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GSC400 Series

1. bit0 Warm up finished bitl ETS is on bit2 Glow plug is on bit3 Cool Down is active bit4 Over crank occurred bit5 High engine temperature failure bit6 High engine temperature warning bit7 Low oil pressure failure bit8 Low oil pressure warning bit9 Under speed failure bit10 Under speed warning bit11 Over speed failure bit12 Over speed warning bit13 Low fuel level failure 0114 Low fuel level warning bit15 Battery low and high level failure 610 Battery low and high level warning bit1 Not used bit2 Low coolant level failure bit3 Controller is not in auto bit4 Failure has occurred bit5 Cranking rest active bit6 Controller is in RUN mode after crank success bit7 Controller is cranking bit8 Exerciser pre alarm active this bit will flash bit9 Battery charging pre alarm is active this bit will flash bit10 AC under voltage warning User Manual for the GSC400 Series Automatic Gen Set Controller 83 of 98 bit11 AC over voltage warning bit12 AC over current warning bit13 Fuel in basin warning bit14 Voltage Regulator Digital Output feature is on 0115 Low engine temperature warning bit0 Backlight is on bitl Auxiliary warning bit2 Maintenance is required bit3 System is OK definition no warning including not in auto warning bit4 Common fault 1 digital output feature bit5 Common fault 2 digital output feature bit6 Dumm
2. 39 of 98 6 Advanced Setup Important After changing any settings on the controller the controller needs to be reset This can be done one of two ways 1 Power off wait for 2s and power on the controller 2 Press the Run key wait until the controller begins the start sequence and then press the OFF key You will see a flickering of the screen as the controller updates The GSC400 incorporates an Advanced Setup menu Menu adjustments include input output and other advanced settings The possible advanced menu selections are covered in this section Only OEMs or advanced and knowledgeable users should change these parameters Before entering the Advanced menu a password is required to be entered The password will consist of a four digit number PASSWORD Each number needs to be selected using the up or down arrows on the GSC400 1234 Simply choose the correct password number Js for each selected position by scrolling to the Enter Next proper number followed by the Enter key Off Exit The default password is 0 0 0 0 The password may be changed anytime See Password Setup section The Advanced Setup menu on the GSC400 ADVANCED SETUP is shown to the right BACK J1939 Setup Engine Temp Oil Pressure Fuel Level User Manual for the GSC400 Series Automatic Gen Set Controller 40 of 98 Table 7 Advanced Menu Layout Summary The J1939 setup contains general settings for J1939 such
3. Start Stop 10 18 mA Allows Manual Start Stop of Engine Active Start Inactive Stop Ground 11 18 7mA Ground Ground 12 18 Ground V Bat 1 18 1 5A Positive Battery Voltage Output A 2 18 200mA Configurable Output B 3 18 200mA Configurable Output C 4 18 200mA Configurable Output D 5 18 200mA Configurable Output E 6 18 200mA Configurable Output F 7 18 200mA Configurable Output G 8 18 200mA Configurable Output H 9 18 200mA Configurable V Bat 10 18 1 5A Positive Battery Voltage See Table 13 on page 59 for possible selections These are sinking outputs i e switched to ground User Manual for the GSC400 Series Automatic Gen Set Controller 18 of 98 RS485 A 1 18 7mA RS485 Connection High Ground 2 18 Ground Terminal Connection RS485 B 3 18 7mA RS485 Connection Low RS485 A 4 18 mA RS485 Connection High Ground 5 18 mA Ground Terminal Connection RS485 B 6 18 RS485 Connection Low DANGER For safety it is highly recommended to install a switch on either the RS485 A or B lines locally at the generator This can be used to prevent an unexpected start remotely while performing maintenance or repairs Phase A 18 mA Monitor Generated AC Voltage Phase B 18 7mA Monitor Generated AC Voltage Phase C 18 7mA Monitor Generated AC Volt
4. A solid red illuminated LED represents a Low Fuel Level Failure condition Yellow Solid A solid yellow illuminated LED represents a Yellow Low Fuel Level Warning condition wx m E x Solid A solid green illuminated LED represents a Green normal battery condition Flashing Controller in Auto mode Waiting to start Green Yellow Solid A solid yellow illuminated LED represents a Yellow Low Battery condition xe User Manual for the GSC400 Series Automatic Gen Set Controller Red Solid Red 33 of 98 A solid red illuminated LED represents a Not in Auto condition Red Amber Solid Red Solid Amber A solid red illuminated LED represents a Low Coolant Temperature and or Level failure condition A solid yellow illuminated LED represents a Low Coolant Temperature Warning condition Green Solid Green A solid green illuminated LED represents an active Pre Heat condition Green Red Solid Green Solid Red A solid green illuminated LED indicates that the generator is supplying load and is operating normally A solid red indicates load is detected on the generator when none should be See section 5 11 2 on page 35 for more information about EPS Supplying Load 4 2 Solid Red A solid red illuminated LED represents a general Failure condition User Manual for the GSC400 Series Automatic Gen Set Controller 34 of 98 The GSC400 inco
5. TECHNOLOGIES INC GSC400 Series Automatic Gen Set Controller Manual Revision 2 5 DynaGen RUNNING Ac PHASE ale A N 120 2 11 219 5 GSC400 Automatic Gen Set Controller Installation and User Manual Full Version File GSC400 User Manual Rev2 5 doc December 2009 2 of 98 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 The GSC400 Gen set controller carries a five year warranty For more information refer to the standard terms and conditions of sale at http www dynagen ca Dynagen GSC400 Webpage For up to date manuals and other information please see the GSC400 section of the Dynagen website at www dynagen ca products GSC400 htm We welcome your comments and suggestions Please contact us at DynaGen Technologies Inc Phone 1 888 396 2436 902 406 0133 Fax 90
6. controllers Revision A controllers pin 2 can also be used The six analog input pins are divided into two groups those that support low resistance senders and those that support high resistance senders Low resistance senders have a maximum resistance of less or equal to 500 Ohms High resistance senders have a maximum resistance of greater than 500 Ohms usually they are a few kOhm Note that the senders listed in Table 11 cannot be used on all outputs for the reasons given in the previous paragraph Table 11 also lists what sender tables may be loaded on each input If your sender is not supported or you wish to use a sender on an unsupported input then you have to use the sender table configuration utility built into the PC Interface that allows you to create new sender tables or to modify supported ones for the input you desire Refer to the PC Interface manual for more information User Manual for the GSC400 Series Automatic Gen Set Controller 53 of 98 The speed sensing menu allows you to select the source to use for sensing the rotational speed of the engine There are three options to choose from 1 J1939 Input If the engine generator comes equipped with an engine control module ECM that supports the J1939 protocol then the GSC400 can obtain the engine speed from the ECM 2 Magnetic Pickup If the engine generator is equipped with a magnetic pickup sensor then the sensor can be connected to the SPEED 1 and SPEED 2 s
7. 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 100 50 Disable Enable Delay to Start Glowplug Time Crank Time MidHeat Time Crank Rest Time Crank Attempts Fuel Crank Rest False Restart Post Heat Time ETS On Duration Warm up Time RPM Disconnect Cool Down Delay Crank Oil pres 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 Extra Relay Output A Output B Output C Output D Output E Output F Output G Output H Disable Warm Up ETS Glowplug Cooldown Over Crank High Temp Fail High Temp warn Low Oil Fail Low Oil Warning Under RPM Fail Under RPM Warn Over RPM Fail Over RPM 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 User Manual for the GSC400 Series Automatic Gen Set Controller 45 of 98 Exerciser Alarm Recharge Alarm Under Volt Warn Over volt warn Over Amp Warn Fuel in Basin Volt Regulator Low Temp Warn Back Light Auxiliary Warn Maintenance System Ready Common Output 1 Common Output 2 Dummy Loads High Fuel Warn Current Latch Config Warn 1 Config Warn 2 Config Fail 1
8. Friction Torque 46 Fuel Temperature C Load Fuel Rate L min Engine Torque Boost Pressure kPa Friction Torque Oil Temperature Ce Load Fuel Rate L min Set Speed RPM Barometric Pressure kPa ECM Battery V Fuel Temperature Cc Load 96 Oil Temperature C User Manual for the GSC400 Series Automatic Gen Set Controller 48 of 98 Fuel Rate L min OUR Barometric Pressure kPa Ld o Fuel Temperature Cc 0 Fuel Rate L min Oil Temperature C Engine Torque 90 Boost Pressure kPa Friction Torque 46 Oil Temperature CC Load Fuel Rate L min No Display No Display There is also a Loss of ECM submenu in the J1939 menu that you should enable if using J1939 When enabled the controller will shut down on a failure when certain J1939 messages have not been received on the CAN bus for 6 seconds Also when there has been no data received for a specific parameter that parameter will display N A in place of the value This will disappear once data for parameter is received from the bus This will also occur on startup until the GSC400 accesses the data from the bus Note that loss of ECM may not be triggered since other parameters may be receiving data from the bus Some Engine Control Modules ECMs require significant time to power up and initialize before they are ready to control the engine The GSC400 can be programmed to leave the fuel relay output
9. see section 5 13 on page 36 occur an entry is created in TOTAL 99 the GSC400 Event History Log 02 OVERCRANK FAILURE A total of 100 entries can be recorded 10 15 DEC 01 Entries may be viewed simply by scrolling up or down using the UP and DOWN keys In addition to the entry reason information the associated date and time of the entry will be displayed The 100 entries are subdivided into a maximum of 30 events 40 failures and 30 DTCs This prevents one type from flushing the other types from the log Simply scroll through the Failure 3 History Log by pressing the Y or FAILURE HISTORY Hit Enter To Exit keys located on the GSC400 TOTAL 99 03 The event history log can store up to LOW COOLANT FAILURE 30 event 30 DTCs and 40 failures 10 00 DEG 01 entries If these are exceeded the entry is replaced with the newest entry The events failures and DTC entries are displayed together in the log in reverse chronological order i e newest entry first Upgrading the controller firmware to revision 1 50 from an earlier revision will cause the history log to be reset User Manual for the GSC400 Series Automatic Gen Set Controller 31 of 98 Some industry standard failures warnings and events on the GSC400 are indicated by a series of LEDs on the left side of the em controller unes DynaGen Specific LED indicators will be illuminated depending upon the condition of the controller The GSC4
10. 3 440 VAC Over Volt Warn 4 630 VAC User Manual for the GSC400 Series Automatic Gen Set Controller 71 of 98 Over Volt Fail 4 650 VAC Under Volt Warn 4 570 VAC Under Volt Fail 4 550 VAC Current source Enable Turns Ratio 100A 5A Over Current Warn 1 90 A Over Current Fail 1 100A Over Current Warn 2 80A Over Current Fail 2 90A Over Current Warn 3 20A Over Current Fail 3 25A Over Current Warn 4 15A Over Current Fail 4 20A Delay to Start 0 seconds Pre heat Time 0 seconds Crank Time 15 seconds MidHeat Time 0 seconds Crank Rest Time 15 seconds Crank Attempts 3 Fuel Crank Rest Enable False Restart Enable Post Heat Time 0 seconds ETS On Duration 0 seconds Warm up Time 600 seconds Crank Disconnect 650 RPM Cool Down Delay 0 seconds Crank Oil pres 10 PSI Extra Relay Disable Output 1 Disable Output 2 Disable Output 3 Disable Output 4 Disable Output 5 Disable Output 6 Disable Output 7 Disable Output 8 Disable Exerciser Enable Disable Run Duration 30 minutes Pre Alarm Delay 5 minutes Repeat Frequency 336 hours 14 days Start Hour 12 Start Date 8 Input 1 Bat Disable Input 2 Bat Disable Input 3 Bat Disable Input 4 Bat Disable Input 5 Gnd Disable Input 6 Gnd Disable Input 7 Gnd Disable User Manual for the GSC400 Series Automatic Gen Set Controller 72 of 98 User Manual for the GSC400 Series Automatic Gen Set Controller 73 of 98 2 i me
11. 98 58 Short Oil Pressure sender 59 Open Fuel Level sender 60 Short Fuel Level sender 61 Open Oil Level sender 62 Short Oil Level sender 63 Open Fuel Basin sender 64 Short Fuel Basin sender 65 Open Engine Temperature sender 66 Short Engine Temperature sender 70 EMERGENCY STOP 71 Auxiliary Warn 72 Under Frequency warning 73 Over Frequency warning 255 OxFF Empty No message in queue Active Failure 0 44 R Read Only If the controller is in an active FAILURE mode the failure number in register 40108 corresponds to the below failure mode 0 reserved 1 Internal reserved 1 ADE Read 2 Internal reserved 2 KEYBOARD 3 Internal reserved 3 ADC read 4 Internal reserved 4 RS485 5 Internal reserved 5 RS232 6 Internal reserved 6 ADE Write 7 Internal reserved 7 TLE6230 8 Internal reserved 8 EEPROM 9 Reserved 10 HIGH ENGINE TEMP 11 LOW OIL PRESSURE 12 UNDER SPEED 13 OVER SPEED 14 LOW FUEL LEVEL 15 LOW BATTERY 16 LOW COOLANT 17 OVER CRANK 18 OVER VOLTAGE 19 UNDER VOLTAGE 20 OVER CURRENT 21 EPS LOADS ERROR 22 LOW AIR PRESSURE 23 LOW HYDRAULIC User Manual for the GSC400 Series Automatic Gen Set Controller 89 of 98 24 LOW OIL LEVEL 25 LOCKED ROTOR 26 HIGH BATTERY 27 LOSS OF ECM COMMUNICATION 28 OPEN ENG TEMP 29 SHORT ENG TEMP 30 OPEN OIL PRES 31 SHORT OIL PRES 32 OPEN FUEL LEVEL 33 SHORT FUEL LEVEL 34 OPEN OIL LEVEL 35 SHO
12. A H 300 mA Max Extra Relay 40A Max Exerciser Enable Disable 10 240 Minutes Battery Recharge Enable Disable 10 240 Minutes Password 4 Digit 0 9 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 Programming Manual Software Field upgradeable J1939 Interface Low emission capable Relays Replaceable 40A relays for Crank Fuel Extra output 12 or 24VDC Coil Dimensions WxHxD 139x 113x 65 mm 5 47 x 445 x 2 56 in Weight 0 45 Kg 1 0 Lb Use of Industry Standard CT Required 40A output at room temperature The LCD display will exhibit color and response time changes at high and low temperatures respectively but will not be damaged as long as within Operating Temp User Manual for the GSC400 Series Automatic Gen Set Controller 4 of 98 Table of Contents 1 GSC400 Controller Series ES 7 1 1 This Manta bessser eases EEA EEE E E EN 7 2 Receiving Handling and 5 8 3 GSC400 Product Number 0 9 4 GSC400 Series Installation and Wiring eese 10 4 Safety Information el Nc 10 4 2 Mounting ocio LO 11 421 0050400 Mounting Dimensions retro tic t Cotta D Rene
13. Input is active This section applies if J1939 is enabled for one or more parameters The parameters will be displayed the same for J1939 as they are for analog inputs The only difference is that when a certain parameter is not read from the J1939 bus the text N A is displayed in place of the parameter value If the Loss of ECM setting is enabled the GSC400 will shut the generator down on Loss of ECM if no communications are detected on the J1939 bus For generators using Cummins electronic engines the GSC400 has the capability of switching between Idle speed and operating speed i e the speed at which the generator produces load if enabled This feature is activated by applying a signal to one of the GSC400 digital inputs see section 6 1 1 on page 48 for more information on how to setup this feature User Manual for the GSC400 Series Automatic Gen Set Controller 36 of 98 This section applies for electronic generators only i e generators that use J1939 The GSC400 can read J1939 diagnostic trouble codes DTCs from an electronic ECM if enabled see section 6 1 2 on page 49 for information on how to configure and customize the GSC400 DTC feature When the engine s ECM detects a fault it will send an Active Diagnostic Trouble Code message The message sent by the ECU will also contain information on the type of fault as well as the number of occurrences for the fault If multiple DTCs are present ea
