GSC400 Series
Contents
1. 18 GSC400 Quick Fit Terminal 8 PIN HEADER MOLEX oo ese 5 6 PIN HEADE MOLEX 39 28 1063 AC CURRENT AC VOLTAGE 12 PIN HEADER SENSING SENSING MOLEX i iex ONE 7 39 28 1123 Mee o ey Iw A NY C a 5 o LN LN cy LN C EXTRA 7 in o Je RELAY D q 5 6 7 o olt 8 fo ollfe2. EMPLA GSC400 CUTLIU User Manual for the GSC400 Series Automatic Engine Controller N van x3 Ps NOLOG c MZ WW NX N DYNAGE DRAWN BE 10 4 3 GSC400 Typical Connector Layout Electrical Installation Note Many electrical connections need to be installed to the GSC400 for proper operation Wire harnesses and or wire harness plug connectors may be supplied to the customer upon request Wire harnesses connectors would include Two 2 6 position connectors 2x3 for AC current sensing and RS485 Input One 1 4 position connector 2x2 for J1939 One 1 8 position connector 2x4 for Analog Input One 1 10 position connector 2x5 for Digital Output One 1 12 position connector 2x6 for Digital Input Additionally there are several 1 4 blade type quick connect terminals for the higher voltage current connections Quick connects would include Two 2 Quick connects for speed sensing Four 4 Quick connects for AC voltage sensing Four 4 Quick connects for power connection Four 4 Quick connects for Fuel Crank and extra relay connection User Manual for the GSC400 Series Automatic Engine Controller 4 4 GSC400 Typical Connector Information Aueyeg Aayeg Maneg
3. TECHNOLOGIES INC GSC400 Series Automatic Engine Controller Dyna Gen RUHHIHa AC PHASE VOLTAGE j MH 120 2 WY B H Ll NZ EFS Supping Load P rei rd o i n a r y z m Fain er n Ln mU GSC400 Automatic Engine Controller Installation and User Manual Full Version File GSC400 Rev1 2 doc April 2006 Thank You For Purchasing This DynaGen Product Please Read Manual Before Installing Unit Receipt of Shipment and Warranty Return Information Upon receipt of shipment carefully remove the unit from the shipping container and thoroughly examine the unit for shipping damage In case of damage immediately contact the carrier and request that an inspection report be filed prior to contacting DynaGen All returned items are to be shipped prepaid and include a Return Material Authorization RMA number issued by DynaGen RMA forms are available by contacting DynaGen Technical Support through the contact methods listed below Limited Warranty DynaGen will repair or replace any GSC400 series engine controller which proves to be defective under normal and proper use within Three Years from the date of shipment This constitutes the only warranty and no other warranty shall be implied We welcome your comments and suggestions Please contact us at DynaGen Technologies Inc Phone 1 888 396 2436 902 562 0133 Fax 902 567 0633 Email support dynagen ca WEB SITE www dynagen ca Us
4. b Voltage Display Select to display type line line or line neutral Voltage measured in line neutral only line line uses calculated value c Voltage Group Select the AC power type being used 1 Single 2 Three 3 Hi Wye or 4 Three Phase The group selected will determine what type of set points to use Please note when digital input volt select is used for sensing the voltage group selection will be overwritten d Over Voltage When the AC voltage level is monitored warning 1 2 3 or 4 may Warning be selected depending upon the voltage group This warning value 1 2 3 or 4 is the level in which the controller will recognize if the generated voltage exceeds the setting and indicate a warning Please note that if warning level is set to a greater value then failure level no warning will be generated e Over Voltage When the AC voltage level is monitored failure 1 2 3 or 4 may Failure be selected depending upon the voltage group 1 2 3 or 4 The Failure value is the value in which the controller will recognize if the generated voltage exceeds the setting and will recognize a failure f Under Voltage When the AC voltage level is monitored warning 1 2 3 or 4 may Warning be selected depending upon the voltage group 1 2 3 or 4 This warning value is the level in which the controller will recognize if the generated voltage falls beneath the setting indicate a warning Settings apply only to the specific voltage group sele
5. HIGH HIGH VOLTAGE VOLTAGE The GSC400 may carry high Voltage Current which can cause Serious injury or death Extreme caution must be exercised when connections are being installed to or from the controller All wiring connections must be de energized before any installations are performed Wiring of the GSC400 should be performed by qualified electricians only 4 1 General Information All GSC400 engine controllers are factory tested and approved Customer installation requires the mounting of the controller as well as all external wiring for normal operation Once the GSC400 engine controller is properly installed it should be visually inspected and approved before any testing is performed 4 2 Mounting Location Figure 1 GSC400 Mounting Locations The GSC400 engine controller must be properly mounted for safe operation Caution must be taken at the installation site to make sure the site is free from excessive moisture fluctuating temperature ranges dust corrosive materials etc The controller should be safely mounted in a secure location using the 3 mounting screws provided See mounting location in figure 1 Mounting Location DynaGen RUNNING Mounting Location Caution Mounting screws must be installed at the mE recommended torque of 10 inch pounds User Manual for the GSC400 Series Automatic Engine Controller 4 2 1 GSC400 Mounting Dimensions APPROVED DATE A Q eh
6. Units h Warning Level 1 Failure Level Input 2 7 may be configured to Low Engine Temp An input can only be assigned to any given function once at any given time If using a sender be careful to select a Low or High impedance input location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain a low engine temperature failure The J1939 interface may be selected for a J1939 compliant engine The switch input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types When to recognize a low engine temperature failure Bypass delay is the time in seconds the GSC400 will wait after crank success before checking engine temperature When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable Fahrenheit or Celsius selectable Using an electronic sen
7. Battery Setup Set Password 6 4 1 J1939 Setup a Manufacturer Exerciser Enable Run Duration Pre Alarm Delay Repeat Frequency Start Hour Start Date Input A Bat Input B Bat Input C Bat Input D Bat Input E Gnd Input F Gnd Input G Gnd Input H Gnd Low Auto Charge Charge Pre Alarm Charge Duration Recharge Level Low Warn Level Low Fail Level High Warn Level High Fail Level Password No 1 Password No 2 Password No 3 Password No 4 30 Disable enable 10 240 minutes 1 20 minutes 1 672 hours 0 23 1 31 Disable Low Air Pressure Low Hydraulic Pressure EPS Supply Load Alarm Silence Low Coolant Volt Select 1 Volt Select 2 Idle Mode Start Stop Auxilary Warn Failure Disable enable 1 60 minutes 10 240 minutes 7 24 volts 7 24 volts 7 24 volts 12 32 volts 12 32 volts Select engine manufacturer from list John Deere Volvo b Display Groupl Enable Disable extra display parameters displayed while running c Display Group2 Enable Disable extra display parameters displayed while running Engine Manufacturer Display Group 1 Display Group 2 John Deere Volvo Penta Percent Engine Torque Percent Friction Torque Percent Load Percent Engine Torque Percent Friction Torque Percent Load Intake Temperature Fuel Temperature Fuel Rate Boost Pressure Oil Temperature Fuel Rate User Manual for the GSC400 Series Automatic Engine Controller 3l 6 4
