Auto Start Engine Controller
Contents
1. y LED 4 ENGINE RUNNING LED 5 LOW ENGINE BATTERY LED 6 PREHEAT ETS NOT IN AUTO STARTING DISABLED 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 Operating amp Installation Manual for the GSC300 Engine Controller Progress 17 Sample Screen From PC Interface GSC300 Configurator File About Help Technologies Inc a GSC CONTROL Crank Disconnect Hz High Temp Setpoint degF Delay To Start sec poo Crank Time sec 10 Rest Time sec 3 Restart On False Start Enable Disable Switch Sender OIL TEMPERATURE Overspeed Hz es Disable Low Dil Setpoint psi Preheat Time sec 7 Cooldown Time sec 6 4 Speed Sensing Geno p MPU Postheat C Enable Disable Crank Tries p Battery Y oltage MVDC 109 Oil Bypass Time sec fio Warmup Time sec l Enable Extra Relay C ETS Preheat Fuel During Crank Rest On C Off Switch Sender NO D serw C NC Switch Sender Switch Sender CONTROL Read GSC Data Store GSC Data Set Port Address Save to Disk Change Messaging Exit Feedback Operating amp Installation Manual for the GSC300 Engine Controller 182. TECHNOLOGIES INC DynaGen GSC300 Auto Start Engine Controller Installation and User Manual for the GSC300 Auto Start Engine Controller Full Version File GSC300rev2 3 doc Jan 27 2005 Thank You For Purchasing This DynaGen Product Please Read Manual Before Installing Unit Receipt of Shipment and Warranty Return Information Upon receipt of shipment carefully remove the unit from the shipping container and thoroughly examine the unit for shipping damage In case of damage immediately contact the carrier and request that an inspection report be filed prior to contacting DynaGen All returned items are to be shipped prepaid and include a Return Material Authorization RMA number issued by DynaGen RMA forms are available by contacting DynaGen Technical Support through the contact methods listed below Limited Warranty DynaGen will repair or replace any GSC300 controller which proves to be defective under normal and proper use within Three Years from the date of shipment This constitutes the only warranty and no other warranty shall be implied We welcome your comments and suggestions Please contact us at DynaGen Technologies Inc Phone 1 888 396 2436 902 562 0133 Fax 902 567 0633 Email support dynagen ca WEB SITE www dynagen ca Operating amp Installation Manual for the GSC300 Engine Controller SPECIFICATIONS FOR THE GSC300 Operating Voltage 7 to 30VDC continuous with zero volts cranking dropo
3. TROUBLESHOOTING GUIDELINES TROUBLE POSSIBLE CAUSE SUGGESTED ACTION powered to test mode and re attempt testing controller unit ground terminal 110n controller unit Engine starts and Improper speed range Check to ensure that the speed sensing immediately goes into wires of the controller are connected to the Overspeed shutdown generator output Engine does not crank connected check crank connections controller ground terminal 5 amp 6 on controller unit Crank relay damaged Or on board fuse is Check wiring in line fuse and slave relay blown Replace fuse relay and re test controller again Engine cranks but does not Out of fuel Check fuel level add fuel if necessary start Ignition control wiring not installed Refer to engine control wiring section and properly check ignition connections Fuel relay damaged Check fuel relay and replace if damaged Engine starts but shuts Oil Temp Auxiliary input wiring improperly Check wiring for proper connections down after Oil Bypass connected period due to low oil high temp Aux input Fault LED works OK but Fault short or overload on general fault Check for fault once fault is corrected then general fault output does not output output operation resumes activate Flashing Overspeed LED Speed signal improperly connected missing or damaged damaged speed signal source Crank output damaged not working Check wiring and replace controller if necessary S
4. Auxiliary Sender Switch Input Operating amp Installation Manual for the GSC300 Engine Controller 11 CONTROLLER OVERVIEW The GSC300 Features the Following Functions 1 Controller Programming Adjustability 2 General Fault Conditions 3 Not In Auto 4 Low Battery Voltage Alarm 5 Oil Pressure Input 6 Coolant Temperature Input 7 Fuel Level Auxiliary Input 8 Speed Signal Sensing 9 Adjustable Input Programming 10 Magnetic Pick Up Capability Option 1 CONTROLLER PROGRAMMING ADJUSTABILITY Adjustable Parameter Ranges Crank Disconnect 12 to 140Hz Generator Output Version 44 to 300Hz Magnetic Pick up Version Overspeed 60 4156Hz Generator Output Version OR DISABLED BY PC INTERFACE 300 8492Hz Magnetic Pick up Version OR DISABLED BY PC INTERFACE Crank Tries 1 to 10 Crank Rest 3 to 32 seconds NOTE If the engine speed seen by 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 GENERAL FAULT CONDITIONS The following scenarios can cause the unit to enter the general fault condition Low Fuel Auxiliary Failure XTR_FAIL Low Oil High Coolant Temperature Overcrank Overspeed Loss of Speed SPDLOSS The General Fault output is rated 300mA Max Operating amp Installation Manual for the GSC300 Engine Controller 12 3 NOT IN AUTO When the controller is in the OFF Mode
