GSC300 User Manual R2.9 (for front panel programming)
Contents
1. 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 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 10 of 29 2 4 Terminal Description Table 3 GSC300 Terminals Tem 969 Fuel Output provides 12V 40A 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 Auto Terminals Main Battery power connection to controller These terminals are internally connected together on GSC300 controller Crank Output provides 12V 40A 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 module2. y 5 FUEL gt RELAY PROGRAMMING CONNECTOR OFF MODE SWITCH gt Figure 3 13 of 29 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 SPEED OUTPUT 11 OVER CRANK OUTPUT 14 of 29 OFF AUTO RUN Modes 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 GENERAL FAILURE CONDITIONS The following conditions can cause the GSC300 con
3. 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 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 High Engine Temperature 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 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 GSC300 controller programming The sender or switch must be connected to ground for proper operation If Battery is connected to
4. 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 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 ther
5. 6 4 Speed Sensing Geno p Midheat Postheat Warmup Time sec Enable Extra Relay C ETS Preheat Fuel During Crank Rest Other Tasks Save to Disk Load From Disk Change Messaging Enable Disable Enable Disable On Off The speed sensing magnetic pickup setting only supports frequencies up to 3000Hz Figure 7 Power leads to unit are reversed Bad ground connection from engine to controller unit Improper Overspeed setting Battery is low or terminals are dirty 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 properly Fuel relay and or fuse damaged 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 23 of 29 Confirm correct
6. A good ground connection directly from the battery is required for proper operation These terminals are internally connected together GSC300 controller Preheat ETS Output 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 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 T 9 10 do not have 13 sam polarity sensitivity therefore the AC generator output leads can be connected in any polarity configuration Do not exceed 300VAC on speed sensing input terminals Mag Pickup H Version The magnetic pickup only works for frequencies up to 3000Hz this is max of 100 teeth at 60Hz General The GSC300 does not have loss of speed detection If there is no speed signal during crankino run but the genset starts up and runs the starter will remain engaged for the remainder of the crank cycle Overcrank Annunciation Output closes to 12 24VDC on Overcrank Failure 300mA max Overspeed Annunciation Output closes to 12 24VDC on Overspeed Failure 300mA max High Temp Output closes to 12 24VDC upon High Temp Failure 300mA max Low Oil Output closes to 12 24VDC upon Low Oil Failure 300mA max Low
7. laying flat and viewed from the bottom see image below This Mode Switch can be set using a ballpoint pen or small tool to allow the controller to be put into Program Mode The first line on the LCD will display PROGMODE when the switch is in the Program position Figure 5 The first three LED s 3 2 amp 1 on the front of the controller correspond to which Parameter is being adjusted and the next three 6 5 amp 4 LED s show the Value for that particular Parameter LED 1 2 Low oil pressure LED 2 High water temp LED 3 Overcrank LED 4 Overspeed LED 5 Engine Running LED 6 Low engine battery LED7 Preheat ETS LED8 NOT IN AUTO starting disabled The picture below shows the LED numbering and the location of the Mode Switch The highlighted circle in the table refers to the LED being illuminated 20 of 29 Table 5 GSC300 Front Panel Programming Parameter Value Table a Jd cm ca Parameter meee 281 s s 20 2 55 s is 25 2 os Pome o fs 29 se ve 224 rman o z To scroll through the parameters simply press the Auto button on the front panel of the GSC300 To scroll through the range of values for that parameter simply press the Manual Start button To program the value into the controller
8. s memory press the OFF button In this manner the settings of the controller can be adjusted by simply using the three buttons on the front panel of the controller Be sure to press the OFF button when you have selected the parameter value wanted The current value of the parameter will not be shown by LEDs 4 5 and 6 LEDs 4 5 and 6 always show the first lowest value of the parameter i e LED 4 5 and 6 off The user then presses the Manual Start button to scroll up in values if required Numbering of LED s and Location of Mode Switch new front picture LOW OIL PRESSURE b a HIGH WATER TEMP x na m OVERCRANK OIL TEMP BATTERY OVERSPEED ENGINE RUNNING LOW ENGINE BATTERY PREHEAT ETS NOT IN AUTO STARTING NS Mode Switch Figure 6 21 of 29 The mode switch must be in the normal position Ensure the LCD does not display PROGMODE when using the PC Interface to program the GSC300 The GSC300 cannot be powered while using the parallel port or USB programmer The GSC300 could be damaged The GSC300 can also be programmed using the PC interface 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 sour
