GSC102 User Manual R2.0
Contents
1. TECHNOLOGIES INC DynaGen GSC102 Auto Start Engine Controller Installation and User Manual for the GSC102 Auto Start Engine Controller Full Version File GSC102 12_R2 doc November 14 2006 LIMITED WARRANTY POLICY The Seller warrants articles sold hereunder to be free from defects in material and workmanship These express warranties are the sole warranties of the Seller and any other warranties expressed implied in law or implied in fact are hereby specifically excluded The Seller s sole obligation under its warranty shall be at its option to either issue a credit or repair or replace any article or part thereof which is proved to be defective Any adjustment of credits will be based upon original billing prices All warranties shall expire 5 years from date of shipment by the Seller unless otherwise specified in other written communications from the Seller Any replacement product provided to the Buyer shall be subject to the original warranty period which will expire 5 years from the date of shipment of the original article Notice of claimed breach of warranty must be given within the applicable period No allowances shall be made to the Buyer for any transportation duties brokerage fees labor costs or parts adjustments or repairs or any other work unless said charges are authorized in writing in advance by the Seller The Seller shall in no event be liable for special or consequential damages or for loss of profit2. 350mA Common Ground for annunciation output loads 16 18 300mA General Failure Output 17 18 300mA Engine Run Output 18 18 300mA Overcrank failure to start Output 19 18 300mA Low Oil Pressure Output 20 18 300mA High Engine Temperature Output 21 18 300mA Overspeed Output 22 18 300mA Low Battery Output 23 18 300mA Underspeed Output 24 18 350mA Common Ground for annunciation output loads Operating amp Installation Manual for the GSC102 12 Engine Controller WIRING GUIDELINES 1 DO NOT use wire smaller than 18 AWG as smaller wire has a tendency to crack and break over time 2 The connections supplying DC power to the GSC102 12 panel should preferably run directly from the battery posts with no splices or other connections Avoid as much as possible using chassis aluminum or iron engine parts as return conductor for battery negative voltage copper wiring is recommended Failure to follow the above may result in erratic operation due to large voltage drops across wiring connections 3 DO NOT exceed the maximum rated current and voltage on each of the controller outputs Do not exceed 1A for the Fuel and Crank Outputs Do not exceed 300mA for the General Fault Output or any annunciation outputs Do not exceed 500mA for annunciation outputs combined 4 The fuel and crank outputs do not provide short circuit protection DO NOT short Crank Output or Fuel Outputs to ground This will cause damage to the control board
3. Fuel Output provides 1A maximum Fuel Output closes to 12 VDC when start signal is initiated and opens when either an engine failure is detected or when stop signal is applied Oil Pressure Switch For proper operation oil input must be connected to ground or 12VDC via an oil switch This switch must be the N O type close on failure low pressure Temperature Switch For proper operation temperature input must be connected to ground or 12VDC via a temperature switch This switch must be the N O type close on failure high temperature Annunciation common ground Common ground for annunciation outputs only Do not exceed 500mA combined on all annunciation outputs General Failure Output Do not exceed 300mA Engine Run Output Do not exceed 300mA Overcrank Output Do not exceed 300mA Low Oil Pressure Output Do not exceed 300mA High Engine Temperature Output Do not exceed 300mA Overspeed Output Do not exceed 300mA Low Battery Output Do not exceed 300mA Underspeed Output Do not exceed 300mA Annunciation common ground Common ground for annunciation outputs only Do not exceed 500mA combined on all annunciation outputs P 16 19 20 N 2 23 4 N Term Ea ce 4 Ie L202 20 22 B lt Operating amp Installation Manual for the GSC102 12 Engine Controller Wiring Connection Diagram GSC102 12 A A Ah A Operating amp Installation Manual f