5. Temp Output 14 18 300mA Low Oil Output 15 18 300mA Low Battery Output 16 18 300mA Engine Run Output 17 18 100mA Not in Auto Output 18 18 300mA General Failure Output 19 18 7mA Start Stop Input 20 18 7mA Oil Pressure Sender Switch Input 21 18 7mA Temperature Sender Switch Input 22 18 7mA Fuel Level Auxiliary Sender Switch Input Operating amp Installation Manual for the GSC300 Engine Controller WIRING GUIDELINES 1 DO NOT use wire smaller than 18 AWG 2 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 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 3 DO NOT exceed the maximum rated current and voltage on each of the controller outputs Do not exceed 40A 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 4 DONOT short Crank Output or Fuel Output to ground This will cause damage to the unit 5 To verify the operation of engine controller outpu
6. or switch and when using a sender the failure point in degree Fahrenheit can be adjusted using the PC Interface 7 FUEL LEVEL AUXILIARY INPUT For proper operation while using a switch the switch must be the N O 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 8 SPEED SIGNAL SENSITIVITY The controller will accept to a maximum of 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 9 HOUR METER The controller can display a log of generator run times 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 Each increment would represent 6 minutes For example if the hour meter displays 000010 5 than the generator had ran for 10 hours and 30 minutes 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 only 3 minutes the display may not increment but this time would be stored and added to the next generator run time 10 MAGNETIC PICK UP CAPABILITY OPTION The Magnetic Pick Up Capability Option can be provided on the GSC300 upon req
7. Needs no power to program using the PC Interface uses power from parallel port of PC Specifications May Change Without Notification Operating amp Installation Manual for the GSC300 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 AWG 1 12 40A Fuel Output Terminal 2 12 40A Auto Battery Terminal Connection 3 12 40A Auto Battery Terminal Connection 4 12 40A Crank Output Terminal 5 12 40A Ground Terminal Connection 6 12 40A Ground Terminal Connection 7 12 40A Preheat ETS Terminal 8 12 40A Preheat ETS Terminal 9 18 100mA Speed Signal Connection 10 18 100mA Speed Signal Connection 11 18 300mA Overcrank Output 12 18 300mA Overspeed Output 13 18 300mA High
8. er to be put into Program Mode The first three LED s 3 2 amp 1 correspond to which parameter is being adjusted and the next three 6 5 amp 4 LED s show the setting for that particular parameter The picture on the next page shows the LED numbering and the location of the Mode Switch vA ses Tese Jeee feee e00 one Tee COREE Ceann ooe 5 10 15 20 25 20 95 0 ce a RR Preheat Time ee o 5 10 10 25 ree pe fa e e fa e T wm eeo o 28 56 ee 11a 140 108 106 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 set the value into the controller 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 By not pressing the off button to set the value the value of that parameter will not be stored into memory and remain at it s previous setting Operating amp Installation Manual for the GSC300 Engine Controller 16 Numbering Of LED s and Location of Mode Switch OIL TEMP A Mode Switch Programming Using the PC Interface LED 1 LOW OIL PRESSURE HIGH WATER TEMP __ amp LED 2 OVERCRANK _ n LED 3 OVERSPEED
9. gnal 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 Overcrank Annunciation Output closes to 12 24VDC on Overcrank 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 Start Stop Input 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 Oil pressure sender switch This oil pressure sender switch can be N O or N C meaning that for N O ground is a failure while Vbatt is Engine OK for N C ground means engine OK and Vbatt means failure The operation failure point of the output in response to the sender can be set using the PC Interface p Temperature sender switch For proper operation this input must be connected to ground via a Low Battery Output closes to 12 24VDC on Low Battery Condition 300mA max i ilure 12 _ Overspeed Annunciation Output closes to 12 24VDC on Overspeed Failure 300mA max 3 al aes ial pie i 18 1 1 1 1 1 1 1 1 1 1 2 2 sender switch The operation failure point of the output in response to the sender can be set using the PC Interface 0 1 2 3 4 5 6 7 8 9 0 1 22 Fuel Level Auxiliary Failure Input For proper ope