14. PSI KPa Warning Level 0 90 PSI 0 90 KPa Failure Level 0 90 PSI 0 90 KPa Input Pin Reserve Analog 2 7 Signal Source Switch input Sender Bypass Delay 0 60 Seconds Switch Setting GND Warning OPEN Warning GND Fail Open Fail Shorted Sender Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Percentage Warning Level 0 90 Failure Level 0 90 0 1000 Ohms data sheet or measured 0 Fuel Level value 0 1000 Ohms data sheet or measured 25 Fuel Level value 0 1000 Ohms data sheet or measured 50 Fuel Level value 0 1000 Ohms data sheet or measured 75 Fuel Level value 100 Fuel Level 0 1000 Ohms data sheet or measured User Manual for the GSC400 Series Automatic Gen Set Controller 43 of 98 value 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 Percentage 0 100 0 100 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 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Percentage 0 90 0 90 Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Units Warning Leve
15. The Sleep Delay determines how long to wait after the last key press before turning off the LCD backlighting The Sleep Delay also controls the automatic exit from the menu system First the controller exits to the basic menu after the first sleep delay exits to the Off state after the second sleep delay and finally goes into sleep mode after the third sleep delay The sleep delay does not work in the Run Mode or during cranking User Manual for the GSC400 Series Automatic Gen Set Controller 29 of 98 The controller can be made to NOT sound the alarm when the controller is not in the AUTO mode This is controlled by the Not In Auto setting The OFF Mode Start setting can be set to Enable to allow a manual start from the OFF mode Otherwise a manual run can only be performed when the controller is in the AUTO mode Table 5 Basic Setup Menu 5 95 1 10s 1 10 1 is shortest delay 10 is longest 10 600s Shorter is ideal to extend the backlighting life Read only Displays the amount of hours until next service if this feature is enabled If service is overdue the hours become negative Disable Beep Enable Beep Disable Enable User Manual for the GSC400 Series Automatic Gen Set Controller 30 of 98 5 9 3 Event History Log The GSC400 incorporates an event history logging system When engine FAILURE HISTORY failures events or DTCs Diagnostic Hit Enter To Exit Trouble Codes
16. also turned on If the engine speed does not go above the Crank Disconnect Setting before the crank time then the crank output is turned off and the controller waits a period specified by the Crank Rest Time The locked rotor condition is also checked while cranking see 6 5 1 1 Locked Rotor below The fuel output is also turned off unless the Fuel On During Crank Reset is enabled User Manual for the GSC400 Series Automatic Gen Set Controller 58 of 98 THE LCD WILL TURN OFF DURING THE FIRST 2 SECONDS OF CRANKING TO LIMIT THE VOLTAGE DIP DURING CRANKING If the Midheat Time is greater than zero the glow plug output remains on during cranking but not during crank rest The glow plug output turns off if a crank failure occurs once crank success is reached unless the PostHeat is set to a value greater than Os or if the Midheat time expires After the crank rest delay expires the controller turns on the fuel and crank outputs and attempts to start the generator again This is repeated until the number of tries equals the Crank Attempts If the controller cannot start the generator after the set number of crank attempts the failure state is entered and an over crank failure is displayed on the screen If the generator starts successfully and the Restart on False Start submenu is set to Enabled then the engine speed is monitored for 10 seconds If the Off key is pressed during these 10 seconds the engine will go into OFF mode w
17. applies if the Diagnostic Trouble Code DTC feature is enabled See section 5 13 for more information on DTCs The GSC400 does not have the ability to detect when the generator ECM has shutdown the generator In the case of an ECM shutdown the GSC400 will display one of the following failures reasons 1 Low Oil Pressure 2 Under Speed 3 Under Frequency 4 Under Voltage The failure message display will depend on the user s failure set points for the above On one of the above failures the user can check the Event History Log see section 5 9 3 on page 30 about the history log to determine if there has been a shutdown of the generator due to a DTC DM 1 User Manual for the GSC400 Series Automatic Gen Set Controller 35 of 98 The GSC400 is often used to control a utility backup generator When the generator is started and load is detected on the generator when the GSC400 is in the RUN mode the EPS Supplying Load LED on the GSC400 front panel will turn green This indicates that the generator is supply load as normal If load is detected on the generator when it is not in the Run mode e g the GSC400 is cranking preheating etc the GSC400 terminates starting and enters the failure mode and the EPS Supplying Load LED on the GSC400 front panel will turn red The generator is considered loaded when either the AC current is equal to or greater than 5 of the over current failure setpoint or if the EPS Supplying Load Switched
18. either 12V or 24V electrical systems The GSC400 is UL listed to UL508 For conditions of acceptability refer to UL file number E250327 or contact DynaGen The GSC400 controller is designed to operate on 12 or 24 VDC systems When operating on 12VDC systems the fuel crank and extra outputs require 12VDC relays and 24VDC relays when operating on 24VDC systems The GSC400 comes preinstalled with the correct relays depending on the product number specified when ordered see section 3 on page 9 Contact DynaGen if replacement relays are required quote Dynagen Part numbers from Table 22 on page 76 UL Listed relays for 12 or 24VDC system operation are as follows e HASCO CAR 1A 40 DC12 S for 12VDC operation HASCO CAR 1A 40 DC24 S for 24 operation CAUTION The above relays must be installed in the GSC400 for it to meet UL 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 than stated in the load specs which could damage the 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 the current draw on each relay does not exceed the fuse current limit An approved 40A fuse is LITTLEFUSE 257040 32VDC 40A auto fas
19. go into Cool User Manual for the GSC400 Series Automatic Gen Set Controller 59 of 98 Down mode where an output is turned on one of the digital outputs must be set to Cool Down Once the Cool Down time is expired the fuel relay is turned off and the controller enters the OFF state If the ETS On Duration is set to a value greater than 0 seconds an output will be turned on for the time set one of the digital outputs must be set to Energize to Stop by the ETS On Duration submenu There are eight 200mA digital outputs all switched to ground and one 40A digital output dry contact the Extra output all of which are configurable Each feature listed in Table 13 below is permitted to be set to only one digital output Table 13 Digital Output Selections This sets up the output to be controlled by the Warm up feature See section 6 5 1 for more details The Warm up time is set in the engine logic menu This is an active low output i e the output remains off during warm up and turns on after warm up is finished The output always remains off when the controller is not in the RUN mode This allows the Energize to Stop feature to control an output The time duration is set in the engine logic menu See section 6 5 2 for more details This allows the Preheat Midheat and Postheat features in the engine logic menu to control the output The Preheat time is set in the engine logic menu See section 6 5 1 for more details This allow
20. injury or death De energize all AC power sources before any connections are performed NEVER energize AC power with AC current sensing connector unplugged An DANGER energized unplugged connector could result in severe injury or death Never unplug an energized connector User Manual for the GSC400 Series Automatic Gen Set Controller 11 of 98 The GSC400 gen set controller must be Mounting Location properly mounted for safe operation Caution must be taken at the installation site to make sure the site is free from excessive moisture fluctuating temperatures dust corrosive materials etc The controller should be safely mm DynaGen mounted in a secure location using the 3 mounting screws provided See Figure 2 for gt the mounting locations UN RUNNING HASE Caution Mounting screws must be installed at the recommended torque of 10 inch pounds Mounting Location Figure 2 GSC400 Mounting Locations User Manual for the GSC400 Series Automatic Gen Set Controller 12 of 98 Figure 3 gives the precise dimensions of the mounting hardware 4 250 157 1756 0187 E TH T i 2 2 000 E 5 9 2229 900 2 2 000 275 i TH g m in n Ep LE Mo A TOLERANCE Figure 3 Dimensions of mounting holes User Manual for the GSC400 Series Automatic Gen Set Controller 13 of 98 The GSC400 controller can be placed in
21. may simultaneously press the up and down arrow keys to perform a lamp test AUTO Mode When the GSC400 is set to the Auto Mode automatic starting will be DynaGen enabled Possible triggers include TU 9 00AM DEC 01 start stop battery recharge and enced WAITING TO START exerciser features all of which s Lemp are controllable from menu Fuel Hours system If the engine is started failures will be automatically detected allowing for safe engine operation User Manual for the GSC400 Series Automatic Gen Set Controller 22 of 98 While in Auto Mode the controller will display engine temperature battery voltage fuel level and engine hours 3 RUN Mode The controller starts the engine generator and enters the RUN Mode automatically on certain triggers DynaGen low battery voltage or to SEU 9 00AM DEC 01 exercise the generator or the MUNI FOR LAMP TEST user can manually start the MET engine generator by pressing the START DISABLED Run key Another option is to use the remote start contacts located on the digital input connector The controller will automatically shut the engine generator down and re enter the auto mode if it initiated an engine generator start When the controller is in the OFF Mode automatic starting is disabled When the controller is in the RUN Mode generator parameters will be displayed on the screen to allow the user to monitor the engine
22. menu will allow you to set the clock The clock is important if you are planning to use the event log records all failures and warnings and when they occurred or the exerciser feature starts the generator for a settable period Table 4 Clock Setup Menu 2000 2099 January December 01 31 Monday Sunday 00 23 00 59 12 Hours 24 Hours The GSC400 internal clock information can remain in memory for approximately 2 weeks when no DC power is supplied to the controller Two week memory storage is available in a completely charged controller clock DC power is required to be supplied continually to the GSC400 for approximately 1 hour to allow a complete clock charge The Basic Setup menu will allow the user to customize the basic features of the GSC400 to their preference The Contrast Adjustment allows the user to adjust the contrast of the LCD The Page Roll Delay controls how long each group of parameters are displayed in the RUN state 1 e when the engine generator is running before displaying the next set of parameters The second line of the GSC400 LCD screen is usually dedicated to displaying warnings and events The State Roll Delay determines how long the warning or event message is displayed before moving on to the next message Setting the State Roll Delay to a larger value may cause some warning or event messages to not be displayed if the event or warning is of a short duration
23. second Bit7 Bit5 of the byte 3 is spn18 spn16 register is byte 3 Low Byte is Byte 4 See right column for more information 7 0 of the byte 2 is spn15 spn8 and the Bit7 BitO of byte 1 is spn7 spnO FMI FMI is 5 bits value data range is from 0 to 31 It is the 4 0 of byte 3 OC OC is 7 bits value data range is from 0 to 126 It is Bit6 BitO of the byte 4 User Manual for the GSC400 Series Automatic Gen Set Controller 97 of 98 User Manual for the GSC400 Series Automatic Gen Set Controller 98 of 98 This appendix was created to assist the user in decoding the information contained in the modbus DTC DM1 and DM2 registers if the generator ECM does not support newest DTC conversion method The diagnostic trouble codes on J1939 are specified in a specific format Older J1939 specifications had three conversion methods for the SPN and it was impossible to tell them apart from the DTC data alone One had to consult the engine manufacturer Newer J1939 specifications follow one SPN method Version 4 and the user can determine if this method applies by looking at the CM bit It will be set to 1 if Version 4 applies and set to 0 if Versions 1 2 or 3 applies If the CM bit is 0 see below for the three conversion methods Byte 1 to Byte 4 refers to the individual bytes in the GSC400 DTC Modbus registers See registers 40115 and 40116 on page 96 above DTC Conversion Method Ver
24. status These include engine speed generator voltage and current and engine temperature as well as others The parameters are displayed in groups and the screen scrolls between the various groups The Page Roll Display menu option controls how long each parameter group is displayed on the screen before moving on to the next group See Table 5 on page 29 for more information If an analog input is set to a Switch the GSC400 will display SW where normally the value is displayed If the analog input is set to J1939 or an Input Pin then the actual value of the input will be displayed When in the RUN Mode the GSC400 LCD screen can be locked to display a particular parameter group To do this press the up or down keys to scroll to the parameter group you wish to view and then press the ENTER key to lock the screen You will see a lock symbol displayed on the top right hand side of the display just under the date and time To unlock the screen press Enter again which causes the lock symbol to disappear and the screen will start to scroll though the parameter groups again The screen will automatically unlock after 10 minutes User Manual for the GSC400 Series Automatic Gen Set Controller 23 of 98 There are three ways to start the generator start conditions 1 Modbus Sending a Start using the appropriate register 2 Remote Start Contacts Pins 10 and 11 of the digital input connector 3 Run key Located on the
25. to perform its normal function User Manual for the GSC400 Series Automatic Gen Set Controller 26 of 98 The GSC400 incorporates a menu system to allow the end user to adjust basic settings The menu system will also allow technicians and OEMs to ELA DynaGen adjust advanced settings this feature is password protected onis a BACK CLOCK SETUP BASIC SETUP With the controller in the Off Mode the ADVANCED SETUP FAILURE HISTORY menu system may be selected simply by pressing the Enter key In the off state press ENTER to access the GSC400 Menu System This is called the Basic Menu The following keys perform the menu navigation 1 Scroll up using the up key 2 Scroll down using down key V Venter 3 Enter menus by pressing the enter key Eg Each menu has a Back selection To go back to the previous menu scroll up to the Back selection and press the Enter key When in the basic menu you can go back to the OFF mode by pressing the OFF key When you press the Enter key in the OFF mode you will enter the basic menu which includes the Clock Setup Basic Setup Advanced Setup and Failure History submenus Clock Setup 9 00AM DEC 01 Basic Setup Advanced Setup Failure History FAILURE HISTORY User Manual for the GSC400 Series Automatic Gen Set Controller 27 of 98 User Manual for the GSC400 Series Automatic Gen Set Controller 28 of 98 The Clock Setup
