DynaGen GSC300 automatic engine controller Installation and User Manual

GSC300
Auto Start Engine Controller
Revision 2.9
Installation and User Manual for the GSC300 Auto Start Engine
Controller
File: MAN-0039 R2.9, GSC300 User Manual.doc
May 2011
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Thank You For Purchasing This DynaGen Product
Please Read Manual Before Installing Unit
Receipt of Shipment and Warranty Return Information
Upon receipt of shipment, carefully remove the unit from the shipping container and
thoroughly examine the unit for shipping damage. In case of damage, immediately contact the
carrier and request that an inspection report be filed prior to contacting DynaGen.
All returned items are to be shipped prepaid and include a Return Material Authorization
(RMA) number issued by DynaGen.
Limited Warranty
For warranty information refer to the standard terms and conditions of sale at http://www.dynagen.ca.
Dynagen GSC300 Webpage
For up-to-date manuals and other information please see the GSC300 section of the DynaGen
website at: www.dynagen.ca/products/GSC300.htm or www.dynagen.ca/support
U
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GSC300 Specifications
Operating Voltage
7 to 30VDC continuous
Zero volts operation for 100mS (assumes supply was 12VDC before initiating
starting)
Operating
Temperature
Physical Dimensions
-40 ºC to +85 ºC (LCD Display operates from to -16 ºC to 70 ºC)
Actual Unit Weight
0.458 lbs
Enclosure
High Impact Resistant, Injection Molded Plastic Enclosure
Front Panel Indications
LCD Display
High intensity LED’s with regulated brightness
-Ultra-bright, Backlight LCD display with optimum viewing angle of 0 to -25º from
perpendicular
-Display Size (mm): 8 (W) x 32 (H) x 12.8 (D) x (2line x 8 character display)
Adjustments
Warm-up
Cool-Down
Crank
Disconnect
Overspeed
Crank Rest
Delay on Start
Crank Tries
Oil Bypass
Low Battery
Indication
Glow
Plug/Preheat
Timer Adjustments
4.5"(H) x 5.5"(W) x 1.25"(D)
0 - 200 Seconds (After Oil Bypass Feature)
0 - 812 Seconds
12 to 140Hz
40 – 200Hz
4 - 32 Seconds
0 – 59 Seconds
1 to 10
10 – 55 Seconds
7 – 35VDC
0 - 255 Seconds
Energize To
Stop (ETS)
Inputs
Protection
Energizes for 15 Seconds on failures, or energizes until 5 Seconds
after engine speed goes to zero upon removing power from
Start/Stop terminal or removing the unit from manual mode using
the front panel buttons.
-Generator Output Speed Sensing
Speed Sensing
-Maximum Input Voltage: 300VAC RMS
-Minimum Input Voltage: 0.7VAC RMS Generator Output Sensing
-60Hz Rejection Filter Included
-Loss of Speed Signal Included
Sender/Failure Oil Pressure
Inputs
Coolant Temperature
Fuel Level / Auxiliary Input
-Accepts standard industry low impedance (0-500 ohm) sender
inputs (VDO, Stewart-Warner, Datcon, Murphy, etc.)
-Programmable for either switch or sender configuration using PC
Interface
-Adjustable failure set-points using PC Interface
-Three on-board replaceable 40A fuses protect Fuel, Crank, and Timer Outputs
-Reverse polarity protected
-Short circuit & overload protection on annunciation outputs
-Inputs are electrostatic discharge protected
J1113-11 Transients – Pulse 1A (Supply Disconnect), Pulse 2A (Sudden
Disconnect), Pulse 4 (Starter Motor Engagement), Pulse 5 (Load Dump). Details of
the test parameters are available, please consult with factory.
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-All outputs switched to +battery (sourcing)
-Fuel, Crank, and Timer Outputs: (12V/40A or 24V/20A) each, using standard 40A
automotive relays
-Annunciation Outputs: 300mA individually, 350mA combined
Connections
-Removable terminal block for annunciation outputs and low power connections
-0.25" spade terminals for high current and Main power inputs
Programming
-Windows based software interface utilizing the parallel port of your PC
-Option of programming through 3-button interface (limited parameter adjustment) on
the front panel or the PC Interface that has full parameter programming ability.
-Needs no power to program using the PC Interface – uses power from parallel port
of PC
-Specifications May Change Without Notice
Outputs
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Table of Contents
1.
2.