8. EG WARNING s VOLTAGE VOLTAGE It is extremely important to connect each phase to the appropriate terminal location Never mix phase inputs Always match terminal details to the matching terminal location E rm a E a Phase A ee ee PasC 3 18 5A __ Phase Ccurrent sensing CT phase A 34 18 SA Phase A current sensing CTE PhaeB 5 18 5A PhaseBcumentsensng CT PhaeC 6 18 5A ___ Phase C current sensing CT GSC400 J1939 Canbus Connection The GSC400 J1939 Canbus connector is used to communicate between J1939 complaint engines Terminal Terminal Wire Size n Function n pe ANO CANH 18 mA CANH Connection Haa 2 18 m Ground Terminal Connection CANL CANL Connection Ground Terminal Connection User Manual for the GSC400 Series Automatic Engine Controller 5 0 GSC400 Operation Modes The GSC400 incorporates 3 modes of operation l 2 3 OFF Mode AUTO Mode Manual Run Mode OFF Mode When the GSC400 is set to the Off Mode starting will be disabled No automatic controls will be initiated The Off Mode may be initiated when no engine controls are required or when the menu system requires adjustment AUTO Mode When the GSC400 is set to the Auto Mode automatic starting will be enabled Auto Mode allows for the automatic control of the engine Possible causes of starting include start stop battery recharge and exerciser features Failu
9. Please note that 1f warning level 1s set to a greater value then failure level no warning will be generated d Over Current When the AC current level is monitored Failure 1 2 3 or 4 may Failure be selected depending upon the voltage group 1 2 3 or 4 This Failure value is the value in which the controller will recognize if the current draw exceeds the setting and will recognize a failure A value of between 0 6500A may be selected Settings apply only to the specific voltage group selected User Manual for the GSC400 Series Automatic Engine Controller 6 4 9 Engine Logic This function allows a Delay to Start b Pre heat Time c Crank Time d MidHeat Time e Rest Time f Crank Attempt g Fuel Crank Rest h False Restart 1 Post Heat Time j Warm up Time 4 the user to select the following settings This is the time in seconds that the GSC400 will wait before star ng the generator User adjustable 0 60 s This is the time in seconds that the GSC400 will preheat the engine Preheat occurs before the engine cranking cycle User adjustable 0 60 s This is the time in seconds the GSC400 will continue to crank the generator The controller will engage the flywheel until engine start or the crank time expires User adjustable 3 60 s If no speed after 2s of crank time controller looks for locked rotor condition This is the time in seconds that the GSC400 will preheat the e
10. switch senders must be grounded to the ground terminal on the connecter If more then two 2 wire switch senders are used sender grounds must be tied together at the ground terminal on the connecter a a AWG Ground Oe 7mA Ground Terminal Connection Iput2 High 2 18 7mA j Configmabe Ipu3 Low 3 18 7m _ Configurable Iput4 Low 4 18 7mA JjConfiguabe Input High 6 18 7mA Configuable Grund 8 18 7mA Ground ISenders requiring high pull up use input 2 5 6 7 which use high impedance pull up 2Senders requiring low pull up use input 3 4 which use low impedance pull up GSC400 Digital Input Connection The GSC400 digital input connector is used to connect digital input devices to the controller such as senders Single wire senders may be connected to the proper input terminal with grounding supplied at the sender itself Two wire senders must be grounded to the ground terminal on the connecter If more then two 2 wire senders are used sender grounds must be tied together at the ground terminal on the connecter Start Stop and Emergency stop are energized to ground only Detail Location AWG max IputC BAT 6 18 7mA Configurable InptA BAT 8 18 7mA Configurable Emer Stop 9 18 7mA_ Allows Manual Emergency Stop See Advanced Setup Menu Chart under Digital Input Setup for pos
11. up or down arrows on the GSC400 Off Exit Simply choose the correct password number for each selected position by scrolling to the proper number followed by the enter button The default company password will be 0 0 0 0 The password may be changed anytime See Password Setup section The Advanced Setup menu on the ADVANCED SETUP GSC400 ET Ye 41939 Setup Engine Temp Oil Pressure Fuel Level User Manual for the GSC400 Series Automatic Engine Controller 2 DynaGen ADVANCED SETUP BACK J1939 Setup Engine Temp Oil Pressure Fuel Level Advanced Setup Menu FUNCTION SELECTION AND RANGE Manufacturer Select J1939 ECU manufacturer J1939 Setup Display Group 1 Display Group 2 Enable Disable Enable Disable High Engine Temp Oil Pressure Fuel Level User Manual for the GSC400 Series Automatic Engine Controller Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Reserve Analog 2 7 J1939 Switch input Sender 0 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Fahrenheit Celius 10 265 F 10 265 C 10 265 F 10 265 C Reserve Analog 2 7 J
12. In addition to displaying messages and failure status indications on the controllers LCD display the uses of LED indicators are included within the GSC400 Specific LED indicators will be illuminated depending upon the condition of the controller The benefit of the GSC400 LED indicators allows a quick visual representation of the controller s condition The GSC400 displays multi color LED s for specific condition representation Red Represents Failure Conditions Green Represents Active Conditions Yellow ae Represents Warning Conditions 51 Overcresk DynaGen Hi Erg Tero Lo O4 Press Overipted Low Fon Batt Status Mx n uto FP its EFS Supr wap ra o o F siure Protest Overcrank High Temp Low Oil Overspe Low Fuel Batt Status Not in Auto Low Coolant Preheat Load On Failure LED section of the GSC400 An LED test may be performed by the user for illumination of all controller LED s The LED test may be performed by simultaneously pressing the UP button and the DOWN button ld on the GSC400 A User Manual for the GSC400 Series Automatic Engine Controller 52 7 1 GSC400 LED Indication Chart The following chart represents a visual representation of status LED located on the GSC400 LED s DESCRIPTION LED STATUS Indication Over Crank Battery Status Solid Green A solid green illuminated LED represents an accurate battery condition
13. RPM level is measured the GSC400 can be configured for a choosing failure value The Failure value is the value in RPM which the controller will recognize a failure A value of between 100 5000 RPM may be selected This warning value is the value in RPM which the controller will recognize if the RPM level goes beneath the setting and indicate a warning condition A value of between 100 5000 RPM may be selected Please note that 1f warning level is set to a less value then failure level no warning will be generated When the engine is running the RPM level is measured the GSC400 can be configured for choosing a failure value The Failure value is the value in RPM which the controller will recognize a failure A value of between 100 5000 RPM may be selected User Manual for the GSC400 Series Automatic Engine Controller 38 6 4 6 AC FREQUENCY This function allows the user to select the following settings a Frequency Disconnect b Over Freq Warning c Over Freq Failure d Under Freq Warning e Under Freq Failure The AC frequency level of the engine is monitored allowing the engine starter to disconnect at a settable value A value of between 1 100 HZ may be selected Please note that the frequency disconnect may be used as a backup to crank disconnect settings Both settings will be monitored simultaneously This 1s the value in HZ which the controller will recognize when the fre