26. used Table 22 Relay Part List RLY0029 AZ 973 1C 12DC RLY0043 AZ 973 1C 24DC RLY0053 CAR 1A 40 DC12S RLY0054 CAR 1A 40 DC24S User Manual for the GSC400 Series Automatic Gen Set Controller 77 of 98 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 Table 23 GSC400 fuse part list FUS0012 Littlefuse 257040 User Manual for the GSC400 Series Automatic Gen Set Controller 78 of 98 Modbus communications uses master slave communication in which only the master can initiate a transaction called a query The slave addressed by the query will respond by either supplying the requested data to the master or by performing the requested action A slave device never initiates communications and will always generate a response to the query unless certain error conditions occur The GSC400 is designed to communicate on the Modbus only as a slave device A master can query slaves individually or query all slaves collectively by initiating a broadcast message A slave does not send a response message to a broadcast query If a query requests actions unable to be performed by the slave the slave response message will contain an Exception Response Code defining the error detected Query and response messages share th
27. 0 Positive values count down the hours to Sie ede next maintenance Negative values count 16 bit up the hours since maintenance should have been performed Positive or negative values can be identified by read the high byte of MSB A 1 in bit 15 corresponds to a negative number while a 0 corresponds to a positive number Read Previous Entry 0x6C93 27795 Read Next Entry 0x639C 25500 Write control command to holding register address cleared i e set to 0 The controller will check the log request every 1 second Each time a new command is received the controller will scroll either down or up one message until it reaches either the bottom or top of the message log one message and update the log content in address 40131 to 40141 Once at the top of the log registers 40131 to 40141 are not changed if a Read Previous Entry command is received Once at the bottom of the log registers 40131 to 40141 are not changed if a Read Next Entry command is received After 20s of receiving further commands in register 40130 all registers are User Manual for the GSC400 Series Automatic Gen Set Controller 94 of 98 Log Type Only R supports the values listed in format column 1 Internal reserved 1 ADE Read 2 Internal reserved 2 KEYBOARD 3 Internal reserved 3 ADC read 4 Internal reserved 4 RS485 5 Internal reserved 5 RS232 6 Internal res
28. 00 LED indicators allow a quick check of the controller s condition The GSC400 displays multi color LED s for specific condition representation Red Represents Failure Conditions Green Represents Normal Active Conditions z Yellow Represents Warning Conditions An LED test may be performed by the A user for illumination of all controller LED s The LED test may be performed by simultaneously pressing the UP key y and the DOWN key the GSC400 User Manual for the GSC400 Series Automatic Gen Set Controller 32 of 98 Table 6 GSC400 Lamp Indication Meanings Red Solid Red A solid red illuminated LED represents an Over Crank condition on the final crank attempt This is a Failure Yellow m A solid yellow illuminated LED represents an Over Crank Warning condition when there are crank attempts still remaining Red Solid Red A solid red illuminated LED represents a High engine Temp Failure condition v Yellow Solid A solid yellow illuminated LED represents a Yellow High engine Temp Warning condition Red Solid Red A solid red illuminated LED represents a Low Oil Pressure Failure condition Yellow Solid A solid yellow illuminated LED represents a Yellow Low Oil Pressure Warning condition Red Solid Red A solid red illuminated LED represents an Over Speed Failure condition Yellow Solid A solid yellow illuminated LED represents an Yellow Over Speed Warning condition Red Solid Red
29. 2 567 0633 Email support dynagen ca WEB SITE www dynagen ca User Manual for the GSC400 Series Automatic Gen Set Controller GSC400 Specifications 3 of 98 VDC Rating 12 24 VDC Standby Current 50 mA 12 VDC Consumption Operating Temp 40 C to 85 C 40 F to 185 F LCD Operating 20 C to 60 C 4 F to 140 F Temp Function Function Selection Range Selection Speed Sensing Generator pickup 0 300vac 0 3600rpm Range Magnetic pickup 0 300vac 0 3600rpm Voltage Sensing Single phase Max 700vac 1 Three phase Max 700vac 1 Delta Wye Max 700vac 1 Current Sensing Enable Disable Max 5A 1 Frequency Sensing Enable Disable 1 100 HZ Engine Temp GND Fail Open Fail 10 265 F 10 265 C Oil Pressure GND Fail Open Fail 0 90 PSI 0 90 Kpa Oil Level GND Fail Open Fail 0 90 Fuel Level GND Fail Open Fail 0 100 Engine Logic Delay to start 0 60 seconds Pre heat 0 60 seconds Crank 3 60 seconds Rest Time 1 60 seconds Mid Heat 0 60 seconds Crank attempts 1 60 tries False restart Enable Disabled Post heat 0 60 seconds Warm up 0 600 seconds Cooldown 0 600 seconds Crank oil pressure 0 90 KPa Crank Disconnect 100 2000 RPM Analog Input Input 2 5 7 High Z Gnd Fail Open fail Input 3 4 Low Z mA Digital Input Input A D Sw to Bat Bat Fail 7mA Max Input E H Sw to Gnd Gnd Fail 7mA Max Digital Output Output
30. 54 piii akbaccantes aes feas ai es 54 SCN teil clea Ra O Mu P Mu CE M RUE 54 04 37 icu e E tn 56 6 4 4 AC Current and Voltage 57 6 5 Logi oos oc o a a a era buh te dub dtd it oie Pa 57 Gado Startup Seuduellt E su catum ditus opaco ted 57 6 2 Shutdown SEQUENCE acte sal ina ei Pa 58 6 6 Digital Output SEQUpoc s endet ene eds 59 6 7 Exerciser SOU PER 61 6 8 Digital Input 62 6 9 Battery cu m 64 Gal Low Battery Recharte uu odorem hut aah oad kde 64 93107 tubi 65 Maintains oo oio peel datiuo debout 66 6 12 MOG e 66 User Manual for the GSC400 Series Automatic Gen Set Controller 6 of 98 6 13 Common Faults ties Ges otia suene ot ade te aetate d 66 6 14 Set D mmy Lotsd a au ieec Ba ee eee de ae d d ud 67 T Recommended Matntenatiee ueteres eos En RETE eeu EV deo 68 8 Default Configuration Settings oeste Gr donee tage ta se es aa Urna e
31. An RS232 interface is provided that allows communication with the DynaGen GSC400 PC Interface to change settings or display information on the PC An RS485 port is provided for Modbus communications slave only for remote annunciation or communications In addition to the monitoring features the GSC400 controller can be used to automatically start stop a generator system as well as provide protective warnings or shutdowns This manual is divided into three sections 1 Hardware installation 2 Operation configuration 3 Advanced configuration User Manual for the GSC400 Series Automatic Gen Set Controller 8 of 98 Receiving Every effort is made to ensure that your GSC400 gen set controller arrives at its destination undamaged and ready for installation The packaging is designed to protect the GSC400 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 may have occurred during transportation Any damage should be reported to a DynaGen representative after a thorough inspection has been completed A shipping label affixed to the shipping box includes a variety of product and shipping information such as items and Custom
32. Config Fail 2 Exerciser Enable Run Duration Pre Alarm Delay Disable enable 10 240 minutes 1 20 minutes Repeat Freq 1 672 hours Start Hour 0 23 Start Date 1 31 Input A Bat Disable Low Air Pres Input B Bat Low Hyd Pres Low Oil Pres Input C Bat EPS Supply Load Input D Bat Alarm Silence Low Coolant Input E Gnd Volt Select 1 Volt Select 2 Input F Gnd Idle Mode Start Stop Input G Gnd Auxiliary Fail Auxiliary Warn Input H Gnd Charger Fault1 Charger Fault2 High Fuel Warn Config Warn 1 Config Warn 2 Config Fail 1 Config Fail 2 located at bottom of menu Global Trig Crank Trig Run Trig Crank Run Trig Low Auto Charge Disable Enable Charge Pre Alarm 1 60 minutes Charge Duration 10 240 minutes Recharge Level 7 24 volts Low Warn Level 7 24 volts Low Fail Level 7 24 volts High Warn Level 12 32 volts High Fail Level 12 32 volts Low Vol InCrank 4 18 volts Password No 1 Digit 1 0 9 Password No 2 Digit 2 0 9 Password No 3 Digit 3 0 9 Password No 4 Digit 4 0 9 Reset Counter No Yes Enable Counter Disable Enable Count Interval 10 to 1000 Hours in 10 hour increments Device Address 1 247 Baud Rate 9600 19200 38400 57600 User Manual for the GSC400 Series Automatic Gen Set Controller 46 of 98 User Manual for the GSC400 Series Automatic Gen Set Controller 47 of 98 The GSC400 will work with any generator as long as it suppo
33. DOWN key after the screen has been locked If the user stops at a specific DTC message the display screen will remain on that message for a period of 10 seconds before it begins scrolling again Once the last DTC message is displayed the display will begin scrolling though other GSC400 parameters as normal The DTC messages are no longer available for viewing DM2 messages are previously active faults messages which are stored to permanent memory on the engine ECM These stored messages can be retrieved by the host GSC400 controller and displayed on the controller when a request is initiated by the user The DM2 messages display the same type of information as the DM1 messages The GSC400 controller can support a maximum of 32 messages When previously active DTC messages are requested and received the GSC400 controller will display the stored messages on the GSC400 front panel LCD screen If multiple stored messages are received the user can either manually scroll through each stored message or the screen will scroll between each DTC stored message at a 3 second interval If the user intervenes the interval will change to 10s The DTC stored message display appears as follows Figure 7 32 stored DTC messages the 5 stored code being displayed User Manual for the GSC400 Series Automatic Gen Set Controller 38 of 98 To Trigger a DM2 Request simultaneously press the UP and DOWN keys for a period of 3 seconds in e
34. EM DM E 28 59 3 Ev nt Hist ry Log Mc 30 5 10 GSC400 LED Status Indicators 31 User Manual for the GSC400 Series Automatic Gen Set Controller 5 of 98 adl Warnings and Farle Seresta 34 5 11 1 Diagnostic Trouble Code Shutdowns 34 5 11 2 EPS SUppl yang Loads ereot ens Coe 35 512 JVIZ ae a 35 5 12 1 Cummins Idle Speed ERU REN 25 5 13 11939 Diagnostic Trouble Code DTC 36 5 13 1 5 36 5 13 2 ICS 37 5 13 3 DMI Eyent Log erns 38 Adyanced ICE 39 6 1 11939 Setup iactu SU Ubaldi nias e es 47 Cummins Idle te IR Baer boda 48 6 1 2 Diagnostic Trouble Codes DTCs see ses a oa in SO 49 6 2 Analog oes tpe ene eae Qe 50 6 2 1 Level Sender Special C386 51 6 2 2 GSC400 Sender Support y ic scyccecsnsdcdevassesccsanssanes eeseanasbebadovardecetsseaeaas 51 6 3 Speed Sensing vices ptt esos icy eri gens 53 6 3 1 Rated Speed iiis i 53 6 4 Generator AC Voltage Current Frequency Setup
35. Figure 9 GSC400 terminal names and layout View from rear of controller Table 17 GSC400 Harness Part Numbers 1373R3 5 12523 1375R2 5 All circuits 1377R2 5 L234 1376R2 5 1234 1378R2 5 4 7 8 9 10 11 12 1 The new Rev 3 of this harness contains a terminating resistor If the GSC400 is not the last device on the network this resistor can be cut out Circuits 9 and 12 are tied together This disables the emergency stop input For users who desire this feature cut this wire User Manual for the GSC400 Series Automatic Gen Set Controller 74 of 98 The following table identifies all the wiring harnesses as part of the GSC400 controller Table 18 GSC400 Wiring Harness Part List DWG1373R3 5 5 Feet llo 225 i dl 1 DWG1377R2 5 5 Feet 4 7 8 a 10 11 Call DynaGen Call DynaGen Call DynaGen The AC Current Sensing Digital Input and Analog Input Harness can be purchased together as a starter kit Stock Code ACC0086 1 Circuits 9 and 12 are tied together This disables the emergency stop input For users who desire this feature cut this wire 2 See Figure 4 on page 15 for information on pin numbers Table 19 GSC400 Programmer Part List GSC400 PGMRB User Manual for the GSC400 Series Automatic Gen Set Controller 75 of 98 Current transformers are required for display of AC current One CT is required for each phase to be displayed The wiring for CT s is as fol
36. Fuel In Basin 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 Line Voltage A B 0 999 9 R 1 bit 0 1V V Readi d Line Voltage B C R eading 9999 corresponds V to 999 9 V Line Voltage C A R V Phase Voltage A R V Phase Voltage B R V Phase Voltage C R V Phase A Current 0 999 9 R 1 bit equal to 0 1A A Phase B Current R Reading 9999 corresponds A to 999 9A Phase C Current R A AC frequency 0 100 0 R AC frequency Hz Reading 600 corresponds to 60 0Hz Battery voltage 0 31 8 R 1 bit equal 0 1V V Reading 318 corresponds to 31 8V PCB Board 55 130 R 1 bit 0 1C C temperature Signed Reading 1000 corresponds to 100 0C Integer 16 bit m Positive or negative values can be identified by reading the high byte of MSB A 1 in bit 15 corresponds to a negative number while a 0 corresponds to a positive number User Manual for the GSC400 Series Automatic Gen Set Controller 93 of 98 Current Run time 0 6553 5 1 bit 0 1 hour Hours Total run time on active 65535 corresponds to running event 6553 5Hs NOTE Timer is reset to Zero after active running event has been terminated OFF or AUTO mode waiting to start Engine hours 0 255999 9 Total Accumulated Hours running hours the reading in 40177 1 bit equal to 0 1 hour The reading in 40178 1 bit equal to 1000 hours So the total hours 40178 1000 40177 10 Maintenance Time 1000 The unit is 0 1 hour 1 bit 0 1 hour 100
37. GSC400 front panel There are two features that can automatically start the generator 1 Battery Recharge 2 Exerciser The battery recharge and exerciser options will only start the generator when the GSC400 is in the AUTO mode These features will not interrupt a shutdown When the controller is in the AUTO mode the three manual start conditions above can be used to start the generator When the controller is in the RUN mode it will display the reason for start on the screen Modbus Run Remote Start Run Manual Run Stopping the Generator If the controller is in the RUN mode due the remote contacts or modbus for the first 10s either of the two can be used to place the controller back in the OFF state the remote start contacts cannot be used to stop the generator unless it was the cause of start After this 10s period only the start condition that caused the start can be used to place the controller back in the AUTO or OFF mode The OFF key can be used to place the GSC400 in OFF regardless of the start condition Preventing a Stop when in Cool Down An exception to the above is that once the GSC400 is in cool down and another start condition was received the controller will exit cool down and remain running It will display the new start condition on the screen OFF key pressed during Manual Run If the OFF key is pressed during a manual Run a cool down popup will display on the GSC400 Press the AUTO key to immediately enter
38. RT OIL LEVEL 36 OPEN FUEL BASIN 37 SHORT FUEL BASIN 38 OPEN ENGINE TEMP 39 SHORT ENGINETEMP 40 AUXILIARY FAIL 41 UNDER FREQUENCY 42 OVER FREQUENCY 162 USER TEXT FAIL 1 163 USER TEXT FAIL 2 255 OxFF Empty No failure message System Sub state delay countdown 0 65535 The value of register 40109 corresponds to the count down delay for one of the below mentioned sub states To determine which sub state is in countdown mode read register 40101 Resolution is 1 second The following sub states incorporate delay countdown DLY TO START PREHEATING CRANKING WARMUP CRANK REST COOLDOWN IDLE COOL COOLDOWN IN IDLE LOW DC BATTERY CHARGING EXERCISER RUNNING User Manual for the GSC400 Series Automatic Gen Set Controller 90 of 98 Digital Input 0 1023 Read Status of controller digital inputs OFF Only means the input is not active or not connected 0 Input 0 OFF 1 ACTIVE Input 0 OFF 1 ACTIVE 2 Input BAT 0 OFF 1 ACTIVE Bit3 Input D BAT 0 OFF 1 ACTIVE 4 Input E GND 1 0 ACTIVE Bit5 Input F GND 1 OFF 0 ACTIVE Bit6 Input G GND 1 OFF 0 ACTIVE Bit7 Input H GND 1 OFF 0 ACTIVE Bit8 Start Stop 1 OFF 0 ACTIVE Emergency Stop 0 OFF 1 ACTIVE Note Do not read the start stop digital input Bit 8 as a means to determine if start signal active or not activ
