

Corporate Headquarters lower VOLTAGE / POW. FAC.

Rockford IL, USA
G

(three-position controller) Start relay / Gas valve

higher
Ph: +1 (815) 877-7441 LSB/LSX alternative:
Analog controller output
Ready for operation
www.woodward.com/power
3

Generator voltage L3

Generator voltage L2 Input 14 E

Generator voltage L1 Input 13 D

s1 (k) Input 12 C
Generator current L3
s2 (l) Input 11 B

s1 (k) Input 10 A
Generator current L2
s2 (l) Input 9 9
For more information contact:

Input 8 or
s1 (k) 8
Block emergency operation
Generator current L1
Input 7 or
s2 (l) 7
Close GCB w/o engine monitoring
Reply: GCB is open Input 6 6

Input 5 5
Command: close GCB
GCB

GCP-22 Genset Control Package

Input 4 or
4
Open transition
Input 3 or
3
Lock operation mode
Command: open GCB
Input 2 or
2
Crank terminate
Input 1
L2 1
(fault class 3: emergency STOP)
Busbar voltage
L1 Common
3

Reply: MCB is open

(freely program-
Relay manager

Relay 2
mable relays)

Release MCB
MCB

Command: close MCB Relay 1

Subject to technical Common (terminal 3/4/5/6/53/54)

modifications. Command: open MCB
Multi-function terminal
3

This document is distributed for s1 (k)

Mains current L1
Automatic 2

informational purposes only. It is not s2 (l) Automatic 1

to be construed as creating or
Mains voltage L3 0 V DC
becoming part of any Woodward
Governor Company contractual or Mains voltage L2 12/24 V DC
warranty obligation unless expressly Mains voltage L1 N
stated in a written sales contract. Printed 10/2001; subject to technical mocifications. 2006-01-26 / GCP-20 Wiring Diagram Woodward gcp20ww-0406-ap.skf

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about the content of our
publications. Please send comments
including the document number
below to
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Company

All Rights Reserved

03243C - 06/3/S