GSC300 User Manual R2.12
Contents
1. 5mm CRANK 12VDC EE 5mm CRANK 24VDC S RELAY RELAYS RELAY RELAYS s m 14 FT bA 14 FUEL 1 N FUEL D LL IRA gt RELAY n gt RELAY 11 o 12VDC RELAYS MUST 24VDC RELAYS MUST BE INSTALLED FOR 12VDC BE INSTALLED FOR 24VDC SYSTEM OPERATION SYSTEM OPERATION Figure 1 The GSC300 controller is designed to operate in either 12 or 24VDC system voltages When operating in 12VDC systems the Fuel Crank and Preheat ETS relays need to be the 9 of 28 12VDC relay type When operating in 24VDC systems these relays need to be the 24VDC relay type Contact the factory if relays are required Approved relays for 12 or 24VDC system operation are as follows e AZETTLER AZ973 1C 12DC for 12VDC operation e AZETTLER AZ973 1C 24DC for 24VDC operation Table 3 GSC300 Terminals Fuel Output provides 12V 30A or 24V 20A maximum Fuel Output closes to 12 24VDC when start signal is received and opens when either an engine failure occurs or when Cool Down period has ended Battery Positive Terminals Main Battery power connection to controller These terminals are internally connected together on GSC300 controller Crank Output provides 12V 30A or 24V 20A maximum Crank Output closes to 12 24VDC during cranking and opens when the engine has started or during Crank Rest Main Battery Ground connection for the controller mod2. Programming the GSC300 requires a special USB programmer supplied by Dynagen The part number is GSC300 USB PGMR Detailed instructions on the PC interface are included with the GSC300 Configurator software A sample interface screen is illustrated on the following page General Programming Notes 1 The GSC300 must be unpowered when programming Ensure it is not connected to battery or other power source Parallel Port Programming Note 1 The parallel port programmer has been discontinued 2 Black wire should face towards center of GSC300 USB Programming Note 1 Blue wire should face towards centre of GSC300 2 If the presto ON LINE LED it not lit and the presto USB cable is plugged in the USB drivers did not properly install Go to the device manager and locate ASIX PRESTO Programmer under Universal Serial Bus Controllers Right click on it and select Update Driver or similar The drivers are located in the directory you installed the PC Interface to For Vista and 7 they should have been placed on your desktop during installation Both the parallel port and USB programmers directly power and program the EEPROM on the GSC300 The GSC300 on board microcontroller is not involved so it is not simple serial communications like the GSC400 20 of 28 Sample Screen from PC Interface NOTE Factory default settings are outlined in the photo below GSC 300 Configurator File Options Help Switch Sender OIL
3. dl j 19 7 armup f 5 ETS Relay Speed m Sensing 09 N Crank R Relay Battery Contacts 3 N Fuel PC Config Relay 119 H U8 J Annunciator 7 Outputs Internal Battery General Failure lt 18 Auto 17 Engine 16 Low Battery 15 Low l4 High Tem 13 Overspeed 12 Overcrank lt 1 GSC300 Wiring Diagram DWG1461R1 0 Figure 2 GSC300 System Wiring Diagram BATTERY GROUND BATTERY GROUND STARTER OUTPUT BATTERY BATTERY FUEL OUTPUT CRANK O RELAY gt 5 FUEL gt RELAY A RELAY 9 10 SPEED SIGNAL INPUTS PROGRAMMING CONNECTOR ON OFF MODE SWITCH Figure 3 Note fuses 30 not 40 14 of 28 22 AUX SWITCH INPUT 21 TEMP SWITCH INPUT 20 OIL SWITCH INPUT 19 REMOTE START INPUT 18 GENERAL FAIL OUTPUT 17 NOT IN AUTO OUTPUT 16 ENGINE RUN OUTPUT 15 LOW BATTERY OUTPUT 14 LOW OIL OUTPUT 13 HIGH TEMP OUTPUT 12 OVER SP
4. DYNAGEN contro solutions you can trust GSC300 Auto Start Engine Controller Revision 2 12 LOW PRESSURE HIGH WATER TEMP Installation and User Manual for the GSC300 Auto Start Engine Controller File MAN 0039 R2 12 GSC300 User Manual doc June 2014 2 of 28 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 Limited Warranty For warranty information refer to the standard terms and conditions of sale at http www dynagen ca Dynagen GSC300 Webpage For up to date manuals and other information please see the GSC300 section of the DynaGen website at www dynagen ca products GSC300 htm or www dynagen ca support GSC300 Specifications 3 of 28 Operating Voltage Current Consumption 7 to 30VDC continuous Zero volts operation for 100mS assumes supply was 12VDC before initiating starting Standby current 40mA Operating Temperature 40 C to 70 C LCD Display operates from to 16 C to 70 C Physical Dimensi