39. ad at the output of the fuel sender Pull up Resistance in Ohms and depends on the analog input It is 1000 Ohms for pins 2 3 and 4 and 5110 Ohms for pins 4 6 and 7 Only pins 2 and 6 will give the full range of the sender It is recommended to use pin 6 In the Fuel Level menu located in the Advanced Setup menu you will also need to set the controller type or hardware version LS LX or LSB LXB The controller hardware version can be found on the back label contained in the product number under the bar code Section 3 on page 9 explains how to read the product number In the Signal Source submenu in each of the six analog input menus there is a selection of three preloaded sender tables from which to choose in addition to the J1939 Input and Switch Input choices The sender tables that are preloaded into the controller are given in Table 11 The PC Interface Sender Utility name for versions 1 8 1 and above are User Manual for the GSC400 Series Automatic Gen Set Controller 52 of 98 shown for reference and to provide more information to allow the user to determine which sender to use Refer to the PC Interface manual Table 11 Default Sender Tables Front Panel Datcon 330F VDO 266F Murphy 368F 4910hm 488 488 Low Low Low 3 4 3 4 3 4 Front Panel Datcon 1 VDO1 Murphy 1 Datcon 99PSI VDO 99PSI Murphy 99PSI 241 1360hm 2370hm Low Low Low 3 4 3 4 3 4 Revision
40. age Neutral 18 mA AC Voltage Neutral connection j Place 1A fuse between the hot lines and the voltage sensing terminals of J GSC400 d Phase 1 18 5 Phase current sensing CT Phase B 2 18 5A Phase B current sensing CT Phase C 3 18 5A Phase C current sensing CT Phase A 4 18 5A Phase A current sensing Phase 5 18 5A Phase B current sensing CT Phase C 6 18 5A Phase C current sensing CT DANGER It is extremely important to connect each phase to the HIGH appropriate terminal location Never mix phase inputs VOLTAGE Always match terminal details to the matching terminal L 4 location The current transformers CTs negative leads must be terminated individually into the GSC400 AC Current connector User Manual for the GSC400 Series Automatic Gen Set Controller 19 of 98 CANH 1 18 7mA CANH Connection Ground 2 18 7mA Ground Terminal Connection CANL 3 18 CANL Connection Ground 4 18 7mA Ground Terminal Connection 7 LN Important 120Ohm resistors must be placed on either end of the bus The CAN communication bus s CANL and CANH lines must be terminated with 1200hm resistors on either end of the bus If you are not connecting to an existing bus you must do this If you are connecting to an existing bus check that it has the proper terminating resistors To check for proper resistance d
41. agram Figure 4 on page 15 for more details Each GSC400 undergoes an advanced two point calibration at the factory and typically does not required calibration except in the following instances Current Transformers CT are used that have poor tolerances 2 The uncommon occurrence where the AC signal from the generator is distorted with a high total harmonic distortion THD DynaGen has a software utility that can perform a basic calibration of the current and voltage The Engine Logic menu contains the settings that control the starting and stopping of the engine All parameters in bold below are located in the engine logic menu unless otherwise noted The Crank Disconnect setting determines the speed that must be attained before the crank output is turned off and the engine is considered to be running The Crank Oil Pressure parameter is used to determine when to check for the Locked Rotor condition If the oil pressure is lower than the Crank Oil Pressure the GSC400 will check the engine speed for a locked rotor condition see section 6 5 1 1 on Locked Rotor All parameters in bold below are located in the engine logic menu unless otherwise noted When performing an automatic or manual start the controller will wait for the Delay To Start duration and then turn on the glow plug output for the Preheat duration After the preheat time the crank output is turned on for the duration specified by the Crank Time The fuel output is
42. ailure Each of the sender types support Warnings and or Failures In the case of high engine temperature if the data from the sender or J1939 exceeds the value set then the controller will give a warning or failure For the other analog input types the data from the source must drop below the warning and or failure setting Warnings and failure thresholds are only supported when using senders or J1939 The Low Oil Level and Fuel In Basin warnings are global meaning they are always active even in the OFF state The warnings for these also ignore the Bypass Time If you have the Input Type as a sender then you also need to set the Open Sender Detection or Shorted Sender Detection to Warning Failure or Disable The Open Sender Detection will trigger if the analog input voltage rises above 4 76V The Shorted Sender Detection will trigger if the voltage drops below 0 122V You will need to know the resistance of the sender at 0 25 75 and 100 fuel levels The resistance values must be either monotonically increasing e g 1 2 3 4 5 or monotonically decreasing e g 5 4 3 2 1 If you have an electronic sender that outputs a voltage between 0 and 5V you can use it on the GSC400 You must convert the voltage output to a corresponding resistance so you can enter it in the menu To do this use the following formula Resistance Voltage Output x Pull up Resistance 5 Voltage Output Where Voltage Output the voltage re
43. al damages Check all hardware including controller wiring terminals etc for any looseness due to vibrations etc Clean area around controller Periodically inspect and remove any debris dirt from within or near the controller Check for any overheating due to loose Perform regular testing of controller Check for any discoloration melting or connections blistering of any wiring or connections Perform regular testing of the controller to check for proper operation User Manual for the GSC400 Series Automatic Gen Set Controller 69 of 98 GSC400 s are factory programmed and shipped with default settings loaded into the controller Table 16 GSC400 Default Settings Manufacturer John Deere Display Group 1 Disable Display Group 2 Disable DTC Display Disable Active DTC Log Disable Read Stored DTC Disable Auto Power ECM Disable ECM Power Delay 6 seconds Cummins Idle Disable Conversion Method Conversion 2 Input Pin Input Pin 2 Signal Source Switch Bypass Delay 30 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Fahrenheit Warning Level 200 F Failure Level 220 Input Pin Disable Signal Source Switch Bypass Delay 30 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units PSI Warning Level 20 PSI Failure Level 15 PSI Input Pin Disabled Signal Source Switch Bypass Delay 30 Seconds Switch Setting SW Cl
44. as shutdown on loss of messages To read parameters from the J1939 bus please see Analog Inputs below High Engine Temp Analog Inputs These control all aspects of the specific J1939 Setup Oil Pressure analog input listed in the left column such as whether it is a switch sender or Fuel Level obtained from J1939 You can also set the input you want it to connect to The Oil Level warnings and failures as well as open and shorted sender detection shutdowns Fuel In Basin are also configurable Low Engine Tmp Great The speed sensing source magnetic pickup generator voltage J1939 under and over speed warnings and failures AC Frequency The crank disconnect frequency and the over under frequency warning failures The AC voltage sensing display is SUO EE contained here as well as the over and under voltage warnings and failures The CT ratio AC current sensing and uen display enable are contained in this menu Engine Logic All the basic start and shutdown logic are contained in this menu This menu allows you to assign a feature action to one of eight digital outputs For example you can turn on a digital output when an under speed failure occurs Generators require periodic operation as part of their scheduled maintenance This menu allows settings to control how often the engine generator is started and for how long This menu allows you to assign features warnings f
45. ch will be transmitted over the J1939 network When the DM1 messages are received by the GSC400 controller there are 3 important pieces of information that are captured and displayed FMI Failure Mode Indicator The type of failure You must refer to the engine manufacturer s documentation to identify the meaning of the failure mode indicator number OC Occurrence Count Identifies the number of times the failure has occurred SPN Suspect Parameter Number The parameter number If one of these DTCs appears please consult your engine manufacture for the definition of this fault With some engine manufacturers the text of the message can also vary slightly between engine types When active DTC messages are being received this will cause the controller display to lock and display the messages If multiple active DTCs are received the controller will scroll and display each DTC message The time between scrolling will be 3 seconds The DTC message display will look at follows aN Ven WARM UP 4155 NEW ACTIVE DT ACTIVE DTC Enter 01 01 5 Figure 5 Single Active DTC message User Manual for the GSC400 Series Automatic Gen Set Controller 37 of 98 Dyna WARM UP 5718 DTC FMI oc 0133 G03 ACTIV SPN Figure 6 Five active DTC messages and 3 one being displayed The user can also manually cycle through the DTC messages by activating either the UP or
46. d the opposite side accessible to the user Ground 1 18 7mA Ground Input 2 p 18 7mA Configurable Low Resistance Gain of 1 Input 3 3 18 7mA Configurable Low Resistance Gain of 3 Input 4 4 18 7mA Configurable Low Resistance Gain of 3 Input 5 5 18 7mA Configurable High Resistance Gain of 3 Input 6 6 18 mA Configurable High Resistance Gain of 1 Input 7 7 18 mA Configurable High Resistance Gain of 3 5V out 8 18 ImA Power for electronic sensors Revision B hardware only For revision A hardware this input spec is High Resistance Gain of 3 Revision B hardware only For revision A hardware this input has a gain of 3 Revision B hardware only For revision A hardware this terminal is a ground User Manual for the GSC400 Series Automatic Gen Set Controller 17 of 98 Ground input to generate logic high 2 Tie input to battery to generate logic high Input H 1 18 7mA Configurable GND Input G 2 18 7mA Configurable GND Input F 2 18 7mA Configurable GND Input E 4 18 7mA Configurable GND Input D 5 18 7mA Configurable BAT Input C BAT 18 7mA Configurable Input B BAT 18 7mA Configurable Input A 18 7mA Configurable BAT Emer Stop 9 18 mA Allows Manual Emergency Stop Open Active
47. dummy load feature allows the user to turn on an output if the AC current is below a settable threshold Load On Point This is useful for applications where the generator must have a minimal load to prevent damage to the generator Upon crank success RUN Mode entered if enabled the feature waits for a configurable bypass time then starts to monitor the AC current If the AC current remains above the Load On Point for 6 5 seconds then the dummy load digital output is turned on If the AC current rises and remains above a settable threshold Load Off Point for 1 5s the dummy load digital output is turned off A digital output must be set to dummy load to use this feature User Manual for the GSC400 Series Automatic Gen Set Controller 68 of 98 The actions in Table 15 should be performed routinely D WARNING When performing any GSC400 or Engine maintenance be certain controller is in OFF Mode is isolated from all possible sources of power and the Crank wire is removed from the Controller Making the controller safe for inspection and maintenance Table 15 Recommended Maintenance Disconnect all possible power sources before controller inspection Inspect controller mounting location for possible safety issues Inspect controller for loose fasteners terminals and wiring connections Inspect mounting location for any safety or fire issues Inspect for dirt wiring damage and mechanic
48. e please read the register 40100 for system state Digital Output 0 2047 R Read Status of controller outputs 0 Only corresponds to output OFF or NOT ACTIVE while a 1 corresponds to output ON or ACTIVE BitO Output A 0 OFF 1 ACTIVE Output 0 OFF 1 ACTIVE User Manual for the GSC400 Series Automatic Gen Set Controller 91 of 98 Bit2 Output C 0 OFF 1 ACTIVE Bit3 Output D 0 OFF 1 ACTIVE Bit4 Output E 0 OFF 1 ACTIVE Bit5 Output F 0 OFF 1 ACTIVE Bit6 Output G 0 lt 1 Output H 0 OFF 1 ACTIVE Bit8 Extra Relay 0 OFF 1 ACTIVE Bit9 Fuel Relay 0 OFF 1 ACTIVE 10 Crank Relay 0 OFF 1 ACTIVE Engine Speed 0 6553 0 R 1 bit equal 0 1 RPM RPM Reading 18000 corresponds to 1800RPM High Engine 0 250 0 R 1 bit equal 0 1 unit C Temperature Reading 1000 corresponds to 100 0C Low Engine 0 250 0 R I bit equal 0 1 unit C Temperature Reading 1000 corresponds to 100 0C Fuel Level 0 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 User Manual for the GSC400 Series Automatic Gen Set Controller 92 of 98 Oil Pressure 0 0 1000 0 R 1 bit equal 0 1 unit KPa Reading 1000 corresponds to 100 0KPa Oil Level 0 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0
49. e Un Eee aen peas 69 O Appendix At ESL daos cecinere te dnte are eel en N anf qn eR iR 13 9 1 GSC400 Controller Harness 10 0 13 9 2 GSC400 Programmer Assembly eade eeu une p ex vin aye 74 9 3 CT s Current Transformers eese eene eene eene nnns 75 9 4 Engine Sending Units irte e NINE 76 9 5 GSC400 replaceable 12 24VDC relays eese 76 9 6 GSC400 Fusing eric Rt a n REX UR RAS EO He qn uS 74 10 Appendix BiModbus Map necne tates euer ege aequ tee Eo THp eg 78 IOF SModbus Comitidngass soe deed ode 79 19 2 ae 80 11 Appendix C J1939 Old DTC Conversion Methods eese 98 User Manual for the GSC400 Series Automatic Gen Set Controller 7 of 98 The GSC400 is designed for use on generator sets with either mechanical or GSC400 Front View electronic J1939 engines It can monitor analog data from senders on the engine and generator such as oil pressure coolant RE temperature current voltage and engine 2 DynaGen speed and generator frequency The GSC400 can also gather engine parameters from the engine ECM via J1939 and use them to control the engine or for display purposes RUNNING
50. e controller to receive currently active DTCs DM1 messages and display then on the screen as well as optionally store then to the Event Log The controller can also receive previously active DM2 messages and display them on user command DM2 messages are intended for technician troubleshooting and are not stored to the Event Log The GSC400 supports the following J1939 standards when reading DM1 messages 1 Single package frame J1939 71 2 Multi packages frame J1939 21 a BAM b TP DP The GSC400 supports the following J1939 standards when reading DM2 messages 1 DM2single package frame J1939 71 2 Multi package frame J1939 21 a BAM b RTS CTS c TP DP The user can enable disable the DTC feature and configure its behavior with the following settings DTC DISPLAY This setting enables or disables active fault messages DM1 monitoring When the DTC DISPLAY feature is enabled the GSC400 can receive active faults in the RUNNING OFF and AUTO modes on the J1939 bus Any new received active faults will trigger a message NEW ACTIVE DTC and the user can read the message on the GSC400 front panel display This new message will also be stored into the controller s event log if this feature was enabled ACTIVE LOG DTC The setting enables disables the storing of active faults DM1 in GSC400 Event Log The Event Log reserves 30 storage locations for DM1 messages READ STORED DTC The setting enables disables the ability to request stor
51. e digital output if the Low Fuel Warning is activated See section 6 2 for more details This turns on the digital output if the Low or High Battery Failure is activated See section 6 9 for more details This turns on the digital output if the Low or High Battery Warning is activated See section 6 9 for more details This turns on the digital output if the Low Coolant Failure is activated This is controlled by the Low Coolant Digital Input described in Table 14 in section 6 8 Reserved for future use Selecting this feature will have no effect This turns on the digital output when the controller is not in the Auto state Section 5 3 describes the various states of the controller This turns on the digital output when any failure is active This turns on the digital output when the controller is in the crank rest state after a crank attempt The crank rest duration is set in the engine logic menu See section 6 5 1 for more details This turns on the digital output when the controller enters the run state crank success The run state is described in section 5 3 This turns on the digital output when the crank output is on See section 6 5 1 for more details This turns on the digital output when the engine generator starts on an exerciser event section 6 7 This turns on the digital output when the engine generator starts on a low battery event section 6 2 This turns on the digital
