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GSC400 User Manual R4.3

1. Ground 1 7mA Ground Input 2 2 18 7mA Low Ohms Gain of 1 Input 3 3 18 7mA Low Ohms Gain of 3 Input 4 4 18 7mA Low Ohms Gain of 3 Input 5 5 18 7mA High Ohms Gain of 3 Input 6 6 18 7mA High Ohms Gain of 1 Input 7 7 18 7mA High Ohms Gain of 3 5V out 8 18 7mA 5V Power output LSB LXB controllers only For LS LX controllers this input spec is High Ohms Gain of 3 LSB LXB controllers only For LS LX controllers this input has a gain of 3 LSB LXB controllers only For LS LX controllers this terminal is a ground Input H 1 Active Battery Input G 2 18 7mA Active Battery Input F 3 18 7mA Active Battery Input E 4 18 7mA Active Battery Input D 5 18 7mA Active Battery Input C 6 18 7mA Active Battery Input B 7 18 7mA Active Battery Input A 8 18 7mA Active Battery Emer Stop 9 18 7mA Open Active Battery Inactive Remote 10 18 7mA Battery Start Start Open Stop Ground 11 18 7mA Battery reference Ground 12 18 7mA Battery reference 17 of 147 CANH V Bat 1 18 1 5A Battery Output A 2 18 200mA These are sinking outputs Output B 3 18 200mA i e switched to ground Output C 4 18 200mA Output D 5 18 200mA Outp
2. S T T 20 254 Generator AC eda han en decli sas 20 2 5 2 Magneti PICk p iiis dte ge in rte ie 20 VADE LU 20 2 5 4 jro bleshooting iie Hee te ie reci bea 20 2 6 SENSOR INPUTS SENDERS SWITCHES sse nre 22 20 39WICIIBS Mann teehee NL LU TA 22 202 ecd nce emule cae tsa ie AU i S 23 2 6 3 Electronic Sensors 0 to 5VDC sse 24 2 64 Troubleshooting eee irin essen sente einen tne nn E teen ense teens teen enne these nene 25 2 7 AC VOLTAGE AC FREQUENCY cccccscccsssscosseseseesssssecesssecaeestestestensecsessecatesteseestenseceessecateate 27 2 8 AG CURRENT ee E E E A ee 31 2 9 AC CURRENT AND VOLTAGE CALIBRATION cech 32 2 10 CONFIGURABLE SWITCHED INPUTS CONFIGURABLE OUTPUTS seen 33 2 10 1 Timed Output on Failure Shutdown sse 35 2 11 CAN E COBES ISIS EE 36 2 12 MODBUS SETUP eniinn 38 2 13 IDE MODE M ORTA 40 2 13 1 Idling Engine during Warm up and Cool down sse 40 Figure 3 below gives the dimensions of the mounting hardware The GSC400 gen set controller must be properly mounted for safe operation Caution must be taken at the installation site to make sur
3. 108 279 1 8 3 8 67 03201500 ACCO122 0 5VDC 0 150 PSI 1 4 NPTF 2A DATCON 02022 00 1 8 ACC0027 MEE DATCON 02024 00 3 8 ACCO098 Press DATCON 02025 00 1 2 ACCO099 Men The GSC400 controller is designed to operate in either 12 or 24 VDC battery start systems When operating in 12VDC systems the fuel crank and extra relays need to be rated 12VDC coil When operating in 24VDC systems these relays need to be rated 24VDC coil To maintain the UL rating the HASCO relays must be used 123 of 147 Table 34 Relay Part List RLY0029 AZ 973 1C 12DC RLY0043 AZ 973 1C 24DC RLY0053 CAR 1A 40 DC12S RLY0054 CAR 1A 40 DC24S Output relays are protected by onboard 30A fuse protection Smaller amperage fuses matched to the actual load are recommended Table 35 GSC400 fuse part list FUSO0011A Littlefuse 287030 124 of 147 The GSC400 follows the Modbus standard Modbus is a master slave communication protocol in which only the master can initiate a communication request A slave device never initiates communications Please refer to the standard for more details The GSC400 communicates on Modbus only as a slave device The GSC400 supports only the Modbus RTU Remote Terminal Unit mode The port configuration is 8 N 1 The Modbus packet structure is as below Refer to the Modbus standard for more information Function Code Slave Address 1 Byte 0x03 Data 1 Byte
4. 145 APPENDIX G ADDITIONAL DRAWINGS eere eee etete teens to tots tn tntn 146 8 of 147 1 1 How TOUSE THIS ttt re RR EH EE EG HN ane Bare ERN 9 1 2 SAFETY INFORMATION eerie RENI HERD EIER EHE RUDI Here eiat ee nih 9 1 3 GSC400 PRODUCT NUMBER IDENTIFICATION eene enne 10 The GSC400 is designed for use on generator sets with either mechanical or electronic J1939 engines It can monitor analog data from senders on the engine and generator such as oil pressure coolant temperature current voltage and engine speed and generator frequency The GSC400 can also oo CIO gather engine parameters from the engine ECM via J1939 and use them to control the engine or for display aS DynaGen urposes Pane p p x RUNNING An RS232 interface is provided that AC PHASE VOI eg gt amp allows communication with the aN 12176 219 5 DynaGen GSC400 PC Interface to V change settings or display information on the PC An RS485 port is provided mer for Modbus communications slave only for remote annunciation or communications In addition to the monitoring features the GSC400 controller can be used to automatically start stop a generator system as well as provide protective warnings or shutdowns 9 of 147 This manual is divided into three main sections 1 Installation and wiring Section 2 2 Technician level configuration Section
5. aate ERE n IERI HIER EA 83 4 4 4 1 Locking the GSC400 Screen While in RUN Mode seen 84 2142 dle Modes ee ee Ce eee fe mettent ette M CU 84 4 5 GSC400 START STOP eene teen nnt tnn 85 AG gt EXERCISING irere n aE 86 4 7 GSC400 MENU SYSTEM OPERATION esses eene ener ennt nennt enne nnn 87 4 8 BASIC S Serata 87 AST MEE ci guo 89 482 SOU soie teo nen 89 483 Event History LOg serene Ree eerie iier NER 91 4 9 GSC400 LED STATUS INDICATORS cccccessesssssssesssessesecsessesessessssesaesaseeseeseseesseseseesaesaseesaees 96 4 10 WARNINGS AND FAILURES ssseeseseseenenenen ener nennen nennen 99 4 10 1 Returning to OFF Mode from a Failure esses 100 4 10 2 Diagnostic Trouble Code Shutdowns sees 100 4 10 3 Hourmeter Display esses eene enne enne enne nennen tenen enn 100 939 A 101 4 12 1939 DIAGNOSTIC TROUBLE CODE DTC DISPLAY sss 102 4 12 1 DM1 Messages neret nennen 102 4 12 2 DM2 Messages eene nenne nennen entere 103 4 12 3 DM1 Event E095 i aie t ERR ERE ERE HER EH e RT e 104 79 of 147 The actions in Table 21 should be performed routinely DANGER WARNING When performing any maintenance on the
6. LOGO E m 75 3 16 2 ECD Healet ees 76 3 16 3 FAN 76 44 of 147 Important For Firmware Versions Below 2 00 After changing any settings on the controller the controller needs to be reset This can be done one of two ways 1 Power off wait for 2s and power on the controller 2 Press the Run key wait until the controller begins the start sequence and then press the OFF key You will see a flickering of the screen as the controller updates The GSC400 incorporates an Advanced Setup menu Only OEMs or knowledgeable users should change these parameters Before entering the Advanced menu a password is required The password consists of a four digit number Each PASSWORD number needs to be selected using the up or down arrows on the GSC400 1234 Simply choose the correct password number for each selected position by Next scrolling to the proper number followed xix by the Enter key The default password is 0 0 0 0 The password may be changed anytime See Password Setup section on page 73 Y The Advanced Setup menu on the ADVANCED SETUP GSC400 is shown to the right BACK J1939 Setup See Table 7 below for a list of the various submenus in the Advanced menu and a description of each Appendix A on page 106 lists the various submenus the settings they contain and the range of each setting Engine Temp Oil Pressure Fuel
7. FAILURE HISTORY 88 of 147 89 of 147 The Clock Setup menu will allow you to set the clock The clock is important if you are planning to use the event log records all failures and warnings and when they occurred or the exerciser feature starts the generator for a settable period Table 23 Clock Setup Menu 2000 2099 January December 01 31 Monday Sunday 00 23 00 59 12 Hours 24 Hours The GSC400 internal clock information can remain in memory for approximately 2 weeks when no DC power is supplied to the controller Two week memory storage is available in a completely charged controller clock DC power is required to be supplied continually to the GSC400 for approximately 1 hour to allow a complete clock charge The Basic Setup menu will allow the user to customize the basic features of the GSC400 to their preference The Contrast Adjustment allows the user to adjust the contrast of the LCD The Page Roll Delay controls how long each group of parameters are displayed in the RUN mode before displaying the next set of parameters The second line of the GSC400 LCD screen is usually dedicated to displaying warnings and events The State Roll Delay determines how long the warning or event message is displayed before moving on to the next message Setting the State Roll Delay to a large value may cause some warning or event messages to not be displayed if the event or war
8. The fan control behavior is given below The fan control also has a fan control configurable output that must be set Often two outputs are required to control a fan In most of those cases the Engine Run output is used Figure 12 below and Table 20 below describe its logic GSC400 Engine Temperature Fan output on High Fan On AN a v o eke A High Fan Setting 59C Fan output off Fan output off Time Start crank Signal success Fan Switch Fan Switch 01 Setting Dly Setting Engine Run output on Engine Run output off Fan output off Figure 12 Fan Control Logic T1 of 147 78 of 147 This section will explain how to operate the GSC400 and the settings the end user can change such as the time and date 4 1 RECOMMENDED MAINTENANCE nnne nenne nennen 79 4 2 POWER UP tae eect dla ible eee one eee 79 424 Controller AIHInITIQ stetit de ER t Og et e EO DR RN 80 4 3 REMOTE START CONTACTS EMERGENCY STOP rennen ener 80 4 4 CONTROLLER STATES EET RC Re ERU SP Ete se Set eee 82 441 ce tto a aue n ea x d a RR V RET EER 82 BAD Seep E 82 443 AUTO ERO REE GER EU Re ESPERTI EH RR UN 83 444
9. C Fuel Rate L min Engine Torque 96 Friction Torque 96 Load 96 Boost Pressure kPa Oil Temperature 9C Fuel Rate L min Set Speed RPM ECM Battery V Load 96 Fuel Rate L min Barometric Pressure kPa Fuel Temperature C Oil Temperature 9C Set Speed RPM ECM Battery V Load 96 Fuel Rate L min Barometric Pressure kPa Fuel Temperature C Oil Temperature 9C Engine Torque 96 Friction Torque 96 Load 96 Boost Pressure kPa Oil Temperature 9C Fuel Rate L min No Display No Display Engine Torque 96 Friction Torque 96 Load 96 Boost Pressure kPa Oil Temperature 9C Fuel Rate L min Barometric Pressure kPa Boost Pressure kPa Engine Torque 96 Intake Temperature 9C Load 96 ECM Battery Voltage V Engine Torque 96 Load 96 Intake Temperature 9C Fuel Rate L min Barometric Pressure kPa ECM Battery Voltage V Loss of ECM Setting There is also a Loss of ECM submenu in the J1939 menu that you should enable if using J1939 When enabled the controller will shut down on a failure when certain J1939 messages have not been received on the CAN bus for approximately 6 seconds Parameter Display Special Case When there has been no data received for a specific parameter that parameter will display N A in place of the value This will disappear once data for the parameter is received from th
10. DYNAGEN contro solutions you can trust GSC400 Series Automatic Gen Set Controller Manual Revision 4 3 MANUAL RUH Batt Status B Not in Auto Low Coolant EPS Supplying WP Load Am 7 Preheat x 3 Failure L GSC400 Automatic Gen Set Controller Installation and User Manual MAN 0076 Rev4 3 GSC400 User Manual doc June 2015 2 of 147 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 GSC400 Webpage For up to date manuals and other information please see the GSC400 section of the Dynagen website at www dynagen ca support www dynagen ca products GSC400 GSC400 Specifications 3 of 147 VDC Rating 12 24 VDC Standby Current 50 mA 12 VDC Operating Temp 40 C to 70 C 40 F to 158 LCD Operating 20 C to 70 C 4
11. Modbus Devices RA400 Annunciator WS100 200 g 5 Internet Cellular MPU Use 120 impedance twisted GEN i pair cable for A and B Sensor Modbus ground must be common connected between all puis N Do NOT modbus devices B ids Mer Pressure connect to atte using generator mains Tor Battery 12VDC 28 Use 12VDC relay for 12VDC speed J17 J18 must connect or chassis or battery use 24VDC relay for to generator mains GSC400 24VDC battery does not sense speed via the GSC400 LS HARDWARE USERS Note mne lI ENGINE J1939 Pin 8 of the analog input terminal is ground not CANL BUS indi Engine 5V as indicated 8 if applicable Temperature Firmware 2 04 06 Note Connect engine temp sender to pin 3 or 4 if using the Dynagen supplied sender Pin 2 cannot be used for firmware below 2 04 06 out of the box Example only Not required if using J1939 GSC400 LSB System Wiring Diagram DWG1439 Rev1 9 Figure 4 General GSC400 System Wiring Diagram 16 of 147 Table 2 GSC400 Terminal Details Crank 12 30A at Crank Output Terminal Battery x 2 12 12VDC Positive Battery Terminal Battery x 2 12 20A at Negative Battery Terminal Fuel 12 24VDC Fuel Output Terminal Extra Relay 1 2 12 Extra Relay Dry Contact Speed 1 2 18 100mA Speed Signal Connection Total controller current output max 60A at 12VDC 30A at 24VDC
12. 7mA Max Input E H Sw to Gnd Gnd Fail 7mA Max Digital Output Output A H 200 mA Max Extra Relay 30A Max Exerciser Enable Disable 10 240 Minutes Battery Recharge Enable Disable 10 240 Minutes Password 4 Digit 0 9 LCD Display 128x64 Graphic display Backlit 60 viewing angle LED Display Red Green Yellow LED representation Daytime Visible 60 viewing angle Programming Manual Software Field upgradeable J1939 Interface Low emission capable Relays Replaceable relays for Crank Fuel Extra output 12 or 24VDC Coil Dimensions W x H x D 139 x 113 x 65 mm 5 47 x 4 45 x 2 56 in Weight 0 45 Kg 1 0 Lb t Voltage measured L N L L is calculated Use of Industry Standard CT Required 30A max at room temperature 20A max for 24VDC The LCD display will exhibit color and response time changes at high and low temperatures respectively but will not be damaged as long as within Operating Temp 4 of 147 Abbreviated Table of Contents 1 GSC400 CONTROLLER SERIES INTRODUCTION eere eene entente nett nnns 8 2 INSTALLATION AND WIRING eere en eee ee tnnt nentes tots tn tata tatu snas tatnen enne 11 3 GSC400 CONFIGURATION eere eres ee tn tata tatnen inta sn sn stata tse n esent soto tots tn tn en enen en tn snas 43 4 OPERATION AND END USER CONFIGURATION eere erento tatnen tatnen tn tnsn 78 APPEN
13. Crank Disconnect 650 RPM Cool Down Delay 0 seconds Crank Oil pres 0 PSI Shut Inhib Src Disabled Shut Inhib Thr 10 0 PSI Bypass Cooldwn Disable Extra Relay Glowplug Output A Disable Output B Disable Output C Disable Output D Disable Output E Disable Output F Disable Output G Disable Output H Disable Exerciser Enable Disable Run Duration 30 minutes Pre Alarm Delay 5 minutes Repeat Frequency 336 hours 14 days Start Hour 12 Start Date 8 116 of 147 Input A Bat Disable Input B Bat Disable Input C Bat Disable Input D Bat Disable Input E Gnd Disable Input F Gnd Disable Input G Gnd Disable Input H Gnd Disable Low Auto Charge Disable Charge Pre Alarm 1 minute Charge Duration 91 minutes Recharge Level 10 4 volts Low Warn Level 11 2 volts Low Fail Level 7 volts High Warn Level 15 volts High Fail Level 16 volts Low Vot InCrank 8 Password No 1 0 Password No 2 0 Password No 3 0 Password No 4 0 Reset Counter N A Enable Counter Disable Count Interval 210 hours Device Address 1 Baud Rate 9600 Failure Table 1 Warning Table 1 Events Table 1 Failure Table 2 All failures checked All Warnings checked All Events unchecked All failures unchecked Warning Table 2 All Warnings unchecked Events Table 2 All Events unchecked Dummy Load Disable Dummy Load Dly 10s Dummy Load On 50A Dummy Load Off 50A LCD Heater Disable High Fan On 90 C Fan Switch Dly 6s 117
14. GSC400 ensure that the controller is in the OFF mode is isolated from all possible sources of power and the crank wire is removed from the controller Table 21 Recommended Maintenance Making the controller safe for inspection Disconnect all possible power sources and maintenance before controller inspection Inspect controller mounting location for Inspect mounting location for any safety or possible safety issues fire issues Inspect for dirt wiring damage and mechanical damages Inspect controller for loose fasteners Check all hardware including controller terminals and wiring connections wiring terminals etc for any looseness due to vibrations etc Clean area around controller Periodically inspect and remove any debris dirt from within or near the controller Check for any overheating due to loose Check for any discoloration melting or connections blistering of any wiring or connections Perform regular testing of controller Perform regular testing of the controller to check for proper operation The very first time the controller is powered up the unit will go through an initialization where all the configurable settings are set to factory default values This will happen only on the first power up Once the initialization is finished the controller will display the firmware and hardware version on the screen and flash the indicator lamps on the side of the controller this wil
15. Generator RPM too high See section 3 5 on page 55 Generator voltage high See section 3 7 2 on page 58 GSC400 was powered up from unpowered state Software in the GSC400 encountered a problem and had to perform an automatic recovery If this occurs record the numbers displayed and contact Dynagen The GSC400 was started stopped from the remote start contacts These are internal GSC400 failures Try power cycle the GSC400 If the failure occurs repeatedly the unit could be defected Analog sender reads zero volts or close to zero This could be caused by a shorted sender This is an internal GSC400 failure Try power cycling the GSC400 If the failure occurs repeatedly the unit could be defected The generator frequency is too low See section 3 7 1 on page 58 The engine speed is too low See section 3 5 on page 55 95 of 147 The generator output voltage is too low See section 3 7 2 on page 58 96 of 147 Some industry standard failures warnings and events on the GSC400 are indicated by a series of LEDs on the left side of uds the controller i DynaGen Specific LED indicators will be illuminated depending upon the condition of the controller The GSC400 LED indicators allow a quick check of the controller s condition The GSC400 displays multi color LED s for specific condition representation Red Represents Failure Conditions z Yello
16. Temp High Fail Temp Low Warn Temp Low Fail Pres Units Pres High Warn Pres High Fail Pres Low Warn Pres Low Fail Level Units Level High Warn Level High Fail Level Low Warn Level Low Fail Analog Group Switch Input Sender Input 10 60 Seconds Closed Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Fahrenheit Celsius 10 265 F 10 265 C 10 265 F 10 265 C 10 265 F 10 265 C 10 265 F 10 265 C PSI kPa 0 700PSI 0 700 kPa 0 700PSI 0 700 kPa 0 700PSI 0 700 kPa 0 700PSI 0 700 kPa Percentage 0 10096 0 100 0 10096 0 10096 Temperature Pressure Level Signal Source Rated Freq Rated RPM Over RPM Warn Over RPM Fail Under RPM Warn Under RPM Fail J1939 Mag pickup Gen output 10 9990 Hz 200 4000 RPM 100 5000 RPM 100 5000 RPM 100 5000 RPM 100 5000 RPM DisconnectFreq Over Freq Warn Over Freq Fail UnderFreq Warn UnderFreq Fail 1 100 Hz 1 100 Hz 1 100 Hz 1 100 Hz 1 100 Hz Voltage Source Voltage Display Voltage Group Group 1 Setting Group 3 Setting Group 4 Setting Over Volt Warn 1 Over Volt Fail 1 Disable Enable Line Line Line Neutral Both 1 Single 2 Three 3 Hi Wye 4 Three phase 3 Wire Single 2 Wire Single Normal Voltage 2 Times Voltage Four Wire Delta Three Phase 0 700 VAC 0 700 VAC 109 of 147 Under Volt Warn 1 0 700 VAC Under Volt Fail 1 0 700 VAC Over Vol
17. 0x06 only MOORES GAG High Slave Address This is the slave GSC400 address Function Code The GSC400 supports two Modbus commands 0x03 Read Holding Register 4x and 0x06 Write Single Register Data 0x03 Read Holding Register The GSC400 deviates from the Modbus spec in that it only allows a master to read 20 bytes at a time Reading more than 20 registers at a time will give an illegal address error Also be careful to not read invalid registers as the GSC400 register map is not continuous The Data field contains 4 bytes 1 The first two bytes specifies the starting register to read value Modbus register 40001 For example use 0x00 0x01 for Modbus register 40002 Use 0x01 Ox2B for Modbus register 40300 2 The third and fourth bytes specifies the number of registers to read Larger requests will generator a Modbus error For example use 0x00 0x14 to read 20 registers 125 of 147 0x06 Write Single Register Note There are only two addresses that support the 0x06 command 40098 and 40130 The Data field contains 4 bytes 1 The first two bytes specifies the starting register to write to value Modbus register 40001 2 The second two bytes specifies the 16bit value to write The LSB of each byte of data transmitted first The GSC400 supported baud rates are 9600 19200 38400 and 57600 The recommended request rate is 1000ms but at least ensure a 50ms delay
18. 14 2 4 POWERING THE GSC400 AND BASIC CONNECTIONS eere 18 2 5 SPEEDINPUTS creen ae deiade Lu e 20 25 1 Generator AC Voltage eene 20 23 2 Magnetic PICKUp s eH ERE ERRARE EE EUER tad eae 20 PEEL EE 20 224 Troubleshooting iis eet RR at eases testa an ten ERREUR URN ERA He 20 2 6 SENSOR INPUTS SENDERS SWITCHES sse nennen 22 PW EMEN ITI EET 22 2 6 2 Senders ic ie RR ERR HR Re 23 2 6 3 0 SVD 24 264 Troubleshooting sss RR RE EEEE AAEN 25 2 7 AG VOLTAGE AG F REQUENCY o RED dre e Bante aes DUE ORC gebe toe dirae 27 2 8 dS eR ER ERR rhet Bec CUR HR pea QM DOR 31 2 9 AC CURRENT AND VOLTAGE CALIBRATION sseseseeeeeeeetne enne nennen nennen 32 2 10 CONFIGURABLE SWITCHED INPUTS CONFIGURABLE OUTPUTS 33 2 10 1 Timed Output on Failure Shutdown sese 35 241 QAN J1939 s inue eR RUBIO I RR ee HE EC HUS 36 2 12 MODBUS SETUP ree PI HERR RI UG RU eee 38 2 13 IDLE MODE Mc EE 40 2 13 1 Idling Engine during Warm up and 1 40 GSCA00 CONFIGURATION stato aee eH vae ERE 43 3 1 MAKING MENU SELECTIONS cccccccesecsesscsseecsseecesecosesecssesecsacsecsaccseeaecstcsecsacsecsaseeeeaseasensens 44 3 2 ADVANCED SETUP MENU OVERVIEW essere nennen 45 3 3 ENGINE LOGIC T
19. 147 The following table lists the defaults for the Auxiliary Analog 1 and 2 Table 5 Default Senders for Auxiliary Analog Inputs 1 and 2 Temperature Pressure 3 and 4 Note there is no default stored for Level types You must use the PC Configurator to store a custom table Each sender has a particular pin it is supported on If your sender part number is not listed in the table or your desired pin is not supported the PC Configurator can be used to create and store a custom table refer to manual MAN 0079 the GSC400 PC Interface manual The GSC400 has Open and Shorted sender diagnostic features These are disabled by default The Shorted and Open Sender Detection will trigger on the voltages given in the below table You may not be able to enable these features as some sender tables encroach on these voltages Table 6 Analog Input Shorted and Level Thresholds 0 12 4 76 0 04 1 59 0 04 1 59 0 04 1 59 0 12 4 76 0 04 1 59 If you have an electronic sender that outputs a voltage between 0 and 5VDC you can use it on the GSC400 You will need to create a sender table for it See manual MAN 0079 GSC400 PC Interface Guide for information on creating and using sender tables Only pins 2 and 6 will give the full range of the sender The other inputs have a gain of three which will multiply the analog signal of the electronic sender three times thus limiting it to the range