14. Red Solid Red A solid red illuminated LED represents an Over Crank Failure condition Yellow Solid Yellow A solid yellow illuminated LED represents an Over Crank Warning condition Solid Red A solid red illuminated LED represents a High Temp Failure condition Red Yellow Solid Yellow A solid yellow illuminated LED represents a High Temp Warning condition Solid Red A solid red illuminated LED represents a Low Oil Failure condition Red Yellow Solid Yellow A solid yellow illuminated LED represents a Low Oil Warning condition Solid Red A solid red illuminated LED represents an OverSpeed Failure condition Red Yellow Solid Yellow A solid yellow illuminated LED represents an OverSpeed Warning condition Solid Red A solid red illuminated LED represents a Low Fuel Failure condition Red Yellow Solid Yellow A solid yellow illuminated LED represents an Low Fuel Warning condition Flashing Green Controller in Auto mode Waiting to start Yellow Solid Yellow A solid yellow illuminated LED represents a Low Battery condition User Manual for the GSC400 Series Automatic Engine Controller 53 LED DESCRIPTION LEDCOLOR LED STATUS Indication Not In Auto Red Solid Red A solid red illuminated LED represents a Not in Auto condition Low Coolant Solid Red A solid red illuminated LED represents a Low Coolant failure condition Yellow Solid Yellow A solid yellow illuminated LED represents a Low Coolant Warning cond
15. Time Crank Time MidHeat Time Crank Rest Time Crank Attempts Fuel Crank Rest False Restart Post Heat Time ETS On Duration Warm up Time Crank Disconnect Cool Down Delay Crank Oil pres Extra Relay Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Exerciser Enable Run Duration Pre Alarm Delay Repeat Frequency Start Hour Start Date Input 1 Bat Input 2 Bat Input 3 Bat Input 4 Bat Input 5 Gnd Input 6 Gnd Input 7 Gnd Input 8 Gnd Low Auto Charge Charge Pre Alarm Charge Duration Recharge Level Low Warn Level Low Fail Level High Warn Level High Fail Level Password No 1 Password No 2 Password No 3 Password No 4 50 0 seconds 10 seconds 15 seconds 0 seconds 15 seconds 3 Disable Disable 0 seconds 0 seconds 0 seconds 650 RPM 0 seconds 10 PSI Disable Low Fuel Failure High Temperature Failure Over Crank Failure Over Speed Failure Common Failure Not in Auto Engine Running Battery Warning Disable 30 minutes 5 minutes 336 hours 14 days 12 8 Low Air Pressure Low Hydraulic Pressure EPS Supply Load Alarm Silence Low Coolant Level Voltage Select 1 Voltage Select 2 Idle Mode Disable minute 10 minutes 10 4 volts 11 2 volts 9 volts 15 volts 16 volts User Manual for the GSC400 Series Automatic Engine Controller 7 0 GSC400 LED STATUS INDICATOR The GSC400 incorporates an advanced failure status system
16. VA and fy byttous on the GSC400 Enter selections by depressing the enter button G a k DynaGen 9 00AM DEC 01 amp y FOR LAMP TEST OFF MODE Net in Asko START DISABLED Low Conard 1 EiS Te E Load 1 Probe l Fature User Manual for the GSC400 Series Automatic Engine Controller The backlight display will illuminate automatically upon button activation The backlight will stay on for a period of 60 seconds 24 6 1 GSC400 Controller Menu Overview The GSC400 Controller Features the Following Menu Functions 1 Clock Setup 9 00AM DEC 01 2 Basic Setup COLI SEND 3 Advanced Setup BASIC SETUP 4 Failure History ADVANCED SETUP FAILURE HISTORY 6 2 CLOCK SETUP Back 12 24 hour time display 1 Year User selectable allowing current year LCD display 2 Month User selectable allowing current month LCD display 3 Date User selectable allowing current date LCD display 4 Day User selectable allowing current day LCD display 5 Hour User selectable allowing current hour LCD display Hour must always be set in 24 hour time regardless of the 12 24 display setting 6 Minute User selectable allowing current minute LCD display 7 12 24 User selectable allowing current time LCD display Time may be displayed in 12 24 hour status User Manual for the GSC400 Series Automatic Engine Controller 29 6 3 BASIC SETUP Cheer mente DynaGen Hi Erg Tero Le O4 Pret BASIC S
17. effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable Fahrenheit or Celsius selectable Using an electronic sender or J1939 input a value of 10 265 may be selected to initiating a warning Please note that if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender or J1939 input a value of 10 265 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 6 4 3 Oil Pressure 32 This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g Units h Warning Level 1 Failure Level Input 2 7 may be configured to Oil Pressure A specific input can be assigned only once to any given function at any one time If using a sender be careful to select a Low or High impedance input location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain an oil pressure failure The J1939 interface may be selected for a J1939 compliant engine The switch input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types When to recognize an oil p
18. future reference Default password 0 0 0 0 User Manual for the GSC400 Series Automatic Engine Controller 47 6 5 FAILURE HISTORY The GSC400 incorporates an advanced failure status history logging system When engine aon failures occur the failure Hi Eng Temp DynaGen condition information 1S ooma oee documented into the GSC400 ow4 HitEnter To Exit failure history log The failure were TOTAL 99 log may be displayed by 5 OVERSPEED FAILURE entering the GSC400 menu E LL E 10 30 DEC 01 system as explained in section TAM 4 GSC400 Menu System e A total of the last 99 failure conditions will recorded within the FAILURE HISTORY log Failure conditions may be Hit Enter To Exit viewed simply by scrolling up or T down throughout the menu In TOTAL 29 addition to the failure condition U2 information the associated date and OVERCRANK FAILURE time of the failure will be displayed 10 15 DEG 01 FAILURE HISTORY Simply scroll through the failure i did B Hit Enter To Exit history log by depressing the or TOTAL ga A Buttons located on the GSC400 US E LOW COOLANT FAILURE 10 00 DEC 01 User Manual for the GSC400 Series Automatic Engine Controller 48 6 6 Default GSC400 Settings GSC400 s are factory programmed and shipped with Default settings Customized settings may be factory programmed upon request FUNCTION DEFAULT SETTINGS J1939 High Engine Temp Oil Pressure
19. m m R m a J o 2 Do m 0x Fuel Relay 40A LL Speed 1 LL Speed 2 Phase A LILI A AC Current Phase B RS232 sensing oe peers oO Analog Input Analog Input 4 Ground Analog Input 3 _ L Analog Input 7 Analog Input2 L Analog Input 6 Ground Analog Input 5 Ground Lir Ground CANH 1 CANL J1939 CanBus AC Voltage Sensing S S 1261002 Aug dois AoueBueul3 doisS ueis g 1nduj epig LJ 3 mdno rensa v duj enig J wsersy a nding ebia yea A LIE a LAL punoJe d 58vr SH punoJe jeg A 2 1nduj jeybig d 1nduj eyg 3 1ndu enig 4 jnduj jeybiq c ynduy enig H ynduy eyg 3 yndyno jeybiq H andino jeybiq a 1ndino jey6ig 9 mdo reser v jndino jewbig E C 4 yndyno jeybig User Manual for the GSC400 Series Automatic Engine Controller Phase A Phase B PhaseC Neutral Phase C Phase B Phase A Digital Input 1 12 4 5 GSC400 AC Voltage Connection E WARNING s VOLTAGE VOLTAGE AC power may carry high Voltage Current which can cause serious injury or death De energize all AC power sources before any connections are performed AC electrical connections need to be applied to the GSC400 for proper AC voltage sensing AC power is supplied to NEUTRAL the AC Voltage Sensing blade terminals f located on the GSC400 Connections A AC VOLTAGE SENS