5. 21 uri Mer m eae 7 22 MPH 7 2 3 390300 12 24VDC System 8 2 4 Terminal CT 9 2 5 System Wiring 12 26 n mt 14 3 Controller iced o EE 15 Sd ORE AUTON RUIN MOdES DR NS ERE NN 15 General Failure Conditions n ems 15 3 3 HAGUE oom 16 or EEG op e e n 16 39 LED T 17 3 6 LED aeo etuer 18 4 Programming ihe G9U300 snis rom cun a aa 19 5 Troubleshooting Guidelines 21 6 Technical Notes and FAQ OT 22 6 1 Controller Memory Clear MUN omm 22 6 2 Step Down Transformer Use On Speed Sensing Cable With Inverter Systems 22 6 3 Pulland Hold COM i 23 6 4 Emergency Stop 23 6 5 Automatic Start on Low Battery 23 6 6 GGP300 Panel Optional ES DE 24 6 7 GSC300 Cutout Template 2
6. Sensor Type Delay 5 Switch Sender 3 NC Setpoint TEMPERATURE Sensor Type Delay 5 nec wi B s Switch Sender FUEL Sensor Type Delay s mmu n s Switch Sender Parallel Port User Settings DEM Settings GSC CONTROL Crank Disconnect Overspeed 22 Disable Temp Setpoint degF Oil Setpoint psi Delay To Start sec Preheat Time sec Crank Time sec Cooldown Time sec 10 6 4 Rest Time Speed Sensing Restart On False Start Enable Disable Geno p Midheat Postheat C Enable Disable Crank Tries B Battery Voltage 103 Oil Bypass Time sec 10 Warmup Time sec Enable Extra Relay C ETS Preheat Fuel During Crank Rest On C Off The speed sensing magnetic pickup setting only supports frequencies up to 3000Hz Figure 5 Read GSC Data Store GSC Data Set Port Address Read GSC Data Store GSC Data Dther Tasks Save to Disk Load From Disk Change Messaging Power leads to unit are reversed Bad ground connection from engine to controller unit Improper Overspeed setting Battery is low or terminals are dirt Crank circuitry wiring improperly connected Bad ground connection from engine to controller Crank relay damaged Or on board fuse is blown Out of fuel Ignition control wiring not installed roperly Fuel relay and or fuse damage
7. and then stopped the running time is stored in permanent memory and then adding to the next running period The same would be true if the controller were to enter a failure mode as the controller would permanently store the remaining time for the next running cycle The maximum hour count is 99 999 9 hours after which it will continue to display 99 999 9 indefinitely If a switched output is overloaded it will go into a fault state and turn off You must remove power to the GSC300 for 30s to reset the outputs 17 of 28 3 5 LED Layout Front View of GSC300 LOW OIL PRESSURE DYNA HIGH WATER TEMP you can trust OVERCRANK OVERSPEED ENGINE PARAMETERS 1 3 ENGINE RUNNING LIN LOW ENGINE BATTERY ENGINE STATUS HOURS PREHEAT ETS NOT IN AUTO isranTING DISABLED Figure 4 18 of 28 The GSC300 does not have a LED lamp test feature Table 4 Front Panel LED Indications Unit is in OFF state and automatic starting is disabled OFF no 12 24VDC to main power terminal Engine generator failed to start after the specified number of cranking attempts Speed Signal present above Overspeed setting The speed signal was Zero while running The engine has stalled overload or lack of fuel or the speed signal has been lost operation resume soon 19 of 28 The GSC300 cannot be powered while using the parallel port or USB programmer The GSC300 could be damaged
8. 6 6 of 28 The GSC300 series catalog order number provides information pertaining to a specific model The Product Number Identification Table see Table 1 provides details on the breakdown of the model number Table 1 Identification Table GSC300 L Low 12 12VDC LS Standard GSC300 H High consult 24 24VDC LX Customized factory Example The product number GSC300 L 12 LS would be described as follows GSC300 series automatic engine controller configured for a 12 VDC system The controller is factory configured for low speed range generator speed range which includes standard labeling A GSC300 serial number would be displayed as GSC300 L 12 LS 00000 7 of 28 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 See section 6 7 on page 26 for the GSC300 mounting dimensions The maximum torque is 7in Ibs for the three GSC300 mounting screws The screws are zinc platted 8 32 X 5 16 machine screws Following these instructions will help avoid common installation problems during wiring and setup Table 2 Wiring Sizes 12 12V 30A 24V 20A Fuel Output Terminal 12 12V 30A 24V 20A Auto Battery Terminal Connection 12 12V 30A 24V 20A Auto Battery T