20. 3 this section is meant to be consulted when going through section 2 3 GSC400 Operation Day to day end user operation and configuration Section 4 In addition there are appendixes that contain detailed supplementary information Generator systems contain high voltage circuitry Failing to power down and lock out equipment can cause damage to the equipment or injury or death to personnel Wiring of the GSC400 should be performed by qualified electricians only The below will be used in this document to classify information Indicates something that you should take special note of but that is not a threat to safety DANGER Indicates a potential for injury or death DANGER HIGH This is similar to Danger above but relates specifically to VOLTAGE conditions where high voltage is encountered DANGER The following general safety precautions should be followed 1 The GSC400 may carry high Voltage Current which can cause serious injury or death Extreme caution must be exercised when connections are being made or broken from the controller All wiring connections must be de energized before any installations are performed 2 AC power may carry high Voltage Current which can cause serious injury or death De energize all AC power sources before any connections are performed 3 NEVER energize AC power with AC current sensing connector unplugged An energized unplugged connector could result in severe inj
21. 34 OPEN OIL LEVEL 35 SHORT OIL LEVEL 36 OPEN FUEL BASIN 37 SHORT FUEL BASIN 40 AUXILIARY FAIL 41 UNDER FREQUENCY 42 OVER FREQUENCY 44 POWER ON 45 AUTO ENABLE 46 OFF ENABLE 47 MANUAL START 49 REMOTE START 51 EMERGENCY STOP 52 CHARGE START 53 CHARGE OVER 54 MAINTAIN NEEDED 55 INITIALIZING 56 MAINTAINED 57 NEXT EXERCISER 58 RUN EXERCISER 59 EXERCISER OVER 62 LOG CORRUPTED 63 MODBUS START 162 0xA2 CONFIG FAIL 1 163 0xA3 CONFIG FAIL 2 176 OPEN AUX ANALOG 1 177 SHORT AUX ANALOG 1 178 LOW AUX ANALOG 1 179 HIGH AUX ANALOG 1 180 OPEN AUX ANALOG 2 181 SHORT AUX ANALOG 2 182 LOW AUX ANALOG 2 183 HIGH AUX ANALOG 2 233 OxE9 DTC 235 OxEB System Recovery Log Time stamp Decimal Decimal format Minute 143 of 147 Minutes 0 59 High 4 bit tens 0 5 Low 4 bit ones 0 9 Log Time stamp Decimal Decimal format Hour Low 4 bit ones 0 9 Log Time stamp Decimal Decimal format Day Date 1 31 High 4 bit tens 0 Low 4 bit ones 0 9 Log Time stamp Decimal Decimal format Month Month 1 12 High 4 bit tens 0 1 Low 4 bit ones 0 9 0 255 Lowest byte of SPN bit 8 Log DTC code 0 39 Middle byte of SPN bit 8 MSB Only valid if entry 0 31 3 highest bits of SPN and the bit contains DTC 8 is SPN MSB and bit 5 is FMI MSB Bit 8 CM other 7 bits OC bit 7 MSB message if Log Type register 40131 equals 233 Log
22. Inhibit Threshold 50 of 147 The GSC400 has support for the following sensor types Table 8 GSC400 Engine Parameters High Engine Tmp Oil Pressure Fuel Level Oil Level Fuel In Basin Low Engine Tmp Aux Analog 1 Aux Analog 2 Negative engine temperatures are not allowed for the sender inputs on the GSC400 The above sensor types can be set to a switch sender sender1 sender2 sender3 or J1939 This is done in the Signal Source menu The switch and sender choices are covered in this section For J1939 refer to section 3 8 on page 63 For each of the sensor input types you must select the pin 2 to 7 that the sender or switch is connected to in the Input Pin menu See Figure 4 on page 15 for the pin locations of the sensor input connector If you are not using one of the inputs then select Disabled Two different sensor types cannot share the same pin with the exception of the Low Engine Temperature and High Engine Temperature Input Pin Disable Note When the Input Pin is set to disabled it is actually set to a virtual input where the voltage read is 5V the signal source is set to a switch and the switch setting is set to Closed Fail This effectively disables the input If changing the signal source ensure that the Input Pin is not set to disabled If you disabled the Input Pin and are still seeing the warnings failures for the parameter set the Input Pin to
23. Sensing R Inputs VIEW LOOKING ON WIRE ENTRY END To GSC400 AC Voltage Terminals RETAINING CLIP 4 Black w Red Trace Phase A Pins 1 and 10 of the Configurable Battery Output terminal provide access to Configurable Switched Inputs 9 GREY Emergency Stop 8 Blue Switched Input A Switch Inputs A to D can be tied to any Battery point 7 Yellow Switched Input B Pins 11 and 12 provide access to Battery GND as a convenience for users Switched inputs E to F can be tied to any Battery point 4 Orange Switched Input E To use Emergency stop insert a N C switch in this loop Linen Ground Remote Start 10 Purple Remote Start Stop Contacts Sensor Inputs 1 Brown Sensor Common If not required remove Do not connect to Battery or chassis 1 Wire Senders Connect as shown in drawing Ground is provided through the chassis Pin 1 Brown wire is not needed Ensure that there is a proper ground though the chassis back to the GSC400 Extra Sensor Input wire fuel level oil level Oil Pressure Engine Temperature 2 Wire Senders The sender provides a second wire terminal for ground Connect this to pin 1 Brown wire of the GSC400 Sensor Inputs terminal f using Dynagen supplied senders connect as shown Otherwise sender types can be connected to any sensor input Battery as a convenience for users Generator 1
24. The controller will automatically shut the GenSet down and re enter the AUTO mode if it initiated a generator start When the controller is in the RUN mode generator parameters will be displayed on the screen to allow the user to monitor the engine status These include engine speed generator voltage and current and engine temperature as well as others The parameters are displayed in groups and the screen scrolls between the various groups The Page Roll Display menu option controls how long each parameter group is displayed on the screen before moving on to the next group See Table 24 on page 90 for more information If an analog input is set to a Switch the GSC400 will display SW where normally the value is displayed If the analog input is set to J1939 or an analog input then the actual value of the input will be displayed When in the RUN mode the GSC400 LCD screen can be locked to display a particular parameter group To do this press the up or down keys to scroll to the parameter group you wish to view and then press the ENTER key to lock the screen You will see a lock symbol displayed on the top right hand side of the display just under the date and time To unlock the screen press Enter again which causes the lock symbol to disappear and the screen will start to scroll though the parameter groups again The screen will automatically unlock after 10 minutes For generators that have the capability of idling at a lower speed
25. The sensor types Dynagen supports out of the box for engine temperature and oil pressure are given in the following table Fuel Level Oil Level and Fuel in basin senders are not supported out of the box the PC Configurator must be used to store a custom table for these types Table 4 Default Senders for Temperature and Oil Pressure Tem 4 2 129 to 330 F 9 2 72 to 267 OF High Temp 3 and 4 77 to 266 F Low Oil Pres 3 and 4 0 to 99 PSI Low Oil Pres 3 and 4 0 to 99 PSI Hon OM yes 6 0 to 100 PSI Electronic The table above applies to controllers with firmware version 2 04 06 and above Other firmware versions do not support Datcon on pin 2 or Sensata out of the box The PC Interface is required Dynagen supplies these senders as part of the GSC400 starter kit optional 2 If the high engine temperature sender is set to pin 3 or 4 do not enable the shorted sender detection features 3 Dynagen supplies and recommends the Sensata oil pressure sensor for heavy duty or 24 7 applications 4 The GSC400 will only display the minimum or maximum value of the range for readings below or above the Sensing Range respectively 5 Although the GSC400 supports the VDO oil pressure sender above VDO does not warranty their senders if used in electronic controls such as the GSC400 6 The recommended maximum torque for the Stewart amp Warner sender is 8 in lbs 24 of
26. This input generates a Low Air Pressure failure when active only in Crank It is ignored in the OFF AUTO and RUN modes This input generates a Low Hydraulic Pressure failure when active only in Crank It is ignored in the OFF AUTO and RUN modes This input generates a Low Oil Pressure failure when active only when the controller is in the RUN mode This digital input is used to meet NPFA110 requirements but is not required if using AC current sensing as the GSC400 Front Panel EPS Supplying load indication lamp will light if AC current is detected See the current sensing setup section 3 7 3 on page 62 for more information After crank success if the input is active the EPS Supplying Load lamp on the GSC400 front panel will turn on A message over modbus is also sent to support RA400 remote panel or custom project If the generator is starting up but is not running i e the controller is not in the RUN Mode and if the EPS supplying load input is active the GSC400 will cancel the start sequence and enter the failure state on an EPS load failure Note in firmware version 2 03 and below the EPS Supplying load failure will also trigger if the output becomes active within 10s after the RUN state was entered Note the AC current method does not generate an EPS Supplying Load Failure condition it only turns the lamp on or off This input silences the buzzer on the GSC400 unit when active This input g
27. crank output is turned off and the controller waits a period specified by the Crank Rest Time The locked rotor condition is also checked while cranking see 3 3 1 1 Locked Rotor below The fuel output is also turned off unless the Fuel On During Crank Rest is enabled 48 of 147 If the Midheat Time is greater than zero the glow plug output remains on during cranking but not during crank rest The glow plug output turns off if a crank failure occurs once crank success is reached unless the PostHeat is set to a value greater than Os or if the Midheat time expires After the crank rest delay expires the controller turns on the fuel and crank outputs and attempts to start the generator again This is repeated until the number of tries equals the Crank Attempts If the controller cannot start the generator after the set number of crank attempts the failure state is entered and an over crank failure is displayed on the screen If the generator starts successfully and the Restart on False Start is set to Enabled then the engine speed is monitored for 10 seconds If the engine speed goes below the crank disconnect speed the controller attempts to restart the engine generator If the Off key is pressed during these 10 seconds the engine will go into the OFF mode without cooling down if cool down is enabled At the same time if the Warm up sub menu is set to a value greater than zero a configurable output can be set to turn on one of
28. indicate lamp status Bit 6 5 red stop lamp status Bit 4 3 amber warning lamp status Bit 2 1 protect lamp status Low byte reserved for lamp status Previous Active DTC 0 65536 R No 1 Same format 0 65536 R as Active DTC registers above Registers 40183 to 40244 are not shown They contain Previously Active DTC No 2 to 32 and are in the same format as above Same format as Active DTC registers above 145 of 147 This appendix was created to assist the user in decoding the information contained in the modbus DTC DM1 and DM2 registers if the generator ECM does not support the newest DTC conversion method The diagnostic trouble codes on J1939 are specified in a specific format Older J1939 specifications had three conversion methods for the SPN and it was impossible to tell them apart from the DTC data alone One had to consult the engine manufacturer Newer J1939 specifications follow one SPN method Version 4 and the user can determine if this method applies by looking at the CM bit It will be set to 1 if Version 4 applies and set to 0 if Versions 1 2 or 3 applies If the CM bit is 0 see below for the three conversion methods Byte 1 to Byte 4 refers to the individual bytes in the GSC400 DTC Modbus registers See registers 40115 and 40116 on page 144 above DTC Conversion Method Version 1 Byte 1 8 most significant bits of 16 most significant bits of SPN Byte 2 8 least significant bit
29. magnetic pickup generator voltage J1939 under 3 5 55 and over speed warnings and failures AC Frequency The crank disconnect frequency and the over under frequency warning failures The AC voltage sensing display is SO EIS contained here as well as the over and 3 7 58 under voltage warnings and failures AC Cure The CT ratio AC current sensing and display enable are contained in this menu Engine Logic All the basic start and shutdown logic are 33 EM 3 47 contained in this menu This menu allows you to assign a EIN feature action to one of eight configurable 3 10 69 outputs For example you can turn on an output when an under speed failure 46 of 147 occurs Exerciser Set Generators require periodic operation as part of their scheduled maintenance This menu allows settings to control how often the engine generator is started and for how long 3 11 72 Inputs Setup i e Configurable Switched Inputs This menu allows you to assign features warnings for example low oil pressure to one of eight digital inputs 3 9 67 Battery Setup This menu controls the settings for the battery under and over voltage warnings and failures It also allows the user to set at what battery voltage to start the generator and how long the generator is to remain running 3 6 57 Set Password The advanced menu requires a password for access The user can change the passwo
30. minutes Recharge Level 7 24 volts Low Warn Level 7 24 volts Low Fail Level 7 24 volts High Warn Level 12 32 volts High Fail Level 12 32 volts Low Vol InCrank 4 18 volts 111 of 147 Password No 1 Digit 1 0 9 Password No 2 Digit 2 0 9 Password No 3 Digit 3 0 9 Password No 4 Digit 4 0 9 Reset Counter No Yes Enable Counter Count Interval Disable Enable 10 to 1000 Hours in 10 hour increments Device Address Baud Rate 1 247 9600 19200 38400 57600 Failure Table 1 Warning Table 1 Events Table 1 Failure Table 2 Warning Table 2 Events Table 2 Failures Disable Over Crank Locked Rotor HighEngineTemp LowOil Pressure Over Speed Low Fuel Level Oil Level Low Coolant Low Air Pres Low Hydraulic Auxiliary Fail Low Battery High Battery UnderSpeed Under Voltage Over Voltage Over Current Loss of ECM EPS Load Fail Config Fail 1 Config Fail 2 Warnings Disable HighEngineTemp LowOil Pressure Over Speed Low Fuel Level Oil Level Fuel In Basin Auxiliary Warn Charger Fault Low Battery High Battery Under Speed Under Voltage Over Voltage Over Current LowEngine Temp High Fuel Level Config Warn 1 Config Warn 2 Events Disable EPS Load On Idle Running Service Needed Not In Auto LoBatt InCrank Dummy Load Dummy Load Dly Dummy Load On Dummy Load Off LCD Heater High Fan On Fan Switch Dly Disable Enable 10 120s 0 500A 0
31. relay is on with the exception of crank rest where it remains active regardless of the state of the fuel relay It is off when the fuel relay is off The output is usually used to turn off the generator voltage regulator but can be used for any purpose Transitioning from IDLE Mode to RUN Mode When coming out of Idle mode the warnings and failures behave the same as from the AUTO mode Warnings come into effect after 5s and failures come into effect after 8s You may need to tune the electronic governor so that the engine is up to full speed in time For users who have engines that idle during warm up and or cool down two configurable outputs be set to Warm up and Cool down and tied to the Idle Mode switched input via one or two external relays shown in Figure 9 below Refer to the previous section to setup the Idle Mode Switched Input and then follow the diagram below 41 of 147 If Idle Mode set to Input A to D Idle Mode Input trigger on battery GSC400 Warm up Output Cooldown Output If Idle Mode set to Input E to H Battery Idle Mode Input trigger on battery GSC400 Cooldown Output Battery Warm up Output Idle Mode In Warm up Cooldown App Note DWG1465R1 0 Figure 10 Idle Mode during warm up and cool down application note 42 of 147 This page intentionally left blank 43 of 147 This section will explain the various menus used to configure
32. the configurable outputs or Extra relay must be set to Warm Up when the warm up is finished This is used to disengage any load or potential loads until the gen set is warmed up During the Warm up time the output remains off Once the controller enters the Running state and if the PostHeat time is greater than 0 the glow plug output is turned on for the duration of the PostHeat time Locked rotor is a genset protection feature using the oil pressure sender input To disable this feature set the Crank Oil Pressure in the engine logic menu to 0 The Crank Oil Pressure is the lowest normal oil pressure seen while the engine is cranking During cranking if the oil pressure is below the Crank Oil Pressure engine logic menu and if the engine speed and AC frequency are both 0 the crank time is shortened to 3s including the time passed in cranking If the genset has not reached the crank disconnect speed frequency or the Crank Oil Pressure at the end of the 3s the GSC400 will stop cranking and go into a Locked Rotor Failure This feature limits damage to the generator if something is preventing the engine crankshaft generator rotor from rotating When the OFF key is pressed while the engine generator is running and if the Cool Down submenu is set to a value greater than 0 seconds the generator will 49 of 147 go into Cool Down mode where an output is turned on one of the configurable outputs must be set to Cool Down Once the Cool Do
33. tie common of each CT to its designated negative terminal on controller tie common of CTs together Figure 7 CT Installation Do s and Don ts from DWG1469R1 0 Each GSC400 undergoes an advanced two point calibration at the factory and typically does not require calibration except in the following instances 1 Current Transformers CT are used that have poor tolerances 2 The AC signal from the generator is distorted with a high total harmonic distortion THD One cause is VFD Variable Frequency Drive devices DynaGen has a software utility that can perform a basic calibration of the current and voltage Menu Location Page 1 Configurable Advanced Setup gt Inputs Setup 67 Switched Inputs 2 Configurable Advanced Setup gt Outputs Setup 69 Outputs Configurable Switched Inputs Four of the switched inputs A to D trigger when battery is applied The other four inputs E to H trigger when battery is applied The switch inputs are user programmable They are disabled by default Configurable Switched Outputs All 8 of the switched outputs switch the output pin to battery negative when activated Each switched output can be user programmed to activate on an event that occurs in the controller They are disabled by default Note Pins 11 and 1 also provide battery Cground for convenience Configurable Switched Inputs A to D require a high s
34. to a Sender for these to work See section 3 4 6 on page 53 for more information 72 of 147 The GSC400 can be set to automatically start the genset at regular intervals while in the AUTO mode This is controlled by the Exerciser Setup menu The Exerciser Enable should be set to Enabled if this feature is desired The GSC400 will display a message and sound the buzzer for a set amount of time Pre Alarm Delay to alert nearby personnel that the generator is about to start The engine generator will run for a set period of time Run Duration and then shut down The Start Date and Start Hour determine the date 0 to 31 and time when the engine generator will first start After the first exerciser start the engine generator will start up on regular intervals given by the Repeat Freq which is measured in hours Pre Alarm Delay V Repeat Interval Engine Run E Run Duration Engine Off Time Start Start Date Hour The exerciser feature depends on the GSC400 internal clock Make sure the clock is set to the proper time and date GSC400 internal clock information can remain in memory for approximately 2 weeks when no DC power is supplied to the controller Two week memory storage is available in a completely charged controller clock DC power is required to be supplied continually to the GSC400 for approximately 1 hour to allow for a completely charged clock The remote start contacts
35. value must drop below the warning and or failure setpoint Warnings and failure thresholds are only supported when using senders or J1939 The Low Oil Level and Fuel In Basin warnings are global meaning they are always active even in the OFF state The warnings for these also ignore the Bypass Time 53 of 147 Open Sender Detection or Shorted Sender Detection provides diagnostics on the sender See the installation chapter for more details Set to Warning Failure or Disable When changing the units the controller will do a conversion of all settings to the new unit It is possible that the conversion will cause one or more settings to go out of bounds The Low and High Engine Temperature types can share the same sender To do this set both to the same input pin as follows 1 Set the High Engine Temperature to the desired pin e g Analog2 You will see a checkmark beside Analog2 2 Set the Low Engine Temperature to the same pin You will see a dash beside the one occupied by High Engine Temperature Select the same pin and the dash will turn into a checkmark If the high engine temperature and low engine temperature are already set to the same input pin you will only see a checkmark in each You will need to know the resistance of the sender at 0 25 75 and 100 fuel levels The resistance values must be either monotonically increasing e g 1 2 8 4 5 or monotonically decreasing e g 5 4 3 2 1 In the Fuel Leve