52. e same message structure Each message is comprised of four message fields the Device Address the Function Code the Data Block and the Error Check field Query Response Message Structure Device Address Function Code Eight Bit Data Bytes Error Check Device Address Field The Device Address field contains the unique Modbus address of the slave being queried The addressed slave will repeat its address in the Device Address field of the response message This field is 1 byte Function Code Field The Function Code field in the Query message defines the action to be taken by the addressed slave This field is echoed in the Response message and will be altered by setting the MSB of the field to 1 if the response is an error response This field is 1 byte Data Block Field The query Data block contains additional information needed by the slave to perform the requested function The response Data block contains data collected by the slave for the queried function An error response will substitute an Exception Response Code for the Data Block The length of this field varies with each query Error Check Field The Error Check field provides a method for the slave to validate the integrity of the query message contents and allows the master to confirm the validity of response message contents This field is 2 bytes User Manual for the GSC400 Series Automatic Gen Set Controller 79 of 98 Serial Transmission Details A
53. ed fault codes from the ECM DM2 When this setting is enabled GSC400 will allow manually triggered requests of stored faults from the ECM s memory DM2 User Manual for the GSC400 Series Automatic Gen Set Controller 50 of 98 The GSC400 has support for the following analog input types Fuel In Basin Low Engine Temperature 1 High Engine Temperature 2 Oil Pressure 3 Fuel Level 4 Oil Level 5 6 For each of the analog input types you can select the pin 2 to 7 for the type of analog sender that is connected to it See Figure 4 on page 9 for the pin locations of the analog input connector If you are not using one of the inputs indicated then select Disabled Also you must select a pin even if you are using J1939 instead of a physical sensor Two different analog types cannot share the same pin with the exception of the Low Engine Temperature and High Engine Temperature as this allows the user to use one sender to measure both low engine temperature and high engine temperature Input Pin Disable Note When the Input Pin is set to disabled it is actually set to a virtual input where the voltage read is 5V the source is set to a switch and the switch setting is set to Closed Fail This effectively disables the input If changing the source ensure that the Input Pin is not set to disabled In addition you must select the Input Type such as sender J1939 or switch see the section below for more info
54. eed Input 02 2 2 2 Gad 5 mas Pe 5 0 6 87 6 5 443 Modbus To annunciator panel or allah e 4 remote communication device 10 093 MODBUS DEVICE NET power 5 1 electronic sensors if used Pins 5 to 7 other sensors if used Sensors can be grounded at chasis Oil Pressure grounded here if not 1200 05021 ENGINE 11939 BUS IF AVAILABLE Engine Temperature Example only Not required if using 11939 GSC400 LSB System Wiring Diagram DWG1439 Rev1 4 Figure 4 General GSC400 System Wiring Diagram User Manual for the GSC400 Series Automatic Gen Set Controller 16 of 98 Table 2 GSC400 Terminal Details Crank 12 40 Crank Output Terminal Battery 12 40A Positive Battery Terminal Battery 12 40A Negative Battery Terminal Fuel 12 40A Fuel Output Terminal Extra Relay 12 40A Configurable Dry Contact Extra Relay Other side of Configurable Dry Contact Speed 1 18 100mA Speed Signal Connection Speed 2 18 100mA Speed Signal Connection controller current output max 60A This is a configurable output See Table 13 on page 59 for possible selections 2 normally open SPST relay with user access to both sides of the switch This is unlike the Fuel and Crank relay outputs which have one side connected internally with battery positive an
55. en the current measured on the GSC400 AC Current terminals is 5A The GSC400 current terminals can handle a maximum of 5A Larger currents can damage the GSC400 The AC Current menu is also used to set the over current warnings and shutdowns These are grouped in terms of the voltage group 1 to 4 The current warning and failure depends on the voltage group selected in the Voltage Group submenu of the AC Voltage menu The Hi Wye Current parameter second to last entry in the AC Current menu is used to double the current reading 50 selection If this is not desired then the 100 selection should be selected Some generators have two wires for each phase and as such the current transformer which is placed on one lead will see only 50 of the current from each phase The Cur Warn Latch option last entry in the AC Current menu is used to latch on a special digital output see Current Latch in Table 13 on page 59 that turns on when the current exceeds the Current Warning Threshold and can only be turned off by the user User Manual for the GSC400 Series Automatic Gen Set Controller 57 of 98 from the front panel On a current latch condition the LCD displays Over Current Latched and lt Up Arrow Down Arrow for Unlatch The current transformers CTs negative leads must be terminated individually into the GSC400 AC Current connector Do not tie the negative leads together to a common neutral See the system wiring di
56. ents number 18 Battery Voltage High bit 4 0 Low Battery Voltage During Cranking bit 9 5 Locked Rotor bit 14 10 Events number 19 Events number 20 Events number 21 Common Fault 1 Warning Shutdown bit 4 0 Common Fault 2 Warning Shutdown bit 9 5 Reserved bit 14 10 Reserved LED Status GSC400 Front Panel 0 OFF R Over Crank Failure red 1 bitl Over Crank Warning amber bit2 High engine temp failure red bit3 High engine temp warning amber bit4 Low oil pressure failure red bit5 Low oil pressure warning amber bit6 Engine over speed failure red bit7 Engine over speed warning amber bit8 Low fuel level failure red bit9 Low fuel level warning amber bit10 Low Battery warning amber bit11 Battery Ok solid green in OFF and RUN modes flashing green in AUTO mode bit12 Not in auto red bit13 Not used bit14 Low coolant level shutdown red bit15 Low coolant level warning amber User Manual for the GSC400 Series Automatic Gen Set Controller 82 of 98 bit0 EPS supplying load shutdown red bit1 EPS supplying load green bit2 not used bit3 Glow plug on green 6114 Failure is active Red Failure LED bit5 to bit7 not used bit8 Crank relay On no LED bit9 Fuel relay ON no LED bit10 Extra relay ON no LED bit11 to bit13 Reserved bit14 and bit 15 not used Events Warnings 0 OFF R Status 1 ON
57. er 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 is ready for installation Handling wrsux As previously mentioned each GSC400 gen set controller is packaged in its own individual box Protect the equipment from impact at all times and do not carelessly stack Once the controller is at the installation site and ready to be installed the packaging material may be removed 2 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 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 F with a relative humidity of 80 or less Do not stack other equipment on top of the stored controllers Storage User Manual for the GSC400 Series Automatic Gen Set Controller 9 of 98 The GSC400 series product numbering scheme i e product number provides various information including options selected by the customer about the unit A product number has the format given in Figure 1 The product number is located on the backside of the GSC400 controll
58. er under the bar code GSC400 0 Controller 12 12VDC LS Standard A letter is placed in Uniquely Series 24 24 LX Customized this position to indentifies the GSC400 indicate the particular unit hardware revision level No letter indicates revision A Figure 1 GSC400 product numbering scheme User Manual for the GSC400 Series Automatic Gen Set Controller 10 of 98 Generator systems contain high voltage circuits Working on powered equipment can cause damage to equipment injury or death The following symbols will be used in this document to classify information Caution This is used to indicate something that A you should take special notice of but that is not normally a threat to safety NG ER Danger This is used to indicate a potential for injury or death HIGH Danger High Voltage This is similar to Danger VOLTAGE above but releases specifically to conditions where high voltage is encountered The following general safety precautions should be headed 1 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 2 power may carry high Voltage Current which can cause serious
59. erved 6 ADE Write 7 Internal reserved 7 TLE6230 8 Internal reserved 8 EEPROM 9 Reserved 10 HIGH ENGINE TEMPERATURE 11 LOW OIL PRESSURE 12 UNDER SPEED 13 OVER SPEED 14 LOW FUEL LEVEL 15 LOW BATTERY 16 LOW COOLANT 17 OVER CRANK 18 OVER VOLTAGE 19 UNDER VOLTAGE 20 OVER CURRENT 2 EPS LOADS ERROR 22 LOW AIR PRESSURE 23 LOW HYDRAULIC 24 LOW OIL LEVEL 25 LOCKED ROTOR 26 HIGH BATTERY 27 LOSS OF ECM COMMUNICATION 28 OPEN ENG TEMPERATURE 29 SHORT ENG TEMPERATURE 30 OPEN OIL PRESSURE 31 SHORT OIL PRESSURE 32 OPEN FUEL LEVEL 33 SHORT FUEL LEVEL 34 OPEN OIL LEVEL 35 SHORT OIL LEVEL 36 OPEN FUEL BASIN 37 SHORT FUEL BASIN 38 OPEN ENGINE TEMPERATURE 39 SHORT ENGINE TEMPERATURE 40 AUXILIARY FAIL 41 UNDER FREQUENCY User Manual for the GSC400 Series Automatic Gen Set Controller 95 of 98 42 OVER FREQUENCY 43 HIGH FUEL LEVEL 44 POWER ON 45 AUTO ENABLE 46 OFF ENABLE 47 MANUAL START 48 MANUAL STOP 49 REMOTE START 50 REMOTE STOP 51 EMERGENCY STOP 52 CHARGE START 53 CHARGE OVER 54 MAINTAIN NEEDED 55 INITIALIZING 56 MAINTAINED 57 NEXT EXERCISER 58 RUN EXERCISER 59 EXERCISER OVER 60 CHARGER 1 FAULT 61 CHARGER 2 FAULT 62 LOG CORRUPTED 63 MODBUS START 64 MODBUS STOP 162 0xA2 CONFIG FAIL 1 163 0xA3 CONFIG FAIL 2 233 9 DTC Log Time stamp Decimal Decimal format Minute Minutes 0 59 High 4 bit tens 0 5 Low 4 bit ones 0 9 Log Time sta
60. es the Warm up and Cool down digital outputs can be tied to the Idle Mode digital input For Cummins electronic engines the GSC400 will control the engine using the J1939 speed control feature Whenever the Idle Mode digital input is active the GSC400 will send a command over J1939 to put the engine into idle See section 5 12 1 of page 35 for more information To program this feature using the GSC400 front panel menu see section 6 1 1 on page 48 The GSC400 startup and shutdown behavior can be set by the user from the Advanced menu password protected such as the amount of time to wait before starting whether to preheat and for how long the crank time etc See sections 6 5 1 Startup Sequence and 6 5 2 Shutdown Sequence starting on page 57 for more information on the options for starting and stopping the generator respectively The controller has a low power Sleep Mode that it can enter when in the OFF or AUTO states In this state the LCD screen backlighting is turned off The time it takes to enter Sleep Mode is configurable in the menu It is recommended that the Sleep Delay is set as short as possible to prolong the life of the backlighting and to reduce battery consumption User Manual for the GSC400 Series Automatic Gen Set Controller 25 of 98 The backlight display will illuminate automatically when a key is pressed A key press will only cause the controller to exit the Sleep Mode The key must be pressed again
61. event warning per register Ensure that controller is not in sleep mode before reading 0 READING ABORT DTC reading 1 Low Voltage In Crank 2 Charger 1 Fault 3 Need Maintenance 4 CRANK FAILURE 5 Charger 2 Fault 6 Custom Warning 1 7 Custom Warning 2 8 CRANK SUCCESS 9 Empty Space 11 REQUESTING DTC 14 LAMP TEST 15 High Fuel Level 16 Warning 17 Low AC Voltage 18 Over Cur Latched User Manual for the GSC400 Series Automatic Gen Set Controller 87 of 98 191 FOR UNLATCH 20 READ DTC SUCCESS 21 FUEL OFF If fuel turned off during crank rest 22 Low Engine RPM 23 High Engine RPM 24 High AC Current 25 High AC Voltage 26 High Engine Temp 27 Low Oil Pressure 28 Low Fuel Level 29 EXERCISE Prealarm 30 CHARGE Prealarm 31 NO DTC AVAILABLE 32 DM2 REQUEST FAIL 33 KEEP FUELING If fuel remains on during crank rest 34 Lock Mark symbol screen locked when in Run Mode 35 NOT IN AUTO 36 OFF FOR SILENCE 37 OFF FOR ALARM 38 POWER ON ECM 39 WAITING ECM 40 NEW ACTIVE DTC 41 DTC PROCESS DOWN 43 FAILURE 45 WAIT TO START 46 Low Oil Level 47 Low Speed Warn 48 Locked Rotor 49 Fuel In Basin 50 Low Battery 51 High Battery 52 AUTO FOR SILENCE 53 AUTO FOR ALARM 54 Low Engine Temperature warning 55 Open Engine Temperature sender 56 Short Engine Temperature sender 57 Open Oil Pressure sender User Manual for the GSC400 Series Automatic Gen Set Controller 88 of
62. he scan rate When sending the start address use the following formula start address register address 40 000 1 Obtain the correct holding register address from the register map below 2 The GSC400 device only supports reading up to 20 registers at a time reading more than 20 registers at a time will give an illegal address error Also be careful to not read invalid registers as the GSC400 register map is not continuous 3 The recommended scan rate is 1000ms The GSC400 updates holding register address from 40050 to 40244 every 1 second 4 All registers that are written too and all modbus registers in the range of 1 to 10 are updated every 250ms As an example a user wanting to read the engine speed and other related parameters the engine speed holding address is 0x40150 would use the 0x03 command with start address 0x40150 and quantity 20 and a scan rate of 1000ms The user s device will continue polling address 0x40150 to 0x40169 at 1000ms duration User Manual for the GSC400 Series Automatic Gen Set Controller 80 of 98 Note There are only two addresses that support the 0x06 command the address are 0x40098 and 0x40130 NOTE All parameters are assumed to be unsigned integer values unless otherwise specified in the Range column Table 24 Modbus Register Map Highest Severity Event bit 16 Alarm State bit 15 14 Severity Bits 13 10 Reserved Bits 9 1 Event Previous Highest Sever
63. input is active the GSC400 will cancel the start sequence and enter the failure state on an EPS load failure After crank success if the input is active the EPS Supplying Load lamp on the GSC400 front face will turn on This input silences the buzzer on the GSC400 unit when active This input generates a Low Coolant Level failure when active These inputs allow the user to change the supported generator configuration without having to go into the controller menu See section 6 4 2 1 for more details User Manual for the GSC400 Series Automatic Gen Set Controller 63 of 98 This input when active allows the generator to run at a lower speed without triggering under voltage under frequency or under speed warnings or failures Idle Running is displayed on the GSC400 display when this input is active See section 5 5 on page 24 for more information on the Idle Mode feature The idle mode can also turn on a digital output see the Voltage Regulator digital output feature in Table 13 on page 59 This output is usually used to turn off the generator voltage regulator when idle mode is entered but can be used for any purpose This is also used for Cummins J1939 Idle Feature See section 5 12 1 on page 35 for more information When the digital input is active the generator is started if in the Auto mode If the digital input becomes inactive this places the controller back into the Auto mode shuts down