4. If protection is required for short circuit conditions it is advised to install a Fuse on each of the individual controller outputs to protect the control board 5 DO NOT use AC coil slave relays from controller outputs Use intermediate relays of suitable size and coil rating 6 To verify the operation of engine controller outputs measure voltage i e meter in volts when outputs should be ON 7 There is an internal diode connected between AUTO and Start Stop terminals This diode provides the capability of starting and running the engine generator system when battery is only supplied to the Start Stop terminal This diode is provided for compatibility with AUTO OFF TEST switch configuration If a wiring fault occurs such that battery is connected to Start Stop terminal and Battery Ground is connected to AUTO terminal this will cause a short circuit to be applied across the controller terminals and result in damage to control board We recommend the installation of a fuse on the main battery connection wired to AUTO OFF TEST switch A 3A fuse is recommended in this line 8 The Low oil pressure and High engine temperature sensors must be the switch type In the case of the oil pressure switch it would be open during normal engine run i e oil pressure ok and close to either ground or battery on low oil pressure failure similarly the high engine temperature switch would be open during normal engine conditions and close to ground or batte
5. Pressure Failure check engine oil Steady High Temperature LED Over Temperature Failure check coolant Steady Overcrank LED Engine would not start after specified Crank tries Check fuel supply and check starter to confirm it is operating correctly Steady Overspeed LED Speed signal present above Overspeed setting Check engine governor and verify AC frequency Underspeed LED The speed signal was below 53 HZ while Was Engine Cranking running The engine has stalled the speed signal has been lost or the engine Was Engine Running generator was overloaded Steady Engine Running LED Engine controller is in running mode of operation Flashing Engine Running LED Crank Rest period OR TDES period WARNING Cranking will resume begin soon Operating amp Installation Manual for the GSC102 12 Engine Controller powered to Test mode Engine does not crank Engine cranks but does not start Engine starts but shuts y down after Oil Bypass period due to low oil high temp Annunciation output not working Underspeed failure LED on Solid oil LED immediately on start up without engine actually cranking or starting 13 TROUBLE SHOOTING TIPS TROUBLE POSSIBLE CAUSE SUGGESTED ACTION Unit does not operate when Power leads to unit are reversed TA correct wiring for ground and battery and re attempt testing Bad ground connection from engine to controller unit Battery Voltage is too low T wir
6. illuminated Bypass timer period 7 HIGH TEMPERATURE INPUT The High Temp Input can close to Battery or to ground to initiate a failure The engine temperature switch must be the type that is NORMALLY open while running and closes on failure high engine temperature Note high engine temperature monitoring is only enabled 15 seconds after the engine has started and GREEN running LED is illuminated Bypass timer period 8 LED TEST Automatic LED test is provided on power up of the controller unit When power is applied to AUTO terminal the controller flashes all the front panel indicating LED s 3 times allowing the user to verify the functionality of the LED s As an alternative an LED test switch can be connected to the controller unit which allows means to turn on all the front panel LED s This LED test terminal must be switched to battery to illuminate all the LED s 9 SPEED SIGNAL SENSITIVITY The controller will accept up to 300 VAC 60 Hz from Direct Generator Output for speed sensing The following values are minimal recommended voltages for speed signal sensing 20 HZ 075 V 75mV 60 HZ 6V 600mV 10 TIME DELAY ON ENGINE START T D E S The GSC102 12 has a feature which provides a delay before the engine is started this feature is provided to prevent nuisance starting of the engine generator system during brief power outages The Engine Run LED will flash during this delay The Time Delay on Engine S
7. The warranty shall not extend to any articles or parts thereof which have been installed used or serviced other than in conformity with the Seller s application specifications manuals bulletins or instructions or if none shall have been subjected to improper installation misuse or neglect The warranties shall not apply to any materials or parts thereof furnished by the Buyer or acquired from others at the Buyer s request and or to the Buyer s specifications or designs The foregoing limitations on the Seller s liability in the event of breach of warranty shall also be the absolute limit of the Seller s liability in the event of the Seller s negligence in manufacture installation service or otherwise with regard to the articles covered hereby and upon the expiration of the stated warranty period all such liabilities shall terminate 7 RETURNS If any article is claimed to be defective in material or workmanship the Seller upon notice promptly given will issue a written return material authorization RMA with shipping instructions for return to the Seller All returns must be accompanied by an RMA number or shipments will not be accepted by the Seller Articles which are returned as defective but are found to meet the specifications agreed upon will be subject to a re testing charge At the discretion of the Seller unused and undamaged Standard Products may under certain circumstances be accepted back for credit or excha