36. wired Table 30 lists the circuits i e wires that are included as part of the harness Table 1 GSC400 Terminal Information Manufacturer and Part Number Molex 39 28 1123 Molex 39 01 2120 Molex 39 28 1103 Molex 39 01 2100 Molex 39 28 1063 Molex 39 01 2060 Molex 39 28 1063 Molex 39 01 2060 Molex 39 28 1043 Molex 39 01 2040 Molex 39 28 1083 Molex 39 01 2080 Major League Electronics TSHS 1 05 D 16 A C Amp 872275 5x5pin double header 0 1 spacing Keystone 4901 Standard 0 25 wide female 0 25 wide quick connect These are the GSC400 terminals that the wiring harness mates to Molex connectors require the following contacts Molex 39 00 0039 The hand crimp tool required to crimp the contacts to the wire is Molex 0638190900 The extraction tool part number is Molex 011030044 which allows you to remove contacts from the Molex connector without damaging the contact The extraction tool is available from DynaGen part number ACC0097 Table 2 lists the minimum wire size maximum current capacity name and function of each circuit The wire gages given in the table are the minimum recommended only To maintain UL rating the correct wire gauge as specified by UL must be used Dynagen has tested the switched inputs switched outputs analog inputs and J1939 for proper operation at wire runs of 5ft It is responsibility of the user to test ru
37. 00 for system state Digital Output 0 2047 R Read Status of controller outputs 0 Only corresponds to output OFF or NOT ACTIVE while a 1 corresponds to output ON or ACTIVE BitO Output A 0 OFF 1 ACTIVE Bit Output B 0 OFF 1 ACTIVE 138 of 147 Bit2 Output C Bit3 Output D Bit4 Output E 5 Output F Bit6 Output G Bit7 Output H 0 OFF 1 ACTIVE 0 OFF 1 ACTIVE 0 OFF 1 ACTIVE 0 OFF 1 ACTIVE 0 OFF 1 ACTIVE 0 OFF 1 ACTIVE Bit8 Extra Relay 0 OFF 1 ACTIVE Bit9 Fuel Relay 0 OFF 1 ACTIVE Bit10 Crank Rly 0 OFF 1 ACTIVE Advanced Modbus register support 1 ENGINE GENERATOR PARAMETERS Read Only Running parameters will update every 1 second The engine speed high engine temperature low engine temperature oil pressure and fuel level parameters display OxFFO1 if not available if source is J1939 The six sender inputs High Engine Temperature Low Engine Temperature Fuel Level Oil Pressure Oil Level and Fuel In Basin parameters display OxFFOO if set to switch or disabled 40150 Engine Speed 0 6553 0 R 1 bit equal 0 1 RPM RPM Reading 18000 corresponds to 1800RPM 40151 High Engine 0 250 0 R 1 bit equal 0 1 unit Reading 1000 corresponds to 100 0C Temperature 40153 Low Engine 0 250 0 R 1 bit equal 0 1 unit C Reading 1000 corresponds to 100 0C Temperature
38. 1 2 3 4 Are RS485 and common connected properly Try reversing and Are the device address and baud rate set properly in GSC400 Modbus menu under Advanced menu Is the cable type suitable for RS485 communications How long is the cable and how noisy is the environment Communication errors Even if sent an invalid command read write request for an invalid register or a read request over 20 registers the GSC400 will return an error message to the master Do not just look for register updates on the PC to determine if Modbus is working 40 of 147 Menu Location Page 1 Configurable Advanced Setup gt Inputs Setup 67 Switched Inputs 2 Configurable Advanced Setup gt Outputs Setup 69 Outputs For generators that have the capability of idling at a lower speed than the speed at which power is produced the GSC400 controller has an Idle Mode feature that suppresses the warnings and failures for under voltage under frequency and under speed The GSC400 displays Idle Running when this feature is enabled Idle Mode Switched Input The controller enters and remains in Idle Mode as long as the Idle Mode configurable switched input is active Switched Output Option If the user requires a configurable switched output to be used during Idle Mode the Voltage Regulator switched output feature can be used It is off when the controller is in Idle Mode otherwise it is on when the fuel
39. 3 1 EPS Supplying Load Front Panel Lamp sess 62 3 8 J1939 SETUP apa nie ocu eut ob NL 63 3 8 Auto Power ECM areant 65 3 8 0 Diagnostic Trouble Codes 5 65 3 8 Cummins Idle Speed 66 3 8 4 Volvo EMS2B tesserae eie e lem e E IS 66 3 9 DIGITAL INPUTS CONFIGURABLE SWITCHED INPUTS SETUP esses enne 67 3 10 DIGITAL OUTPUTS CONFIGURABLE OUTPUTS SETUP sssssesseeseeeennnnen nennen 69 3 11 EXERCISER SETUP tte ottiene tive dee t ttis ous ED UNI 72 312 PASSWORD OSETUP stereo t ete e e ee A A okt etn 73 3 13 SET MAINTAIN petiisse ote t eer tne Oed me t ettet PE otis 74 3445 3SET MODBUSCAS c ner i Datei ie tape i dient 74 3 15 COMMON FAULES cb ee etr Po re PP e e HU bn ED i e tr at 74 3 16 OTHER SETTING iicet ene et e PR t P HOD e e He tra Pr ED e PR nd aga 75 3 16 1 Dummy EOad 5 edet ee ee ee e ee e ren aee iege 75 3 16 2 A GY BY ipM ETC C 76 3 16 3 Fant CONUOM DP 76 OPERATION AND END USER CONFIGURATION scscssssssssssscssssssscessssssssssessesssserseees 78 4 1 RECOMMENDED MAINTENANCE eeseeeeeneerene nennen ener enne 42 POWER UP id oils SR ait ERE RE Ra 42 1 Controller entente teen nennen enne retener nennen 4
40. 3 REMOTE START CONTACTS EMERGENCY STOP 4 4 CONTROLEER STATES So sete onc tite otis EE MM DIU oh hae ate 4 4 1 OFF Mode disi e ee ge ere eMe IHRE E eee ER 44 2 Sleep Mode eee Reel eee rede Hoe eee Ert Eee eee oen eden 44 3 AUTO Mode iss seeded eie GEAR DR HE RH e ee es 444 RUN Mode seus uei secet cer 4 4 4 1 Locking the GSC400 Screen While in RUN Mode ALAA Die Mode ene it Ee P RH ER IET E Re IRAM 4 5 GSC400 START STOP BEHAVIOR sessi ener nre 4 6 EXERGISING iicet erronee sieh iet inue ides tet ee D et ester Gee ee eed 4 7 GSC400 MENU SYSTEM 4 8 BASIO MENU ree Ee Tee et tete eb e se EN LEL COCK Setup sso sab RR eno ee ORNA eee SO A aoa 48 2 Basic Setup odo e ode OA en boat fs 48 3 Event History E0g x sot on rehenes n eget atem eds 4 9 GSC400 LED STATUS INDICATORS niscenire E AEN e ae a r S ER 4 10 WARNINGS AND FAILURES sees etato trennen serene aE e e enne nennt enne 4 10 1 Returning to OFF Mode from a Failure sss 4 10 2 Diagnostic Trouble Code Shutdowns sse 4 10 3 Ho rmeter DIsplay a esae epeutesenedeatteten dence nei eo 4 11 ii etit se eset eR tete etai nba eite ON Rat 4 12 1939 DIAGNOSTIC TROUBLE CODE DTC DISP
41. 40154 Fuel Level 0 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 40155 Oil Pressure 0 0 R 1 bit equal 0 1 unit KPa 1000 0 Reading 1000 corresponds to 139 of 147 100 0KPa Oil Level 0 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 Fuel In Basin 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 Line Voltage A B 0 999 9 R 1 bit 0 1V V Line Voltage B C R ji idi V corresponds to 999 9 V Line Voltage C A R V Phase Voltage A R V Phase Voltage B R V Phase Voltage C R V Phase A Current 0 999 9 R 1 bit equal to 0 1A A Phase B Current R Reding 9999 A corresponds to 999 9A Phase C Current R A AC Frequency 0 100 0 R AC frequency Hz Reading 600 corresponds to 60 0Hz Engine Hours new 0 255999 9 R 32bit word register 172 Hours f w versions 2 02 is low 16bits 173 is high 16bits 1bit 0 1 and above Hours Battery Voltage 0 31 8 R 1 bit equal 0 1V V Reading 318 corresponds to 31 8V Current Run time 0 6553 5 R 1 bit 0 1 hour Hours Total run time on active 65535 corresponds to running event 6553 5Hs NOTE Timer is reset to Zero after active running event has been terminated OFF or AUTO mode waiting to start Engine Hours old 0 255999 9 R Total Accumulated Hours way use registers 40172 40173 running hours th
42. 47 of 147 GSC400 ACC0086 Typical User Setup DWG1447 Rev1 2
43. 500A Disable Enable 20 C to 120 C in 1 C increments 1 120s in 1s increments 112 of 147 GSC400 s are factory programmed and shipped with default settings loaded into the controller These are the defaults of the settings located in the Advanced Setup Menu Table 28 GSC400 Default Settings Manufacturer John Deere Display Group 1 Disable Display Group 2 Disable DTC Display Disable Active DTC Log Disable Read Stored DTC Disable Auto Power ECM Disable ECM Power Delay 6 seconds Cummins Idle Disable SPN Conversion Version 3 EMS2B Freq Sel Primary EMS2B Acc Pedal 50 Input Pin Signal Source Analog2 Low Z Dat Pin2 Sender2 Bypass Delay 30 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Fahrenheit Warning Level 200 F Failure Level 220 F Input Pin Analog3 Low Z Signal Source Datcon 1 Bypass Delay 30 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units PSI Warning Level 20 PSI Failure Level 15 PSI Input Pin Disabled Signal Source Switch Bypass Delay 30 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Percentage Warning Level 25 Failure Level 5 113 of 147 Input Pin Disable Signal Source Switch Bypass Delay 10 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Percentage Warnin
44. 7 50 173 0 74 0 74 181 5 116 0 52 43 5 202 0 84 0 84 175 128 0 57 37 232 0 94 0 94 167 5 142 0 62 30 5 263 1 04 1 04 160 154 0 67 25 296 1 14 1 14 155 168 0 72 20 330 1 24 1 24 149 2 182 0 77 16 367 1 34 1 34 144 1 196 0 82 12 406 1 44 1 44 140 1 210 0 87 8 446 1 54 1 54 134 8 226 0 92 3 8 491 1 65 1 65 129 241 0 97 0 628 1 93 120 7 736 2 12 114 2 855 2 30 107 996 2 49 99 6 1160 2 69 92 4 1349 2 87 85 4 1579 3 06 79 4 1860 3 25 72 b HIGH VOLTAGE 27 of 147 Menu Location Page 1 AC Voltage Advanced Setup gt AC Voltage 58 2 AC Frequency Advanced Setup gt AC Frequency 58 The GSC400 controller requires a neutral reference from the generator All voltages are measured line to neutral and then converted for display as line to line if required Battery negative needs to be connected to the neutral of the electrical system as the GSC400 AC voltage sensing requires a battery negative reference Follow all applicable standards The GSC400 may not sense AC Voltage and Current properly if VFD Variable Frequency Drives devices are connected to the generator The harmonic frequency must be below 260Hz Do not place more than 600VAC line to line on the GSC400 AC Voltage terminals 1A fuses should be placed in series with the voltage sensing wires to the GSC400 see Figure 4
45. C MIT 47 3 3 1 Startup 47 3 3 1 1 LOCKED sioe 48 3 3 3 Shutdown Sequence sisse nennen 48 3 3 2 1 Shutdown Inhibit for Engine Driven Compressors eese ener 49 3 4 SENSOR INPUTS rio err erm te ce n e he e e PEE 50 34 1 Switched Inputs 51 MEN ID 52 3 4 5 Warnings and Failures 71939 or Senders sss enne 52 3 44 Low and High Engine Temperature 53 34 5 Fuel Level Sender sede eere tpe teres bene 53 3 46 Auxiliary Analog 1 and 2 eene eene tenen enenne ees 53 3 5 SPEED SENSING tirer t HO RH IO ae UTR e ee e E TREES ERR ere a De re 55 3 5 1 Rated Speed sese tie eter E n RE bern IIT 35 3 5 3 Rated 55 3 6 s wii M 57 3 6 1 Start on Low Battery retener nnne eterne nnne 57 3 7 GENERATOR AC VOLTAGE CURRENT FREQUENCY SETUP 58 34d AGFrequency et ee du Re REA 58 6 of 147 34 24 FAG VONAGC sc as eA A eis Be eb e E eS 58 3 7 2 1 Voltage Select Inputs t rede tr hee ere debe REGE 61 3435 AG GUITODE ne eee i m EI 62 3 7
46. C400 To GSC400 1 1 n N 1 1 B Generator 1 1 C 3 Wire Delta Select Group 2 3 or 4 1A Fuse Note 3 wire Delta configurations are not supported by Dynagen To GSC400 1A Fuse Generator 1A Fuse Stinger high leg must be connected to phase C on the 1A Fuse SC400 4 Wire Delta Select Group 4 and set Group GSC400 Voltage Configs 4 option to Four Wire Delta DWG1468R1 2 Figure 5 GSC400 Three Phase Voltage Configurations To GSC400 2 1 A N Generator 2 1 B 2 1 C Wye Select Group 3 and set group 3 option to 2 Times Voltage 3 Wire Delta To GSC400 2 1 To Load N 2 1 B 2 1 C Select Group 3 and set group 3 option to 2 Times Voltage Note It is not possible to step down the voltage for a 4 wire delta configuration Note This drawing is provided for informational purposes only These configurations are not supported by Dynagen 1 Amp fuses are required to be placed on each sensing line before the primary of the transformer Figure 6 Three Phase AC Voltage Step down Options GSC400 AC Voltage Stepdown DWG1470R1 1 HIGH VOLTAGE DANGER HIGH VOLTAGE E Menu Location Page 1 AC Current Advanced Setup AC Current 62 The GSC400 controller is designed to measure AC current from the generator with the use of current transformers CTs CTs with a rating of 5A on the secondary are required
47. DIX A GSC400 DETAILED ADVANCED MENU 106 APPENDIX B DEFAULT CONFIGURATION SETTINGS eese eeeeetetetntntnennnn 112 APPENDIX C GSC400 FIXED WARNING FAILURE EVENT 117 APPENDIX D ACCESSORY Bl 121 APPENDIX E MODBUS MABP eere reete eene tette tatnen inen tn sn sn stata tatnen nene eese totos tn ts tuts en en 124 APPENDIX F J1939 OLD DTC CONVERSION METHOD csssssssssssssssssssssssssssssssseseseseees 145 APPENDIX G ADDITIONAL DRAWINGS eere eene entente nene ts tots ta tn tn 146 5 of 147 Detailed Table of Contents 1 GSC400 CONTROLLER SERIES INTRODUCTION eese eere esee teen enano tatnen 8 1 1 HOW TO USE THIS MANUALS eec teeth eee et ertet rere eta reto eire uh 9 1 2 SAFETY INFORMATION mIRC 9 1 3 GSC400 PRODUCT NUMBER IDENTIFICATION c ccccesscssesecsscescsssescesecseesecssesecsceecascateaeeaees 10 INSTALLATION AND WIRING Q 0 0 ssssscsccesscsesscsssececsssessssesecessssesscsssecessesesscsesecessesessesesecsssesers 11 2 1 Msc e 11 2 2 GSC400 COMPONENT RATINGS STANDARDS cessere enne eren 13 2 3 WIRING OVERVIEW cccccccesscocesscsscstesseceesecoecsscssessesseseensecatesscstestensesuensecatssscatestcecenensecneease
48. F to 158 F Temp 40 C to 70 C 40 F to 158 F with heater H option consult factory Function Function Selection Range Selection Speed Sensing Generator pickup 0 300vac 0 3600rpm Range Magnetic pickup 0 300vac 0 3600rpm Voltage Sensing Single phase 70 346vac L N 600V L L L Three phase L calculated from L N Delta Wye Accuracy 1 L N Full Scale Current Sensing Enable Disable Max 5A 2 Full Scale Harmonics present on the AC lines cannot exceed 260Hz VFD Variable Frequency Drive devices often cause harmonics that exceed this value Frequency Sensing Enable Disable 1 100 HZ Engine Temp GND Fail Open Fail Depends on sender Oil Pressure GND Fail Open Fail Depends on sender Oil Level GND Fail Open Fail 0 100 Depends on sender Fuel Level GND Fail Open Fail 0 100 Depends on sender Engine Logic Delay to start 0 60 seconds Pre heat 0 60 seconds Crank 3 60 seconds Rest Time 1 60 seconds Mid Heat 0 60 seconds Crank attempts 1 60 tries False restart Enable Disabled Post heat 0 60 seconds Warm up 0 600 seconds Cool down 0 600 seconds Crank oil pressure 0 700 PSI Crank Disconnect 100 2000 RPM Analog Input Input 2 Low Z Gain 1 Gnd Fail Open fail 7mA Input 3 4 Low Z Gain Max 3 Note On LS LX controllers Input 5 7 High Z Gain Input 2 is High Z Gain 3 and Input 6 has a gain of 3 Input 6 High Z Gain 1 Digital Input Input A D Sw to Bat Bat Fail
49. G 1 warning 77 HIGH AUX ANALOG 1 warning 78 OPEN AUX ANALOG 2 warning 79 SHORT AUX ANALOG 2 warning 80 LOW AUX ANALOG 2 warning 135 of 147 81 HIGH AUX ANALOG 2 warning 255 OxFF Empty No message in queue Active Failure R Read Only If the controller is in an active FAILURE mode the failure number in register 40108 corresponds to the below failure mode 0 reserved 1 Internal reserved 1 ADE Read 2 Internal reserved 2 KEYBOARD 3 Internal reserved 3 ADC read 4 Internal reserved 4 RS485 5 Internal reserved 5 RS232 6 Internal reserved 6 ADE Write 7 Internal reserved 7 TLE6230 8 Internal reserved 8 EEPROM 9 Reserved 10 HIGH ENGINE TEMP 11 LOW OIL PRESSURE 12 UNDER SPEED 13 OVER SPEED 14 LOW FUEL LEVEL 15 LOW BATTERY 16 LOW COOLANT 17 OVER CRANK 18 OVER VOLTAGE 19 UNDER VOLTAGE 20 OVER CURRENT 21 EPS LOADS ERROR 22 LOW AIR PRESSURE 23 LOW HYDRAULIC 24 LOW OIL LEVEL 25 LOCKED ROTOR 26 HIGH BATTERY 27 LOSS OF ECM COMMUNICATION 28 OPEN ENG TEMP applies to both High and Low Engine Temperature 29 SHORT ENG TEMP applies to both High and Low Engine Temperature 30 OPEN OIL PRES 31 SHORT OIL PRES 136 of 147 32 OPEN FUEL LEVEL 33 SHORT FUEL LEVEL 34 OPEN OIL LEVEL 35 SHORT OIL LEVEL 36 OPEN FUEL BASIN 37 SHORT FUEL BASIN 40 AUXILIARY FAIL 41 UNDER FREQUENCY 42 OVER FREQUENCY 162 USER CONFIG FAIL 1 163 USER CO
50. GSC400 generates a warning only No failure setting is possible 52 of 147 Table 9 Default Sender Tables Front Panel E Menu Name Datcon 1 Dat Pin2 VDO2 Datcon DAH Datcon DAH e g 2022 00 e g 2022 00 02024 00 02024 00 DO 328 421 02025 00 02025 00 3 4 2 3 4 Front Panel Menu Name Datcon 1 VDO 1 Sensata Datcon 2505 00 STEWART amp Sensata 67CP WARNER VPO 360 004 0320150GFNA0C 279B F 3 4 3 4 6 For LSB LXB LSC LXC controllers For LS LX controllers pin 2 can also be used Some senders can be supplied by Dynagen Refer to Table 25 Senders Part List on page 122 for the Dynagen stock code Datcon 2505 00 ACC0074 replaced by STEWART amp WARNER 279B F ACCO0108 which is drop in replacement Note that the senders listed in Table 9 can only be used on the inputs given in the table If your sender is not supported or you wish to use a sender on an unsupported input then you have to use the sender table configuration utility built into the PC Configurator that allows you to create new sender tables or to modify supported ones for the input you desire Refer to the PC Interface manual for more information Each of the sensor types supports Warnings and or Failures In the case of high engine temperature if the data from the sender or J1939 exceeds the setpoint then the controller will give a warning or failure For the other sensor input types the
51. LAY sss 4 12 1 DMT enne teen tne teens teen 4 12 2 DM2 esee seen enne teen enne teen enne 4 12 3 DMT Event eene etaed eade APPENDIX A GSC400 DETAILED ADVANCED MENU LAYOUT APPENDIX B DEFAULT CONFIGURATION SETTINGS 112 APPENDIX C GSC400 FIXED WARNING FAILURE EVENT DELAYS 117 APPENDIX D ACCESSORY 121 7 of 147 D 1 GSC400 CONTROLLER HARNESS ACCESSORIES eeeeeeeneeeeee etre 121 D 2 GSC400 PROGRAMMER oreet ee D e e REO CU DE UU ede te E ep v LEE REDDE DER NRI 121 D 3 CT S CURRENT TRANSFORMERS csccccssesssscsseseescseeseeecsessececseeseeecsecsececsecsececsecseeeeseeaeeeses 122 D 4 SENDERS hon e EE bese Ree NEL d ey Ca Sea A LE 122 D 5 GSC400 REPLACEABLE 12 24VDC RELAYS ccceecccessecessceescecessecessecessecessecesseeessecesseeeneeens 122 D 6 GSC400 FUSING rs eoo netto eth ieee GR ae eed 123 APPENDIX E MODBUS 124 E 1 GOMMU NICATION DETAILS et bam BER IB EU 124 E 2 REGISTER MAP a d a tre be labe ich eL te 126 APPENDIX F 1939 OLD DTC CONVERSION 6
52. LSB 2 40094 MSB 4 40094 LSB 5 40095 MSB 0 131 of 147 SYSTEM DISABLE 0x5DA2 23970 40095 LSB NOT USED When 0x5DA2 is written to address 40098 this places the controller in the OFF mode System disabled The register is read in all controller operating modes Running Auto Failure Menu sleep modes CAUTION when received in the Running mode the controller immediately goes to the OFF mode no cool down is performed When received in failure mode this will reset the system failure and revert to the OFF mode SYSTEM ENABLE Ox5BA4 23460 When 0x5BA4 is written to address 40098 this places the controller in the AUTO mode waiting to start The register is read only in the OFF mode of operation and ignored in all other operating modes START 0x9768 38760 When 0x9768 is written to address 40098 this initiates an automatic start This register is only read in the AUTO mode of operation and is ignored in other modes STOP 0x57A8 22440 When 0x57A68 is written to address 40098 this initiates a shutdown stop of the equipment This register is only monitored when the system is running start signal received and is ignored in all other operating modes When cool down is enabled and a stop command is received the controller will proceed to the cool down mode then shutdown equipment 132 of 147 REQUEST DM2 0 44 Send a requ
53. Level 3 1 Making Menu Selections In some menus you are required to make a selection from a list of options Once you are in the menu the current active selection will have a checkmark beside it You may need to scroll up or down using the Up and Down Keys to see it 45 of 147 e lf you are satisfied with the selection then you must highlight the selection and then press enter You will then be taken back to the previous menu e If there is no checkmark you must make a selection See the next bullet point e f you wish to make another selection scroll down to the desired selection and press enter A checkmark should appear beside the option selected Then with the desired option still selected press enter again to exit the menu Table 7 Advanced Menu Layout Summary The J1939 setup contains general settings for J1939 such as shutdown on loss of messages To read parameters 3 8 63 from the J1939 bus please see Analog Inputs below High Engine Temp Sensor Inputs These control all aspects of the specific Oil Pressure analog input listed in the left column such as whether it is a switch sender or Fuel Level obtained from J1939 You can also set the input you want it to connect to The 3 4 50 Oil Level warnings and failures as well as open and 4 50 shorted sender detection shutdowns are Fuel In Basin also configurable Low Engine Tmp The speed sensing source
54. NFIG FAIL 2 176 OPEN AUX ANALOG 1 177 SHORT AUX ANALOG 1 178 LOW AUX ANALOG 1 179 HIGH AUX ANALOG 1 180 OPEN AUX ANALOG 2 181 SHORT AUX ANALOG 2 182 LOW AUX ANALOG 2 183 HIGH AUX ANALOG 2 255 OxFF Empty No failure message System Sub state delay countdown 0 65535 The value of register 40109 corresponds to the count down delay for one of the below mentioned sub states To determine which sub state is in countdown mode read register 40101 Resolution is 1 second The following sub states incorporate delay countdown DLY TO START PREHEATING CRANKING WARMUP CRANK REST COOLDOWN IDLE COOL COOLDOWN IN IDLE LOW BATTERY PRELARM LOW DC BATTERY CHARGING EXERCISER PREALARM EXERCISER RUNNING Digital Input R Read 137 of 147 Status of controller digital inputs OFF means the input is not active or Only not connected Bito Input A BAT 0 OFF 1 ACTIVE Bit Input B BAT 0 OFF 1 ACTIVE Bit2 Input C O OFF 1 ACTIVE Bit3 Input D 0 OFF 1 ACTIVE Bit4 Input E GND 1 OFF 0 ACTIVE Bits Input F GND 1 0 ACTIVE Bit6 Input G GND 1 OFF 0 ACTIVE Bit7 Input H GND 1 OFF 0 ACTIVE Bit8 Start Stop 1 0 ACTIVE Bit9 Emergency Stop 0 OFF 1 ACTIVE Note Do not read the start stop digital input Bit 8 as a means to determine if start signal active or not active please read the register 401
55. OV to 1 33V It is recommended to use pin 6 because its 5 11k Ohm pull up will have less of an effect on the voltage input of the electronic sender than the 1k Ohm pull up of pin 2 25 of 147 For firmware versions 2 04 06 and above the Sensata electronic oil pressure sensor supplied by Dynagen works out of the box on Sender or Sensata in the oil pressure signal source menu on pin 6 e Symptom High Engine Temperature reads around 130 F This is normal when engine temperature is set to pin 3 or 4 Set to Dat Pin2 firmware 2 04 06 and higher and change sender to pin 2 For firmware 2 04 03 and below set signal source to pin 2 and then once this is done program the DatCon K LowZ to the controller using the GSC400 programmer and PC configurator The high engine temperature will then read down to 729F e Symptom High Engine Temperature or Low Oil Pressure not reading correctly Note applies to Dynagen supplied mechanical senders only For troubleshooting on the electronic oil pressure sensor refer to the insert that came with that sensor 1 Confirm that the sender is connected to the correct input pin terminal Check the wiring for continuity Check that the GSC400 is setup correctly in the advanced menu 2 With the generator not running unplug the sensor analog inputs plug from the controller It s the 2x4 pin connector on the bottom On the GSC400 sensor terminal measure the DC voltage of the input pin t