9. ED Overcrank Overcrank failure is indicated by a steady on RED Overcrank LED Overspeed Overspeed failure is indicated by a steady on RED Overspeed LED Loss of Speed SPDLOSS Loss of speed signal is indicated by a flashing RED Overspeed LED The General Failure output annunciation is triggered during any of the above failure conditions and is rated 300mA Max NOT IN AUTO When the controller is in the OFF Mode the NOT IN AUTO LED will illuminate and the NOT IN AUTO Output will be triggered During this OFF mode Automatic engine starting is disabled The LCD display will read OFF and the backlight on the LCD display will be off NOTE Battery must be permanently connected to the main power terminal for the NOT IN AUTO feature LOW BATTERY VOLTAGE ALARM When the battery voltage drops below the user defined set point which can be programmed between 7 and 35VDC the engine controller displays a Low Battery Condition The Low battery warning Led will be illuminated at any time during OFF AUTO 16 of 28 and Manual run modes The LCD display will indicate the message The LOW battery warning will be disabled during failure conditions LOW OIL INPUT The Low Oil Input can be wired to a resistive sender or from a NO or NC type switch NC refers to the state of the contacts during normal engine operation engine oil pressure ok When utilizing a resistive sender the display units are fixed in PSI by th
10. EED OUTPUT 11 OVER CRANK OUTPUT 15 of 28 On power up the controller defaults to the mode it was in when power was last removed AUTO or OFF OFF mode can be entered by pressing the OFF button on the front panel When the GSC300 is in the OFF mode the Not In Auto LED will be lit on the front panel NOT IN AUTO below When the GSC300 is in the OFF mode starting either from the remote start contacts or from the front panel run button is disabled To start the genset the GSC300 needs to be placed in the AUTO mode by pressing the AUTO button on the front panel Once in AUTO mode the genset can be started by pressing the RUN button Once crank success is achieved i e engine has started the GSC300 enters the RUN mode and the front panel ENGINE RUNNING LED will be lit Removing power while the controller is in the RUN mode may corrupt the EEPROM f this occurs the GSC300 will have to be reprogrammed The following conditions can cause the GSC300 controller to shutdown the engine generator system unexpectedly To reset a failure press the Off key for 3 seconds This will exit the FAILURE mode and take the controller back to the OFF mode Auxiliary Failure XTR_FAIL X Extra failure is indicated by a flashing RED Low oil pressure LED Low Oil Pressure Low Oil pressure is indicated by a steady on RED Low oil pressure LED High Coolant Temperature High coolant temperature is indicated by a steady on RED High water temp L
11. Failure High Temp Output closes to 12 24VDC upon High Temp Failure 11 of 28 14 Low Oil Output closes to 12 24VDC upon Low Oil Failure Low Battery Output closes to 12 24VDC Low Battery Condition When a low battery condition is detected this output turns on immediately When the low battery condition is removed this output remains on for 5s before turning off 16 Engine Run Output closes to 12 24VDC on Engine Run Condition Stes ac Not In Auto Output closes to 12 24VDC when unit is not in auto General Failure Output closes to 12 24VDC on a General Failure Start Stop Input i e Remote Start Contacts Apply 12 24VDC to this terminal while unit is in Auto Mode to start engine Remove 12 24VDC to stop engine or enter Cool Down mode Maximum distance for the remote start contacts There is no absolute maximum since this depends on the size and type of the wire used There needs to be a minimum voltage of 8VDC at the Start Stop input for a start to be detected The wiring should be rated assuming a maximum 0 1A current draw There could be large voltage drops over long distances Mounting an external relay close to the controller and controlling it with the remote switch is a good solution 20 22 Sensor Inputs Engine Sensor type MUST be selected and programmed properly to GSC300 switch or sender type Failure to do so may result in the controller not shutting down on true engine failure Low oil pr
12. be the resistive type Sender or can be the switch type The proper type of sensor must be selected during GSC300 controller programming The sender or switch must be connected to ground for proper operation If Battery is connected to input terminal this can result in damaged to GSC300 controller When using a sender the proper sender manufacturer must be selected as each sender manufacturer s characteristics are different the sender failure set point must also be selected When using a switch the switch must be the NO type on normal engine run and close to ground on failure Fuel Level sensor or Auxiliary failure input This sensor can be the resistive type Sender or can be the switch type The proper type of sensor must be selected during GS C300 controller programming The sender or switch must be connected to ground for proper operation If Battery is connected to input terminal this can result in damaged to GSC300 controller When using a sender the proper sender manufacturer must be selected as each sender manufacturer s characteristics are different When using a switch the switch must be the NO type on normal engine run and close to round on failure See below Glow Plug Battery 12VDC or 24VDC Engine Temperature Generator Gen AC Out 300VAC max Fuel Level Oil Pressure Preheat