8. d Failure is triggered The controller will shut down the engine locking out the engine from further starting The RED Underspeed LED will be illuminated and the General Failure Output will be energized To reset the fault power must be removed from the AUTO terminal and then re applied NOTE Underspeed failure verification is only enabled 30 seconds after the engine has started and GREEN running LED is illuminated Operating amp Installation Manual for the GSC102 12 Engine Controller 10 4 NOT IN AUTO When there is no power applied to the AUTO terminal and 12 VDC maintained to the NOT IN AUTO terminal the RED NOT IN AUTO LED will illuminate NOTE Battery must be permanently connected to the NOT IN AUTO terminal for the NOT IN AUTO condition and LED indication to function properly 5 LOW BATTERY VOLTAGE In the event the battery voltage drops below 11 VDC the engine controller displays a Low Battery condition The Low Battery Voltage condition can occur when the AUTO OFF TEST switch is in the AUTO or START STOP conditions but not while the unit is in the cranking mode or in failure mode 6 LOW OIL INPUT The Low Oil Input Pressure input can close to Battery or to Ground to initiate a failure The oil pressure switch must be the type that is NORMALLY open while running and closes on failure low oil pressure Note Low Oil Pressure monitoring is only enabled 15 seconds after the engine has started and GREEN running LED is
9. e directly from battery to the ground terminal 110n main e controller unit To verify low battery wait 10 to 20 seconds and see if Engine Run light flashes re charge battery indicating Crank Rest Measure battery voltage appearing on Bad ground connection from engine to controller Slave relay on crank damaged or in line fuse is blown AUTO position Battery is low or terminals are dirty Clean terminals and re charge battery Crank circuitry wiring improperly Refer to engine control wiring section and connected check crank connections Run wire directly from battery to the ground terminal 110n main connector on controller unit Check wiring slave relay and fuse re test controller again properly check ignition connections Oil Temp input wiring improperly connected Fault short or overload on one of the annunciation outputs Speed signal improperly connected missing or damaged Crank output damaged not working Starter or starter solenoid damaged Generator overloaded while running False Speed Signal being detected by controller This problem can sometimes occur in installations where there is AC power from inverters near generator output lines connected to the speed signal wires Check wiring for proper connections Disconnect oil pressure and engine temperature wires and confirm the switches are open during normal engine operation Check wiring for fault The annunciation out
10. m the secondary of the transformer are connected to the two wires of the speed sensing terminals on the GSC102 12 controller The step down transformer acts to reduce the false speed signal on the line to a level that the engine controller will not recognize as the engine running A common size transformer that would serve this purpose would be 24VA Step Down Trensfonmer Connections On Speed Sensing Cable 12VAC secondary Step Down Tronstormer Ee a ll winding es as Fe ae 5 To Generator Outat we Line Neuiral 120V AC Twisted pair of wires Connected bo Speed sereng lerias on GS 1m Operating amp Installation Manual for the GSC102 12 Engine Controller