56. Oil Warning Under RPM Fail Under RPM Warn Over RPM Fail Over RPM Warn Low Fuel Fail Low Fuel Warn Battery Fail Battery Warn Low Coolant Fail Low Coolant warn Not in Auto Failure Crank Rest Engine Running Crank On Exerciser Alarm Recharge Alarm Under Volt Warn Over volt warn Over Amp Warn Fuel in Basin Volt Regulator Low Temp Warn Back Light Auxiliary Warn Maintenance System Ready Common Output 1 Common Output 2 Dummy Loads High Fuel Warn Current Latch Config Warn 1 Config Warn 2 Config Fail 1 Config Fail 2 Engine Fan Low AuxA1 Warn Low AuxA1 Fail High AuxA1 Warn High AuxA1 Fail Low AuxA2 Warn Low AuxA2 Fail High AuxA2 Warn High AuxA2 Fail Exerciser Enable Run Duration Disable enable 10 240 minutes Pre Alarm Delay 1 20 minutes Repeat Freq 1 672 hours Start Hour 0 23 Start Date 1 31 Input A Bat Disable Low Air Pres Input B Bat Input C Bat Input D Bat Input E Gnd Input F Gnd Input G Gnd Input H Gnd Low Hyd Pres Low Oil Pres EPS Supply Load Alarm Silence Low Coolant Volt Select 1 Volt Select 2 Idle Mode Start Stop Auxiliary Fail Auxiliary Warn Charger Fault1 Charger Fault2 High Fuel Warn Config Warn 1 Config Warn 2 Config Fail 1 Config Fail 2 Start Inhibit located at bottom of menu Global Trig Crank Trig Run Trig Crank Run Trig Low Auto Charge Disable Enable Charge Pre Alarm 1 60 minutes Charge Duration 10 240
57. QUENCY SETUP 58 DV MEE odds 58 442 AC VOolfage i eee beet ione de esperada ade dde 58 3 7 2 1 Voltage Select INDUS aiio ANAR ENESE E 61 373 CUNEN ic e RR RR Red t ete pete be ned e edle ecd eaa 62 3 7 3 1 EPS Supplying Load Front Panel Lamp sese 62 3 8 JN OSO SETUP M 63 3 8 Auto Power ECM eeccccccesceseseseesesesenssceseseseecensesseseseeecnescssesesecaenesaeaeseseceeseneeaeeeeseaeeeataeees 65 3 8 2 Diagnostic Trouble Codes DTCs sse eene eene 65 3 8 3 Cummins Idle Speed eene nennen eene nnne 66 3 84 Volvo EMS2B isse e etii S 66 3 9 DIGITAL INPUTS CONFIGURABLE SWITCHED INPUTS SETUDP cccsscccccececsessecececececsensaeeeeeceeeenses 67 3 10 DIGITAL OUTPUTS CONFIGURABLE OUTPUTS SETUP csesssscssssesessesesessesesnesceeetssesnsneseeeees 69 3 11 cete ed e debet eA NEE AE AENEA Ah T2 3 12 PASSWORD SETUP Vessan ena a p etre 73 3 13 SEL MAINTAIN tote ae 74 3 14 SET MODBUS piani Weck Hie ilar oie ate ont en etal eee 74 3 15 COMMON FAULT Skast bbe 74 3 16 OTHER SETTING celer le 75 3 16 1
58. QUESTING FAIL and turn off the fuel output if there is no valid response on the fourth try The default ECM address for DM2 request is 0 and the ECM address can only be changed from the GSC400 PC interface The GSC400 may also show READING ABORT if communication is unsuccessful If the request was successful the GSC400 will show READ DTC SUCCESS and start to display the messages The GSC400 Event Log see section 4 8 3 on page 91 can store up to 30 DM1 messages DM2 messages are not stored Once the 30 limit has been reached the oldest message is removed from the log to be replaced by the incoming DM1 All entries in the log are stored in a reverse chronological order with the most recent event displayed first 105 of 147 This page intentionally left blank 106 of 147 Table 27 Submenus of the Advanced Menu Manufacturer Loss of ECM Display Group 1 Display Group 2 DTC Display Active DTC Log Read Stored DTC Auto Power ECM ECM Power Delay Cummins Idle SPN Conversion EMS2B Freq Sel EMS2B Acc Pedal John Deere Volvo Cummins Yanmar Detroit Diesel Others Volvo EMS2B Isuzu GM PSI Enable Disable Enable Disable Enable Disable Disable Enable Disable Enable Disable Enable Disable Enable 5 30 seconds Disable GCP Enable GC1 Enable Version 1 Version 2 Version 3 Primary Secondary 40 60 Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Disable Analo
59. RSC are ignored in an exerciser started run until the GSC400 enters cool down or AUTO To prevent the engine from shutting down set the cool down time to a value other than 0 While in cool down the GSC400 will detect the RSC and will go back into the RUN mode without shutting down When finished the exerciser feature will send a shutdown request and retry once a minute if the engine remains running It will also log exerciser over in the log when it sends the request Multiple logs for exerciser over in the event log indicates that the engine could not be shutdown For example the remote start contacts are active 73 of 147 3 12 Password Setup The GSC400 allows a 4 digit password to be entered to protect the advanced setup menu from any unauthorized changes This EI DvnaGen password will be needed to RAN z perform any changes to the advanced setup If the password is entered incorrectly the controller will allow 3 more tries before the GSC400 returns back to the main menu To set each digit of the password do the following c et Password e Select Password No 1 Digit 1 vet Passworc Enter the desired number 0 9 lt BACK e Select Password No 2 Digit 2 Password No 1 Enter the desired number 0 9 Dacewr 2 SSWOIC e Select Password No 3 Digit 3 xcd NO Enter the desired number 0 9 Password No e Select Password No 4 Digit 4 Password No Enter the desired number 0 9 Remember to write down t
60. Rotor condition If the oil pressure is lower than the Crank Oil Pressure the GSC400 will check the engine speed for a locked rotor condition see section 3 3 1 1 on Locked Rotor Set this to 0 to disable it All parameters in bold below are located in the engine logic menu unless otherwise noted If one of the configurable switched inputs is set to Start Inhibit located in Inputs Setup menu and the configurable switched input is not active then the GSC400 will not perform a manual or automatic start Once the configurable switched input becomes active a start will be allowed This feature is in firmware versions 2 06 and above When performing an automatic or manual start the GSC400 will wait for the Delay To Start duration and then turn on the glow plug output for the Preheat glow plug duration The fuel output is also turned on If Preheat is O this is skipped Normally the fuel remains off in the AUTO mode until Preheat is entered For electronic engines some applications require that the ECM usually powered by the Fuel Relay output to be powered in the AUTO mode in order to start the generator as quick as possible The J1939 menu has settings to allow the fuel output to turn on in the AUTO mode See section 4 1 1 on page 65 After the preheat time the crank output is turned on for the duration specified by the Crank Time If the engine speed does not go above the Crank Disconnect Setting before the crank time then the
61. Sequence 1 100 Current log being read Total Log Number 1 100 Total number of entries in the log Active DTC lamp status and reserved lamp status 0 65536 The High byte of 40114 holding register Bit 7 6 malfunction indicate lamp status Bit 5 4 red stop lamp status Bit 3 2 amber warning lamp status 144 of 147 Bit 1 0 protect lamp status Low byte reserved for lamp status Active DTC No 1 0 65536 R Each DTC code will 0 65536 R be stored in 2 holding register High Byte of the first register is Byte 1 Low byte is byte 2 high byte of second register is byte 3 Low Byte is Byte 4 See right column for more information Registers 40117 to 40126 not shown They contain Active DTC No 2 to 6 and are in the same format as above DTC was defined in SAE J1939 73 Bit7 of Byte 4 SPN Conversion Method bit If CM 0 below applies else see below the table SPN SPN is 19 bits value the MSB of SPN is spn18 and the LSB of SPN is spnO Data range is from 0 to 524 287 Bit7 Bit5 of the byte 3 is spn18 spn16 Bit7 BitO of the byte 2 is son15 spn8 and the Bit7 BitO of byte 1 is spn7 spnO FMI FMI is 5 bits value data range is from 0 to 31 It is the Bit4 BitO of byte 3 OC OC is 7 bits value data range is from 0 to 126 It is the Bit6 BitO of the byte 4 Previous Active DTC 0 65536 R lamp status and reserved lamp status Bit 8 7 malfunction
62. The maximum allowed current on the GSC400 AC current terminals is 5A Use large AWG wires for runs longer than 5ft The shunt resistors used for sensing of current are very low resistance The accuracy can be affected by resistance of CT wires User is responsible for testing for applications requiring over 5ft of wire When Current Transformers CTs are operated open circuit they produce extremely high voltages which can be deadly to personnel Always disconnect or disable sources of power when working on CTs CT shorting bars or blocks should be installed It is extremely important to connect each CT to its proper terminal location Never mix A B and C phase CTs CT is required for each phase The wiring for CTs is as follows For single phase two wire applications e CT 1 leads to terminals Phase A and A For single phase three wire applications e CT 1 leads to terminals Phase A and A e CT 2 leads to terminals Phase B and B For three phase applications e CT 1 leads to terminals Phase A and A e CT 2 leads to terminals Phase B and B e CT 8 leads to terminals Phase C and C The CTs can be connected in any polarity The GSC400 measures and displays the absolute value of the current The current transformers CTs leads must be terminated individually into the GSC400 AC Current connector Do not tie the leads together See the system wiring diagram Figure 4 on page 15 for more details DO
63. This section applies if J1939 is enabled for one or more parameters The parameters are displayed the same for J1939 as they are for analog inputs The only difference is that when a parameter cannot be read from the J1939 bus the text N A is displayed in place of the parameter value If the Loss of ECM setting is enabled the GSC400 will shut the generator down on Loss of ECM if no communications are detected on the J1939 bus for the parameters the GSC400 monitors for 102 of 147 This section applies for electronic generators i e generators that use J1939 which have the DTC feature enabled The GSC400 can read J1939 diagnostic trouble codes DTCs from an electronic ECM if enabled see section 4 1 3 on page 65 for information on how to configure and customize the GSC400 DTC feature When the engine s ECM detects a fault it will send an Active Diagnostic Trouble Code DM1 message The DM1 message sent by the ECU will also contain information on the type of fault as well as the number of occurrences for the fault If multiple DTCs are present each will be transmitted over the J1939 network When the DM1 messages are received by the GSC400 controller there are 3 important pieces of information that are captured and displayed FMI Failure Mode Indicator The type of failure You must refer to the engine manufacturer s documentation to identify the meaning of the failure mode indicator number OC Occurrence Count Identifies
64. When engine failures events or Hit Enter To Exit DTCs Diagnostic Trouble Codes occur an entry is created in the GSC400 Event History Log See 02 Table 25 Event Log Entries OVERCRANK FAILURE below for the possible events that 10 15 DEC 01 are stored TOTAL 99 A total of 100 entries can be recorded Entries may be viewed simply by scrolling up or down using the UP DOWN keys In addition to the entry reason information the associated date and time of the entry will be displayed The 100 entries are subdivided into a maximum of 30 events 40 failures and 30 DTCs This prevents one type from flushing the other types from the log Simply scroll through the Failure History Log by pressing the y FAILURE HISTORY or keys located on the Hit Enter To Exit GSC400 TOTAL 99 03 The event history log can store LOW COOLANT FAILURE up to 30 events 30 DTCs and 40 10 00 DEC failures entries If these are exceeded the oldest entry is replaced with the newest entry The events failures and DTC entries are displayed together in the log in reverse chronological order i e newest entry first Upgrading the controller firmware to revision 2 00 or above from an earlier revision will cause the history log to be reset 92 of 147 Table 25 Event Log Entries A beside the Event Entry indicates the Event is a GSC400 event All other events are fa
65. Wires with crimps DWG1410R2 5 as not all I O are populated in above harnesses The AC Current Sensing Digital Input and Analog Input Harness can be purchased together as a starter kit Stock Code ACC0086 See section Appendix G on page 146 for the drawing 1 Circuits 9 and 12 are tied together This disables the emergency stop input Users who desire this feature can cut this wire and route it to a switch See Figure 4 on page 15 for information on pin numbers 3 This harness also provides power and ground for modbus devices via connections to the GSC400 extra power and ground terminals DWG1373R3 5 5Fet 1 2 3 4 The GSC400 programmer can be used to configure the GSC400 settings instead of using the front panel menu and load new firmware software for the GSCA00 that gives it new feature performance improvements or bug fixes Table 31 GSC400 Programmer Part List GSC400 PGMRC 122 of 147 Table 32 Current Transformers Part List ACC0045 PC amp S 546 100 L ACCO0046 PC amp S 546 200 L ACC0047 PC amp S 546 300 L ACC0048 PC amp S 546 500 L ACCO0049 PC amp S 546 600 L ACC0050 PC amp S 546 1000 L ACCO0057 PC amp S 546 1500 L Senders are required if display of engine parameters warnings and failures are required Otherwise switches could be used if only failure indication and shutdown is required Table 33 Senders Part List
66. above Place close to the sensing source For runs longer than 5ft use twisted pair cabling User is responsible for testing for applications requiring over 5ft of wire It is recommended that AC voltage wiring be run separately from the AC Current wiring to prevent interference The GSC400 supports the following voltage configurations Refer to Figure 6 below for three phase configurations 1 Single Phase a Two Wire 120VAC Connect to Phase A Connect phase B to neutral if you experience problems b Three Wire 120 240VAC Connect to Phase A and B 2 Three Phase Connect to Phase A B and C a Wye 4 wire b Four Wire Delta center taped only c Three Wire Delta 1 1 transformers required to create a neutral reference This is not supported by Dynagen d Note Corner grounded delta configurations are not supported With three wire Delta and 4 wire Wye configurations it is possible to use 2 1 voltage transformers to step down the voltage by 1 2 This allows AC voltage 28 of 147 sensing up to 1200VAC line to line This is not possible for 4 wire delta configurations Refer to Figure 6 below This is not supported by Dynagen To Load 1A Fuse Generator 1A Fuse Wye 1A Fuse Select Group 2 3 or 4 To Load To GSC400 A 1A Fuse Generator 1A Fuse 1A Fuse C Wye Voltage Sensing Center Tapped Select Group 3 and set Group 3 option to 2 Times Voltage To GS
67. an available pin then set it to Disabled again This should fix the issue A Bypass Time can be selected for each input this applies to J1939 senders and switches After crank success the bypass period will start and during this period the controller will not enable the warning or failure checks for this input After the bypass period if there are any warnings or failures they will be 51 of 147 triggered The controller will display a message and sound the alarm in the case of a warning or will shut down and sound the alarm in the case of a failure If using a switch it must be switched to ground but can be either normally open or normally closed Set the Signal Source menu to Switch Input and the Switch Setting menu to Closed Fail for normally open switches or Open Fail for normally closed switches If the Signal Source is set to a switch in the RUN mode see section 3 4 on page 82 the controller will display SW in place of the value that would be displayed if it was set to J1939 or Sender Warnings and Failures Except for a couple of cases when set to a switch the GSC400 will shutdown if the switch becomes active The cases where this does not happen are 1 Fuel Level The fuel level can be set to warn or fail shutdown if the switch becomes active This is controlled in the Switched Setting submenu of the Fuel Level menu 2 Low Engine Temperature When the switch becomes active the
68. anual will give more information of the specific warning and failures for each type of input When a warning occurs the second line the area under the time and date display of the LCD is used to display the warning text Also after the warning is displayed instructions are displayed showing the user how to silence the buzzer When in the AUTO or RUN mode pressing the Auto key silences the alarm while in the OFF mode pressing the Off key performs this function When a failure occurs although most failures only occur in the RUN mode the Low Fuel Level and Low Coolant Level failures occur in any state including OFF and AUTO the controller exits the RUN mode skips cool down and enters the FAILURE mode turning off the Fuel output and other outputs on or off depending on the advanced settings and displays the failure message The alarm will sound and remain on until it is silenced by the user The Auto key can be pressed to silence the alarm Once the alarm is silenced the controller can be placed into the OFF mode by pressing the Auto key and then the Off key This returns the controller to the OFF mode The failure is recorded in the event log accessible from the Basic menu In the case of a Low Fuel Level failure cool down will be allowed to run before entering the failure mode 100 of 147 FAILURE When the GSC400 enters in the FAILURE mode press the Off key LOCKED ROTOR 08 3 37 2 LU This will silenc
69. arning or shutdown occurring 0 Not Active 1 Active b2 b1 The severity of the event 0 Take No Action 1 2 Warning Acknowledge 2 Action Required 3 Take Immediate Action shutdown b3 Alarm Action indicates if GSC400 is sounding buzzer 0 No Audible Alarm 1 Sound Audible Alarm b4 Warning Failure Feature Enabled Disabled 0 Disabled 1 Enabled Events number 1 System Ready bit 4 0 Events number 2 Over crank bit 9 5 Events number High Engine Temperature Warning Shutdown bit 14 10 Events number 4 Low Oil Pressure Warning Shutdown bit 4 0 Events number 5 Over speed bit 9 5 Events number 6 Emergency Stop bit 14 10 Events number 7 Low Coolant Level bit 4 0 Events number 8 Low Coolant Temperature bit 9 5 Events number 9 Low Fuel Level In Tank bit 14 10 Events number 10 Low Fuel Pressure bit 4 0 Events number 11 Emergency Power Supplying Load bit 9 5 Events number 12 Generator Running bit 14 10 127 of 147 Events number 13 Generator Not In Auto Mode bit 4 0 Events number 14 Battery Charger Fault bit 9 5 Events number 15 Battery Voltage Low bit 14 10 Events number 16 Battery Voltage High bit 4 0 Events number 17 Low Battery Voltage During Cranking bit 9 5 Events number 18 Locked Rotor bit 14 10 Events number 19 Common Fault 41 Warning Shutdown bit 4 0 Events number 20 Common Fault 2 Warning Shutdown bit 9 5 Events number 21 Reserved bit 14 10 Reserved GSC400 Fr
70. arning shutdown trip points relating to AC voltages and currents This is useful for mobile generators D d where the voltage selections can be selected via a CAM switch Warning The Voltage Select Inputs override the Voltage Group parameter Table 15 Voltage Select Inputs 1 Phase 3 wire 2 wire option also selectable Open Circuit Open Circuit 3 Phase 4 wire Wye ungrounded delta ACTIVE Open Circuit 3 Phase 4 wire Wye ungrounded Delta 2x display voltage option also selectable Open Circuit ACTIVE 3 Phase 4 wire Wye ungrounded Delta 4 wire corner grounded Delta option also selectable ACTIVE ACTIVE defined as a switched to GND connection If Digital Input Pin A B C or D is used then ACTIVE is defined as a switched to BAT connection If Digital Input Pin E F G or H is used then ACTIVE is NOTE If only a single AC Group Sel function is selected then the remaining unassigned AC Group Sel is equivalent to an Open Circuit in the above table 62 of 147 The GSC400 controller is designed to measure AC current from the generator with the use of current transformers CTs The maximum current on the AC current terminals of the GSC400 is limited to 5A The Turns Ratio sub menu is used to setup the CT ratio All numbers in this menu are in terms of 5A For example selecting 1000 is the same as 1000 5A the GSC400 displays 1000A on the scr
71. ature to control an output The time duration is set in the engine logic menu See section 3 3 2 for more details This allows the Preheat Midheat and Postheat features in the engine logic menu to control the output The Preheat glow plug time is set in the engine logic menu See section 3 3 1 for more details This allows the Cool Down feature to control the output This output is active during cool down The Cool Down duration is set in the engine logic menu See section 3 3 2 for more details This turns on the digital output when the Over Crank Failure is activated See section 3 3 1 for more details The number of crank attempts is set in the engine logic menu This turns on the digital output if the High Engine Temperature Failure is activated See section 3 4 for more details This turns on the digital output if the High Engine Temperature Warning is activated See section 3 4 for more details This turns on the digital output if the Low Oil Pressure Failure is active This can be caused by the Low Oil Pressure Analog Input or the Low Oil Pressure digital input See section 3 4 or section 3 9 for more details This turns on the digital output if the Low Oil Pressure Warning is activated See section 3 4 for more details This turns on the digital output if the Under Speed Failure is activated See section 3 5 for more details This turns on the digital output if the Under Speed Warning is activated See section 3 5 for more detai
72. automatic starting will be disabled No automatic controls will be initiated The OFF mode may be initiated when no generator controls are required or when the controller configuration requires adjustment The user can disable manual start in OFF mode in the basic menu See section 4 8 2 All of the failures and most of the warnings are disabled when the controller is in the OFF mode The controller may beep if the Not In Auto parameter is set in the basic menu every few seconds to alert the user that the unit is in the OFF mode and cannot automatically start To silence this alarm press the off key as instructed on the screen In OFF mode you may simultaneously press the up and down arrow keys to perform a lamp test The controller has a low power Sleep Mode that it can enter when in the OFF state In this state the LCD screen backlighting is turned off The time it takes to enter Sleep Mode is configurable in the menu The backlight display will illuminate automatically when a key is pressed A key press will only cause the controller to exit the Sleep Mode The key must be pressed again to perform its normal function It is recommended that the Sleep Delay set the basic menu is set as short as possible to prolong the life of the backlighting and to reduce battery consumption unless you are using a remote device to control the GSC400 then it should be set to 1 minute or longer 83 of 147 When the GSC400 is set to