9. Battery Output closes to 12 24VDC on Low Battery Condition 300mA max 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 Engine Run Output closes to 12 24VDC on Engine Run Condition 300mA max 17 Not In Auto Output closes to 12 24VDC when unit is not in auto 300mA max 18 General Failure Output closes to 12 24VDC a General Failure 300mA max 1 2 4 1258 9 10 11 12 13 14 15 16 17 18 11 of 29 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 1 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 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
10. DYNAGEN power controls you can trust GSC300 Auto Start Engine Controller Revision 2 9 Installation and User Manual for the GSC300 Auto Start Engine Controller File MAN 0039 R2 9 GSC300 User Manual doc May 2011 2 of 29 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 29 Operating Voltage 7 to 30VDC continuous Zero volts operation for 100mS assumes supply was 12VDC before initiating starting Operating Temperature 40 C to 85 C LCD Display operates from to 16 C to 70 C Physical Dimensions 4 5 H x 5 5 W x 1 25 D Actual Unit Weight 0 458 105 Enclosure Hig
11. atic 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 DO NOT exceed the maximum rated current and voltage on each of the controller outputs DO NOT exceed 12V 40A or 24V 20A each for the Fuel Output Crank Output or Preheat Output DO NOT exceed 300mA individually or 350mA combined for the General Fault Output or Annunciation Outputs 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 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 pressure 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 5 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 du
12. ce Parallel Port Programming Note 1 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 22 of 29 Sample Screen from PC Interface NOTE Factory default settings are outlined in the photo below E GSC 300 Configurator File Options Help Switch Sender OIL Sensor Type Delay s Switch Sender uh ub Setpoint TEMPERATURE Sensor Type Delay 5 m Switch Sender FUEL Sensor Type Delay s Switch Sender gt Parallel Port Read GSC Data User Settings DEM Settings GSC CONTROL Crank Disconnect sms Temp Setpoint degF Crank Tries B Battery Voltage MDC 103 Delay To Start sec Preheat Time sec Oil Bypass Time sec Overspeed Disable Oil Setpoint Store GSC Data Set Port Address Read GSC Data Store GSC Data Crank Time sec 10 Rest Time sec r gt Restart On False Start Cooldown Time sec
13. de Ip eu Ec 7 2 1 ATH 7 22 V Oen RET 8 2 3 GSC300 12 24VDC System 9 24 Terminal pnt e exa uqu 10 25 System Wiring Diagram ebevle ta deans ded diac ie dese ER cdi ehe RET eur 11 26 T 13 ooo SEDE 14 cx EE C10 1 40 7 1 Pre 14 32 5 1 17 EE Indications EUM 18 4 Programming the GSC300 19 4 1 Using the Front Panel Interface erties etel eed etae Met anu ir een 19 4 2 Programming Using the PC 21 5 Troubl shootimg GUIOelIIGS sse itx Fr xe eens Ee repr rev bue Rd dee 23 6 Technical Notes and a 24 61 Controller Memory Clear E ER Mou Reg 24 6 2 Step Down Transformer Use On Speed Sensing Cable With Inverter Systems 24 6 3 Pulamd GIO eM 25 64 Emergency Stop Switch eor 25 GOP300 Panel Optional c i un uuu a oo ra cud e Ev MUR E 25 6 6 GSC300 Cutout Temp
14. e illuminated at any time during OFF AUTO and Manual run modes The LCD display will indicate the message LOW The LOW battery warning will be disabled during failure conditions 15 of 29 LOW OIL INPUT The Low Oil Input can be wired to a resistive sender or from a NO or NC type switch NO 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 the 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 Disp
15. e 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 two 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 Secondary Winding To Generator Output Winding Line to Neutral 120VAC Twisted pair of wires connected to speed sensing terminals on GSC300 10 25 of 29 Some fuel pumps
16. h 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 Oil Bypass 10 55 Seconds Low Battery 7 35VDC 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 0 7VAC RMS Generator Output Sensing 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 etc Programmable for either switch or sender configuration using PC Interface Adjustable failure set poi
17. hat 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 9 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 CTP3 terminals for Phase A B and C current sensing respectively 4 The black wires of the current transformers connect to the three COM terminals The COM terminals are all connected together internally so order is not important 26 of 29 AMPS 5 AMP RATIO BLACK CROMPTON GRAVES SWITCH I 4 4 WIRED BY DYNAGEN WIRED BY CUSTOMER PANEL TERMINAL POINT CUSTOMER SUPPLIED Powe 978 F Figure 8 GCP300 Drawing L2 L3 NEUTRAL A1 CTP4 A2 CTP2 A3 CTP3 COM COM Figure 9 GCP300 User Terminal Block Label 27 of 29 See below Not to Scale GSC300 CUTOUT TEMPLATE NOT TO SCALE 188 1786 ejos 19e I I Y Y R 073 2 000 2 000 Ls 5 222 2 900 29 of 29 Notes
18. 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 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 Ifa lower 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 t he Emergency Stop switch would have to energize the fuel coil to stop the engine The GCP300 is an option t