20. switch to Bat inputs to activate Inputs E H are switch to Gnd inputs to activate Inputs may be assigned to the following functions 1 Low Air Pressure 7 Volt Select 2 2 Low Hydraulic Pressure 8 Idle Mode 3 EPS Supply Load 9 Start Stop 4 Alarm Silence 10 Auxiliary Warn 5 Low Coolant 11 Auxiliary Fail 6 Voltage Select 1 User Manual for the GSC400 Series Automatic Engine Controller 45 6 4 13 Battery Setup This function allows the user to select the following settings a Low Auto Charge b Charge Pre Alarm c Charge Duration d Recharge Level e Low Failure Level f Low Warning Level g High Failure Level h High Warning Level Low auto charge allows for the automatic starting of the engine in low battery conditions The engine will run to charge the battery User selectable as disabled or enabled Charge pre alarm allows for the automatic warning of the engine starting in low battery conditions The alarm will sound to warn of a low battery condition and that the engine will be starting User selectable from 1 60 seconds Charge duration is the number of minutes the engine will run to charge a low battery User selectable from 10 240 minutes The level which a low battery will be charged to when requiring charging not exceeding the charge duration User selectable from 7 24 volts The battery level detected as a low voltage requiring engine start User selectab
21. would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable Percentage Using an electronic sender a value of 0 100 may be selected to initiating a warning Please note that if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender a value of 0 100 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 6 4 6 Fuel in Basin 35 This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g Warning Level h Failure Level Input 2 7 may be configured to Fuel in Basin An input can only be assigned to any given function once at any given time If using a sender be careful to select a Low or High input impedance location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain a fuel in basin failure The J1939 interface may be selected for a J1939 compliant engine The switch
22. 0 internal components as well as the enclosure Care should be taken to protect the equipment from impact at all times Do not remove the protective packaging until the equipment is at the installation site and ready to be installed When the GSC400 reaches its destination the customer should inspect the shipping box and controller for any signs of damage that occurred during transportation Any damage should be reported to a DynaGen representative once a through inspection is complete A shipping label affixed to the shipping box includes a variety of product and shipping information such as items and Customer numbers Make certain that this information matches your order information Each GSC400 controller is packaged in its own box Do not discard the packing material until the controller 1s ready for installation Important documents will be found inside the GSC400 controller protective packaging box including the GSC400 user and installation manual and system wiring diagrams Handling Pewrsmek As previously mentioned each GSC400 engine controller is packaged in its own individual box Protect the equipment from impact at all times and do not carelessly stack Once the controller 1s at the installation site and ready to be installed the packaging material may be removed Storage Although well packaged this equipment is not suitable for outdoor storage If the GSC400 is to be stored indoors for any period of time it should
23. 1939 Switch input Sender 0 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown PSI KPa 0 90 PSI 0 90 KPa 0 90 PSI 0 90 KPa Reserve Analog 2 7 J1939 Switch input Sender 0 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Percentage 0 90 0 90 Fuel Level continued Oil Level Fuel In Basin Low Engine Temperature Spd Sensing AC Frequency A C Voltage 0 Fuel Level 25 Fuel Level 50 Fuel Level 75 Fuel Level 10046 Fuel Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Signal Source Rated Freq Rated RPM Over Speed Warn Over Speed Fail Under Speed Warn Under Speed Fail Frequency Disconnect Over Freq Warn Over Freq Fail Under Freq Warn Under Freq Fail Voltage Source Voltage Display Voltage Group Over Volt Warn 1 Over Volt Fail 1 Under Volt Warn 1 Under Volt Fail 1 Over Volt Warn 2 Over Volt Fail 2 0 1000 Ohms data sheet or measured value 0 1000 Ohms data sheet or measured value 0 1000 Ohms data sheet or measured value 0 1000 Ohms data sheet or measured value 0 1000 O
24. 2 High Engine Temp d This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g Units h Warning Level 1 Failure Level Input 2 7 may be configured to High Engine Temp A specific input can be assigned only once to any given function at any one time If using a sender be careful to select a Low or High impedance input location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain a high engine temperature failure The J1939 interface may be selected for a J1939 compliant engine The switch input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types When to recognize an engine temperature failure Bypass delay is the time in seconds the GSC400 will wait after crank success before checking engine for high engine temperature When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no
25. ETUP 4 BACK Contrast Adjust Page Roll Delay State Roll Delay 5 95 1 Contrast Adjust User selectable allowing different percent LCD contrast ratios 2 Page Roll Delay User selectable allowing page roll delay times during run mode 3 State Roll Delay User selectable allowing state roll delay times during run mode The contrast and delay settings will be automatically temperature compensated below 0 C The compensated settings will allow the LCD display to be better viewable at lower temperatures Please note that this is an automatic compensation and does not effect the actual contract adjust setting If the controller is set for a 50 brightness level the display will stay at the level through a temperature change User Manual for the GSC400 Series Automatic Engine Controller 26 6 4 ADVANCED SETUP The GSC400 incorporates an advanced setup menu function l DynaGen Advanced setup features include Mos input output and other advanced 9 00AM DEC 01 P crates 4 BACK settings which are adjustable by ATOR SEDE the user 1f required See the asus BASIC SETUP l ADVANCED SETUP possible advanced setup menu ew FAILURE HISTORY selections on the following page A password is required to be correctly entered allowing access to the advanced menu selections The password will PASSWORD 7 consist of a four digit number Each 1234 E number needs to be selected using the MES E a Enter Next
26. EXTRA d D e 8 9H o3 i RELAY IP Q poc s gt DIGITAL INPUTS d 1049 off4 RAT e e 11 9 eiS 9n bd ae 10 PIN HEADER e o EES MOLEX s l l z ey ho 2928 1103 amp m 6 E 1 BA H ID q e 69 7 o ec gt T ia 2 X 5 HEADER 8 Ue JL 3 DIGITAL OUTPUTS d e 8 AMP 9 o o 4 i ae 87227 5 i Wen em CRANK PF ae e e 4 o off 1 EE con sl e eje RS485 INPUTS FUEL Day i Ej RE uS 3 I 6 o 3 Im 9 o 9 oO 9 9 O C 6 PIN HEADER a Lo Ao MP LEA L98 MOLEX 7 4 3 gt 2 39 28 1063 ERTICAL QUICKFIT TERMINAL SERIAL PORT LYSTUNE CRS232 ANALOG 31939 D CADE 4 PIN HEADER 4901 INPUTS CCAN BUS MOLEX 39 28 1043 The GSC400 quick Fit terminals are used for high power connections Controller relay outputs are also connected to the quick fit terminal section Terminal Wire Size Current max Function ae R 0A Crank Output Terminal Crak Battery 12 40A Positive Battery Terminal Fuel Output Terminal Extra Relay Extra Relay Output Terminal 100mA Speed Signal Connection Speed 1 Speed 2 Speed Signal Connection Total controller current output max 60A User Manual for the GSC400 Series Automatic Engine Controller 19 GSC400 Analog Input Connection The GSC400 analog input connector is used to connect analog input devices to the controller such as switches or senders Single wire switch senders may be connected to the proper input terminal with grounding supplied at the sender itself Two wire