73. between receiving a reply and sending a request as the GSC400 needs time to perform other tasks The GSC400 updates holding register addresses from 40050 to 40244 every 1 second All other Modbus registers are updated every 250ms For firmware versions below 2 00 the GSC400 power must be cycled off and on for menu changes to take effect Firmware versions 1 38 to 1 46 support 1 generation Modbus registers Firmware versions 2 00 and above supports both 1 generation as well as 2 generation registers For new applications it is recommended to utilize 2 49 generation modbus registers 1 Registers 40086 40173 and 40174 are supported by firmware versions 2 03 and above 2 Registers 40146 to 40149 are supported by firmware version 2 07 and above When the GSC400 controller goes from the Run to OFF or Menu to OFF Modbus communications will be unavailable until the controller is in the OFF mode for 2 seconds 126 of 147 NOTE All parameters are assumed to be unsigned integer values unless otherwise specified in the Range column Table 36 Modbus Register Map Highest Severity Event bit 16 Alarm State bit 15 14 Severity Bits 13 10 Reserved Bits Read only 9 1 Event Previous Highest bit 16 Alarm State bit 15 14 Severity Bits 13 1 Event 4 Severity Event R Each event uses 5bits b4 b3 b2 b1 bO where bO is the least significant bit bO The event status w
74. cting to an existing bus check that it has the proper terminating resistors To check for proper resistance disconnect the CAN bus harness from the GSC400 and measure across the CANH and CANL pins on the harness connector It should be 60 Ohms two 120 Ohms in parallel If you measure 1200hms then only one resistor has been installed If using the optional J1939 harness DWG1373R3 5 from Dynagen there is a 120Ohm resistor built in It can be cut out if the GSC400 is not the last device on the bus If you are using DWG1375R2 5 this version of the J1939 harness does not have a terminating resistor 37 of 147 Troubleshooting Notes 1 To check for proper CAN communications place GSC400 in AUTO mode with the ECU powered and check that the engine temperature on the front panel display is not displaying N A engine temperature must be set to J1939 N A indicates no communications with the ECM The ECM should start and run the engine even if there are no CAN communications with the GSC400 when the GSC400 turns on the fuel and crank outputs If there are no communications between the ECM and GSC400 the GSC400 will not stop the crank cycle when the engine is running as it is not receiving the engine speed If the ECM is not starting the engine then there is an issue with the wiring on the ECM Most ECMs have multiple power and ignition inputs that must be connected for it to operate properly 38 of 147 Menu Location Pag
75. d Rotor to one of Occurred High Engine Waming configurable Turn Temperature outputs output Modbus Table Enable Disable Failure Warning Update To RA400 modbus Common register Fault LED Bold indicates feature is enabled Un bold indicates i feature is disabled Figure 11 Example of Common Fault 1 Usage The Other Setting menu contains the settings used to control the features in the following sections The dummy load feature allows the user to turn on an output if the AC current is below a settable threshold Load On Point This is useful for applications where the generator must have a minimal load to prevent damage to the generator Upon crank success RUN Mode entered if enabled the feature waits for a configurable bypass time then starts to monitor the AC current If the AC current remains below the Load On Point for 6 5 seconds then the dummy load configurable output is turned on If the AC current rises and remains above a settable threshold Load Off Point for 1 5s the dummy load configurable output is turned off A digital output must be set to dummy load to use this feature 76 of 147 There is an option for an LCD heater that allows the LCD display to operate normally down to 409C for more information contact Dynagen There is an option in the Other Setting menu called LCD Heater that allows the heater to be enabled or disabled lt is set to disabled by default
76. e 1 Modbus RS485 Advanced Setup gt Set Modbus 74 Modbus has the capability to start and stop the genset and to transition from OFF to AUTO to do this Modbus should be disabled while performing maintenance or repairs by unplugging the Modbus connector GSC400 has a RS485 connection and supports the Modbus protocol It is a slave device only Modbus is active when the GSC400 is powered and cannot be disabled The Modbus port is not isolated If you are running cable longer than 100ft or running cabling outside or using existing cabling it is recommended that 1 a RS485 isolator be installed on the GSC400 end 2 a DC DC power supply be used to power the remote modbus device if it shares power from the same battery as the GSC400 This is to prevent ground loops Note that the connector on the GSC400 is a molex type see Table 1 on page 14 for connector part number The customer must use this connector or they can purchase a premade harness from Dynagen DWG1454 This connects to the GSC400 Modbus and power and has 5 pigtails on the other end Modbus common power and ground Power and ground can be used to power the master device A RS485 twisted pair 120Ohm impedance shielded cable is required for Modbus communications 120Ohm resistors are required on either end of the Modbus bus Two possible options for cables are 1 Beldin 9841 one shielded twisted pair 24AWG Twisted pair ca
77. e reading in 40177 1 bit 140 of 147 instead equal to 0 1 hour The reading in 40178 1 bit equal to 1000 hours So the total hours 40178 1000 40177 10 Maintenance Time 1000 1000 Signed Integer 16 bit The unit is 0 1 hour 1 bit 0 1 hour Positive values count down the hours to next maintenance Negative values count up the hours since maintenance should have been performed Positive or negative values can be identified by read the high byte of MSB A 1 in bit 15 corresponds to a negative number while a 0 corresponds to a positive number Auxiliary Analog 1 Type 0 not available 1 set to a switch 2 Temperature in F 3 Temperature in C 4 Pressure in PSI 5 Pressure in kPa 6 Level Auxiliary Analog 1 Value 09999 1 bit equal 0 1 unit Units depends Reading 1000 the Type above corresponds to 100 0 Auxiliary Analog 2 Type 0 not available 1 set to a switch 2 Temperature in OF 3 Temperature in 0C 4 Pressure in PSI 5 Pressure in kPa 6 Level 96 Auxiliary Analog 2 Value Read Previous 099919 0x6C93 1 bit equal 0 1 unit Units depends Reading 1000 the Type above corresponds to 100 0 Write control command to holding 141 of 147 Entry 27795 Read Next Entry 0x639C 25500 register address The controller will check the log requ
78. e GSC400 will allow manually triggered requests of stored faults from the ECM s memory DM2 The GSC400 can switch between idle and normal operating speed on Cummins generators When the fuel relay is on the GSC400 continuously sends out a speed command every 250ms to tell the generator which of the two speeds to run at A configurable switched input must be set to Idle Mode see Table 18 on page 67 and when this switched input is active the generator runs at idle speed otherwise it runs at normal operating speed To enable this feature set Cummins Idle to GCP Enable or GC1 Enable GC1 is the newest protocol while for older engines you will need to use GCP If you are powering the ECM externally you may get an error message if Cummings Idle Speed and Diagnostic Trouble Codes are enabled see below J1939 Erratic The ECM expects the speed update to be sent continuously and if itis not the ECM thinks there is a problem with the J1939 communications If you selected Volvo EMS2B from the Manufacturer submenu there are two additional parameters you can set 1 EMS2B Freq Sel Frequency Selection Primary or Secondary 2 EMS2B Acc Pedel Acceleration Pedal Position 40 to 60 Please consult the Volvo ECU manual for more information 67 of 147 There are eight configurable switched inputs Each input can be selected to any of the features given in Table 18 below Table 18 Configurable Switched Input Selections
79. e bus This will also occur on startup 65 of 147 until the GSC400 accesses the data from the bus Note that loss of ECM may not be triggered since other parameters may be receiving data from the bus ECM Boot up Delay ECMs can take up to 10s to boot up when they are first powered Ensure that the crank time is long enough to take this into account If extended cranking is not desired the glow plug preheat time can be set to turn on the fuel relay for a set time before cranking begins Ensure that no configurable output is set to preheat Another option is to enable the Auto Power ECM setting This allows the fuel relay come on in the AUTO mode See the next section below Some Engine Control Modules ECMs require significant time to power up and initialize before they are ready to control the engine The GSC400 can be programmed to leave the fuel relay output on while in the AUTO mode by enabling Auto Power ECM This will ensure the ECM is already powered up and ready to go when the user desires to start the generator When the controller exits from the RUN mode the ECM Power Delay setting controls the amount of time the GSC400 waits before turning on the fuel output This is done to prevent the generator from starting up unexpectedly if it hasn t fully shut down when the controller entered the Auto mode The GSC400 has a DTC feature that when enabled allows the controller to receive currently active DTCs DM1 messages and display the
80. e speed at which the generator produces power in RPM revolutions per minute 56 of 147 For example if you have 100 teeth on the flywheel that the magnetic pickup sensor is attached to and the speed that your generator runs to produce power is 1800RPM the calculation would be Rated Frequency Hz 100 x 1800 60 3000Hz You would enter 3000Hz for the Rated Frequency Refer to the following tables for more examples Table 10 Rated Frequency at Table 11 Rated Frequency at 1800RPM Rated Speed 3600RPM Rated Speed 57 of 147 The Battery menu allows the user to set the low and high battery warning and failure levels In addition the generator can be made to automatically start when in the AUTO mode if the voltage drops below the Recharge Level The controller will display Low Voltage During Cranking on the screen if during cranking the voltage drops below the Low Vol InCrank setting Note When the generator is running the battery voltage will equal the alternator charging voltage The actual open circuit battery voltage may be lower than displayed The GSC400 can be setup to automatically run the generator if the battery voltage goes below the Recharge Level This feature must be enabled in the Low Auto Charge submenu If the GSC400 is in the AUTO mode and the battery voltage drops and remains below the Recharge Level for 10s firmware versions 2 03 a
81. e the alarm and ENTER TO RESET will appear on the GSC400 display Press the Enter key to exit the FAILURE mode and enter the OFF mode Note it is not possible to enter the AUTO mode directly from the FAILURE mode FOR LAMP T OFF MODE START DISABLED This section only applies for electronic engines and if the Diagnostic Trouble Code DTC feature is enabled See section 3 14 for more information on DTCs The GSC400 does not have the ability to detect when the generator ECM has shutdown the generator In the case of an ECM shutdown the GSC400 will display one of the following failure reasons 1 Low Oil Pressure 2 Under Speed 3 Under Frequency 4 Under Voltage The failure message displayed will depend on the user s failure set points for the above The user has to check the Event History Log see section 3 10 3 on page 91 about the history log to determine if there has been a DTC DM1 failure sent from the generator ECM The maximum hour count is 200 000 0 hours for mechanically connected engines For J1939 connected engines the maximum is 259 999 9 hours OR the maximum hours count available from the engine ECM whichever is less 101 of 147 For mechanically connected engines once the maximum is reached it will continue to display the maximum unless the hourmeter is reset through an authorized dealer J1939 has the priority it overrides the local engine hour value when the GSC400 is connected to J1939
82. e the site is free from excessive moisture fluctuating Mounting Location temperatures dust corrosive materials etc 1 It is recommended to limit the maximum average ambient temperature around the me GSC400 to 70 C to provide headroom DynaGen RUNNING 2 The controller should be safely mounted in a secure location using the 3 mounting 5 f ah screws provided Mounting screws must be H installed with a torque of no more than 7 inch pounds The screws are Zink plated 8 12 x 5 16 machine screws X 3 Ensure that all wiring to the GSC400 are Mounting Location Figure 2 GSC400 Mounting Locations BACAO CUTOUT TEMPLATE 12 of 147 self supporting Do not allow wiring or harnesses to hang from the GSC400 or to place excessive force on its terminals Keep wiring loose and use strain relief To reduce the possibility of electrical interference install the GSC400 in a grounded enclosure Ensure that the ground wire makes direct contact with the metal in the enclosure scrape off any paint Also consider using shielded spark plugs Isolate the GSC400 enclosure with isolation mounts to prevent excess vibration to the GSC400 4250 Bote ET 786 pos 1187 Se hee TH s 5 22 500 2 000 2750 221 AE I tn en Dod ra cmn TOLEREMZE 4 CB Figure 3 Dimensions of mounting holes N 13 of 147 The GSC400 controller can be used in eit
83. ed freq warning bit13 Low fuel level failure bit14 Low fuel level warning bit15 Battery low and high level failure bit0 Battery low and high level warning bit1 Not used bit2 Low coolant level failure bit3 Controller is not in auto bit4 Failure has occurred bits Cranking rest active bit6 Controller is in RUN mode after crank success bit7 Controller is cranking bit8 Exerciser pre alarm active this 129 of 147 bit will flash bit9 Battery charging pre alarm is active this bit will flash bit10 AC under voltage warning bit11 AC over voltage warning bit12 AC over current warning bit13 Fuel in basin warning bit14 Voltage Regulator Digital Output feature is on bit15 Low engine temperature warning bit0 Backlight is on biti Auxiliary warning bit2 Maintenance is required bit3 System is OK definition no warning including not in auto warning bit4 Common fault 1 digital output feature warning and failure bitb Common fault 2 digital output feature warning and failure 016 Dummy load digital output feature bit7 reserved bit8 Over current latch AC Current feature bit9 User configurable warning 1 digital output feature bit10 User configurable warning 2 digital output feature bit11 User configurable failure1 digital output feature bit12 User configurable failure 2 digital output feature bit13 to bit15 Reserved bitO to b
84. ed up to exercise itself See section 3 11 on page 72 The Auxiliary Analog 1 2 analog input is above the high failure set point The Auxiliary Analog 1 and 2 can be programmed with custom text so the text to the left may not apply Failure occurred due to high battery voltage See section 3 6 on page 57 Failure occurred due to high engine coolant 93 of 147 temperature See section 3 4 on page 50 INITIALIZING EEPROM is being loaded with factory defaults This occurs on first power up or if the user resets the GSC400 to factory defaults from the PC Configurator KEY BOARD FAILURE This is an internal GSC400 failure Try to power cycle the GSC400 If the failure occurs repeatedly the unit could be defected LOCKED ROTOR Cranking attempt failed on locked rotor See section 3 3 1 1 on page 48 LOG CORRUPTED Event Log corrupted and had to be reset This usually occurs when power was loss while the event log was being written to It will also occur when upgrading firmware to version 2 00 or higher from a version below 2 00 for the first time LOSS OF ECM COMM J1939 messages required by the GSC400 have not been received The generator has shut down See section 3 8 on page 63 LOW AIR PRESSURE The low air pressure switched input is active See Table 18 on page 67 LOW AUX AN1 LOW AUX AN2 The Auxiliary Analog 1 2 analog input is below the low failure set
85. een when the current measured on the GSC400 AC Current terminals is 5A The AC Current menu is also used to set the over current warnings and shutdowns These are grouped in terms of the voltage group 1 to 4 The AC current warning and failure depends on the voltage group selected in the Voltage Group submenu of the AC Voltage menu The Hi Wye Current parameter second to last entry in the AC Current menu is used to double the current reading 50 selection if voltage group 3 is selected It has no effect on other voltage groups If this is not desired then the 10096 selection should be selected Some generators have two wires for each phase and as such the current transformer which is placed on only one wire will see only 5096 of the current from each phase The Cur Warn Latch option last entry in the AC Current menu is used to latch on a special configurable output see Current Latch in Table 19 on page 69 that turns on when the current exceeds the Current Warning Threshold and can only be turned off by the user at the front panel On a current latch condition the LCD displays Over Current Latched and lt Up Arrow Down Arrow for Unlatch If the GSC400 AC current rises above 5 of the AC over current warning setpoint the EPS Supplying Load front panel LED is lit Otherwise it remains unlit 63 of 147 The GSC400 will work with any generator as long as it supports the standard messages listed in the SAE J1939 speci
86. electing a Voltage Group to Use The Voltage Group submenu can be used for this purpose Alternatively one or two configurable switched inputs can be used to determine the voltage group to be used See section 3 7 2 1 below The configurable switched inputs override the Voltage Group submenu Table 13 GenSet Configurations and How to Configure Them in the GSC400 Refer to Figure 5 on page 29 for a diagram of each of the various three phase configurations The GSC400 display 1 Set Group 1 Setting to 2 is fixed to L N wire single 120 240VAC 1 Set Group 1 Setting to 3 wire single No neutral reference If using Group 3 set Group Use of 1 1 3 option to Normal transformers 2 3 4 Voltage If using Group 4 required to provide set Group 4 option to neutral reference Three Phase Center tapped on one phase for a neutral reference 4 Set Group 4 Setting to Phase C on GSC400 Four Wire Delta is the stinger high leg Neutral reference If using Group 3 set Group taken from where 3 option to Normal three windings come 2 3 4 Voltage If using Group 4 together set Group 4 option to Three Phase The voltage sensing for the GSC400 is taken from the midpoint of each of 3 Su eee gt opon to 2 imes Voltage the three windings Reduces voltage to controller by 1 60 of 147 Table 14 AC Voltage Submenus that apply to Voltage Groups Group 1 Sett
87. enerates a Low Coolant Level failure when active These inputs allow the user to change the supported generator configuration without having to go into the controller menu See section 4 4 2 1 for more details This input when active allows the generator to run ata lower speed without triggering under voltage under frequency or under speed warnings or failures Idle 68 of 147 Running is displayed on the GSC400 display when this input is active The idle mode can also turn on a configurable output see the Voltage Regulator configurable output feature in Table 19 on page 69 This output is usually used to turn off the generator voltage regulator when idle mode is entered but can be used for any purpose This is also used for Cummins J1939 Idle Feature See section 3 8 3 on page 66 for more information When the digital input is active the generator is started if in the Auto mode If the digital input becomes inactive this places the controller back into the Auto mode shuts down the generator This performs the same function as the remote start contacts An Auxiliary Failure is generated when the input is active This can occur in the Off Auto Cranking and Running states An Auxiliary Warning is generated when the input is active This can occur in the Off Auto Cranking and Running states A Charger 1 Fault warning is generated when the input is active A Charger 2 Fault warn
88. est every 1 second Each time a new command is received the controller will scroll either down or up one message until it reaches either the bottom or top of the message log one message and update the log content in address 40131 to 40141 Once at the top of the log registers 40131 to 40141 are not changed if a Read Previous Entry command is received Once at the bottom of the log registers 40131 to 40141 are not changed if a Read Next Entry command is received After 20s of receiving further commands in register 40130 all registers are cleared i e set to 0 Log Type Only supports the values listed in format column R 1 Internal reserved 1 ADE Read 2 Internal reserved 2 KEYBOARD 3 Internal reserved 3 ADC read 4 Internal reserved 4 RS485 5 Internal reserved 5 RS232 6 Internal reserved 6 ADE Write 7 Internal reserved 7 TLE6230 8 Internal reserved 8 EEPROM 9 Reserved 10 HIGH ENGINE TEMPERATURE 11 LOW OIL PRESSURE 12 UNDER SPEED 13 OVER SPEED 14 LOW FUEL LEVEL 15 LOW BATTERY 16 LOW COOLANT 17 OVER CRANK 18 OVER VOLTAGE 19 UNDER VOLTAGE 20 OVER CURRENT 21 EPS LOADS ERROR 22 LOW AIR PRESSURE 23 LOW HYDRAULIC 24 LOW OIL LEVEL 25 LOCKED ROTOR 26 HIGH BATTERY 27 LOSS OF ECM COMMUNICATION 28 OPEN ENG TEMPERATURE 142 of 147 29 SHORT ENG TEMPERATURE 30 OPEN OIL PRESSURE 31 SHORT OIL PRESSURE 32 OPEN FUEL LEVEL 33 SHORT FUEL LEVEL
89. est to controller for reading the previous DTC codes If the controller read the previous DTC code success the data will be updated in the range of 40180 to 40244 This registers can hold maximum 32 DTC code The possible controller modes are System operating MENU OFF SLEEP mode 0x90 144 mode 0x93 Only OFF mode 0x93 147 0x96 AUTO mode 0x96 150 0x99 FAILURE mode 0x99 153 0x9C RUNNING mode 0x9C 156 When in controller menu OFF sleep mode if the controller is required to go to the AUTO mode a system disable command 40098 must be written followed by system enable command 40098 System Sub state 0 40 R The controller sub mode if applicable 19 DLY TO START 20 PREHEATING 21 CRANKING 22 WARM UP 23 CRANK REST 25 COOLDOWN 26 SHUTDOWN 27 IDLE RUNNING 31 IDLE COOL 32 REMOTE START RUN RSC contacts 33 Front Panel Run Manual Run 34 MODBUS RUN modbus start triggered 35 LOW BATTERY RUNNING 133 of 147 36 EXERCISER RUNNING 0 None of the above 0 corresponds to none of the above sub modes of operation Active Event message queue 0 255 R Read Only A maximum of 6 events warnings are stored concurrently One event warning per register Ensure that controller is not in sleep mode before reading 0 READING ABORT DTC reading 1 Low Voltage In Crank 2 Charger 1 Fault 3 Need Maintenance 4 CRANK FAILURE 5 Charger 2 Fault 6 Cust