13. d Oil Temp Auxiliary input wiring improperly connected Incorrect programming of sensor inputs Speed signal improperly connected missing or damaged Crank output damaged not working or fuse blown on starter output Starter or starter solenoid damaged 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 cable Parameter is gt gt gt ABOVE or lt lt lt BELOW specified manufacturer sender range Warm Up Feature time setting does not begin until the Oil Bypass Time has expired 21 of 28 Confirm correct wiring for ground and bat and re attempt testing Run wire directly from battery to the ground terminal 110n controller unit Verify the Overspeed setting with PC configuration software Confirm that engine s governor is properly calibrated for its intended use Clean terminals and re charge batter Refer to engine control wiring section and check crank connections Run wire directly from battery to the round terminal 5 amp 6 on controller unit Check wiring in line fuse and slave relay Replace fuse relay and re test controller Check fuel level add fuel if necessary Refer to engine control wiring section and check ignition connections Check fuel relay and fuse replace if damaged or blown Check wiring for proper connections Check programming of oil pres
14. e PC programming interface and a failure set point must be selected from the programming menu Note The oil input failure is disabled during the Oil Bypass time HIGH TEMPERATURE INPUT The high temperature input can be wired to a resistive sender or from a NO type switch For proper operation while using a switch the switch must be the NO type which closes to ground upon failure When utilizing a resistive sender the display units are fixed in Fahrenheit by the PC programming interface and a failure set point must be selected from the programming menu Note The engine temperature failure is disabled during the Oil Bypass time FUEL LEVEL AUXILIARY INPUT The Fuel level Aux input can be wired to a resistive sender or from a NO type switch For proper operation while using a switch the switch must be the NO type which closes to ground upon failure If this input is used as a sender no failure will be indicated The sender option is solely for Fuel Level Auxiliary Level Display on the LCD The controller displays a log of total accumulated generator running hours Generator Run times will be displayed on the controllers display screen The display represents both hours and minutes in the form 123456 7 The last digit on the hour meter will represent the time in 1 10 of an hour Please note that although the hour meter displays time in hours and minutes it will record up to the nearest second If the generator was operated for a 3 minute period
15. e wire smaller than 18 AWG as smaller wire has a tendency to crack and break over time IMPORTANT The connections supplying DC power to the GSC300 panel should preferably run directly from the battery posts with no splices or other connections Avoid using chassis aluminum or iron engine parts as return conductor for battery negative voltage Copper wirin is recommended Failure to follow the above may result in erratic operation due to large voltage drops across wiring connections A small fuse should be placed at the battery terminal to provide 12 volts to the Remote Start Contacts to ensure that a short along this line will not cause any damage Follow all instructions guidelines given in Table 3 below for the individual terminals A WARNING ert