27. Fail 2 Over Current Warn 3 Over Current Fail 3 Over Current Warn 4 Over Current Fail 4 Delay to Start Pre heat Time Crank Time MidHeat Time Crank Rest Time Crank Attempts Fuel Crank Rest False Restart Post Heat Time ETS On Duration Warm up Time Crank Disconnect Cool Down Delay Crank Oil pres Extra Relay Output A Output B Output C Output D Output E Output F Output G Output H 20 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC Disable Enable 5 5000A 5A 0 6500 A 0 6500 A 0 6500 A 0 6500 A 0 6500 A 0 6500 A 0 6500 A 0 6500 A 0 60 seconds 0 60 seconds 3 60 seconds 0 60 seconds 1 60 seconds 1 60 Disable Enable Disable Enable 0 60 seconds 0 30 seconds 0 600 seconds 100 2000 RPM 0 600 seconds 0 90 Psi Disable Warm Up ETS Pre heat Cooldown Over Crank High Temp Fail High Temp warn Low Oil Fail Low Oil warn Under Speed Fail Under Speed Warn Over Speed Fail Over Speed Warn Low Fuel Fail Low Fuel Warn Battery Fail Battery Warn Low Coolant Fail Low Coolant warn Not in Auto Failure Crank Rest Engine Running Crank On Exerciser Alarm Recharge Alarm Under Volt Warn Over volt warn Over Amp Warn Fuel in Basin Volt Regulator Low Temp Warn Back Light Aux Warn User Manual for the GSC400 Series Automatic Engine Controller Exerciser setup Digital Input Setup All selections apply to each individual input
28. Fuel Level Oil Level Fuel In Basin Manufacturer Display Group 1 Display Group 2 Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level John Deere Disable Disable Input Pin 2 Sender 1 30 Seconds GND Fail Disable Disable Fahrenheit 200 F 220 F Input Pin 3 Sender 1 30 Seconds GND Fail Disable Disable PSI 20 PSI 15 PSI Input Pin 4 Sender 30 Seconds GND Fail Disable Disable Percentage 25 5 Input Pin 5 Switch 10 Seconds GND Fail Disable Disable Percentage 10 5 Input Pin 6 Switch 11 Seconds GND Fail Disable Disable Percentage 2 5 User Manual for the GSC400 Series Automatic Engine Controller Low Engine Temperature Spd Sensing AC Frequency A C Voltage A C Voltage continued A C Current Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Level Failure Level S
29. ING would be installed as follows In single phase applications e Phase A to terminal Phase A LL Neutral e Phase B to terminal Phase B Phase C e Neutral to terminal Neutral PHASE B Phase B In three phase applications e Phase A to terminal Phase A Phase A e Phase B to terminal Phase B e Phase C to terminal Phase C e Neutral to terminal Neutral a fica In center tapped delta applications e Phase A to terminal Phase A e Phase B to terminal Phase B e Phase C to terminal Phase C e Neutral to terminal Neutral User Manual for the GSC400 Series Automatic Engine Controller 13 4 6 GSC400 AC Current Sensing Kc WARNING s VOLTAGE VOLTAGE AC power may carry high Voltage Current which can cause serious injury or death De energize all AC power sources before any connections are performed Current transformers need to be applied to the electrical wiring between the power source and load connections for current Viam sensing Current transformers are supplied to the AC Current Sensing connector located on the GSC400 Connections would be installed as follows AC CURRENT SENSING In single phase applications e Phase A to terminals Phase A In three phase applications e Phase A to terminals Phase A e Phase B to terminals Phase B e Phase C to terminals Phase C In center tapped delta applications e Phase A to terminals Phase A e Phase B to terminals Phase B e Phase C to terminals Phase C W
30. N SYSTEM OPERATION The GSC400 controller is designed to operate in either 12 or 24 VDC system voltages When operating in 12VDC systems the fuel crank and extra relays need to be the proper 12VDC relay type When operating in 24VDC systems these relays need to be the proper 24VDC relay type Contact the factory if relays are required Approved relays for 12 or 24VDC system operation are as follows e AZETTLER AZ973 1C 12DC for 12VDC operation AZETTLER AZ973 1C 24DC for 24VDC operation User Manual for the GSC400 Series Automatic Engine Controller GSC400 Fuse Protected 40A Relay Output i TERN crand A 3 404 Onboard Replaceable Relay Output Protected Output Relays By 404 Fuse CAUTION needs to be taken when connecting relay outputs to an inductive load Due to the inductive nature of certain loads starters pull coils initial current draw may be higher then stated in load specs causing damage to onboard relays Output relays are protected by onboard 40A fuse protection Smaller amperage fuses from many automotive stores may be used in place of the higher current 40A If installing lower amperage fuse protection be certain that current draw does not exceed the fuse current limit An approved 40A fuse is as follows e LITTLEFUSE 257040 32VDC 40A Auto fast Action User Manual for the GSC400 Series Automatic Engine Controller GSC400 Connector Details
31. be stored with its protective packaging in place Protect the controller at all times from excessive moisture dirty conditions corrosive conditions and other contaminants It is strongly recommended that the package protected equipment be stored in a climate controlled environment of 20 to 65 C 4 to 149 P with a relative humidity of 80 or less Do not stack other equipment on top of the stored controllers User Manual for the GSC400 Series Automatic Engine Controller 3 0 GSC400 Product Number Identification The GSC400 series product numbering scheme provides significant information pertaining to a specific model The product Number Identification Table see Table 1 provides the required interpretation information An example is offered to initially simplify the process A product number GSC400 X XX XX would consist of a combination of information from the following table TABLE1 IDENTIFICATION TABLE m 1 6 Position 10 11 Position 13 14 e Place Value DC Voltage Labeling GSC400 GSC400 No Meaning 12 12VDC LS Standard 24 24VDC LX Customized Example The product number GSC400 0 12 LS would be described as follows A GSC400 series automatic engine controller configured for a 12 VDC system which includes standard labeling A GSC400 serial number would be displayed as GSC400 0 12 LS 00000 User Manual for the GSC400 Series Automatic Engine Controller 4 0 GSC400 Series Installation and Wiring DANGER DANGER
32. c any wiring or connections proper operation User Manual for the GSC400 Series Automatic Engine Controller
33. cted Please note that if warning level is set to a greater value then failure level no warning will be generated g Under Voltage When the AC voltage level is monitored failure 1 2 3 or 4 may Failure be selected depending upon the voltage group 1 2 3 or 4 Failure value is the value in which the controller will recognize if the generated voltage falls beneath the setting and will recognize a failure User Manual for the GSC400 Series Automatic Engine Controller 40 6 4 8 A C Current I This function allows the user to select the following settings a Current Source Allows monitoring of the current draw on the generator The enable option may be selected for monitoring the amount of current being draw from the engine The disable option may be selected if no current monitoring 1s required b Turns Ratio The turns ratio is user adjustable and must match the current CT being used The correct value may be seen on the current CT and must enter the value in the correct format as XA 5A where X is the setting enter from the CT c Over Current When the AC current level is monitored Warning 1 2 3 or 4 may Warning be selected depending upon the voltage group 1 2 3or 4 This warning value is the level in which the controller will recognize if the generated current load exceeds the setting and indicate a warning A value of between 0 6500A may be selected Settings apply only to the specific voltage group selected