64. ion 6 13 for more details This allows the digital output to be controlled by the Dummy Load feature See section 6 14 for more details This turns on the output if the High Fuel Level Warning digital input in Table 14 on page 62 is active This turns on the output if the Cur Warn Latch in the AC Current menu see Table 8 on page 42 is set to Enable and the High Current Warning is active The output can only be turned off by the user See section 6 4 3 on page 56 for more information This turns on the output if the Config Warn 1 digital input Table 14 on page 62 is active This turns on the output if the Config Warn 2 digital input Table 14 on page 62 is active This turns on the output if the Config Fail 1 digital input Table 14 on page 62 is active This turns on the output if the Config Fail 2 digital input Table 14 on page 62 is active The GSC400 can be set to automatically start the engine generator at regular intervals if left in the AUTO state This is controlled by the Exerciser Setup menu The Exerciser Enable should be set to Enabled if this feature is desired The GSC400 will display a message and sound the buzzer for a set amount of time Pre Alarm Delay to alert nearby personnel that the generator is about to start The engine generator will run for a set period of time Run Duration and then shut down The Start Date and Start Hour determine the date 0 to 31 and time when
65. isconnect the CAN bus harness from the GSC400 and measure across the CANH and CANL pins on the harness connector It should be 60 Ohms two 120 Ohms in parallel If you measure 120Ohms then only one resistor has been installed If using the optional J1939 harness DWG1373R3 5 from Dynagen there is a 1200hm resistor built in It can be cut out if the GSC400 is not the last device on the bus If you are using DWG1375R2 5 this version of the J1939 harness does not have a terminating resistor The current transformers CTs negative leads must be terminated individually into the GSC400 AC Current connector Do not tie the negative leads together to a common neutral or ground The negative lead of the CT is usually black User Manual for the GSC400 Series Automatic Gen Set Controller 20 of 98 The very first time the controller is powered up the unit will go through an initialization where all the configurable settings are set to factory default values This will happen only on the first power up Once the initialization is finished the controller will display the firmware and hardware version on the screen and flash the indicator lamps on the side of the controller this will also occur during all subsequent power ups The controller will then enter the OFF mode By default it is possible to manually start the generator in the OFF Mode The user can disable manual start in OFF mode in the basic menu in which case the GSC400 must be in the AUTO m
66. ither the AUTO OFF or RUNNING modes The controller s alarm will sound and the controller will send a request to the ECM A LAMP test will additionally be triggered in the OFF mode The UP and DOWN keys can also be pressed to remove the DM2 message screen If the GSC400 is in the OFF or AUTO mode when the request is triggered the ECM may not be powered on so the controller will energize the fuel relay output and wait for the ECM to power on The GSC400 then sends out the DM2 request In the event there is no response from the ECM the controller will re attempt sending out the DM2 request an additional 3 times every 1 25 seconds It will then display REQUESTING FAIL and turn off the fuel output if there is no valid response on the fourth try The default ECM address for DM2 request is 0 and the ECM address can only be changed from the GSC400 PC interface GSC400 may also show READING ABORT if communication is unsuccessful If the request was successful the GSC400 will show READ DTC SUCCESS and start to display the messages The GSC400 Event Log see section 5 9 3 on page 30 can store up to 30 DM1 messages DM2 messages are not stored Once the 30 limit has been reached the oldest message is removed from the log to be replaced by the incoming DM1 entries in the log are stored in a reverse chronological order with the most recent event display first User Manual for the GSC400 Series Automatic Gen Set Controller
67. ithout cooling down if cool down is enabled If the engine speed goes below the crank disconnect speed the controller attempts to restart the engine generator At the same time if the Warm up sub menu is set to a value greater than zero an output is turned on one of the digital outputs or Extra relay must be set to Warm Up and the input is active low This is used to disengage any load or potential loads until the gen set is warmed up Once the Warm up time has expired the output is turned off input goes high Once the controller enters the Running state and if the PostHeat time is greater than 0 the glow plug output is turned on for the duration of the PostHeat time The GSC400 has a safety feature where a locked rotor condition will be detected This applies to generators only To disable this feature set the Crank Oil Pressure in the engine logic menu to 0 During cranking the locked rotor condition is checked if the oil pressure is above the Crank Oil Pressure parameter engine logic menu The engine speed and AC frequency are checked and if both are 0 the crank time is shortened to 3s including the time passed in cranking If the engine generator has not reached the crank disconnect speed at the end of the 3s the GSC400 will stop cranking and go into a Locked Rotor Failure When the OFF key is pressed while the engine generator is running and if the Cool Down submenu is set to a value greater than 0 seconds the generator will
68. ity bit 16 Alarm State bit 15 14 Severity Bits 13 1 Event Event R Each event uses 5bits b4 b3 b2 b1 bO where 0 is the least significant bit 0 The event status warning or shutdown occurring 0 2 Not Active 1 Active b2 b1 The severity of the event 0 Take No Action 1 Warning Acknowledge 2 Action Required 3 Take Immediate Action shutdown b3 Alarm Action indicates if GSC400 is sounding buzzer 0 No Audible Alarm 1 Sound Audible Alarm b4 Warning Failure Feature Enabled Disabled 0 Disabled 1 Enabled Events number 1 System Ready bit 4 0 Events number 2 Over crank bit 9 5 Events number 3 High Engine Temperature Warning Shutdown bit 14 10 Events number 4 Low Oil Pressure Warning Shutdown bit 4 0 Events number 5 Over speed bit 9 5 Events number 6 Emergency Stop bit 14 10 Events number 7 Low Coolant Level bit 4 0 Events number 8 Low Coolant Temperature bit 9 5 Events number 9 Low Fuel Level In Tank bit 14 10 User Manual for the GSC400 Series Automatic Gen Set Controller 81 of 98 Events number 10 Events number 11 Events number 12 Low Fuel Pressure bit 4 0 Emergency Power Supplying Load bit 9 5 Generator Running bit 14 10 Events number 13 Events number 14 Events number 15 Generator Not In Auto Mode bit 4 0 Battery Charger Fault bit 9 5 Battery Voltage Low bit 14 10 Events number 16 Events number 17 Ev
69. l Reserve Analog 2 7 J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Fahrenheit Celsius 10 265 F 10 265 C Signal Source J1939 Mag pickup Gen output Rated Freq 10 9990 Hz Rated RPM 200 4000 RPM Over RPM Warn 100 5000 RPM Over RPM Fail 100 5000 RPM Under RPM Warn 100 5000 RPM Under RPM Fail 100 5000 RPM DisconnectFreq 1 100 Hz Over Freq Warn 1 100 Hz Over Freq Fail 1 100 Hz UnderFreq Warn 1 100 Hz UnderFreq Fail 1 100 Hz Voltage Source Disable Enable Voltage Display Line Line Line Neutral Both 1 Single 2 Three 3 Hi Wye 4 Three Voltage Group phase Group 1 Setting 3 Wire Single 2 Wire Single Group 4 Setting Four Wire Delta Three Phase Over Volt Warn 1 Over Volt Fail 1 Under Volt Warn 1 Under Volt Fail 1 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC User Manual for the GSC400 Series Automatic Gen Set Controller 44 of 98 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 Hi Wye Current Cur Warn Latch 0 700 VAC 0 700 VAC 0 700 VAC 0 700 VAC
70. lows In single phase applications e Phase A to terminals Phase A AC CURRENT SENSING e Phase B to terminals Phase In three phase applications e Phase to terminals Phase A e Phase B to terminals Phase B e Phase C to terminals Phase C In center tap delta applications e Phase A to terminals Phase A e Phase B to terminals Phase B e Phase C to terminals Phase C White wire assumed positive Black wire assumed negative Figure 10 AC current sensing connections Table 20 Current Transformers Part List ACCO0045 PC amp S 546 100 L ACC0046 PC amp S 546 200 L ACC0047 PC amp S 546 300 L ACC0048 PC amp S 546 500 L ACC0049 PC amp S 546 600 L 0050 PC amp S 546 1000 L 0057 PC amp S 546 1500 L User Manual for the GSC400 Series Automatic Gen Set Controller 76 of 98 Senders are required if display of display of engine sensors are required Connections would be installed as follows Table 21 Senders Part List Datcon 102225 00 1 8 2 27 0074 NPTF Heavy duty version of Datcon 2505 00 Datcon 02022 00 1 8 27 ACC0027 NPTF The GSC400 controller is designed to operate in either 12 or 24 VDC battery start systems When operating in 12VDC systems the fuel crank and extra relays need to be rated 12VDC coil When operating in 24VDC systems these relays need to be rated 24VDC coil To maintain the UL rating the HASCO relays must be
71. mp Decimal Decimal format Hour Hours 02925 High 4 bit tens 0 2 Low 4 bit ones 0 9 Log Time stamp Date Decimal R Decimal format Day 1 2l High 4 bit tens 0 3 Low 4 bit ones 0 9 Log Time stamp Decimal Decimal format Month Month 1 12 High 4 bit tens 0 1 Low 4 bit ones 0 9 User Manual for the GSC400 Series Automatic Gen Set Controller 96 of 98 0 255 Lowest byte of SPN bit 8 MSB Log DTC code Only 0 39 Middle byte of SPN bit 8 MSB valid if entry contains 0 31 3 highest bits of SPN and the FMI bit 8 DTC message if Log is SPN MSB and bit 5 is FMI MSB Bit 8 CM other 7 bits bit 7 MSB equals 233 Log Sequence 1 100 Current log being read Total Log Number 1 100 Total number of entries in the log Active DTC lamp 0 65536 The High byte of 40114 holding register status and Teserved Bit 7 6 malfunction indicate lamp status Bit 5 4 red stop lamp status ERU Bit 3 2 amber warning lamp status Bit 1 0 protect lamp status Low byte reserved for lamp status Active DTC No 1 0 65536 DTC was defined in SAE J1939 73 Each DTC code will 0 65536 CM Bit7 of Byte 4 SPN Conversion be stored in 2 holding Method bit If CM 0 below applies register High Byte of else see below the table 1 SPN SPN is 19 bits value the MSB of SPN is spn18 and the LSB of SPN is 1 Low byte is byte 2 spnO Data range is from 0 to 524 287 high byte of
72. ngs and failures can be triggered for frequencies under and or over settable thresholds The DisconnectFreq setting is used by the GSC400 controller as a backup to the speed input If the speed input is not detected the controller checks the DisconnectFreq settings If the measured frequency is greater than this setting then the engine will be considered running The user can enter under voltage over voltage and over current settings for four different voltage configurations This allows the GSC400 to be used on multiple generator types without having to configure each GSC400 or it allows a single generator to support multiple voltage configurations without having to go into the menu system Each voltage group supports a different generator configuration 1 Voltage Group 1 Single Phase two or three wire 2 Voltage Group 2 Three Phase Delta or Hi Wye 3 Voltage Group 3 Three Phase Hi Wye Hi Wye centre tapped 4 Voltage Group 4 Three Phase three or four wire delta Voltage Group 1 has an option the Group 1 Setting under the AC Voltage menu for two wire Hot and Neutral or three wire A B Neutral single phase If two wire single phase is selected the GSC400 display is fixed to L N Voltage Group 2 can be used for 3 wire delta and non center tapped Hi Wye configurations Voltage Group 3 is the same as Voltage Group 2 There is a Group 3 Setting that can be enabled and is normally used for center tapped Hi Wye application
73. ntroller
74. ode to manually start the generator See section 5 9 2 on page 28 Pressing the Auto key will cause the controller to enter the AUTO mode From this mode the user can manually put the controller into RUN mode i e start the generator or the controller itself will be able to start the generator automatically if required e g remote start capability on low battery if enabled The controller has the ability to remember whether it was in the OFF or AUTO mode the last time it was powered up and will reenter that mode when it is repowered If the emergency stop input of the digital input terminal is not connected to ground the controller will alarm and display Emergency Stop when connected Emergency Stop also forces the controller to the OFF mode To prevent this ground the emergency stop input pin 9 to either of the grounds pins 11 or 12 on the digital input terminal See Figure 4 on page 15 The GSC400 has a dedicated remote start contact located on the digital input connector See Figure 4 on page 15 for the location of the remote start contact A grounded signal on the contact when the controller is in AUTO Mode see below for more information on the AUTO Mode will cause the controller to start Removing the ground will cause the controller to go back into AUTO Mode It is also possible to set one of the programmable digital inputs as a remote start contact This feature works the same way as the dedicated remote start active
75. on while in the AUTO mode by enabling Auto Power ECM This will ensure the ECM is already powered up and read to go when the user desires to start the generator When the controller enters the Auto Mode the ECM Power Delay setting controls the amount of time the GSC400 delays before turning on the fuel output This is useful to prevent the generator from starting up unexpectedly if it hasn t fully shut down when the controller entered the Auto Mode The GSC400 can switch between idle and normal operating speed on Cummins generators When the fuel relay is on the GSC400 continually sends out a speed command every 250ms to tell the generator which of the two speeds to run at A digital output must be set to Idle Mode see Table 14 on page 62 and when this digital input is active the generator runs at idle speed otherwise it runs at normal operating speed To enable this feature set Cummins Idle to GCP Enable or Enable is the newest protocol while for older engines you will need to use GCP If you are powering the ECM externally you may get an error message if Cummings Idle Speed and Diagnostic Trouble Codes see below are enabled 1939 Erratic User Manual for the GSC400 Series Automatic Gen Set Controller 49 of 98 ECM expects the speed update to be sent continuously and if it is not the ECM thinks there is a problem with the J1939 communications The GSC400 has a DTC feature that when enabled allows th
76. or example low oil pressure to one of eight digital inputs This menu controls the settings for the Battery Setup battery under and over voltage warnings and failures It also allows the user to set at what battery voltage to start the Outputs Setup Exerciser Set Inputs Setup User Manual for the GSC400 Series Automatic Gen Set Controller 41 of 98 User Manual for the GSC400 Series Automatic Gen Set Controller 42 of 98 Table 8 Submenus of the Advanced Menu John Deere Volvo Cummins Manufacturer Yanmar Detroit Diesel Others Loss of ECM Enable Disable Display Group 1 Enable Disable Display Group 2 Enable Disable DTC Display Disable Enable Active DTC Log Disable Enable Read Stored DTC Disable Enable Auto Power ECM Disable Enable ECM Power Delay 5 30 seconds Cummins Idle Disable GCP Enable GC1 Enable Input Pin Disable Analog 2 7 Signal Source J1939 Switch input Sender 1 2 or 3 Bypass Delay 0 60 Seconds Switch Setting GND Fail Open Fail Shorted Sender Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Fahrenheit Celsius Warning Level Failure Level 10 265 F 10 265 C 10 265 F 10 265 C Input Pin Reserve Analog 2 7 Signal Source J1939 Switch input Sender 1 2 or 3 Bypass Delay 0 60 Seconds Switch Setting GND Fail Open Fail Shorted Sender Disable Warning Shutdown Open Sender Disable Warning Shutdown Units