16. er than this will cause the hourmeter and other timings to become inaccurate For example at 3500Hz the hourmeter error will be 5 Frequency Number of teeth engine speed in RPM Generator Output Hz E g Number of teeth 100 engine speed 1800RPM Generator Output Hz at 60Hz the frequency would be 100 1800 60 3000 Hz The following values are minimal recommended RMS voltages 1000Hz 0 6V 600mV 3000Hz 0 85V 850mV General The GSC300 does not have loss of speed detection during cranking If there is no speed signal but the genset starts up and runs the starter will remain engaged for the remainder of the crank cycle 11 18 Outputs The maximum rating of each output depends on how many outputs are on simultaneously Do not exceed these values 1 300 mA 2 on 230 mA 3 on 160 mA 4 on 123 mA 5 on 91 mA 6 on 80 7 on 66 mA 8 on 52 Good practice is to use 50 of the maximum rating Do not connect power to the outputs If there is power on these outputs when the GSC300 is unpowered the GSC300 will be damaged Install a diode between the output and power source to prevent back feed The outputs have over current protection which turns off the output in an over current condition To reset the over current protection power down the controller for 30s and power back up Overcrank Output closes to 12 24 on Overcrank Failure Overspeed Output closes to 12 24VDC on Overspeed
17. erminal Connection 12 12V 30A 24V 20A Crank Output Terminal 12 12V 30A 24V 20A Ground Terminal Connection 12 12V 30A 24V 20A Ground Terminal Connection 12 12V 30A 24V 20A Preheat ETS Terminal 12 12V 30A 24V 20A Preheat ETS Terminal 18 100mA Speed Signal Connection 18 100mA Speed Signal Connection 18 350mA Annunciator Outputs 18 300mA Overcrank failure to start Output 18 300mA Overspeed Output 18 300mA High Temp Output 18 300mA Low Oil Output 18 300mA Low Battery Output 18 300mA Engine Run Output 18 300mA Not in Auto Output 18 300mA General Failure Output 18 7mA Start Stop Input 18 7mA Oil Pressure Sender Switch Input 18 7mA Temperature Sender Switch Input 18 7mA Fuel Level Auxiliary Sender Switch Input This is the maximum current for each terminal Use for specifying wire size only Recommended wire size 8 of 28 Battery must be disconnected before any wiring connections are made 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 WARNING Relays are rated for maximum 30A at 12V If relays are being used at 24V maximum rating is 20A Relays are rated for resistive ratings When driving such loads as starter solenoids you must ensure proper de rating of the relays Consult factory for further details us
18. essure or high engine temperature When installing engine sensors oil pressure engine temperature fuel level ensure the switches are connected to ground circuit through the engine sensor Damage will occur to controller unit if the sensor input terminals Terminal s 20 21 and 22 are connected to Battery When using engine sensors that are the resistive type the proper manufacturer of the sender MUST be selected during programming Failure to select the correct manufacturer type will cause inaccurate readings as well as failure to protect the engine during a fault condition 14 15 16 17 18 19 20 Low Oil Pressure sensor input This sensor can be the resistive type Sender or can be the switch type The proper type of sensor must be selected during GSC300 controller programming The sender or switch must be connected to ground for proper operation If Battery is connected to input terminal this can result in damaged to GS C300 controller When using a sender the proper sender manufacturer must be selected as each sender manufacturer s characteristics are different the sender failure set point must also be selected When using a switch NO or NC much be selected from the programming menu NO refers to the state of the contacts during normal engine operation therefore NO refers to normally open at normal engine run and close to ground on low oil pressure failure 12 of 28 High Engine Temperature sensor input This sensor can
19. ong enough for the generator to startup and run The customer will have to test this to confirm for their generator 2 Enable cool down and set the cool down time Once the GSC300 is running and the low battery output turns off the GSC300 will enter cool down The time it spends in cool down can be used to charge the battery The cool down time can be set up to 13 minutes 3 Optional To increase the time the GSC300 is running this can be used for older units as well use a time delay relay The low battery output can be connected to the coil of the timed relay The output of the relay can be connected to the remote start contact The battery charge time would then be the relay delay plus on new units the cool down time 24 of 28 The GCP300 is an option that provides AC Voltage and AC current analog gauges with the GSC300 together in an enclosure AC Voltage and Current Hookup The below drawings explain how to connect to the current transformers and AC voltage lines to the GCP300 in a phase setup Referring to Figure 7 the hookup is as follows 1 The neutral from the generator connects to the NEUTRAL terminal 2 Phase A B and C from the generator connects to the L1 L2 and L3 terminals respectively 3 The white wires of the current transformers connect to the A1 CTP1 A2 CTP2 and A3 terminals for Phase A and current sensing respectively 4 The black wires of the current transformers connect to the three COM