90. fication Standard messages include oil pressure engine temperature and engine speed Some engine control modules have proprietary messages that are intended for specialized devices and are not displayed by the GSC400 Viewing Engine Parameters from J1939 To use J1939 instead of a local switch or sender 1 Go to the Signal Source submenu for each parameter see table below and select J1939 For example to use J1939 to display Oil Pressure you would go to the Advanced Menu go to Oil Pressure go to Signal Source and then select the J1939 option Table 16 GSC400 Engine Parameters High Engine Tmp Oil Pressure Oil Level Low Engine Tmp Negative engine temperatures are displayed on the GSC400 but any reading below 0 C 32 F is set to 0 C for warning and failure level detection purposes The GSC400 can display extra parameters for the engines listed in the Manufacturer submenu No warnings or failures can be generated with this data To enable these messages go to the Display Group 1 and Display Group 2 submenus located in the J1939 menu If you have a different ECM manufacturer than listed under the Manufacturer menu the Display Groups 1 and 2 setting does not apply Table 11 lists the data parameters enabled for each group 64 of 147 Table 17 J1939 Addition Parameter Display Options Engine Torque 96 Friction Torque 96 Load 96 Intake Temperature 9C Fuel Temperature
91. g 2 7 J1939 Switch input Sender 1 2 or 3 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Fahrenheit Celsius Warning Level 10 265 F 10 265 C Failure Level 10 265 F 10 265 C Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Setting Shorted Sender J1939 Switch input Sender 1 2 or 3 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Open Sender Disable Warning Shutdown Units PSI KPa Warning Level 0 90 PSI 0 90 KPa Failure Level 0 90 PSI 0 90 KPa Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Setting Shorted Sender Switch input Sender 10 60 Seconds GND Warning OPEN Warning GND Fail Open Fail Disable Warning Shutdown 107 of 147 Open Sender Units Warning Level Failure Level 096 Fuel Level 2596 Fuel Level 5096 Fuel Level 75 Fuel Level 10096 Fuel Level Disable Warning Shutdown Percentage 0 9096 0 9096 0 1000 Ohms 0 1000 Ohms 0 1000 Ohms 0 1000 Ohms 0 1000 Ohms Input Pin Signal Source Bypass Delay Switch Setting Shorted Sender Reserve Analog 2 7 J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Percentage Warning Level 0 100 Failure Level 0 100 Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Sett
92. g Level 1096 Failure Level 596 Input Pin Disable Signal Source Switch Bypass Delay 11 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Percentage Warning Level 296 Failure Level 596 Input Pin Disable Signal Source Switch Bypass Delay 10 Seconds Switch Setting SW Closed Fail Shorted Sender Disable Open Sender Disable Units Fahrenheit Warning Level 75 Input Pin Disable Signal Source Switch Bypass Delay 10s Switch Setting Closed Fail Shorted Sender Disable Open Sender Disable Temp Units Fahrenheit Temp High Warn 250 0F Temp High Fail 265 0F Temp Low Warn 75 0F Temp Low Fail 50 0F Pres Units PSI Pres High Warn 95 0 PSI Pres High Fail 100 0 PSI Press Low Warn 50 0 PSI Press Low Fail 10 0 PSI Level Units Percentage Level High Warn 90 096 Level High Fail 95 096 Level Low Warn 5 096 Level Low Fail 0 096 Analog Group Pressure 114 of 147 Input Pin Disable Signal Source Switch Bypass Delay 10s Switch Setting Closed Fail Shorted Sender Disable Open Sender Disable Temp Units Fahrenheit Temp High Warn 250 0F Temp High Fail 265 0F Temp Low Warn 75 0F Temp Low Fail 50 0F Pres Units PSI Pres High Warn 95 0 PSI Pres High Fail 100 0 PSI Press Low Warn 50 0 PSI Press Low Fail 10 0 PSI Level Units Percentage Level High Warn 90 0 Level High Fail 95 0 Level Low Warn 5 0 Level Low Fail 0 0 Analog Group Pressure Signal Source Generator Outpu
93. he password G for future reference The default Password No password is all zeros You can only reset the password using the GSC400 PC Interface To reset the passwords click on Load Factory Defaults under File in the top menu This will reset ALL settings to their factory default so make sure to record the controller settings before doing this 74 of 147 This menu controls the service feature that is used to alert the user of required generator maintenance and can be enabled or disabled from this menu If enabled the count interval menu allows the user to set the number of hours until next service The number of hours to next service is displayed in the Basic Setup menu under Maintenance see Table 6 on page 90 Once the count interval reaches 0 hours it displays a service message records the event in the Event History Log and continues to count down displaying negative hours in the Maintenance submenu until it is reset by a technician The reset counter submenu is used by the technician to reset the counter after service is performed The service feature does not count down to the next service until it is reset in this menu The GSC400 acts as a slave on a Modbus RS 485 network and can on request by the master device remotely transmit warning failure and event indications The device address and baud rate can be set from this menu See Appendix E Modbus Map on page 124 for more communication interface details Modb
94. he run state crank success The run state is described in section 4 4 4 This turns on the digital output when the crank output is on See section 3 3 1 for more details This turns on the digital output when the engine generator starts on an exerciser event section 3 11 This turns on the digital output when the engine generator starts on a low battery event section 3 6 This turns on the digital output when the AC Under Voltage Warning section 3 7 2 is activated This turns on the digital output when the AC Over Voltage Warning section 3 7 2 is activated This turns on the digital output when the AC Over Current Warning section 3 7 3 is activated This turns on the digital output if the Low Fuel In Basin Warning section 3 4 is activated This allows the digital output to be controlled by the idle feature The idle feature also requires a digital input to be set to Idle Mode see section 3 9 See section 2 13 on page 40 for more information on the Idle Mode feature On when the fuel relay turns on and off when fuel relay turns off Following exceptions 1 Does not turn off during crank rest if fuel turns off 2 Off during idle mode This turns on the digital output if the Low Engine 71 of 147 Temperature Warning section 3 4 is activated This turns off the digital output if the LCD backlighting turns off The controller enters the sleep mode section 4 4 2
95. her 12V or 24V electrical systems The GSC400 comes preinstalled with 12VDC automotive style relays For 24VDC systems you must order separate 24VDC relays The relays are 40A but are rated only 30A max resistive at 12VDC 20A max resistive at 24VDC UL Listed relays for 12 or 24VDC system operation are as follows e HASCO CAR 1A 40 DC12 S for 12VDC operation e HASCO CAR 1A 40 DC24 S for 24VDC operation CAUTION The above relays must be installed in the GSC400 for it to meet UL CAUTION needs to be taken when connecting relay outputs to an inductive load Due to the inductive nature of certain loads starters pull coils initial current draw may be higher than stated in the load specs which could damage the onboard relays The GSC400 three relay outputs crank fuel and extra have external replaceable 30A automotive spade type fuses If the full 30A is not needed smaller amperage fuses suited to the load are recommended UL listed 30A fuse is LITTLEFUSE 287030 32VDC 30A auto fast action CAUTION The above relays must be installed in the GSC400 to meet UL This section will explain how to wire your application to the GSC400 Table 1 gives the type and part number for all the mating plugs that plug into the GSC400 terminals If you do not wish to crimp your own plugs Table 30 on page 121 gives the part numbers of the various starter kit harnesses you can order from DynaGen Only commonly used circuits on each connector are
96. ignal to trigger Signal from outside source Configurable Signal Switched from Inputs E to H outside require a low source ground signal m p m m to trigger Ac Cement acm Conti lemex 15 All Configurable Dutputs when turned Relay on provide the pin CA Load to H with a connection to ground Ge switched to ground For example if driving relays one side of Relay the relay would be Load connected to the GSC400 for ground while the other side would be connected to battery V Bat ins provide battery If using V Bat pins to feed ue y multiple switched outputs distribute the outputs evenly among the two V Bat pins Note Relays on systems using 24V batterys require a 24V rating GSC400 Digital Inputs and Outputs Application Note DWG1458 Rev 1 0 Figure 8 Configurable Switched Input Configurable Output Example 35 of 147 If you wish to provide a timed output when the engine shuts down you can do the following Set the Energized to Stop feature to one of the Switched Inputs A to H Set the Energized to Stop duration in the Engine Logic menu to the duration you wish to time the configurable output Set the desired Configurable Output you wish to have timed Only failures are valid 1 2 3 Wire the GSC400 as shown below Power out Energized to COM Stop Switched Output A to H N To Batt COM Desired Co
97. ilures see page section 4 10 on page 99 Description These are internal GSC400 failures Try power cycle the GSC400 If the failure occurs repeatedly the unit could be defected Auto button on front face of controller pressed GSC400 placed in AUTO mode The Auxiliary Fail switched input was active See Table 18 on page 67 The battery charge run period for low battery is finished and the generator has shut down Multiple entries in a row indicate a failure to shut down See section 3 6 1 on page 57 The generator has started up due to low battery voltage See section 3 6 1 on page 57 The Config Fail 1 2 switched input has been triggered See Table 18 on page 67 The text displayed is the text the user entered from the PC Configurator This is an internal GSC400 failure Try to power cycle the GSC400 If the failure occurs repeatedly the unit could be defected The emergency stop input located on the switched input terminal has been activated AC current sensing indicating that the generator is outputting current when the generator is not running This could indicate something is wrong with the GSC400 If the generator was running when it was due for an exercise run See section 3 11 on page 72 The exerciser run period is over and the generator has shut down Multiple entries in a row indicate a failure to shut down See section 3 11 on page 72 The generator has start
98. ing Shorted Sender J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Percentage Warning Level 0 90 Failure Level 0 90 Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Setting Shorted Sender J1939 Switch input Sender 10 60 Seconds GND Fail Open Fail Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Fahrenheit Celsius Warning Level 10 265 F 10 265 C Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Temp Units Temp High Warn Temp High Fail Temp Low Warn Temp Low Fail Pres Units Pres High Warn Pres High Fail Pres Low Warn Switch Input Sender Input 10 60 Seconds Closed Fail Open Fail Disable Warning Shutdown Disable Warning Shutdown Fahrenheit Celsius 10 265 F 10 265 C 10 265 F 10 265 C 10 265 F 10 265 C 10 265 F 10 265 C PSI kPa 0 700PSI 0 700 kPa 0 700PSI 0 700 kPa 0 700PSI 0 700 kPa 108 of 147 Pres Low Fail 0 700PSI 0 700 kPa Level Units Percentage Level High Warn 0 100 Level High Fail 0 10096 Level Low Warn 0 100 Level Low Fail 0 100 Analog Group Temperature Pressure Level Input Pin Reserve Analog 2 7 Signal Source Bypass Delay Switch Setting Shorted Sender Open Sender Temp Units Temp High Warn
99. ing Group X Setting Over Volt Warn 1 Some voltage groups support special genset Over Volt Fail 1 configurations See Table 13 above Under VoltFail1 Over voltage warning setpoint in VAC L L for Over Volt Warn 2 voltage group X n ii na oia Over Volt Warn X DEUS Over Voltage Failure Setpoint L L for Under VoltFail2 voltage group X Group 3 Setting Over Volt Warn 3 UnderVoltWarnx Over Volt Fail 3 Under Voltage Warning in VAC L L for voltage group X UnderVoltWarn3 Under VoltFail3 UnderVoltFailX Group 4 Setting Under Voltage pa in ee L L for voltage or group X Over Volt Warn 4 Over Volt Fail 4 AN Note Warnings failures for voltage UnderVoltWarn4 group 2 2 wire option enabled are in UnderVoltFail4 units of VAC L N even though the units displayed in the menu are L L GenSet Voltages above 600VAC Voltage Group 3 with the Group 3 Setting set to Two Times Voltage is also useful in 4 wire Wye and 3 wire Delta applications where the user wishes to measure a voltage greater than 600VAC the maximum voltage the GSC400 supports In this case the user can use a 2 1 potential transformer PT to step down the voltage to the GSC400 and still have the GSC400 display the correct voltage You can choose a voltage configuration by setting one or two of the configurable 61 of 147 switched inputs to Volt Select 1 and Volt Select 2 This allows the GSC400 to automatically re configure its voltage display as well as w
100. ing is generated when the input is active A High Fuel Level Warning is generated when the input is active These inputs when active generate a warning failure and a configurable text message is displayed to the screen when the input is active The text message can only be configured from the GSC400 PC Interface The length of the message is limited to 15 characters The user can control the states in which these features are enabled The selections are 1 Global Everywhere 2 Crank From start of delay to start to the end of cranking 3 Run RUN Mode only 4 Crank Run Combination of 2 and 3 above These settings are located at the bottom of the menu for each input When inactive this prevents a manual or automatic start 69 of 147 There are eight 200mA configurable outputs all switched to ground and one relay output dry contact the Extra Relay output all of which are configurable Each feature listed in Table 19 below is permitted to be set to only one configurable output Table 19 Configurable Output Selections This sets up the output to be controlled by the Warm up feature See section 3 3 1 for more details The Warm up time is set in the engine logic menu This is an active low output i e the output remains off during warm up and turns on after warm up is finished The output always remains off when the controller is not in the RUN mode This allows the Energize to Stop fe
101. is likely the GSC400 is picking this up If the frequency reads 50 60Hz then the controller will assume the generator has started already Try another L L or L N connection If necessary install an isolation transformer to prevent stray signals 22 of 147 Menu Location Page 1 High Engine Advanced Setup High Engine Tmp Temperature 2 Low Oil Pressure Advanced Setup gt Oil Pressure 3 Low Fuel Level Advanced Setup gt Fuel Level 4 Low Oil Level Advanced Setup gt Oil Level 5 Low Fuel In Basin Advanced Setup gt Fuel In Basin 50 6 Low Engine Advanced Setup gt Low Engine Tmp Temperature 7 Auxiliary Analog Advanced Setup gt Aux Analog 1 Input 1 8 Auxiliary Analog Advanced Setup gt Aux Analog 2 Input 2 The Aux Analog Inputs 1 and 2 are only supported in firmware 2 06 and greater The user has the option of connecting either senders or switches to the sensor inputs Single wire switches and senders get their ground from engine chassis via their threads The GSC400 requires a good ground from its Battery negative terminal to the sensor body or there may be intermittent problems with shutdowns etc or it may not be able to read the sender properly at all Teflon tape can cause grounding issues as it can act as an electrical insulator If using switches they must be switched to ground but can be either normally open or normally closed 23 of 147
102. it4 Reserved bit5 Low oil level failure bit6 Low air pressure failure digital input bit7 Low hydraulic failure digital input 130 of 147 bit8 Auxiliary input failure bit9 Low battery level failure bit10 High battery level failure bit11 AC over voltage failure bit12 AC under voltage failure bit13 AC over current failure bit14 J1939 Loss of ECM failure bit15 EPS load failure bit0 PGN 61444 EEC1 not available engine speed biti PGN 65263 Fluid level not available oil pressure bit2 PGN 65262 Engine temperature not available bit3 Emergency stop active bit4 Low battery voltage during cranking active bits Battery charger fault active bit System not ready active bit7 Low oil level warning active GSC400 hardware 1 00 9 99 Version format is Decimal version number format where X represents a number GSC400 fi 1 00 9 99 from 1 9 and is stored in the high Irmware 29 byte of 40090 represents a version number decimal number from 00 to 99 and is stored in the lower byte of 40090 GSC400 serial 4 to 7 The serial number is stored in 7 digit number characters decimal format with the high byte of register 40092 containing the high MSB and the low byte of register 40095 containing the LSB Unused characters are stored as zeros For example serial number 0012450 would be stored as follows 40092 MSB 0 40092 LSB 0 40093 MSB 1 40093
103. l also occur during all subsequent power ups LCD Contrast Adjustment If the screen is hard to read or is fuzzy the contrast of the unit may need to be adjusted To do this 1 Press the OFF key to go to the OFF mode 2 Press the ENTER key to go to the menu system 80 of 147 3 Press the DOWN key until Basic Setup is highlighted and press the enter key Press the down key to select Contrast Adj and press enter Use the up and down keys to adjust the contrast and then press enter Then scroll up to select Back and press enter Repeat this again to exit the menu system and go back to the OFF mode The controller will then enter the OFF mode By default it is possible to manually start the generator in the OFF Mode The user can disable manual start in OFF mode in the basic menu in which case the GSC400 must be in the AUTO mode to manually start the generator See section 4 8 2 on page 89 for the basic menu Pressing the Auto key will cause the controller to enter the AUTO mode From this mode the user can manually put the controller into RUN mode i e start the generator or the controller itself will be able to start the generator automatically if required e g low battery start if enabled The controller has the ability to remember whether it was in the OFF or AUTO mode the last time it was powered up and will reenter that mode when it is repowered If the emergency stop input of the digi
104. l menu located in the Advanced Setup menu you will also need to set the controller type or hardware version LS LX or LSB LXB The controller hardware version can be found on the back label under the bar code If you have LSC LXC then chose LSB LXB Section 1 4 on page 10 explains how to read the product number This feature is only in firmware versions 2 06 and above In addition to the six standard sensor types there are two customizable types They can be set to a Switch or Sender and have some of the same settings as the standard types They appear in the Advanced Setup menu as Aux Analog 1 and Aux Analog 2 They also have the following unique settings e They can be programmed to display custom text with the PC Configurator The default text is Aux An1 and Aux 2 It is not possible to set the text from the front panel 54 of 147 e They can be programmed with low and high warning and failure levels The warnings and failures are displayed as Short Aux An1 Open Aux An1 Low Aux An1 and High Aux An1 The Aux An1 is the programmable portion mentioned above e They can be programmed to measure and display three measurement types Temperature Pressure and Level These special submenus are located under the standard submenu items in the Aux Analog 1 2 menus These two sensor inputs are only monitored after crank success 55 of 147 The speed sensing menu allows you to select the
105. le If the GSC400 is unpowered then powered up on power up the GSC400 will use the start date and month to determine the next time to exercise instead of the run duration See section 3 11 on page 72 for the exerciser settings 87 of 147 The GSC400 incorporates a menu system to allow the end user to adjust basic settings The menu system also allows technicians and SEES DynaGen OEMs to adjust advanced settings T s 9 00 AM DEC 01 this feature is password protected BACK c CLOCK SETUP s s BASIC SETUP With the controller in the OFF Mode i ADVANCED SETUP FAILURE HISTORY the menu system may be selected MESISESHISS HOREY simply by pressing the Enter key In the OFF Mode press ENTER to access the GSC400 Menu System This is called the Basic Menu The following keys perform the menu navigation 1 Scroll up using the up key y 2 Scroll down using the down key kd 3 Enter menus by pressing the enter Each menu has a Back selection To go back to the previous menu scroll up to the Back selection and press the Enter key When in the basic menu you can go back to the OFF mode by pressing the off key When you press the Enter key in the OFF mode you will enter the basic menu which includes the Clock Setup Basic Setup Advanced Setup and Event History submenus 1 Clock Setup 9 00AM DEC 01 BACK 2 Basic Setup 3 Advanced Setup BASIC SETUP 4 Events History ADVANCED SETUP
106. ls This turns on the digital output if the Over Speed Failure is activated See section 3 5 for more details 70 of 147 This turns on the digital output if the Over Speed Warning is activated See section 3 5 for more details This turns on the digital output if the Low Fuel Failure is activated See section 3 4 for more details This turns on the digital output if the Low Fuel Warning is activated See section 3 4 for more details This turns on the digital output if the Low or High Battery Failure is activated See section 3 6 for more details This turns on the digital output if the Low or High Battery Warning is activated See section 3 6 for more details This turns on the digital output if the Low Coolant Level Failure is activated This is controlled by the Low Coolant Level Digital Input described in Table 18 in section 3 9 Reserved for future use Selecting this feature will have no effect This turns on the digital output when the controller is not in the Auto state Section 4 4 describes the various states of the controller This turns on the digital output when any failure is active This turns on the digital output when the controller is in the crank rest state after a crank attempt The crank rest duration is set in the engine logic menu See section 3 3 1 for more details This turns on the digital output when the controller enters t