19. 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 ground on failure See below Glow Plug Battery 12VDC or 24VDC Engine Temperature Generator Gen AC Out 300VAC max Fuel Level Oil Pressure Preheat W j 19 7 i 2 ETS Relay Speed m Sensing 09 N Crank R Relay Battery Contacts 3 N Fuel PC Config Relay 19 H U8 J Annunciator Outputs Internal Battery General Failure lt 18 insu Auto 17 Engine Run 16 Low Battery 15 Low Oil l4 High Tem 13 Overspeed 12 Overcrank 11 GSC300 Wiring Diagram DWG1461R1 0 Figure 2 GSC300 System Wiring Diagram PRE HEAT NO PRE HEAT COM BATTERY GROUND BATTERY GROUND STARTER OUTPUT BATTERY BATTERY FUEL OUTPUT a EE 5 PRE HEAT RELAY 9 10 SPEED SIGNAL INPUTS Ke CRANK O RELAY gt TA o V
20. late 27 6 of 29 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 A 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 29 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 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 Table 2 Types and Sizes 12V 40A 24V 20A Fuel O
21. lay on the LCD SPEED SIGNAL SENSITIVITY The controller will accept to a maximum of 300VAC 60Hz from direct generator output for speed sensing The following values are minimal recommended voltages for speed signal sensing Generator Output Option 20Hz 0 075V 75mV 60HZ 0 6V 600mV Magnetic Pickup Option 1000Hz 0 6V 600mV 3000Hz 0 85V 850mV Magnetic Pickup If using magnetic pickup as the speed sensing source the maximum frequency allowed into the controller is 3000Hz Frequencies higher than this will cause the hourmeter and other timings to become inaccurate For example at 3500Hz the hourmeter error will be 596 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 16 of 29 HOUR METER 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 and then stopped the running time is stored in permanent memory and then adding to the next running period The same would be
22. nts using PC Interface Protection Three on board replaceable 40A 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 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 29 Outputs All outputs switched to battery sourcing Fuel Crank and Timer Outputs 12V 40A or 24V 20A each using standard 40A automotive relays Annunciation Outputs _ 300mA individually 350mA combined 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 parallel port of your PC Option of programming through 3 button interface limited parameter adjustment on the front panel or the PC Interface that has full parameter programming ability Needs no power to program using the PC Interface uses power from parallel port of PC Specifications May Change Without Notice 5 of 29 Table of Contents 1 GSC300 Product Number Identification a 6 2 Wiring Installation Guldelli6s prn RR ERREUR eu ERU Iri Up Ebr uude IE n to d
23. ring a fault condition To verify the operation of engine controller outputs measure voltage i e meter in volts when outputs should be ON 10 To verify the operation of the Preheat Output measure the resistance between the Preheat terminals when the Preheat 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 11 Speed sensing input terminals Terminal s 9 and 10 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 9 of 29 PRE HEAT PRE HEAT RELAY RELAY 24VDC RELAYS
24. troller to shutdown the engine generator system unexpectedly Auxiliary Failure XTR_FAIL 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 LED 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 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 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 b
25. 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 17 of 29 3 2 LED Layout Front View of GSC300 LOW OIL PRESSURE DYNA you can trust HIGH WATER TEMP OVERCRANK OVERSPEED ENGINE PARAMETERS ENGINE RUNNING BAT 15 9 RUM ENGINE STATUS HOURS LOW ENGINE BATTERY PREHEAT ETS NOT IN AUTO istantens Figure 4 18 of 29 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 29 The following table shows the LED s that correspond to the various settings of the various parameters To enter the controller into Program Mode you need to move the small switch at the bottom edge of the controller to the Program position the Program position is to the left There is a small viewport in the bottom edge of the controller that is visible with the controller
26. utput Terminal 12 12V 40A 24V 20A Auto Battery Terminal Connection 12 12V 40A 24V 20A Auto Battery Terminal Connection 12 12V 40A 24V 20A Crank Output Terminal 12 12V 40A 24V 20A Ground Terminal Connection 12 12V 40A 24V 20A Ground Terminal Connection 12 12V 40A 24V 20A Preheat ETS Terminal 12 12V 40A 24V 20A Preheat ETS Terminal 18 100mA Speed Signal Connection 18 100mA Speed Signal Connection 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 100mA 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 8 of 29 WARNING Relays are rated for maximum 40A at 12V If relays being used at 24V maximum rating is 20A DO NOT use 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 wiring is recommended Failure to follow the above may result in err
27. 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 battery Refer to engine control wiring section and check crank connections Run wire directly from battery to the ground 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 pressure 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 24 of 29
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