10. he 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 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 12VAC secondary Step Down Transformer 120 AC primary winding o e i To Generator Output on Line Neutral 1204C Twisted pair of wires connected to speed sensing terminals on GSC300 Operating amp Installation Manual for the GSC300 Engine Controller
11. onds to clear the memory a loss of speed will be indicated by the GSC300 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 OFF for 10 seconds before it is returned to the Auto setting the memory will be cleared and it will function as intended 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 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 t
12. ration this input must be connected to ground via a sender switch The operation failure point of the output in response to the sender can be set using the PC Interface Operating amp Installation Manual for the GSC300 Engine Controller Wiring Connection Diagram Wiring Connections For The GSC300 Generator Output up to 300W AC Fuel Auxiliary Sender S witch ili a 5 rs Temperature Sender Switch Preheat LETS 9 10 Relay Crank f Relay Fuel 14 Relay J 11 Oil Pressure Sender Switch General Failure Lamp a Not In Auto Lamp a Engine Run Lamp a Low Battery Lamp Low Qil Lamp muUhOODs a 1 2 Amp Fuse Battery Remote Start Contacts Operating amp Installation Manual for the GSC300 Engine Controller Back Panel Layout GSC300 Back Pannel Layout and Connections Spade Terminal Connectors 910 Speed Sensing Connections Connected to Generator Output Spade Terminals Fuel Output 12 Overspeed Output 11 Overcrank Output lI Preheat ETS 9 10 B 21 Temperature Sender Switch Input Preheat ETS Relay har 20 Oil Pressure Sender Switch Input Ground rm 19 Start Stop Input G d Crank m 18 General Failure Output Crank Output E 16 Engine Run Output Auto batt a B 15 Low Battery Output ue 14 Low Oil Output Auto batt Relay B 13 High Temperature Output Li Aiii Funes PC Interface Connector 12 Position Terminal Block 22 Fuel Level
13. tarter or starter solenoid damaged Replace repair damaged starter or starter solenoid Flashing Run LED amp Solid Oil switch not closed as it should be Check oil switch wiring and switch to make Oil LED sure the switch is closing when there is no oil pressure Solid Oil LED immediately False speed signal being detected by Install a small step down transformer on start up without engine controller This problem can sometimes between the speed sensing wires and the actually cranking or starting occur in installations where there is AC generator output power from inverters near generator output lines connected to the speed signal If the neutral from the generator output is ee not grounded attach it to ground Display Parameter for Parameter is gt gt gt ABOVE or lt lt lt BELOW Install sender with proper range Temperature Oil or Fuel specified manufacturer sender range specifications displayed as gt gt gt or lt lt lt Warm Up Feature appears Warm Up Feature time setting does not Re adjust Oil Bypass and or Warm Up longer then time setting begin until the Oil Bypass Time has timing expired Operating amp Installation Manual for the GSC300 Engine Controller 19 TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS 1 Controller Memory Clear Time 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 a few sec
14. the NOT IN AUTO LED will illuminate and the NOT IN AUTO Output will close to Vbatt indicating the controller is not in the AUTO Mode The LCD display will read OFF however the backlight on the LCD display will not be ON NOTE Battery must be permanently connected to the AUTO terminal for the NOT IN AUTO condition and LED indications to function properly 4 LOW BATTERY VOLTAGE ALARM In the event the battery voltage drops below the user defined set point which can be between 7 and 35VDC the engine controller displays a Low Battery Condition The Low Battery Voltage condition can occur when the controller is in the AUTO or MANUAL TEST Mode but will only occur in the running state or while in standby in AUTO The LCD display will show the message LOW_BATT 5 LOW OIL INPUT The Low Oil Input can accept data from a sender or signal from a N O or N C type switch N O means that ground would be a failure 5V would be Engine OK N C means that ground would be Engine OK and 5V would be a failure The operation of the oil input is set in PSI by the PC Interface and is the only input which has selectable operation in this manner Note The oil input failure is disabled during the Oil Bypass time 6 HIGH TEMPERATURE INPUT For proper operation this must be of the standard N O type where with a switch or sender a ground would be seen as a failure and a 5V would be seen as Engine OK This can be used with a sender