11. nals to appear on wires that are near any power lines being fed by the inverter If the generator output wires are located close to a line being powered by an inverter a small AC signal can appear on the generator output lines when the inverter is on This can fool the engine controller into thinking that the engine generator systems is running if the speed sensing wires are connected to the generator output lines This small AC signal can cause the controller to appear to have a Low Oil Failure when the remote start contacts are closed or the controller is put in the manual test mode The controller may think the generator is already running and immediately check to make sure there is oil pressure Since the engine really hasn t started yet there is no oil pressure and the controller sees a low oil fault This is seen as the Oil LED turning on solid even before the engine starts to engage the starter Without this false speed signal the controller will not look for oil pressure until 15 seconds after the engine has started to run and the crank disengages The false speed signal can be eliminated by installing a small transformer between the generator output and the speed sensing terminals of the controller This transformer should be rated for 120 or 240 volts on the input or primary coil depending on the generator output voltage you are using for speed sensing and have an output voltage of around 12VAC on the secondary of the transformer The two wires fro
12. nge A restocking charge of 15 will apply Unused custom designed products will not be accepted back for credit or exchange For questions or comments regarding this product contact DynaGen Technologies Inc Phone 902 562 0133 Fax 902 567 0633 Email sales dynagen ca WEB SITE www dynagen ca Operating amp Installation Manual for the GSC102 12 Engine Controller Operating VDC Limits Quiescent Current Draw Battery Current Draw Operating Current Draw Reverse Polarity Protected Speed Sensing Input Accepts Speed Sensing Maximum Rating Operating Temperature Range Operating Humidity Range Fuel amp Crank Contact Output Annunciation and Fault Outputs Lamp Test Terminal Actual Unit Weight Shipping Weight Unit Dimensions Shipping Dimensions SPECIFICATIONS 5 0VDC min 16VDC max 8mA Auto position 1 2mA Auto position 140mA at 12VDC Internal protection will prevent damage to unit under a reverse polarity condition Re connect power leads properly and normal operation will resume Generator AC Output Directly Withstands Line Voltage 300 V A C 40 C gt 85 C 0 gt 95 Non condensing 1A max continuous Switch to battery when energized 300mA max per output Continuous Switch to battery when energized Switch to battery to test LED s 138 1b 148 1b 1 lb complete in packaging carton 4 W x 4 75 L x 0 75 D 4 5 W x 7 6 L
13. or the GSC102 12 Engine Controller A Circuit Board Arrangement GSC102 12 Operating amp Installation Manual for the GSC102 12 Engine Controller CONTROLLER OVERVIEW The GSC102 12 is manufactured with the following functions Controller Settings Failure Conditions Underspeed Not In Auto Low Battery Voltage Low Oil Input High Temperature Input LED Test Speed Signal Sensitivity 10 Time Delay on Engine Start 11 Cool Down CH NIAAARWNS 1 CONTROLLER SETTINGS The GSC102 12 has the following fixed settings Crank Disconnect Setting 20 Hz Overspeed Setting 69 Hz Crank Tries 3 Crank Rest Settings 10 seconds crank 10 seconds rest NOTE If the speed of the controller does not go to zero during Crank Rest the controller will wait until the speed goes to zero before re initiating the cranking sequence 2 FAILURE CONDITIONS The following conditions can cause the unit to enter a failure condition Low oil pressure Indicated by solid RED low oil pressure LED High engine temperature Indicated by solid RED high engine temperature LED Overcrank failure to start Indicated by solid RED Overcrank LED Overspeed Indicated by solid RED Overspeed LED Underspeed Indicated by solid RED Underspeed LED The General Fault Output is rated at 300mA maximum 3 UNDERSPEED The GSC102 12 is equipped with an Underspeed function If the speed of the controller falls below 53 Hz for a period of 2 5 seconds an Underspee
14. puts do not provide short circuit therefore there may be damage on control board if short is discovered on annunciation output damaged speed signal source Check wiring and replace controller if necessary Replace repair damaged starter or starter solenoid Turn off loads and restart generator Install a small step down transformer between the speed sensing wires and the generator output If the neutral from the generator output is not grounded attach it to ground Operating amp Installation Manual for the GSC102 12 Engine Controller 14 TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS 1 Controller Memory Reset Time The engine controller needs time for it s memory to reset If one was to turn the power to the controller off and then back on again without waiting a few seconds to clear the memory an underspeed condition will be indicated because the controller still thinks it is in run mode and sees that the generator has stopped This would be indicated by a solid underspeed LED If the controller is left OFF for several seconds before it is put into auto the memory will be cleared and it will function normally 2 Step Down Transformer Use On Speed Sensing Cable With Inverter Systems In some applications engine controllers are used on generators where there is no utility connection and inverters are used to provide AC power instead of a utility Inverters can produce harmonics that can cause small AC sig