107. n Manual Run Stopping the Generator The off key on the front panel can always be used to place the GSC400 in the OFF mode If the controller is in the RUN mode due the remote start contacts or Modbus for the first 10s either of the two can be used to place the controller back in the OFF state although the remote start contacts cannot be used to stop the generator unless it was the cause of start After this 10s period only the start condition that caused the start can be used to place the controller back in the AUTO or OFF mode Preventing a Stop when in Cool Down Once the GSC400 is in cool down and another start condition was received the controller will exit cool down and remain running It will display the new start condition on the screen 86 of 147 Off key pressed during Manual Run If the Off key is pressed during a manual Run a cool down popup will display on the GSC400 Press the AUTO key to immediately enter the Auto mode press the OFF key to immediately enter the OFF mode or press the Enter key to enter cool down If no key is pressed the GSC400 will remain in the Run mode If the OFF key is pressed during another start condition e g Modbus Run a cool down popup will appear again but in this case the only option is to press the OFF key to immediately enter the OFF mode If the GSC400 is programmed to exercise it must be in the AUTO mode to do so If it is in the OFF or RUN modes it will skip the exercise cyc
108. n be used for Modbus and A separate wire or Modbus common would need to be run 2 Beldin 7895A two shielded twisted pairs 20AWG twisted pair for Modbus and 18AWG twisted pair for Modbus common It is recommended to use shielded cable terminating one side to ground It is not recommended to use the drain wire as RS485 common Older GSC400 units had a 100Ohm resistor between Modbus common and battery This can cause problems It is recommended that you run a wire from Modbus common to battery if this is the case This is not an issue with the LSC LXC revision units 39 of 147 Communication Notes 1 The GSC400 only supports commands 0x03 read multiple registers and 0x06 write single register If an attempt is made to send another command the GSC400 returns incorrect command Can only request to read 20 registers at a time If over 20 GSC400 returns illegal data address Also need to watch out for discontinuities in register map The GSC400 will return invalid data for non existing registers often returns a value of 0 If they try to read registers that don t exist GSC400 will return values for those registers that don t exist but it will be invalid data often 0 If they try to write to a register that doesn t exist GSC400 will ignore write request and return OK Refer to Appendix E on page 124 for more detailed Modbus information and the Modbus map Troubleshooting steps
109. n on the screen as well as optionally store then to the Event Log The controller can also receive previously active DM2 messages and display them on command DM2 messages are intended for technician troubleshooting and are not stored to the Event Log The GSC400 supports the following J1939 standards when reading DM1 messages 1 Single package frame J1939 71 2 Multi packages frame J1939 21 a BAM b TP DP The GSC400 supports the following J1939 standards when reading DM2 messages 1 DM2single package frame J1939 71 2 Multi package frame J1939 21 a BAM b RTS CTS c TP DP 66 of 147 The user can enable disable the DTC feature and configure its behavior with the following settings DTC DISPLAY This setting enables or disables active fault messages DM1 monitoring When the DTC DISPLAY feature is enabled the GSC400 can receive active faults in the RUNNING OFF and AUTO modes on the J1939 bus Any new received active faults will trigger a message NEW ACTIVE DTC and the user can read the message on the GSC400 front panel display This new message will also be stored into the controllers event log if this feature was enabled ACTIVE LOG DTC The setting enables disables the storing of active faults DM1 in GSC400 Event Log The Event Log reserves 30 storage locations for DM1 messages READ STORED DTC The setting enables disables the ability to request stored fault codes from the ECM DM2 When this setting is enabled th
110. nd below or 60s firmware versions 2 04 and above the battery charger action is triggered Once activated it is not stopped even if the voltage rises above the Recharge Level First the GSC400 goes though a pre alarm delay displaying a warning and sounding the buzzer set by ChargePrealarm then it starts the generator and runs for the required time set by ChargeDuration Once finished the GSC400 shuts down the generator and goes back to the AUTO mode Note that the GSC400 does not have the capability of charging the battery to a specified voltage level When finished the start on low battery feature will send a shutdown request and retry once a minute if the engine remains running It will also log charge over in the log when it sends the request Multiple logs for charge over in the event log indicates that the engine could not be shutdown For example the remote start contacts are active 58 of 147 The AC Frequency AC Voltage and AC Current menus allow the measurement and display of the AC voltage current and frequency from the generator In the AC Frequency menu under and over frequency warnings and failures can be configured The DisconnectFreq setting is used by the GSC400 controller as a backup to the speed input only if speed is set to magnetic pickup If the speed input is not detected the controller checks the DisconnectFreq settings If the measured frequency is greater than this setting then the engine will be c
111. nfigurable Output A to H N to time Power in Figure 9 Timed Configurable Output on Engine Shutdown 36 of 147 Menu Location Page 1 J1939 Advanced Setup gt J1939 Setup 63 2 Engine Speed Advanced Setup gt Speed Sensing gt Signal 55 Source Warning and or Failure 3 High Engine Advanced Setup gt High Engine Tmp gt Signal Temperature Source Warning and or Failure 4 Oil Pressure Advanced Setup gt Oil Pressure gt Signal Source Warning and or Failure 50 5 Oil Level Advanced Setup gt Oil Level gt Signal Source 6 Low Engine Advanced Setup gt Low Engine Temp gt Signal Temperature Source Warning and or Failure Wiring Dynagen s wiring harness can be used for runs of 5ft or less Otherwise a proper 120Ohm impedance twisted pair should be used Also consider shielding if the application warrants it ECM Power The GSC400 fuel relay output is usually used to power the ECM The fuel relay turns on at the start of preheat even if no output is set to preheat If the preheat time is set to zero the fuel output turns on during the start of cranking The ECM usually must be given time to boot up to allow it to detect the cranking of the engine Bus Termination The CAN communication bus s CANL and CANH lines must be terminated with two 120Ohm 0 5 Watt resistors one on each end of the bus If you are not connecting to an existing bus you must do this If you are conne
112. ning is of a short duration The Sleep Delay determines how long to wait after the last key press before turning off the LCD backlighting The Sleep Delay also controls the automatic exit from the menu system First the controller exits to the basic menu after the first sleep delay exits to the OFF mode after the second sleep delay and finally goes into sleep mode after the third sleep delay The sleep delay does not work in the RUN mode or during cranking 90 of 147 The controller can be made to NOT sound the alarm when the controller is not in the AUTO mode This is controlled by the Not In Auto setting Disable Beep is the default selection The OFF Mode Start setting can be set to Enable to allow a manual start from the OFF mode Otherwise a manual run can only be performed when the controller is in the AUTO mode Table 24 Basic Setup Menu 5 95 96 50 1 10s 2s 1 10 1 is shortest delay 10 is longest 2s 10 600s Shorter is ideal to extend the 600s backlighting life Read only Displays the amount of hours until next service if this feature is enabled N A If service is overdue the hours become negative Read only Displays the GSC400 hardware version software firmware N A version and serial number Disable Beep Enable Beep Disable Beep Disable Enable Enable 9 of 147 4 8 3 Event History Log The GSC400 incorporates an event history logging system FAILURE HISTORY
113. ns longer than 5ft to confirm proper operation J1939 and Modbus applications should use proper cable for those purposes if over 5ft Refer to the J1939 and Modbus sections Load UL Note Branch circuit protection with max ratings of 32V and 25A must be used on each battery supply connection Fuel Crank and Extra Relay connections tul E er e mE i e Phase C Configurable Switched Inputs Battery E 2 a 600VAC L L max Use N O switches to For user connect to Inputs A to H convenience pins 11 and 12 1 provide access G 2 to Battery F3 10 4 Start ELT 5 Contacts Gnd C lle m J6 d El 1 V Bat For user 7 2 8 G B s pins and 10 Fuse K1 J HIT 14 provide access Internal F1 Fuel V Bat 070 5 to Battery GSC400 Relay afa OA Ground _ Configurable Speed J1939 Outputs Config Inputs Gnd S 2 Gnd TL Input ize iHa B 6 3 B aes C a 5 4 3 P Modbus Fuse aa ule
114. nsing may not work properly If you are using a magnetic pickup sensor you must know the number of teeth of the flywheel you are measuring This is needed to configure the GSC400 speed sensing An alternative is to let the generator run at its rated speed the speed at which it produces power and measure the AC frequency with a multimeter Then you can enter this frequency directly instead of calculating the frequency based on the number of teeth See the speed sensing configuration in the next chapter for more information If using an electronic engine you do not need to connect anything to the speed inputs e Symptom Speed is zero generator won t stop cranking Speed 1 and 2 terminals J17 J18 need to be connected to generator output 21 of 147 e Symptom Turns off starter prematurely or does not turn on starter and then goes into a low speed or low AC voltage failure without starting the generator This could be caused by the GSC400 speed sensing terminals picking up stray signals during cranking The speed sensing on the GSC400 is sensitive in order to pick up low voltages during cranking The GSC400 then thinks the generator has started Confirm by checking the speed displayed on the controller during cranking 1 Check that there are no breakers off This can unload the GSC400 sensing inputs allowing the wiring to act as an antenna 2 Check the AC voltage and frequency during cranking If it reads a few volts then it
115. o battery negative Do this on the GSC400 terminal not the plug It should read 5VDC If it does not there may be a problem with the controller 3 Plug the sensor connector back in You may need to do this step with or without the generator running Look at the display on the GSC400 and note the value displayed Then measure the DC voltage from the output of the sensor to battery negative Note the reading Lookup the pressure or temperature value using this voltage in the tables below If it matches the value displayed on the GSC400 then the sender may be bad If it does not there is an issue with the wiring or setup or the controller may be bad 4 Disconnect the sensor plug again and measure the resistance from the pin on the plug to battery negative Refer to the below tables Does the value from the table match the expected value If not the sender or wiring may be bad Datcon 1 Temperature 26 of 147 Datcon 1 Stewart Oil Pressure Resistance QUARE V Temperature Resistance 22 888 V Pressure hms 2 Pins 3 4 CH eis 2 Pins 3 4 d 7 0 03 330 34 0 16 99 28 0 14 300 8 45 0 22 91 49 0 23 0 23 275 57 0 27 82 8 72 0 34 0 34 248 68 0 32 75 3 96 0 44 0 44 221 79 0 37 68 120 0 54 0 54 203 5 92 0 42 57 4 147 0 64 0 64 189 7 104 0 4
116. of 147 The below table lists the fixed delays of the GSC400 Table 29 GSC400 Debounce Times Triggers in RUN mode 2 0s after 10s bypass delay 3 25s Triggers only in 3 5s modes from Delay to Start to Crank 3 755 Success Triggers only in RUN 3 75s mode after crank success 3 0s 1 0s 2 55 Can trigger in OFF 3 0s AUTO and RUN i modes 3 0s 3 0s 3 0s 508 User selectable 3 0s trigger 3 0s 6s 4 5s 5s 6s 4 25s 118 of 147 5s 6s 4s 5s 4s 6s 4 75s 5s 5s 5s 5s 5 25s 4s 6s 4 5s 1 5s 4 5s 1 5s 8s 5s 8s 5s 5s 4s 4 5s 8s 119 of 147 5s 8s 5s 5s 4s 4 5s 8s 5s 8s 5s 5s 4s 4 5s 8s 5s 8s 5s 8s 5s 1s 1 5s 1 75s 1s User settable Decreased to 3s if 3 60s locked rotor detected User settable crank tries crank duration rest time or 3s from when locked rotor is 120 of 147 121 of 147 The following table identifies all the wiring harnesses as part of the GSC400 controller Table 30 GSC400 Wiring Harness Part List DWG1375R2 5 DWG1378R2 5 DWG1376R2 5 All circuits 1 2 3 4 1 DWG1377R2 5 Ab To B O 10 11 DWG1454
117. om Warning 1 7 Custom Warning 2 8 CRANK SUCCESS 9 Empty Space 11 REQUESTING DTC 14 LAMP TEST 15 High Fuel Level 16 Warning 17 Low AC Voltage 18 Over Cur Latched 19 t FOR UNLATCH 20 READ DTC SUCCESS 21 FUEL OFF If fuel turned off during crank rest 22 Low Engine RPM 23 High Engine RPM 24 High AC Current 25 High AC Voltage 26 High Engine Temp 27 Low Oil Pressure 28 Low Fuel Level 29 EXERCISE Prealarm 30 CHARGE Prealarm 31 NO DTC AVAILABLE 32 DM2 REQUEST FAIL 33 KEEP FUELING If fuel remains on during crank rest 134 of 147 34 Lock Mark symbol screen locked when in Run Mode 35 NOT IN AUTO 36 OFF FOR SILENCE 37 OFF FOR ALARM 38 POWER ON ECM 39 WAITING EOM 40 NEW ACTIVE DTC 41 DTC PROCESS DOWN 43 FAILURE 45 WAIT TO START 46 Low Oil Level 47 Low Speed Warn 48 Locked Rotor 49 Fuel In Basin 50 Low Battery 51 High Battery 52 AUTO FOR SILENCE 53 AUTO FOR ALARM 54 Low Engine Temperature warning 55 Open Engine Temperature sender 56 Short Engine Temperature sender 57 Open Oil Pressure sender 58 Short Oil Pressure sender 59 Open Fuel Level sender 60 Short Fuel Level sender 61 Open Oil Level sender 62 Short Oil Level sender 63 Open Fuel Basin sender 64 Short Fuel Basin sender 70 EMERGENCY STOP 71 Auxiliary Warn 72 Under Frequency warning 73 Over Frequency warning 74 OPEN AUX ANALOG 1 warning 75 SHORT AUX ANALOG 1 warning 76 LOW AUX ANALO
118. onsidered running If AC voltage is disabled the controller will still shutdown on under and over AC frequency if there is live voltage on the AC voltage terminals To prevent this disconnect all wiring from the AC voltage terminals This section will cover the configuration of AC Voltage Note that the GSC400 requires a neutral reference from the generator and can only support up to 600VAC L L on its inputs GSC400 Voltage Groups The user can enter under voltage over voltage and over current settings for four different voltage configurations see Table 15 below This allows multiple GSC400 units programmed with identical settings to be used on multiple generator types or a GSC400 to support multiple voltage configurations on a single generator The voltage configuration the GSC400 uses is set by the Voltage Group menu Each voltage group supports a variety of genset configurations Table 12 lists the submenus that apply to all voltage groups Table 12 AC Voltage Submenus Enable or Disable Voltage Sensing AC Current Sensing will not work without voltage sensing enabled This only affects how the AC Voltage is displayed The choices are Line to Line Line to Neutral or Both This is where the user picks which voltage group to use 1 2 3 or 4 There are other submenus under the three listed here but they apply to specific voltage groups See Table 14 below 59 of 147 S
119. ont bito Over Crank Failure red Panel LED Status 1 ON bit1 Over Crank Warning amber bit2 High engine temp failure red bit3 High engine temp warning amber bit4 Low oil pressure failure red bit5 Low oil pressure warning amber bit6 Engine over speed failure red bit7 Engine over speed warning amber bit8 Low fuel level failure red bit9 Low fuel level warning amber bit10 Low Battery warning amber bit11 Battery Ok solid green in OFF and RUN modes flashing green in AUTO mode bit12 Not in auto red bit13 Not used bit14 Low coolant level shutdown red bit15 Low coolant level warning amber 128 of 147 bito EPS supplying load shutdown red bit1 EPS supplying load green bit2 not used bit3 Glow plug on green bit4 Failure is active Red Failure LED bit5 to bit7 not used bit8 Crank relay On no LED bit9 Fuel relay ON no LED bit10 Extra relay ON no LED bit11 to bit13 Reserved bit14 and bit 15 not used Events Warnings Status 0 OFF 1 ON Warm up finished biti ETS is on bit2 Glow plug is on bit3 Cool Down is active bit4 Over crank occurred bits High engine temperature failure bit6 High engine temperature warning bit7 Low oil pressure failure bit8 Low oil pressure warning bit9 Under speed failure bit10 Under speed freq warning bit11 Over speed failure bit12 Over spe
120. point The Auxiliary Analog 1 and 2 can be programmed with custom text so the text to the left may not apply LOW BATTERY Low battery voltage failure See section 3 6 on page 50 LOW COOLANT Level Low coolant level switched input failure See Table 18 on page 67 LOW FUEL LEVEL Failure due to low fuel See section 3 4 on page 50 LOW HYDRAULIC Low Hydraulic digital input was active See Table 18 on page 67 LOW OIL LEVEL See section 3 4 on page 50 LOW OIL PRESSURE See section 3 4 on page 50 MAINTENANCE The generator requires maintenance See NEEDED section 3 13 on page 74 MAINTENANCE Maintenance has been performed on the PERFORMED generator i e the maintenance timer has been reset See section 3 13 on page 74 MANUAL START Generator started manually from the front panel RUN key MANUAL STOP Generator stopped manually from the front panel OFF key OFF ENABLE Front panel OFF key pressed to disable 94 of 147 automatic starting Analog sender always reads the maximum voltage Could indicate that the sender is not connected to the analog input i e broken wire The GSC400 could not start the generator See section 3 3 engine logic on page 47 and section 3 5 speed sensing on page 55 Over current failure See section 3 7 3 on page 62 Generator Frequency over the failure threshold See section 3 7 1 on page 58
121. put Pin 9 of the configurable switched input connector must be grounded can use pins 11 or 12 to disable the emergency stop feature When enabled the emergency stop feature forces the controller to remain in the OFF mode and sounds the buzzer Remote Start Contacts RSC A normally open switch needs to be placed across pin 10 of the configurable switch input connector and ground pin 11 or 12 on the same connector can be used for convenience When the switch closes the GSC400 will start the genset if in AUTO When the switch opens the GSC400 will stop the genset The wiring for the RSC should be specified assuming a maximum 0 5A current draw on the lines LCD Heater GSC400 H versions only If you have a unit with an LCD heater you must enable it See section 3 16 2 on page 76 20 of 147 Menu Location Page 1 Speed Advanced Setup Speed Sensing 55 Sensing The GSC400 senses engine speed via two spade terminals on the bottom of the unit not needed if getting speed from J1939 Magnetic input generator AC voltage or J1939 can be used Two wires must be run to the speed inputs even if using generator output The AC Voltage Sensing terminals provide the AC voltage level and frequency while the speed inputs provide the engine speed sensing Either L N or L L AC voltage can be connected to the speed inputs up to a maximum of 300VAC Neutral must be bonded to battery negative ground or the speed se
122. rd here The default password is 0000 3 12 73 Set Maintain This menu controls the service notification feature for regular maintenance The user can enable disable the feature and set the service interval A technician can reset the service interval here On reset the service counts down to the next service 3 13 74 Set Modbus This sets the modbus slave address and baud rate 3 14 74 Common Faults The user can select a group of failures warnings and events that when triggered will cause a digital output to turn on The user also needs to select this feature in the digital outputs menu for one of the outputs 3 15 74 Other Settings This contains settings to control the following features 1 Dummy Load Places load on genset to prevent a no or low load condition 2 LCD Heater H hardware option only consult factory 3 Fan Control Activate configurable switched output when engine temp is above a certain value 3 16 75 47 of 147 The Engine Logic menu contains settings that control the starting and stopping of the engine All parameters in bold below are located in the engine logic menu unless otherwise noted The Crank Disconnect setting determines the speed that must be attained before the crank output is turned off and the genset is considered to be running The Crank Oil Pressure parameter is used to determine when to check for the Locked
123. s of 16 most significant bits of SPN Byte 3 3 most significant bits of byte contain the 3 least significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC Conversion Method Version 2 Byte 1 8 least significant bits of 16 most significant bits of SPN Byte 2 8 most significant bits of 16 most significant bits of SPN Byte 3 3 most significant bits of byte contain the 3 least significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC Conversion Method Version 3 Byte 1 8 least significant bits of SPN Byte 2 8 second byte of SPN Byte 3 3 most significant bits of byte contain the 3 most significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC conversion method 3 is the same as DTC conversion method 4 the new J1939 standard except that the CM bit is 1 so it is impossible to tell it apart from versions 1 and 2 Version 4 has the bit set to O which allows the user to know the conversion format is Version 4 without having to consult the engine manufacturer 146 of 147 The follow pages include various drawings that may be of benefit Phase A u psp ce ces PEE AC Current