34. der or J1939 input a value of 10 265 may be selected to initiating a warning Please note that if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender or J1939 input a value of 10 265 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 6 4 5 Speed Sensing 37 This function allows the user to select the following settings a Signal Source b Rated Freq c Rated Speed d Over Speed Warning e Over Speed Failure f Under Speed Warning g Under Speed Failure How to obtain engine speed The J1939 interface may be selected for a J1939 compliant engine The magnetic pickup option may be selected for speed sensing from the engine flywheel Generator output option may be selected for speed sensing directly from the generator output Normal running frequency of the engine Used to calculate engine speed Select rated frequency between 10 9990 Hz Normal running speed of the engine Used to calculate engine speed Select rated speed between 200 4000 RPM This warning value is the value in RPM which the controller will recognize if the RPM level exceeds the setting and indicate a warning condition A value of between 100 5000 RPM may be selected Please note that if warning level is set to a greater value then failure level no warning will be generated When the engine is running the
35. er Manual for the GSC400 Series Automatic Engine Controller Table of Contents GSC400 Series Specifications 1 0 GSC400 Product Series 2 0 Receiving Handling and Storage 2 1 Receiving 2 2 Handling 2 3 Storage 3 0 GSC400 Product Number Identification 4 0 GSC400 Series Installation and Wiring 4 1 General information 4 2 Mounting location 4 3 Connector Layout 4 4 Connector Information 4 5 AC Voltage Sensing 4 6 AC Current Sensing 4 7 AC Wiring Diagram 4 8 DC Wiring Diagram 4 9 Analog Input Wiring Diagram 4 10 Digital Input wiring Diagram 4 11 Connector Details 5 0 GSC400 Modes of Operation 5 1 Off mode 5 2 Auto mode 5 3 Start mode 6 0 GSC400 Menu System 6 1 GSC400 menu overview 6 2 Clock setup 6 3 Basic setup 6 4 Advanced setup 6 5 Failure history 6 6 DefaultGSC400 Settings 7 0 LED Status Indicators 7 1 LED indicator chart 8 0 GSC400 Recommended Maintenance User Manual for the GSC400 Series Automatic Engine Controller 22 22 51 54 GSC400 Specifications Function Selection Speed Sensing Generator pickup 0 300vac 0 3600rpm Range Magnetic pickup 0 300vac 0 3600rpm Engine Logic Delay to start Pre heat Crank Rest Time Mid Heat Crank attempts False restart Post heat Warm up Cooldown Crank oil pressure Crank Disconnect Frequency Sensing Enable Disable Engine Temp GND Fail Open Fail 10 265 F 10 265 C GND Fail Open Fail 0 90 PSI 0 90 Kpa Oil Level GND Fail Open Fail 0 90 Fue
36. er The exerciser 1s user selectable as enabled or disabled The Enable exerciser enable only applies when in Auto mode and allows for the automatic starting and stopping of the engine b Run Duration The exerciser will automatically run the engine for a specified duration The run duration is user selectable from 10 240 minutes c Pre alarm This is the delay time that the GSC400 will sound an audible alert Delay before the exerciser starts the engine The higher the delay setting the longer warning will be sounded to anyone who may be around the engine d Repeat Interval The exerciser is capable of automatically starting and stopping the engine at a set interval The user may select the repeat interval according to the start hour and date The selectable range is between 0 672 hours e Start Hour The exerciser will automatically start the engine depending upon the start hour setting f Start Date The exerciser will automatically start the engine depending upon the start date setting Pre Alarm neay Repeat Interval __ Run Duration gt Engine Run Engine Off Time Start Start Date Hour User Manual for the GSC400 Series Automatic Engine Controller 44 imm 6 4 12 Digital Input Setup This function allows the user to select the following settings The GSC400 has 8 inputs available for assignment Each of the available inputs may be assigned only one input function at any given time Inputs A D are
37. hite wire assumed positive Black wire assumed negative NEVER energize AC power with AC current sensing connector unplugged form GSC400 An energized unplugged connector could result in severe injury or death Never unplug energized connector r i i User Manual for the GSC400 Series Automatic Engine Controller 4 7 GSC400 AC Wiring Diagram 4 L2 L3 Neutral a RELAY 40A Sensing SLET AC Current NC Gd nimii AC Voltage GIL Sensing B LL NA 44444444 Ek EVREN RE Tp IRE AI IDA OCR are en ARC SE J Battery User Manual for the GSC400 Series Automatic Engine Controller 15 4 9 GSC400 Analog Input Wiring Diagram Switch Sender Input 4 Switch Sender Input 7 NOTE Switch Sender Input 3 and 4 are Low impedance Switch Sender Input 2 5 6 and 7 are High impedance 4 10 GSC400 Digital Input Wiring Diagram Bat n a w H j o 2 n u E LI Digital Input A Digital Input C Digital Input C Balt NOTE Digital Input A D are switch to Bat Batefail Digital Input E H are switch to Gnd Gnd fail User Manual for the GSC400 Series Automatic Engine Controller GSC400 12 24VDC SYSTEM OPERATION m LI eh EDS Lu i 7 amp Ss 1 Qn r E z 4 d E r s r 1 1 i fr h wl x 3 5 7 A LI a aS an IDC RELAY 12vDC RELAYS MUST BE 24V0C RELAYS MUST BE INSTALLED FOR 12VDC INSTALLED FOR 24VDC SYSTEM OPERATIO
38. hms data sheet or measured value Reserve Analog 2 7 J1939 Switch input Sender 0 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Percentage 0 100 0 100 Reserve Analog 2 7 J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Percentage 0 90 0 90 Reserve Analog 2 7 J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Fahrenheit Celius 10 265 F 10 265 C 10 265 F 10 265 C J1939 Mag pickup Gen output 10 9990 Hz 200 4000 RPM 100 5000 RPM 100 5000 RPM 100 5000 RPM 100 5000 RPM Disable Wye Line Line Line Neutral 1 Single 2 Three 3 Hi Wye 4 Three phase 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC User Manual for the GSC400 Series Automatic Engine Controller 28 A C Voltage continued A C Current Engine Logic Digital Output Setup All selections apply to each individual output A specific selection may be mapped to more then one output to allow for higher current output Under Volt Warn 2 Under Volt Fail 2 Over Volt Warn 3 Over Volt Fail 3 Under Volt Warn 3 Under Volt Fail 3 Over Volt Warn 4 Over Volt Fail 4 Under Volt Warn 4 Under Volt Fail 4 Current source Turns Ratio Over Current Warn 1 Over Current Fail 1 Over Current Warn 2 Over Current
39. ignal Source Rated Freq Rated RPM Over Speed Warn Over Speed Fail Under Speed Warn Under Speed Fail Frequency Disconnect Over Freq Warn Over Freq Fail Under Freq Warn Under Freq Fail Voltage Source Voltage Display Voltage Group Over Volt Warn 1 Over Volt Fail 1 Under Volt Warn 1 Under Volt Fail 1 Over Volt Warn 2 Over Volt Fail 2 Under Volt Warn 2 Under Volt Fail 2 Over Volt Warn 3 Over Volt Fail 3 Under Volt Warn 3 Under Volt Fail 3 Over Volt Warn 4 Over Volt Fail 4 Under Volt Warn 4 Under Volt Fail 4 Current source Turns Ratio Over Current Warn 1 Over Current Fail 1 Over Current Warn 2 Over Current Fail 2 Over Current Warn 3 Over Current Fail 3 Over Current Warn 4 Over Current Fail 4 Input Pin 7 Switch 10 Seconds GND Fail Disable Disable Fahrenheit 12 F 50 F Magnetic pickup 3200 Hz 1800 RPM 1900 RPM 2000 RPM 1700 RPM 1600 RPM Wye Line Neutral Group 1 Single 250 VAC 260 VAC 230 VAC 220 VAC 220 VAC 230 VAC 195 VAC 185 VAC 500 VAC 520 VAC 460 VAC 440 VAC 630 VAC 650 VAC 570 VAC 550 VAC Enable 100A 5A 90 A 100 A 80 A 90 A 20 A 25A ISA 20 A User Manual for the GSC400 Series Automatic Engine Controller Engine Logic Digital Output Setup All selections apply to each individual output Exerciser setup Digital Input Setup All selections apply to each individual input Battery Setup Set Password Delay to Start Pre heat
40. input can only be assigned to any given function once at any given time If using a sender be careful to select a Low or High impedance input location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain an engine temperature failure The J1939 interface may be selected for a J1939 compliant engine The switch input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types Sender values for 0 25 50 75 and 100 are entered When to recognize a fuel level failure Bypass delay is the time in seconds the GSC400 will wait after crank success before checking fuel level When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable Percentage Using an electronic sender or J1939 input a value of 0 90 may be selected to initiating a warning Please note tha