77. osed Fail Shorted Sender Disable Open Sender Disable Units Percentage Warning Level 25 Failure Level 5 Input Pin Disable Signal Source Switch Bypass Delay 10 Seconds Switch Setting SW Closed Fail User Manual for the GSC400 Series Automatic Gen Set Controller 70 of 98 Shorted Sender Disable Open Sender Disable Units Percentage Warning Level 10 Failure Level 5 Input Pin Disable Signal Source Switch Bypass Delay 11 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Percentage Warning Level 2 Failure Level 5 Input Pin Disable Signal Source Switch Bypass Delay 10 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Fahrenheit Warning Level 10 F Signal Source Generator Output Rated Freq 60 Hz Rated RPM 1800 RPM Over Speed Warn 1950 RPM Over Speed Fail 2050 RPM Under Speed Warn 1650 RPM Under Speed Fail 1550 RPM Frequency Disconnect 22 Hz Over Freq Warn 70 Hz Over Freq Fail 75 Hz Under Freq Warn 50 Hz Under Freq Fail 45 Hz Voltage Source Enable Voltage Display Line Neutral Voltage Group Group 1 Single Over Volt Warn 1 250 VAC Over Volt Fail 1 260 VAC Under Volt Warn 1 230 VAC Under Volt Fail 1 220 VAC Over Volt Warn 2 220 VAC Over Volt Fail 2 230 VAC Under Volt Warn 2 195 VAC Under Volt Fail 2 185 VAC Over Volt Warn 3 500 VAC Over Volt Fail 3 520 VAC Under Volt Warn 3 460 VAC Under Volt Fail
78. output when the AC Under Voltage Warning section 7 4 is activated This turns on the digital output when the AC Over Voltage Warning section 7 4 is activated This turns on the digital output when the AC Over Current Warning section 7 4 is activated This turns on the digital output if the Low Fuel In Basin Warning section 6 2 is activated This allows the digital output to be controlled by the idle feature The idle feature also requires a digital input to be set to Idle Mode see section 6 8 See section 5 5 on page 24 for more information on the Idle Mode feature This turns on the digital output if the Low Engine Temperature Warning section 6 2 is activated This turns off the digital output if the LCD backlighting turns off The controller enters the sleep mode section 5 3 when this occurs This turns on the output if the Auxiliary Warning Digital Input see Table 14 in section 6 8 is active This turns on the output if maintenance is required to be performed on the engine generator See section 6 11 This turns on the output if the controller is in the auto state with no User Manual for the GSC400 Series Automatic Gen Set Controller 61 of 98 warnings some warnings are ignored for this feature This turns on the output if the Common Fault feature is active See section 6 13 for more details This turns on the output if the Common Fault 2 feature is active See sect
79. ow Voltage During Cranking on the screen if during cranking the voltage drops below the Low Vol InCrank setting Note When the generator is running the battery voltage will equal the alternator charging voltage The actual open circuit battery voltage may be lower than displayed The GSC400 can be setup to automatically run the generator if the battery voltage goes below a certain point the Recharge Level setting The Charge Enable parameter must be set to Enable to enable the low battery recharge feature The ChargeDuration setting controls the length of time the generator will run before shutting down Note that the GSC400 does not have the capability of charging the battery to a specified voltage level User Manual for the GSC400 Series Automatic Gen Set Controller 65 of 98 6 10 Password Setup The GSC400 allows a 4 digit password to be entered to protect the advanced setup menu from any unauthorized changes This password will be needed DvnaGen to perform any changes to the advanced setup If the password is ADVANCED SETUE a BACK entered incorrectly the controller will ere Set allow 3 more tries before the GSC400 Vince returns back to the main menu wA Set Password To set each digit of the password do the following ni e Select Password No 1 Digit 1 gt Set Password Enter the desired number 0 9 Select Password No 2 Digit 2 Password No 1 Enter the desired numbe
80. p command is received the controller will proceed to the cool down mode then shutdown equipment REQUEST DM2 System operating mode OxBB44 0x93 0x96 0x99 Ox9C R Read Only Send a request to controller for reading the previous DTC codes If the controller read the previous DTC code success the data will be updated in the range of 40180 to 40244 This registers can hold maximum 32 DTC code The possible controller modes are MENU OFF SLEEP mode 0x90 144 OFF mode 0x93 147 AUTO mode 0x96 150 FAILURE mode 0x99 153 RUNNING mode Ox9C 156 When in controller menu OFF sleep mode if the controller is required to go to the AUTO mode a system disable command 40098 must be written User Manual for the GSC400 Series Automatic Gen Set Controller 86 of 98 followed by system enable command 40098 System Sub state The controller sub mode if applicable 19 DLY TO START 20 PREHEATING 21 CRANKING 22 WARM UP 23 CRANK REST 25 COOLDOWN 26 SHUTDOWN 27 IDLE RUNNING 31 IDLE COOL 32 REMOTE START RUN RSC contacts 33 Front Panel Run Manual Run 34 MODBUS RUN modbus start triggered 35 LOW BATTERY RUNNING 36 EXERCISER RUNNING 0 None of the above 0 corresponds to none of the above sub modes of operation Active Event message queue 0 255 R Read Only A maximum of 6 events warnings are stored concurrently One
81. pade terminals on the GSC400 3 Generator Output The GSC400 can also determine the engine speed indirectly from the generator frequency The voltage source of the generator must be connected to the SPEED 1 and SPEED 2 terminals Over speed warnings and failures as well as under speed warnings and failures can be set from the menu in terms of RPM The warnings and failures apply to all three options above For the magnetic pickup and generator output options you must select the rated frequency and rated speed The GSC400 uses these values together to calculate the engine speed from the magnetic input or generator output The rated speed is the speed in revolutions per minute RPM the engine runs at when producing power For example some generators run at 1800RPM while others run at 3600RPM The rated frequency is usually either 50Hz or 60Hz It is the frequency of the generator output when producing power For a magnetic input the rated frequency is determined by the number of teeth on the flywheel and is calculated by Rated frequency Number of teeth x Rated Speed 60 For the generator output option the rated frequency is normally the frequency of the generator 50Hz or 60Hz User Manual for the GSC400 Series Automatic Gen Set Controller 54 of 98 The AC Frequency AC Voltage and AC Current menus allow the measurement and display of the AC voltage current and frequency from the generator In the AC Frequency menu warni
82. r 0 9 e Select Password No 3 Digit 3 Enter the desired number 0 9 Password No 3 e Select Password No 4 Digit 4 Password No 4 Enter the desired number 0 9 Password No 2 Remember to write down the password for future reference The default Password No 1 password is all zeros You can only reset the password using the GSC400 PC Interface To reset the passwords click on Load Factory Defaults under File in the top menu This will reset ALL settings to their factory default so make sure to record the controller settings before doing this User Manual for the GSC400 Series Automatic Gen Set Controller 66 of 98 This menu controls the service feature that is used to alert the user of required generator maintenance and can be enabled or disabled from this menu If enabled the count interval menu allows the user to set the number of hours until next service The number of hours to next service is displayed in the Basic Setup menu under Maintenance see Table 5 on page 29 Once the count interval reaches 0 hours it displays a service message records an event in the Event History Log and continues to count down displaying negative hours in the Maintenance submenu until it is reset by the technician The reset counter submenu is used by the technician to reset the counter after service is performed The service feature does not count down to the next service until it is reset in this menu The GSC400 acts as a slave on a Modbu
83. re is Molex 0638190900 The extraction tool part number is Molex 011030044 which allows you to remove contacts from the Molex connector without damaging the contact The extraction tool is available from DynaGen part number ACC0097 User Manual for the GSC400 Series Automatic Gen Set Controller Load L 50 4 ae 3 Fuses Phase A le Use 1A 15 of 98 For user convenience pins 11 and 12 provide access to Battery Emergency Extra Relay Out Extra Relay Out Battery Glow plug or other device Battery Crank Out Fuel Out Fuel Relay Fuse F2 MPU CRANK pv Connect to generator mains for an Battery Use 12VDC relay for 12VDC alternative signal 12VDC or 24VDC battery use 24VDC relay for source 24VDC battery GSC400 LS HARDWARE USERS Note Pin 8 of the analog input terminal is ground not SV as indicated Stop Use switches to connect to Inputs A to H 22 7B E AC Voltage 8A B F G Configurable E Stop c Switched Start Stop 10 D H Inputs J5 Gnd 1 Remote Start A Gnd 1 Contacts To Battery ZE Configurable 6 1 Outputs 16 7 FA T ins Land 2 5 Switchedto 8168 or user convenience pie an Programming Grund 9H 4 10 provide access to Battery 7RS232 116 M V Bat 2 5 Analog Inputs Sp
84. rmation on senders If using the switch setting you must determine if the switch is of the normally open or normally closed type If it is normally open then you would select the Switch Closed Failure otherwise you would select the Switch Open Failure The factory default sender tables loaded in the GSC400 only support pins 3 and 4 If you need to use other pins you must use the GSC400 PC Interface Sender Utility Refer to the PC Interface manual on more information about the utility See the next section below If the Input Type is set to a switch in the Run Mode see section 5 3 on page 21 the controller will display SW in place of the value that would be displayed if it was set to J1939 or Sender A Bypass Time can be selected for each input After crank success the bypass period will start and during this period the controller will not enable the warning or failure Negative engine temperatures can be displayed on the GSC400 but any reading below 0 C 32 F is set to 0 C for warning and failure level detection purposes e g low engine temperature high engine temperature Same as 1 above User Manual for the GSC400 Series Automatic Gen Set Controller 51 of 98 checks for this input After the bypass period if there are any warnings or failures they will be triggered The controller will display a message and sound the alarm in the case of a warning or will shut down and sound the alarm in the case of a f
85. rporates many types of warnings and failures Some are only active in the RUN mode while others are also active in the AUTO and or OFF modes Warnings and failures can be triggered from a Digital Input Analog Input AC Voltage AC Current Speed Signal Input as well as others The Advanced Setup section of this manual will give more information of the specific warning and failures for each type of input When a warning occurs the second line the area under the time and date display of the LCD is used to display the warning text Also after the warning is displayed instructions are displayed showing the user how to silence the warning When in the AUTO or RUN modes the instructions are to press the Auto key and when in the OFF mode press the Off key When a failure occurs although most failures only occur in the RUN mode the Low Fuel Level and Low Coolant Level failures occur in any state including OFF and AUTO the controller exits the RUN mode and goes to the FAILURE mode turning off the Fuel output and other outputs on or off depending on the advanced settings and displays the failure message The alarm will sound and remain on until it is silenced by the user The Auto key can be pressed to silence the alarm Once the alarm is silenced it can be reset by pressing the Auto key and then the Off key This returns the controller to the OFF mode The failure is recorded in the event log accessible from the Basic menu This section only
86. rts the standard messages listed in the SAE J1939 specification Standard messages include oil pressure engine temperature and engine speed Some engine control modules have proprietary messages that are intended for specialized devices and are not displayed by the GSC400 To use J1939 go to the Signal Source submenu for each parameter see table below and select J1939 For example to use J1939 to display Oil Pressure you would go to the Advanced Menu go to Oil Pressure go to Signal Source and then select the J1939 option Table 9 GSC400 Engine Parameters High Engine Tmp Oil Pressure Fuel Level Oil Level Fuel In Basin Low Engine Tmp Negative engine temperatures can be displayed on the GSC400 but any reading below 0 C 32 F is set to 0 C for warning and failure level detection purposes e g low engine temperature The GSC400 can display extra parameters for the engines listed in the Manufacturer submenu No warnings or failures can be generated with this data To enable these messages go to the Display Group 1 and Display Group 2 submenus located in the J1939 menu If you have a different ECM manufacturer than listed under the Manufacturer menu the Display Groups 1 and 2 setting does not apply Table 10 lists the data parameters enabled for each group Table 10 J1939 Addition Parameter Display Options Engine Torque 90 Intake Temperature C
87. s where the voltage displayed on the controller is double the actual measured voltage Voltage Group 3 with the Group 3 Setting enabled is also useful in non center tapped Hi Wye and 4 wire Delta applications where the user wishes to measure a voltage greater than 600VAC the maximum voltage the GSC400 supports In this case the user can use a 2 1 potential transformer PT to step down the voltage to the GSC400 and still have the GSC400 display the correct voltage Voltage Group 4 has an option the Group 4 Setting submenu under the AC Voltage menu for four wire delta or three phases default The two different configurations are shown in Figure 8 The three wire delta requires three voltage transformers to create the neutral reference User Manual for the GSC400 Series Automatic Gen Set Controller 55 of 98 The GSC400 controller requires a neutral reference All voltages are measured line to neutral and then converted for display as line to line if required unless Voltage Group 1 is selected with the two wire option in which case only Line to Neutral is displayed A Three Phase 3 Wire Delta Three Phase 4 Wire Delta A N B C Figure 8 Three wire versus four wire delta generator configurations It is possible to automatically choose between each configuration by setting one or two of the digital inputs to Volt Select 1 and Volt Select 2 This allows the GSC400 to automatically re configure its voltage display as well as
88. s RS 485 network and can on request by the master device remotely transmit warning failure and event indications The device address and baud rate can be set from this menu See Appendix B Modbus Map for more communication interface details Common Fault 1 and Common Fault 2 menus contain tables of all the events warnings and failures available in the GSC400 controller and allows the user to select those to generate a trigger when active The trigger can be used to turn on a digital output store the status of the trigger active inactive to the Modbus Common Fault registers or both Both the common fault 1 and common fault 2 menus generate their own independent trigger and use separate modbus registers and digital outputs A digital output must be set to Common Fault Output 1 if using the Common Fault 1 menu or Common Fault Output 2 if using the Common Fault Output 2 menu to allow the trigger to turn on the digital output see section 6 6 Digital Output Setup Using the PC Interface the user can also mask the event warning and failure tables for each of the common faults For example the user can set the Common Fault 1 modbus register to respond to events warnings and failures and set the Common Fault 1 digital output to respond to failures only This configuration is not available in the front panel menu system the PC Interface must be used User Manual for the GSC400 Series Automatic Gen Set Controller 67 of 98 The