124. same type of information as the DM1 messages The GSC400 controller can support a maximum of 32 messages When previously active DTC messages are requested and received the GSC400 controller will display the stored messages on the GSC400 front panel LCD screen If multiple stored messages are received the user can either manually scroll through each stored message or the screen will scroll between each DTC 104 of 147 stored message at a 3 second interval If the user intervenes the interval will change to 10s The DTC stored message display appears as follows Dina WARM UP 3 ED DTC 3 FMI 4862 20 021 000 Figure 15 32 stored DTC messages the 5PthP stored code being displayed To Trigger a DM2 Request simultaneously press the UP and DOWN keys for a period of 3 seconds in either the AUTO OFF or RUNNING modes The controller s alarm will sound and the controller will send a request to the ECM A LAMP test will additionally be triggered in the OFF mode The UP and DOWN keys can also be pressed to remove the DM2 message screen If the GSC400 is in the OFF or AUTO mode when the request is triggered the ECM may not be powered on so the controller will energize the fuel relay output and wait for the ECM to power on The GSC400 then sends out the DM2 request In the event there is no response from the ECM the controller will re attempt an additional 3 times every 1 25 seconds It will then display RE
125. source to use for sensing the rotational speed of the engine There are three options to choose from 1 41939 Input If the engine generator comes equipped with an engine control module ECM that supports the J1939 protocol then the GSC400 can obtain the engine speed from the ECM 2 Magnetic Pickup If the engine generator is equipped with a magnetic pickup sensor then the sensor can be connected to the SPEED 1 and SPEED 2 spade terminals on the GSC400 Generator Output The GSC400 can also determine the engine speed indirectly from the generator frequency The voltage source of the generator must be connected to the SPEED 1 and SPEED 2 terminals Over speed warnings and failures as well as under speed warnings and failures can be set from the menu in units of RPM The warnings and failures apply to all three options above The rated speed is the speed in revolutions per minute RPM the engine runs at when producing power For example some generators run at 1800RPM while others run at 3600RPM If using Generator Output The rated frequency is the frequency of the generator usually either 50Hz or 60Hz If using magnetic pickup For a magnetic input the rated frequency is determined by the number of teeth on the flywheel and is calculated by Rated frequency Hz Number of teeth x Rated Speed 60 Where Number of teeth number of teeth on the flywheel the magnetic pickup sensor is attached Rated Speed th
126. t Rated Freq 60 Hz Rated RPM 1800 RPM Over Speed Warn 1950 RPM Over Speed Fail 2050 RPM Under Speed Warn 1650 RPM Under Speed Fail 1550 RPM Frequency Disconnect 22 Hz Over Freq Warn 70 Hz Over Freq Fail 75 Hz Under Freq Warn 50 Hz Under Freq Fail 45 Hz Voltage Source Enable Voltage Display Line Neutral Voltage Group Group 1 Single Group 1 Setting 3 Wire Single Group 3 Setting Normal Voltage Group 4 Setting Three Phase Over Volt Warn 1 Over Volt Fail 1 Under Volt Warn 1 Under Volt Fail 1 Over Volt Warn 2 Over Volt Fail 2 Under Volt Warn 2 Under Volt Fail 2 250 VAC 120 240VAC wire 260 VAC 230 VAC 220 VAC 220 VAC 120 208VAC 230 VAC 195 VAC 185 VAC 115 of 147 Over Volt Warn 3 500 VAC 480VAC Over Volt Fail 3 520 VAC Under Volt Warn 3 460 VAC Under Volt Fail 3 440 VAC Over Volt Warn 4 630 VAC 600VAC Over Volt Fail 4 650 VAC Under Volt Warn 4 570 VAC Under Volt Fail 4 550 VAC Current source Enable Turns Ratio 100A 5A Over Current Wan 1 90A Over Current Fail 1 100A Over Current 2 80A Over Current Fail 2 90A Over Current 3 20 Over Current Fail 3 25A Over Current Warn 4 15A Over Current Fail 4 20A Delay to Start 0 seconds Pre heat Time 0 seconds Crank Time 15 seconds MidHeat Time 0 seconds Crank Rest Time 15 seconds Crank Attempts 3 Fuel Crank Rest Enable False Restart Enable Post Heat Time 0 seconds ETS On Duration 0 seconds Warm up Time 600 seconds
127. t Warn 2 0 700 VAC Over Volt Fail 2 0 700 VAC Under Volt Warn 2 0 700 VAC Under Volt Fail 2 0 700 VAC Over Volt Warn 3 0 700 VAC Over Volt Fail 3 0 700 VAC Under Volt Warn 3 0 700 VAC Under Volt Fail 3 0 700 VAC Over Volt Warn 4 0 700 VAC Over Volt Fail 4 0 700 VAC Under Volt Warn 4 0 700 VAC Under Volt Fail 4 0 700 VAC Current source Disable Enable Turns Ratio 5 5000A 5A Over Current Warn 1 0 6500 A Over Current Fail 1 0 6500 A Over Current Warn 2 0 6500 A Over Current Fail 2 0 6500 A Over Current Warn 3 0 6500 A Over Current Fail 3 0 6500 A Over Current Warn 4 0 6500 A Over Current Fail 4 0 6500 A Hi Wye Current Cur Warn Latch 10095 5095 Disable Enable Delay to Start Glowplug Time Crank Time MidHeat Time Crank Rest Time Crank Attempts Fuel Crank Rest False Restart Post Heat Time ETS On Duration Warm up Time RPM Disconnect Cool Down Delay Crank Oil pres Shut Inhib Src Shut Inhib Thr Bypass Cooldwn 0 60 seconds 0 60 seconds 3 60 seconds 0 60 seconds 1 60 seconds 1 60 Disable Enable Disable Enable 0 60 seconds 0 30 seconds 0 600 seconds 100 2000 RPM 0 600 seconds 0 90 Psi Disabled Aux Analog 1 Aux Analog 2 0 700 PSI 0 700 kPa Disable Enable 110 of 147 Extra Relay Output A Output B Output C Output D Output E Output F Output G Output H Disable Warm Up ETS Glowplug Cooldown Over Crank High Temp Fail High Temp warn Low Oil Fail Low
128. tal input terminal is not connected to ground the controller will alarm and display Emergency Stop when connected Emergency Stop also forces the controller to the OFF mode To prevent this ground the emergency stop input pin 9 to either of the grounds pins 11 or 12 on the digital input terminal See Figure 4 on page 15 The GSC400 has a dedicated remote start contact located on the configurable switched input connector A grounded signal on the contact when the controller is in AUTO mode see below for more information on the AUTO mode will cause the controller to start Removing the ground will cause the controller to go back into AUTO mode It is also possible to set one of the configurable switched inputs as a remote start contact This feature works the same way as the dedicated remote start active start The GSC400 also has a dedicated emergency stop input that when open will stop the generator immediately and the controller will enter the OFF mode see below for more information on the OFF mode and remain in the OFF mode until the emergency stop input is grounded While the emergency stop input is active 81 of 147 the GSC400 will sound an audible alarm and display Emergency Stop on the LCD display See Figure 4 on page 15 for the location of the emergency stop input 82 of 147 The GSC400 incorporates 3 primary modes of operation 1 OFF Mode 2 AUTO Mode 3 RUN Mode When the GSC400 is set to the OFF mode
129. than the normal operating speed the GSC400 controller has an Idle Mode feature that suppresses the warnings and failures for under voltage under frequency and under speed The GSC400 displays Idle Running when this feature is enabled 85 of 147 THE LCD WILL TURN OFF DURING THE FIRST 2 SECONDS OF CRANKING TO LIMIT THE VOLTAGE DIP EFFECT ON THE CONTROLLER DURING CRANKING Since the GSC400 startup and shutdown behavior can be configured by the manufacturer the exact startup and shutdown behavior can vary Behaviors such as the amount of time to wait before starting preheat crank time etc all are programmable There are three ways to start the generator start conditions 1 Modbus Sending a Start using the appropriate register 2 Remote Start Contacts RSC Pins 10 of the digital input connector or setting Switched Input A to H to the Start Stop feature 3 Run key Located on the GSC400 front panel There are two features that can automatically start the generator 1 Battery Recharge if enabled 2 Exerciser if enabled The battery recharge and exerciser options will only start the generator when the GSC400 is in the AUTO mode These features will not interrupt a shutdown When the controller is in the AUTO mode the three manual start conditions above can be used to start the generator When the controller is in the RUN mode it will display the reason for the start on the screen Modbus Run Remote Start Ru
130. the AUTO mode automatic starting will be enabled Possible triggers include RU DynaGen RSC start stop battery recharge and exerciser run all of which are controllable from the menu system If the engine is started failures will be automatically detected allowing for safe engine operation While in AUTO mode the controller will display engine temperature battery voltage fuel level and engine hours The LCD will turn off after a programmable amount of time This is controlled by the sleep delay setting in the basic menu The GSC400 can go from AUTO to OFF under these conditions 1 The OFF key is pressed on the front panel of the GSC400 2 The emergency stop input becomes active A Modbus command is sent over the RS485 connection to place the controller in the OFF Mode When the GSC400 enters the OFF Mode it logs a OFF ENABLED event in the event log The GSC400 can go from OFF to AUTO under these conditions 1 The AUTO key is pressed on the front panel of the GSC400 2 A Modbus command is sent over the RS485 connection to place the controller in the AUTO Mode The controller starts the engine generator and enters the RUN mode automatically on certain triggers low battery voltage or to exercise the generator or the user can manually start the engine generator by pressing the Run key Another option is to use the remote start contacts located on DynaGen 84 of 147 the switched input connector
131. the GSC400 Most GSC400 configuration is done from the Advanced Setup Menu 3 1 MAKING MENU SELECTIONS S oeoo eoep aon re e E E a a O Ns 44 3 2 ADVANCED SETUP MENU OVERVIEW ccccccsscescsscescesecssesecsscsecssssecsaccasesecseesessaseecascaseaeestenss 45 3 3 ENGINE LOGIC act terree P EHE Oed arte e RED e CO REDDE C HL 47 SL jSfanupoeguence ote edite teer t bete teer 47 3 3 1 1 Locked Rotor rire E Renee Ebo ieveas 48 3 3 3 Shutdown Sequence ssssssseeseseeeeeeenent nennen eene nennen nens 48 3 3 2 1 Shutdown Inhibit for Engine Driven Compressors eese nennen 49 3 4 SENSOR INPUTS 50 3 41 Switched Inputs ete 51 342 Nor cmt 52 3 4 5 Warnings and Failures J1939 or Senders sese 52 3 44 Low and High Engine Temperature sse eene 53 3 45 Fuel Level Sender sees ene 53 3 46 Auxiliary Analog 1 and 2 eene nnne 53 3 5 SPEED SENSING re ree etit eiit b ere E ins E Cep EE rid e eie IUE 55 351 Rated Speed sete tutti 55 BDZ Raed Frequency e ete ete e e 55 3 6 BATTERY SETUP seres reet ertet eie tecum teli eter e eR bu 57 3 61 Start on Low Battery eene nnne nennen entes 57 3 7 GENERATOR AC VOLTAGE CURRENT FRE
132. the number of times the failure has occurred SPN Suspect Parameter Number The parameter number If one of these DTCs appears please consult your engine manufacture for the definition of this fault With some engine manufacturers the text of the message can also vary slightly between engine types When active DTC messages are being received this will cause the controller display to lock and display the messages If multiple active DTCs are received the controller will scroll and display each DTC message The time between scrolling will be 3 seconds The DTC message display will appear as follows 103 of 147 ACTIVE DTC Eu I 6666 00 Figure 14 Five active DTC messages and the 3PrdP one being displayed The user can also manually cycle through the DTC messages by activating either the UP or DOWN key after the screen has been locked If the user stops at a specific DTC message the display screen will remain on that message for a period of 10 seconds before it begins scrolling again Once the last DTC message is displayed the display will begin scrolling though other GSC400 parameters as normal The DTC messages are no longer available for viewing DM2 messages are previously active fault messages which are stored to permanent memory on the engine ECM These stored messages can be retrieved by the host GSC400 controller and displayed on the controller when a request is initiated by the user The DM2 messages display the
133. ts a Low Fuel Level Warning condition A solid green illuminated LED represents a normal battery condition Controller in Auto mode Waiting to start A solid yellow illuminated LED represents a Low Battery condition 98 of 147 Red Solid Red A solid red illuminated LED represents a Not in Auto condition Flashing Red A flashing red illuminated LED means the GSC400 is in OFF sleep mode e Red Solid Red A solid red illuminated LED represents a Low Coolant Temperature and or Level failure condition e Amber Solid A solid yellow illuminated LED Amber represents a Low Coolant Temperature Warning condition e Green Solid A solid green illuminated LED Green represents an active Pre Heat condition Green Solid A solid green illuminated LED w Green indicates that the generator is supplying load A solid red indicates load is detected on the generator when none should oe Red Solid Red be This is only supported if using the EPS supplying load configurable switched input feature Red Solid Red A solid red illuminated LED represents a general Failure condition 99 of 147 The GSC400 incorporates many types of warnings and failures Most are only active in the RUN mode while a few are also active in the AUTO and or OFF modes Warnings and failures can be triggered from a Switched Input Analog Input AC Voltage AC Current Speed Signal Input as well as others The Advanced Setup section of this m
134. ures the extra relay output can be set to By default this is programmed to preheat glow plug Bat Batt and Batt are used to power the Bat GSC400 Connect to 12 or 24VDC The 4 Bat two Batt connections are tied together Bat internally as well as the two Batt connections Only one Batt and Batt connections are required to power the GSC400 The other Bat and Bat can be used to power external devices or left unconnected Crank When on this provides battery voltage up to 20A 24VDC or 30A 12VDC to the generator starter motor Fuel When on this provides battery voltage up to 20A 24VDC or 30A 12VDC to power the generator fuel pump or ECU Branch circuit protection with max ratings of 32V and 25A must be used on each battery supply connection Fuel Crank and Extra Relay connections Ensure that the proper 12VDC or 24VDC relay is used based on the system voltage Using improper relays will eventually cause the relay to fail Ensure wire gage is sufficient otherwise especially during cranking there could be a voltage drop across the cable to the controller from the battery causing the GSC400 to display the wrong voltage and negatively affecting the battery related features of the controller 19 of 147 The relay amperage ratings are for a purely resistive load Inductive loads have an initial peak current that must be taken into account Emergency Stop In
135. ury or death Never unplug an energized connector 4 The GSC400 can be stopped started remotely via the RS485 RS485 should be disabled while performing maintenance or repairs by unplugging the RS485 connector 10 of 147 The GSC400 series product numbering scheme i e product number provides various information including options selected by the customer about the unit A product number has the format given in Figure 1 The product number is located on the backside of the GSC400 controller under the bar code 5 400 0 __ 1 ___ Figure 1 GSC400 product numbering scheme The GSC400 is UL listed to UL508 For conditions of acceptability refer to UL file number E250327 or refer to the GSC400 quick start guide The quick start guide is packaged with every unit and can be found on our website 11 of 147 This section contains information on the wiring of the GSC400 controller It is meant to be used in conjunction with Section 3 GSC400 Configuration which covers the configuration of the GSC400 2 1 elucet UEEA 11 2 2 GSC400 COMPONENT RATINGS STANDARDS cccccccssceecsscescesecesesecseesecsacsecaeeatesscsseseenaes 13 2 3 WIRING OVERVIEW ccsccccesscsscsscssecscosecosesscoecsscnsesecnseceessscatensentestenseccesecaeestesetensecsessscatents 14 2 4 POWERING THE GSC400 AND BASIC CONNECTIONS eee ener 18 2 5 SPEEDJINPUTS
136. us is active all the time and cannot be disabled The Common Fault 1 and Common Fault 2 menus allow the user to select multiple warnings failures and events to generate a trigger when active The trigger can be used to turn on a configurable output store the status of the trigger active inactive to the Modbus Common Fault registers or both Both the common fault 1 and common fault 2 menus generate their own independent trigger and use separate modbus registers and digital outputs Not all warnings failures and events are supported A configurable output must be set to Common Fault Output 1 if using the Common Fault 1 menu or Common Fault Output 2 if using the Common Fault Output 2 menu to allow the trigger to turn on the configurable output see section 3 10 Digital Output Configurable Outputs Setup on page 69 Using the PC Interface the user can also mask the event warning and failure tables for each of the common faults For example the user can set the Common Fault 1 modbus register to respond to events warnings and failures and set the Common Fault 1 configurable output to respond to failures only This 75 of 147 configuration is not available in the front panel menu system the PC Configurator must be used By default all failures warnings and events are allowed PC Interface i all enabled by default Failure Table Enable Disable EUN Is Common Crank Over Crank Enable Disable Output 1 set Failure Locke
137. ut E 6 18 200mA Output F 7 18 200 Output 8 18 200 Output 9 18 200 V Bat 10 18 1 5A Battery RS485 A 1 18 7mA RS485 High Ground 2 18 7mA RS485 Common RS485 B 3 18 7mA RS485 Low RS485 A 4 18 7mA RS485 High Ground 5 18 7mA RS485 Common RS485 B 6 18 7mA RS485 Low Phase A 18 7mA Monitor Generated AC Voltage Phase B 18 7mA Phase C 18 7mA Neutral 18 7mA AC Voltage Neutral connection Phase A 1 18 5A Current Transformer Phase B 2 18 5A connections Phase C 3 18 5A Phase A 4 18 5A Phase B 5 18 5A Phase C 6 5A 7mA CANH Connection 1 Ground 2 18 7mA Not Needed CANL 3 18 7mA CANL Connection Ground 4 18 7mA Not Needed 18 of 147 2 4 Powering the GSC400 and Basic Connections Menu Location Page 1 Engine Logic Advanced Setup Engine Logic 47 2 Battery Logic Advanced Setup gt Battery Setup 57 3 Extra Relay Advanced Setup gt Outputs Setup gt 69 Logic Extra Relay There are a group of 8 spade terminals on the back of the GSC400 Their functions are described below L able basic GSU4UU Terminal Name as it appears on label Installation Notes Extra NO Extra Common These are the dry contacts of the Extra Relay Output The extra relay can be set to the same features as the configurable outputs See Table 19 on page 69 for a list of the possible feat
138. w Represents Warning Conditions oe Green Represents Normal Active Conditions An LED test may be performed by the user for illumination of all controller LED s The LED test may be performe by simultaneously pressing the UP nm and the DOWN key on the GSC400 gt 97 of 147 Table 26 GSC400 Lamp Indication Meanings v w x E E XC Red Yellow Red Yellow Red Yellow Yellow Solid Red Solid Yellow Solid Red Solid Yellow Solid Red Solid Yellow Solid Red Solid Yellow Solid Red Solid Yellow Solid Green Flashing Green Solid Yellow A solid red illuminated LED represents an Over Crank condition on the final crank attempt This is a Failure A solid yellow illuminated LED represents an Over Crank Warning condition when there are crank attempts still remaining A solid red illuminated LED represents a High engine Temp Failure condition A solid yellow illuminated LED represents a High engine Temp Warning condition A solid red illuminated LED represents a Low Oil Pressure Failure condition A solid yellow illuminated LED represents a Low Oil Pressure Warning condition A solid red illuminated LED represents an Over Speed Failure condition A solid yellow illuminated LED represents an Over Speed Warning condition A solid red illuminated LED represents a Low Fuel Level Failure condition A solid yellow illuminated LED represen
139. when this occurs This turns on the output if the Auxiliary Warning Digital Input see Table 18 in section 3 9 is active This turns on the output if maintenance is required to be performed on the engine generator See section 3 13 This turns on the output if the controller is in the auto state with no warnings some warnings are ignored for this feature such as low and high battery voltage This turns on the output if the Common Fault 1 or 2 feature is active See section 3 15 for more details This allows the digital output to be controlled by the Dummy Load feature See section 3 16 1 for more details This turns on the output if the High Fuel Level Warning digital input in Table 18 on page 67 is active This turns on the output if the Cur Warn Latch in the AC Current menu is set to Enable and the Over Current Warning is active The output can only be turned off by the user See section 3 7 3 on page 62 for more information This turns on the output if the Config Warn 1 Config Warn 2 Config Fail 1 Config Fail 2 digital input Table 18 on page 67 is active This can be used alone or in combination with the engine run configurable output See section 3 16 3 on page 76 for more information Only supported in firmware versions 2 06 and above Warnings and Failure outputs for Auxiliary Analog 1 and 2 Auxiliary Aux Analog 1 and 2 must be set to an Input Pin and Sender Type must be set
140. wn time has expired the fuel relay is turned off and the controller enters the OFF mode By default it is possible to manually bypass cool down by pressing the OFF or AUTO keys To prevent this the Bypass Cooldwn can be set to disabled If a failure occurs cool down is bypassed and the GSC400 goes into the FAILURE mode The low fuel failure is the exception it will allow cool down The controller then enters one of the OFF AUTO or FAILURE modes If the ETS On Duration is set to a value greater than 0 seconds an output will be turned on one of the configurable outputs must be set to ETS see section 3 10 on page 69 Firmware versions 2 06 and above contain this feature The GSC400 has a feature to protect engine driven compressors by preventing a shutdown until the compressor pressure is below a set pressure The following have to be present for this feature to work 1 Aux Analog 1 or Aux Analog 2 must be set to an input pin Aux Analog 1 2 Input Pin menu and to the Pressure type Aux Analog 1 2 Analog Group menu 2 The Shutdown Inhibit Source must be set to Aux Analog 1 or Aux Analog 2 Engine Logic Shut Inhibit Src menu 3 The Shutdown Inhibit Threshold pressure must be set Engine Logic gt Shut Inhib Thr With these set appropriately the GSC400 will allow cool down but will not allow the engine to stop until the compressor pressure as sensed by the Auxiliary Analog 1 or 2 inputs is below the Shutdown

GSC400 User Manual R4.3

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