41. input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types When to recognize a fuel in basin failure Bypass delay is the time in seconds the GSC400 will wait after crank success before checking for a fuel in basin failure When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable Using an electronic sender a value of 0 90 may be selected to initiating a warning Please note that if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender a value of 0 90 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 36 6 4 7 Low Engine Temp d This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g
42. ition Pre Heat Green Solid Green A solid green illuminated LED represents an active Pre Heat condition Green Solid Green A solid red illuminated LED represents an active load condition M Load Failure Red Solid Red A solid red illuminated LED represents a general Failure condition User Manual for the GSC400 Series Automatic Engine Controller 54 8 0 RECOMMENDED MAINTENANCE b WARNING When performing any GSC400 or Engine maintenance be certain controller in OFF Mode isolated from all possible sources of power and Crank wire is removed from the Controller RA teeter RA iit err KA initio ruri d ie a reer Pie a reer Fie a reer Periodically inspect all fasteners terminals connections and wiring for any loose or damaged parts Periodically inspect and remove any debris dirt from within or near the controller Periodically inspect the operating area of the GSC400 for a safe and accurate mounting environment Procedure Action Making the controller safe for inspection and Disconnect all possible power sources before maintenance controller inspection Inspect controller mounting location for possible Inspect mounting location for any safety or fire safety issues issues Inspect for dirt wiring damage and mechanical damages Inspect controller for loose fasteners terminals and Check all hardware including controller wiring wiring connections terminals etc for any looseness due to vibrations et
43. l Level GND Fail Open Fail 0 100 Input 3 4 Low Z Input E H Sw to Gnd Digital Output Output A H 300 mA Max DMMOM pking O avama OO Battery Recharge Enable Disable 10 240 Minutes Password 4Digt J09 S Voltage Sensing Single phase Max 700vac 1 Three phase Max 700vac 1 Delta Wye Max 700vac 1 1 100 HZ 0 60 seconds 0 60 seconds 3 60 seconds 1 60 seconds 0 60 seconds 1 60 tries Enable Disabled 0 60 seconds 0 600 seconds 0 600 seconds 0 90 KPa 100 2000 RPM Gnd Fail Open fail 7mA Max Bat Fail 7mA Max Gnd Fail 7mA Max LCD Display 128x64 Graphic display Backlit 60 viewing angle LCD operating temperature 30 C to 60 C 22 F to 140 F LED Display Red Green Yellow LED representation Daytime Visible 60 viewing angle Use of Industry Standard CT Required 40A output at room temperature User Manual for the GSC400 Series Automatic Engine Controller 1 0 GSC400 Controller Series The GSC400 automatic engine controller is specifically designed for advanced monitoring GSC400 Front View of power generation systems The GSC400 monitors engine logic features as well as engine characteristics DynaGen The GSC400 automatic engine controller s advanced circuitry 1s specifically designed to monitor engine logic Engine logic consisting of the start and safe shutdown of the engine are included in the GSC400 a
44. le from 7 24 volts The battery level detected as a low voltage to sound warning User selectable from 7 24 volts The battery level detected as a high voltage requiring engine shutdown User selectable from 12 32 volts The battery level detected as a high voltage to sound warning User selectable from 12 32 volts All battery setup settings are available only in auto mode When the Engine is running the battery voltage will equal to alternator charging voltage The actual battery voltage may be lower then displayed User Manual for the GSC400 Series Automatic Engine Controller 46 6 4 14 Password Setup The GSC400 allows a password be entered to protect any modifications from being made to adjustments DvnaGen within the advanced setup menu A 2 ADVANCED SETUP four digit password may be selected 4 BACK This password will be needed to Exerciser Set Inputs Setup perform any changes to the advanced Bolton Setup setup set Password If the password is entered incorrectly three chances will be allowed before the GSC400 returns back to the main menu To set password Set Password e Select Password No 1 Enter the desired number 0 9 4 BACK e Select Password No 2 Password No 1 Enter the desired number 0 9 Password Mo e Select Password No 3 rest Enter the desired number 0 9 eo x ie l e Select Password No 4 Enter the desired number 0 9 Fassword No C Remember to write down the password for
45. nd is user SETA adjustable allowing preference settings of b options and timing The engine controller will control the starting of the engine delays cranking false restarts etc Engine shutdowns are monitored allowing delays and cool down periods The GSC400 s engine logic features will allow engine protection in the event of abnormal starting stopping sequences BS IL RE cp TERES Law Fuel in Status etin Role iz T The GSC400 will continuously and effectually GSC400 Back View monitor engine characteristics Engine characteristics such as temperature pressure RPM voltage current and coolant levels are closely monitored to protect the engine from any malfunctions The GSC400 can be user adjustable to sound an audio alert to warn when a malfunction is in progress before actually shutting down the engine The GSC400 will automatically shutdown the engine depending upon the user settings before any damage is afflicted to the engine All GSC400 automatic engine controllers incorporate an LCD display and LED indications The LCD is used for multi tasks including displaying dates time menu settings status readouts etc User Manual for the GSC400 Series Automatic Engine Controller 2 0 Receiving Handling and Storage Receiving Every effort is made to ensure that your GSC400 engine controller arrives at its destination undamaged and ready for installation The packing is designed to protect the GSC40
46. ngine Midheat occurs during the engine cranking cycle User adjustable 0 60 s This is the time in seconds the GSC400 will wait between crank attempts If engine starting is unsuccessful after the specific crank time the starter will disengage for a specific time period User adjustable 1 60 s This is the number of crank attempts the GSC400 will perform before going into over crack failure User adjustable 1 60 This enables an energized fuel output while the controller is in rest time With this option enabled when the engine stalls within 10 seconds of crank disconnect the GSC400 will re attempt to start the generator User adjustable enable or disable This is the time in seconds that the GSC400 will post heat the engine Post heat occurs during the initial stage of engine run User adjustable 0 60 s This is the time in seconds in order to allow the generator sufficient time to warm up This option must be enable in order to be used User adjustable 0 600 s User Manual for the GSC400 Series Automatic Engine Controller 42 k ETS on Energize to stop Amount of time ETS is enabled during Duration engine shutdown User adjustable 0 30 s Caution Engine may restart with a spinning crank if ETS time set to low 1 Cooldown This is the time in seconds the GSC400 will wait before shutting Delay the generator down under a no load condition in order to allow engine cool down User adjustable 0 600 s m RPM This is the f