89. s the Cool Down feature to control the output The Cool Down duration is set in the engine logic menu See section 6 5 2 for more details This turns on the digital output when the Over Crank Failure is activated See section 6 5 1 for more details The number of crank attempts is set in the engine logic menu This turns on the digital output if the High Engine Temperature Failure is activated See section 6 2 for more details This turns on the digital output if the High Engine Temperature Warning is activated See section 6 2 for more details This turns on the digital output if the Low Oil Pressure Failure is active See section 6 2 or section 6 8 for more details This turns on the digital output if the Low Oil Pressure Warning is activated See section 6 2 for more details This turns on the digital output if the Under Speed Failure is activated See section 6 3 for more details This turns on the digital output if the Under Speed Warning is activated See section 6 3 for more details This turns on the digital output if the Over Speed Failure is activated See section 6 3 for more details This turns on the digital output if the Over Speed Warning is activated See section 6 3 for more details User Manual for the GSC400 Series Automatic Gen Set Controller 60 of 98 This turns on the digital output if the Low Fuel Failure is activated See section 6 2 for more details This turns on th
90. sion 1 Byte 1 8 most significant bits of 16 most significant bits of SPN Byte 2 8 least significant bits of 16 most significant bits of SPN Byte 3 3 most significant bits of byte contain the 3 least significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC Conversion Method Version 2 Byte 1 8 least significant bits of 16 most significant bits of SPN Byte 2 8 most significant bits of 16 most significant bits of SPN Byte 3 3 most significant bits of byte contain the 3 least significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC Conversion Method Version 3 Byte 1 8 least significant bits of SPN Byte 2 8 second byte of SPN Byte 3 3 most significant bits of byte contain the 3 most significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC conversion method 3 is the same as DTC conversion method 4 the new J1939 standard except that the CM bit is 1 so it is impossible to tell it apart from versions 1 and 2 Version 4 has the bit set to O which allows the user to know the conversion format without consulting the engine manufacturer User Manual for the GSC400 Series Automatic Gen Set Co
91. standard Modbus network offers 2 transmission modes for communication ASCH or RTU The GSC400 supports only the RTU Remote Terminal Unit mode Each 8 bit byte in a message contains two 4 bit hexadecimal characters The message is transmitted in a continuous stream with the LSB of each byte of data transmitted first Transmission of each 8 bit data byte occurs with 1 start bit and 1 stop bit Parity checking is none The transmission baud rate is user configurable and both baud rate and Modbus address can be altered during menu operation If altered the new baud rate and or address will not be seen until the after power is recycled on the GSC400 The GSC400 supported baud rates are 9600 19200 38400 and 57600 Firmware versions 1 38 to 1 46 support 1 generation Modbus registers Firmware version 1 50 and above supports both 1 generation as well as a generation registers For new applications it is recommended to utilize 2 generation modbus registers GSC400 supports two Modbus commands 0x03 Read Holding Register 4x and 0x06 Write Single Register To make the communication work user need to setup something in GSC400 setting to corresponding with the RSA unit In the GSC400 Advanced menu there is a menu SET Modbus user can setup the GSC400 device address and device baud rate there To use the 0x03 command to read the holding register the user will need to set the holding register start address quantity of bytes to read and t
92. start See Table 14 on page 62 for more information on the digital input features User Manual for the GSC400 Series Automatic Gen Set Controller 21 of 98 The GSC400 also has a dedicated emergency stop input that when open will stop the generator immediately and the controller will enter the OFF Mode see below for more information on the OFF Mode and remain in the OFF Mode until the emergency stop input is grounded While the emergency stop input is active the GSC400 will sound an audible alarm and display Emergency Stop on the LCD display See Figure 4 on page 15 for the location of the emergency stop input The GSC400 incorporates 3 primary modes of operation 1 OFF Mode 2 AUTO Mode 3 RUN Mode 1 OFF Mode When the GSC400 is set to the Off Mode automatic is starting will be disabled No TELA DynaGen automatic controls will be initiated The Off Mode may be initiated when no generator controls are required or when the SEE MODE BLED controller configuration requires adjustment The user can disable manual start in OFF mode in the un basic menu See section 5 9 2 9 00AM DEC 01 y FOR LAMP TEST All of the failures and most of the warnings are disabled when the controller is in Off Mode The controller will beep every few seconds to alert the user that the unit is in the Off Mode and cannot automatically start To silence this alarm press the off key as instructed on the screen In Off Mode you
93. t action User Manual for the GSC400 Series Automatic Gen Set Controller NS gt 14 of 98 The type and part number for each of the terminal connections are given in Table 1 Figure 4 on the next page shows the location of all terminals on the controller and the numbering of all circuits Table 17 on page 74 gives the part numbers of the various starter kit harnesses you can order from DynaGen Only commonly used circuits on each connector are populated i e connected with a wire on the harness Table 17 also lists the circuits i e pins that are included as part of the harness Table 2 lists the minimum wire size maximum current capacity name and function of each circuit The wire gages given in the table are the minimum recommended only To maintain UL rating the correct wire gauge as specified by UL must be used Table 1 GSC400 Terminal Information Manufacturer and Part Number Molex 39 28 1123 Molex 39 01 2120 Molex 39 28 1103 Molex 39 01 2100 Molex 39 28 1063 Molex 39 01 2060 Molex 39 28 1063 Molex 39 01 2060 Molex 39 28 1043 Molex 39 01 2040 Molex 39 28 1083 Molex 39 01 2080 Major League Electronics Amp 87227 5 TSHS 1 05 D 16 A C 2x5pin double header 0 1 spacing Keystone 4901 0 25 Standard 0 25 wide female wide quick connect The Molex connectors above require the following contacts Molex 39 00 0039 The hand crimp tool required to crimp the contacts to the wi
94. tak dense 12 4 3 GSC400 12 24 V DC System uuo 13 LOU MEIST DIE UU 13 432 SOA icu soi ea ie ee ee ees 13 852 ARS VA gos o moe EER EEA EE EE Ea 13 4 4 GSC400 Vernal 14 4 4 1 CAN Wiring 1980 19 442 Current Transformer CT Wiring 19 5 GSC400 Operation and Basic User Configuration 20 5 1 ce Me A 20 5 1 Controller Alarming HE 20 242 Remote Start Contacts Emergency 20 5 3 Controller States mL Ir 21 5 3 1 Locking the GSC400 Screen While in the Run 22 5 4 GSC400 Start Stop BebaviOE ema vi emp Fk icm Se dead 23 5 5 Idle Mode senan P 24 5 5 1 Commins Electronic Engine 1016 24 5 6 Generator Starting and SEODDITDIg cci ei e obi Irae 24 5 7 Controller anoressia arae EE eaea tU 24 5 8 GSC400 Menu System Operaton sais iccssscieseassseivessascaicesaanceadosstanaevasnasaxvancesaads 26 5 9 p 26 59 1 Eh e o e T 28 59 2 Basic SOUND opti too misi
95. the engine generator will first start After the first exerciser start the engine generator will start up on regular intervals given by the Repeat Freq which is measured in hours User Manual for the GSC400 Series Automatic Gen Set Controller E 62 of 98 Pre Alarm Delay V Repeat Interval Engine Run EE gt l Run Duration gt Engine Off Time Start Start Date Hour The exerciser feature depends on the GSC400 internal clock Make sure the clock is set to the proper time and date GSC400 internal clock information can remain in memory for approximately 2 weeks when no DC power is supplied to the controller Two week memory storage is available in a completely charged controller clock DC power is required to be supplied continually to the GSC400 for approximately 1 hour to allow a complete clock charge There are eight digital inputs Each input can be selected to any of the features given in Table 14 below Table 14 Digital Input Selections This input generates a Low Air Pressure failure when active only in Crank It is ignored in the OFF AUTO and RUN modes This input generates a Low Hydraulic Pressure failure when active only in Crank It is ignored in the OFF AUTO and RUN modes This input generates a Low Oil Pressure failure when active only when the controller is in the RUN mode If the generator is starting up but is not running i e the controller is not in the RUN Mode and if the
96. the Auto mode press the OFF key to immediately enter the Off mode or press the Enter key to enter cool down If no key is pressed the GSC400 will remain in the Run mode If the OFF key is pressed during another start condition e g Modbus Run a cool down popup will appear again but in this case the only option is to press the OFF key to immediately enter the OFF mode User Manual for the GSC400 Series Automatic Gen Set Controller 24 of 98 For generators that have the capability of idling at a lower speed than the normal operating speed the GSC400 controller has an Idle Mode feature that suppresses the warnings and failures for under voltage under frequency and under speed The GSC400 displays Idle Running when this feature is enabled The controller remains in Idle Mode as long as the Idle Mode digital input is active See Table 14 on page 62 for more information on the digital inputs If the user desires a digital output to turn on during Idle Mode the Voltage Regulator digital output can be used It is active when the controller is in Idle Mode and inactive when the controller is not in Idle Mode See Table 13 on page 59 for more information on the digital outputs The output is usually used to turn off the generator voltage regulator but can be used for any purpose For users who have engines that idle during warm up and or cool down See section 6 5 on page 57 for more information on the Warm up and Cool down featur
97. the generator This performs the same function as the remote start contacts An Auxiliary Failure is generated when the input is active This can occur in the Off Auto Cranking and Running states An Auxiliary Warning is generated when the input is active This can occur in the Off Auto Cranking and Running states A Charger 1 Fault warning is generated when the input is active A Charger 2 Fault warning is generated when the input is active A High Fuel Level Warning is generated when the input is active These inputs when active generate a warning failure and a configurable text message is displayed to the screen when the input is active The text message can only be configured from the GSC400 PC Interface The length of the message is limited to 15 characters The user can control the states in which these features are enabled The selections are 1 Global Everywhere 2 Crank From start of delay to start to the end of cranking 3 Run RUN Mode only 4 Crank Run Combination of 2 and 3 above These settings are located at the bottom of the menu for each input User Manual for the GSC400 Series Automatic Gen Set Controller 64 of 98 The Battery menu allows the user to set the low and high battery warning and failure levels In addition the generator can be made to automatically start when in the AUTO state if the voltage drops below the Recharge Level The controller will display L
98. umber 0012450 would be stored as follows 40092 MSB 0 40092 LSB 0 40093 MSB 1 40093 LSB 2 40094 MSB 4 40094 LSB 5 40095 MSB 0 40095 LSB NOT USED SYSTEM DISABLE OxSDA2 W When 0x5DA2 is written to address 23970 40098 this places the controller in the OFF mode System disabled The register is read in all controller operating modes Running Auto Failure Menu sleep modes CAUTION when received in the Running mode the controller immediately goes to the OFF mode no cool down is performed When received in failure mode this will reset the system failure and revert to the OFF mode SYSTEM ENABLE 0 5 4 W When Ox5BAd is written to address 23460 40098 this places the controller in the User Manual for the GSC400 Series Automatic Gen Set Controller 85 of 98 AUTO mode waiting to start The register is read only in the OFF mode of operation and ignored in all other operating modes START 0x9768 38760 When 0x9768 is written to address 40098 this initiates an automatic start This register is only read in the AUTO mode of operation and is ignored in other modes STOP 0 57 8 22440 When 0x57A8 is written to address 40098 this initiates a shutdown stop of the equipment This register is only monitored when the system is running start signal received and is ignored in all other operating modes When cool down is enabled and a sto
99. warning shutdown trip points relating to AC voltages and currents This is useful for mobile generators where the voltage selections can be selected via a CAM switch Warning The Voltage Select Inputs override the Voltage Group submenu parameter in the AC Voltage menu User Manual for the GSC400 Series Automatic Gen Set Controller 56 of 98 Table 12 Voltage Select Inputs 1 Phase 3 wire 2 wire option Open Circuit also selectable 3 Phase 4 wire Wye ACTIVE Open Circuit 3 Phase 4 wire Open Circuit ACTIVE 2x display voltage option also selectable 3 Phase 4 wire Wye ACTIVE ACTIVE 4 wire Delta option also selectable Tf Digital Input Pin A B C or D is used then ACTIVE is defined as a switched to BAT connection If Digital Input Pin E F G or H is used then ACTIVE is defined as a switched to GND connection Open Circuit NOTE If only a single AC Group Sel function is selected then the remaining unassigned AC Group Sel is equivalent to an Open Circuit in the above table The GSC400 controller is designed to measure AC current from the generator with the use of current transformers CTs The maximum current on the AC current terminals of the GSC400 is limited to 5A The Turns Ratio sub menu is used to setup the CT ratio All numbers in this menu are in terms of 5A For example select 1000 means 1000 5A which in turn means the GSC400 displays 1000A on the screen wh
100. y load digital output feature bit7 High fuel level warning bit8 Over current latch AC Current feature bit9 User configurable warning 1 digital output feature bit10 User configurable warning 2 digital output feature bit11 User configurable failurel digital output feature bit12 User configurable failure 2 digital output feature bit13 to bit15 Reserved bitO to bit4 Reserved bit5 Low oil level failure bit6 Low air pressure failure digital input bit7 Low hydraulic failure digital input bit8 Auxiliary input failure bit9 Low battery level failure bit10 High battery level failure bit11 AC over voltage failure bit12 AC under voltage failure bit13 AC over current failure bit14 J1939 Loss of ECM failure bit15 EPS load failure User Manual for the GSC400 Series Automatic Gen Set Controller 84 of 98 GSC400 hardware 1 00 9 99 R Version format is X YY Decimal format where X repr sensum ATS ormat where X represents a number from 1 9 and is stored in the high byte GSC400 firmware 1 00 9 99 R of 40090 YY represents a decimal version number number from 00 to 99 and is stored in the lower byte of 40090 GSC400 serial 4to7 R The serial number is stored in 7 digit mimber TERR decimal format with the high byte of register 40092 containing the high MSB and the low byte of register 40095 containing the LSB Unused characters are stored as zeros For example serial n

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