15. ry on high engine temperature failure 9 Speed sensing input terminals do not have polarity sensitivity therefore the AC generator output leads can be connected in any polarity configuration to the controller speed sensing terminals Do not exceed 300VAC on speed sensing input terminals Operating amp Installation Manual for the GSC102 12 Engine Controller Controller terminal connections Term 1 battery connection to controller module 2 3 Crank Output provides 1A maximum Crank Output closes to 12VDC during cranking and opens when the engine has started or during crank rest 4 Start Stop Terminal When 12 VDC is applied the controller proceeds to initiate starting the engine 5 Auto Terminal When 12 VDC is applied the controller is in the standby mode waiting for a Start Stop signal General Failure This output is energized when a controller fault condition occur This terminal switches to battery when energized Do not exceed 300mA 7 Speed 1 Speed signal input for Crank Disconnect Engine Run and Overspeed sensing 300 VAC max Input voltage Speed 2 Speed signal input for Crank Disconnect Engine Run and Overspeed sensing 300 VAC max Input voltage Lamp Test Connecting 12VDC to lamp test activates all front panel LED s Note there is Automatic Lamp test provisions on power up which can eliminate the need for external lamp test switch connection directly from the battery is required for proper operation
16. tart can be enabled by cutting the RED TDES jumper on the GSC102 12 The TDES time delay is fixed at 10 seconds when the jumper is cut Operating amp Installation Manual for the GSC102 12 Engine Controller 11 11 COOL DOWN The GSC102 12 has a special feature of a Cool Down period which allows the engine generator system to continue to run after the stop signal has been received Note power must be applied to AUTO terminal for cool down timer to function correctly This feature is provided to allow the engine generator system to run unloaded for a period of time The Cool down timer is fixed at a 2 minute delay The Cool Down timer can be disabled by cutting the White Cool Down jumper on the GSC102 12 With the jumper wire cut the Cool Down is disabled and the unit will shut off the engine as soon as the stop signal is received LED LAYOUT Front View Component Side of Board GSC102 stosta engine contreier HIGH WATER TEMPERATURE OVERCRANK FAIL TO START OVERSPEED ENGINE RUNNING UNDERSPEED LOW OIL PRESSURE NOTIN AUTO LOW ENGINE BATTERY Operating amp Installation Manual for the GSC102 12 Engine Controller 12 LED INDICATIONS FRONT PANEL LED INDICATIONS Not in Auto LED is ON Unit does not have 12 VDC to Auto terminal but has 12 VDC to the Not in Auto Terminal No LED s ON OFF no 12 VDC to Auto or Not in Auto terminal Engine Cranking but not running Steady Low Oil LED Low Oil
17. x 1 25 D Specifications May change without notification Operating amp Installation Manual for the GSC102 12 Engine Controller WIRING INSTALLATION GUIDELINES Danger Never work on the engine while its power is on This controller does not generate a warning signal prior to automatic engine start Warning signs should be placed on engine equipment indicating this important safety measure INSTRUCTIONS Following these instructions will help avoid common installation problems during wiring and setup e Battery must be disconnected before any wiring connections are made e Wire length from the engine to the controller should not exceed 6 meters 20 feet Wiring size and type should be as specified below Use stranded wire since solid wire has a tendency to crack break and loosen over time TYPES AND SIZES Terminal Wire Size Current max Function 1 18 100mA Battery Main Power connection 2 18 Not Used 3 18 1A Starter Solenoid Pilot Relay 4 18 3A Start Stop Connection 5 18 3A Auto Switch 6 18 300mA General Failure 7 18 100mA Speed Signal Connection 8 18 100mA Speed Signal Connection 9 18 Not Used 10 18 100mA External LED Test Switch there is an automatic LED test feature on startup 11 18 3A Battery Ground 12 18 1A Fuel Solenoid Pilot Relay 13 18 TmA Oil Pressure Switch 14 18 TmA High Temperature Switch 15 18
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