47. quency level of the engine exceeds the setting and indicate a warning condition A value of between 1 100 HZ may be selected Please note that if warning level is set to a greater value then failure level no warning will be generated This 1s the value in HZ which the controller will recognize when the frequency level of the engine exceeds the setting and perform a failure condition A value of between 1 100 HZ may be selected Please note that 1f failure level 1s set to a lesser value then warning level no warning will be generated This 1s the value in HZ which the controller will recognize when the frequency level of the engine is less than the setting and indicate a warning condition A value of between 1 100 HZ may be selected Please note that if warning level is set to a lower value then failure level no warning will be generated This 1s the value in HZ which the controller will recognize when the frequency level of the engine is less than the setting and perform a failure condition A value of between 1 100 HZ may be selected Please note that 1f failure level 1s set to a greater value then warning level no warning will be generated User Manual for the GSC400 Series Automatic Engine Controller 39 6 4 7 A C Voltage I ea This function allows the user to select the following settings a Voltage Source How to recognize the AC power source The disable option may be selected if no AC power source is being monitored
48. requency at which the GSC400 will disengage the Disconnect crank keeping the fuel on to run the generator User adjustable 100 2000 RPM n Crank Oil This is the oil pressure which is exceeded during cranking Pressure Used for locked rotor detection as a means of detecting if the engine is cranking in the event of a faulty speed signal 6 4 10 Digital Output Setup This function allows the user to select the following settings The GSC400 has 8 outputs plus an additional extra relay available for assignment Each of the available outputs may be assigned only one output function at any given time Outputs may be assigned to the following functions Warm Up ETS Pre heat Cooldown Over Crank High Temp Warn High Temp Fail Low Oil warn Low Oil fail 10 Under Speed warn 11 Under Speed fail 12 Over Speed warn 13 Over Speed fail 14 Low Fuel warn 15 Low Fuel fail 16 Battery warn 17 Battery fail Qe UP eX ere ae 18 19 20 21 22 25 24 22 26 295 Low Coolant warn Low Coolant fail Not in Auto Failure Crank Rest Engine Running Crank On Exerciser Alarm Recharge Alarm Under Voltage warm Under Voltage fail Over Amp warn Fuel in Basin Voltage Regulator Low Temp warn Back Light Aux Warn User Manual for the GSC400 Series Automatic Engine Controller 43 6 4 11 Exerciser Setup This function allows the user to select the following settings a Exercis
49. res will be automatically detected allowing for safe engine operation Manual Run Mode When the GSC400 is set to the manual run Mode starting will be enabled Start Mode allows for immediate manual engine starting and operation When in Start Mode the engine will run until the OFF Mode is chosen or a failure 1s recognized Controller must be in auto mode to initiate Manual run 22 DynaGen 9 00AM DEC 01 DynaGen 9 00 AM DEC 01 WAITING TO START Eng Temp 250 0 F Battery 14 0 V Fuel 85 0 Hours 250 0 H DynaGen RUNNING VOLTAGE 120 2 V 121 4 V 120 4 V User Manual for the GSC400 Series Automatic Engine Controller 6 0 GSC400 Menu System The GSC400 utilizes an advanced yet user friendly menu system The menu system can be initiated to perform adjustments within the GSC400 Adjustments can range from simple basic selections including time settings to more advanced selections including engine logic input selection output selection etc Although the GSC400 is shipped factory configured either to its default or customer requested ranges the internal menu system can be easily initiated for adjustments With the controller in the off mode the menu system may be selected simply by pressing the enter button 23 DynaGen 9 00AM DEC 01 BACK CLOCK SETUP BASIC SETUP ADVANCED SETUP FAILURE HISTORY Press OFF followed by ENTER to initiate GSC400 Menu System Scroll using the
50. ressure failure Bypass delay 1s the time in seconds the GSC400 will wait after crank success before checking engine Pressure When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts would be Failure and closed switch contacts would be a Engine OK When the Sender Input is selected as the signal source a shorted sender can display a warning shutdown the engine or be set to have no effect disable When the Sender Input is selected as the signal source an open sender can display a warning shutdown the engine or be set to have no effect disable PSI or Kpa selectable Using an electronic sender or J1939 input a value of 0 90 may be selected to initiating a warning Please note that if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender or J1939 input a value of 0 90 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 6 4 4 Fuel Level 33 This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g Units h Warning Level 1 Failure Level Input 2 7 may be configured to Fuel Level An
51. sible selections Input A D switch to Bat Bat fail Input E H switch to Gnd Gnd fail User Manual for the GSC400 Series Automatic Engine Controller 20 GSC400 RS485 Input Connection The GSC400 RS485 input connector is used for serial data communications This connector may be used for software programming of the GSC400 using the GSC400 configurator software Detail Location AWG max 7mA RS48 B 6 18 7mA jR 485Conecio GSC400 Digital Output Connection The GSC400 digital output connector is used to connect up to 8 outputs Each output can be assigned of the 34 possible selections Sinking Outputs PU pue p Bat fo E OutputE 6 18 200mA Configurable OuptG 8 18 200mA j Configuable OuptH 9 18 200mA j Configurable See Advanced Setup Menu Chart under Digital Output Setup for possible selections GSC400 AC Voltage Sensing Connection The GSC400 AC Voltage Sensing connector is used to measure the level of AC voltage being supplied to the system Terminal Wire Size Current max Function EE RN PhaseA Monitor Generated AC Voltage Monitor Generated AC Voltage AC Voltage Neutral connection User Manual for the GSC400 Series Automatic Engine Controller 21 GSC400 AC Current Sensing Connection The GSC400 AC Current Sensing connector is used to measure the level of AC current being drawn from the load
52. t if warning level is set to a greater value then failure level no warning will be generated Using an electronic sender or J1939 input a value of 0 90 may be selected to initiating a Failure User Manual for the GSC400 Series Automatic Engine Controller 6 4 5 Oil Level 34 This function allows the user to select the following settings a Input Pin b Signal Source c Bypass Delay d Switch Setting e Shorted Sender f Open Sender g Units h Warning Level 1 Failure Level Input 2 7 may be configured to Oil level An input can only be assigned to any given function once at any given time If using a sender be careful to select a Low or High impedance input location to correspond to the sender specifications Reserve may be selected to configure proper setting without assigning an active input How to obtain an oil level failure The J1939 interface may be selected for a J1939 compliant engine The switch input may be selected for a mechanical switch gauge types Senders may be selected for electronic gauge types When to recognize an oil level failure Bypass delay 1s the time in seconds the GSC400 will wait after crank success before checking oil level When the Switch Input is selected as the signal source the switch setting can be configured for a ground or open failure Gnd means that ground would be a failure BAT would be Engine OK Open means that open switch contacts
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