15. ts measure voltage i e meter in volts when outputs should be ON 6 To verify the operation of the Preheat Output measure the resistance between the Preheat terminals when the Preheat Output should be ON At this time there should be a closed circuit When the output is supposed to be OFF there should be an open circuit between the terminals Operating amp Installation Manual for the GSC300 Engine Controller TERMINAL DESCRIPTION 1 Fuel Output provides 40A maximum Fuel Output closes to 12 24 VDC when start signal is actuated and opens when either an engine failure is detected or when Cool Down period has ended 2 Auto Terminal Connection point on the unit for V Battery power connection Auto Terminal Connection point on the unit for V Battery power connection 4 Crank Output provides 40A maximum Crank Output closes to 12 24VDC during cranking and opens when the engine has started or during Crank Rest 5 Battery Ground connection for the controller module A good ground connection directly from the battery is required for proper operation Battery Ground connection for the controller module A good ground connection directly from the battery is required for proper operation 7 Preheat ETS Output closes to terminal 8 during Preheat or ETS period Dry contacts between terminals 7 amp 8 Preheat ETS Output closes to terminal 8 during Preheat or ETS period Dry contacts between terminals 7 amp 8 Speed 1 Speed Si
16. uest Frequency will not be displayed on the LCD if this option is chosen Operating amp Installation Manual for the GSC300 Engine Controller 13 LED LAYOUT Front View of GSC300 LOW OIL PRESSURE HIGH WATER TEMP OVERCRANK OVERSPEED OIL TEMP BATTERY ENGINE RUNNING LOW ENGINE BATTERY PREHEAT ETS NOT IN AUTO STARTING DISABLED Operating amp Installation Manual for the GSC300 Engine Controller LED INDICATIONS FRONT PANEL LED INDICATIONS Steady Overcrank LED Engine would not start after specified Crank tries Steady Overspeed LED Speed Signal present above Overspeed setting Flashing Overspeed LED Was Engine Cranking No speed signal available while Cranking Was Engine Running The speed signal was Zero while running The engine has stalled or the speed signal has been lost Steady Engine Running LED Engine Controller is in running mode of operation Flashing Engine Running LED Crank Rest period Cranking will resume soon Operating amp Installation Manual for the GSC300 Engine Controller 14 15 Programming The GSC300 Settings Using the Front Panel Interface 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 turn the small switch at the bottom edge of the controller to the program position This Mode Switch can be set using a ballpoint pen or such to allow the controll
17. ut protection Operating Temperature 40 to 85 C Physical Dimensions 4 5 H x 5 5 W x 1 25 D Actual Unit Weight 0 458 Ibs 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 16 characters Adjustments Warm up 0 200 seconds After Oil Bypass Feature Cool Down 0 255 seconds Crank Disconnect 12 to 140Hz Generator Output Version 44 to 300Hz Magnetic Pick up Version Overspeed 60 4156Hz Generator Output Version 300 8492Hz Magnetic Pick up Version Crank Rest 3 32 seconds Delay on Start 0 59 seconds Crank Tries 1 to 10 Oil Bypass 15 55 seconds Low Battery Indication 7 35 VDC Operating amp Installation Manual for the GSC300 Engine Controller Timer adjustments Glow Plug Preheat 0 255 seconds Energize To Stop ETS Energizes for 15 seconds on failures or energizes until 5 seconds 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 Optional Generator Output Speed Sensing or Magnetic Pick Up Model Specified by customer at time of order Maximum Input Voltage 300Vrms Minimum Input Voltage 0 7Vrms Generator O
18. utput Sensing 0 1 Vrms Magnetic Pick Up version 60Hz Rejection Filter Included Loss of Speed Signal Included Sender Failure Inputs Oil Pressure Coolant Temperature Fuel Level Auxiliary Input Accepts standard industry low impedance 0 500 ohm sender inputs VDO Stewart Warner Datcom Murphy etc Data entry available for custom sender inputs Can be configured to accept a switched gauge failure through the PC interface Failure points adjustable Operating amp Installation Manual for the GSC300 Engine Controller 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 Maximum power supply surge before damage 1500V for 250us Outputs All outputs positive switched sourcing Fuel Crank and Timer Outputs AOA 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 quick connections on all other connections Programming Intuitive 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
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