20. ons 4 5 H x 5 5 W x 1 25 D Actual Unit Weight 0 458 105 Enclosure High Impact Resistant Injection Molded Plastic Enclosure Front Panel Indications High intensity LED s with regulated brightness LCD Display Ultra bright Backlight LCD display with optimum viewing angle of 0 to 25 from perpendicular Display Size mm 8 W x 32 H x 12 8 D x 2line x 8 character display Adjustments Warm up 0 200 Seconds After Oil Bypass Feature Cool Down 0 812 Seconds Crank 12 to 140Hz Disconnect Overspeed 40 200Hz Crank Rest 4 32 Seconds Delay on Start 0 59 Seconds Crank Tries 1 to 10 Cil Bypass 10 55 Seconds Low Battery 7 Indication Timer Adjustments Glow 0 255 Seconds Plug Preheat Energize To Energizes for 15 Seconds on failures or energizes until 5 Seconds Stop ETS after engine speed goes to zero upon removing power from Start Stop terminal or removing the unit from manual mode using the front panel buttons Inputs Speed Sensing Generator Output Speed Sensing Maximum Input Voltage 300VAC RMS Minimum Input Voltage 1 5VAC at 20Hz ptp at 60Hz 60Hz Rejection Filter Included Loss of Speed Signal Included Sender Failure Oil Pressure Inputs Coolant Temperature Fuel Level Auxiliary Input Accepts standard industry low impedance 0 500 ohm sender inputs VDO Stewart Warner Datcon Murphy e
21. signals 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 signal can cause the engine controller to react as if the generator 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 steady even before the engine starts to engage the starter Without this false speed signal the controller will not look for oil pressure until the engine has started to run and the crank disengages if oil verification is disabled Simply installing a small transformer between the generator output and the speed sensing terminals on the controller can eliminate this false speed signal 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 t
22. sure engine temperature and aux input Ensure that the sensor type is properly programmed to controller unit Sender Switch type Check speed signal wiring replace damaged speed signal source Check wiring and replace relay of fuse where necessary Replace repair damaged starter or starter solenoid 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 If further accuracy is required it may be necessary to install sender with proper range specifications Re adjust Oil Bypass and or Warm Up timing 22 of 28 The GSC300 needs 10 seconds for its memory to clear When the power to the controller is turned off and then back on again without waiting 10 seconds to clear the memory a loss of speed will may be indicated by the GSC300 if controller is in AUTO mode and start signal is activated because the controller remains in run mode and senses that the generator has stopped This would be indicated by a Flashing Overspeed LED By leaving the GSC300 main power OFF for 10 seconds before main power is re applied this allows the clearing the memory and it will function as intended 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
23. switch can be placed assuming normally closed switch 1 Battery wire going to the GSC300 This would de energize the GSC300 causing the engine to shutdown It has to be able to handle the cranking current 2 If alower amperage emergency stop switch is required it is possible to place the emergency stop switch on the fuel output wire This would cut power to the fuel causing most engines to shutdown A test would have to be performed to ensure that this is the case Note if you have an Energize to Stop engine the above will not work In this case the Emergency Stop switch would have to energize the appropriate device to stop the engine This applies to newer GSC300 units in production August 2011 or latter 4 15 or greater in serial number On new units the low battery output has been changed to stay on for 5 seconds after a low battery condition has actually expired This was changed on request of some customers who wanted to implement an automatic start on low battery feature Implementing Automatic Start on Low Battery Procedure The customer is responsible for determining the adequacy of this for their application Dynagen does not guarantee this procedure will work in all applications 1 Connect the low battery output to the start stop input on the GSC300 When the GSC300 generates a low battery warning this will trigger the remote start and start the generator The low battery output will stay on for 55 This may be l
24. tc Programmable for either switch or sender configuration using PC Interface Adjustable failure set points using PC Interface Protection Three on board replaceable 30A fuses protect Fuel Crank and Timer Outputs Reverse polarity protected Short circuit amp overload protection on annunciation outputs Inputs are electrostatic discharge protected J1113 11 Transients Pulse 1A Supply Disconnect Pulse 2A Sudden Disconnect Pulse 4 Starter Motor Engagement Pulse 5 Load Dump Details of the test parameters are available please consult with factory 4 of 28 Outputs All outputs switched to battery Sourcing Fuel Crank and Timer Outputs 12V 30A or 24V 20A each using standard automotive relays Annunciation Outputs 1 300 mA 2 on 230 mA 3 on 160 mA 4 on 123 mA 5 on 91 mA 6 80 mA 7 on 66 mA 8 52mA Connections Removable terminal block for annunciation outputs and low power connections 0 25 spade terminals for high current and Main power inputs Programming Windows based software interface utilizing the USB port of your PC Needs no power to program using the PC Interface uses power from USB port of PC Specifications May Change Without Notice 5 of 28 Table of Contents 1 GSC300 Product Number 6 2 Wiring Installation 7
25. terminals The COM terminals are all connected together internally so order is not important 7 5 AMP RATIO BLACK CROMPTON GRAVES SWITCH AC VOLTS m l WIRED BY DYNAGEN DYNAGEN TECHNOLOGIES INC WIRED BY CUSTOMER A GCP 300 CONTROL PANEL TYPICAL WIRING 3 PHASE 978 7 PANEL TERMINAL POINT CUSTOMER SUPPLIED Figure 6 GCP300 Drawing 1 12 L3 NEUTRAL A1 1 A2 CTP2 A3 CTP3 COM COM COM Figure 7 GCP300 User Terminal Block Label 25 of 28 26 of 28 See below Not to Scale GSC300 CUTOUT TEMPLATE NOT TO SCALE 188 1786 ejos 19e 1 Y Y R 073 2 000 2 000 gt Ls 5 222 5 200 28 of 28 Notes
26. ule A good ground connection directly from the battery is required for proper operation These terminals are internally connected together on GSC300 controller Preheat ETS Output provides 12V 30A or 24V 20A maximum It provides a set of dry contacts between terminals 7 and 8 When this output is energized terminals 7 and 8 are connected together When output is OFF terminals 7 and 8 have no connection To verify the operation of the Preheat ETS Output measure the resistance between the Preheat ETS terminals when the Preheat ETS Output is ON it should read a closed circuit i e zero ohms When the output is OFF there should be an open circuit between the terminals very high resistance 10 of 28 9 10 Speed Options Generator Output L Version or Mag Pickup H Version Generator Output L Version Speed Signal Input for Crank Disconnect Engine Run and Overspeed sensing 300VAC max input voltage Speed sensing input terminals 9 10 do not have polarity sensitivity therefore the AC generator output leads can be connected in any polarity configuration Do not exceed 300VAC on speed sensing input terminals Refer to the specifications for the minimal input voltages Mag Pickup H Version The magnetic pickup only works for frequencies up to 3000Hz this is max of 100 teeth at 60Hz If using magnetic pickup as the speed sensing source the maximum frequency allowed into the controller is 3000Hz Frequencies high
27. wo wires from the secondary of the transformer are connected to the two wires of the speed sensing terminals on the GSC300 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 Transformer Connections on Speed Sensing Cable Step Down Transformer 9 12VAC 120VAC Secondary Primary To Generator Output Winding Winding Line to Neutral 120VAC Twisted pair of wires connected to speed sensing terminals on GSC300 10 23 of 28 Some fuel pumps have two solenoids instead of the normal one 1 One is called the pull coil and is used to initially turn the pump on 2 The other is the hold coil and is used to keep the pump on The pull coil uses more battery power as it has to handle the initial inrush current Once the pump is on the hold coil is activated and the pull coil is deactivated to reduce power consumption The GSC300 crank output can be attached to the pull coil and the GSC300 fuel output can be attached to the hold coil When the engine is started the fuel and crank output will come on activating both coils but after cranking is successful the crank output will turn off de energizing the pull coil If the engine does not require an energized output to stop there are a couple of locations the emergency stop
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