GSC300 Product Number Identification ......................................................................................... 6
Wiring Installation Guidelines ........................................................................................................ 7
2.1
Instructions ............................................................................................................................. 7
2.2
Wiring Guidelines ................................................................................................................... 8
2.3
GSC300 12/24VDC System Operation ................................................................................... 9
2.4
Terminal Description ............................................................................................................. 10
2.5
System Wiring Diagram ........................................................................................................ 11
2.6
Back Panel Layout ................................................................................................................ 13
3. Controller Operation .................................................................................................................... 14
3.1
Controller Overview .............................................................................................................. 14
3.2
LED Layout ........................................................................................................................... 17
3.3
LED Indications .................................................................................................................... 18
4. Programming the GSC300 Settings ............................................................................................ 19
4.1
Using the Front Panel Interface ............................................................................................ 19
4.2
Programming Using the PC Interface ................................................................................... 21
5. Troubleshooting Guidelines ......................................................................................................... 23
6. Technical Notes and FAQ ............................................................................................................ 24
6.1
Controller Memory Clear Time .............................................................................................. 24
6.2
Step Down Transformer Use On Speed Sensing Cable With Inverter Systems ................... 24
6.3
Pull and Hold Coil ................................................................................................................. 25
6.4
Emergency Stop Switch ....................................................................................................... 25
6.5
GCP300 Panel (Optional) ..................................................................................................... 25
6.6
GSC300 Cutout Template .................................................................................................... 27
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1. GSC300 Product Number Identification
The GSC300 series catalog order number provides information pertaining to a specific
model. The Product Number Identification Table (see Table 1) provides details on the
breakdown of the model number.
Table 1 – Identification Table
Position 1-6
Position 8
Position 10-11
Position 13-14
Series
Speed Range
DC Voltage
Labeling
GSC300 =
GSC300
L=Low
H=High (consult
factory)
12=12VDC
24=24VDC
LS=Standard
LX=Customized
Example: The product number GSC300-L-12-LS would be described as follows:
A GSC300 series automatic engine controller configured for a 12 VDC system.
The controller is factory configured for low speed range (generator speed range) which includes
standard labeling.
A GSC300 serial number would be displayed as:
GSC300-L-12-LS-00000
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2. Wiring Installation Guidelines
Danger: Never work on the engine while its power is on. This controller
does not generate a warning signal prior to automatic engine start. Warning
signs should be placed on engine equipment indicating this important safety
measure.
2.1 Instructions
Following these instructions will help avoid common installation problems during wiring and setup.
 Battery must be disconnected before any wiring connections are made.
 Wire length from the engine to the controller should not exceed 6 meters (20 feet).
Wiring size and type should be as specified below. Use stranded wire, since solid wire has a
tendency to crack, break and loosen over time.
Table 2 – Types and Sizes
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Wire
Size
(AWG)
12
12
12
12
12
12
12
12
18
18
18
18
18
18
18
18
18
18
18
18
18
18
Current max.
Function
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
12V/40A, 24V/20A
100mA
100mA
300mA
300mA
300mA
300mA
300mA
300mA
100mA
300mA
7mA
7mA
7mA
7mA
Fuel Output Terminal
Auto(Battery +) Terminal Connection
Auto(Battery +) Terminal Connection
Crank Output Terminal
Ground Terminal Connection
Ground Terminal Connection
Preheat/ETS Terminal
Preheat/ETS Terminal
Speed Signal Connection
Speed Signal Connection
Overcrank (failure to start) Output
Overspeed Output
High Temp Output
Low Oil Output
Low Battery Output
Engine Run Output
Not in Auto Output
General Failure Output
Start/Stop Input
Oil Pressure Sender/Switch Input
Temperature Sender/Switch Input
Fuel Level/Auxiliary Sender/Switch
Input
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2.2 Wiring Guidelines
1. WARNING: Relays are rated for maximum 40A at 12V. If relays are being used at 24V maximum
rating is 20A.
2. DO NOT use wire smaller than 18 AWG as smaller wire has a tendency to crack and break over
time.
3. IMPORTANT: The connections supplying DC power to the GSC300 panel should preferably run
directly from the battery posts with no splices or other connections. Avoid using chassis
(aluminum or iron engine parts), as return conductor for battery negative voltage. Copper wiring
is recommended. Failure to follow the above may result in erratic operation due to large voltage
drops across wiring connections. A small fuse should be placed at the battery terminal to provide
12 volts to the Remote Start Contacts to ensure that a short along this line will not cause any
damage.
4. DO NOT exceed the maximum rated current and voltage on each of the controller outputs. DO
NOT exceed 12V/40A or 24V/20A each for the Fuel Output, Crank Output or Preheat Output. DO
NOT exceed 300mA individually, or 350mA combined, for the General Fault Output or
Annunciation Outputs.
5. Relays are rated for resistive ratings. When driving such loads as starter solenoids you must
ensure proper de-rating of the relays. Consult factory for further details.
6. Engine Sensor type MUST be selected and programmed properly to GSC300 (switch or sender
type). Failure to do so may result in the controller not shutting down on true engine failure (Low oil
pressure or high engine temperature).
7. When installing engine sensors (oil pressure, engine temperature, fuel level) ensure the
switches are connected to ground circuit through the engine sensor. Damage will occur to
controller unit if the sensor input terminals (Terminal #’s 20, 21 and 22) are connected to +Battery.
8. When using engine sensors that are the resistive type the proper manufacturer of the
sender MUST be selected during programming. Failure to select the correct manufacturer type
will cause inaccurate readings as well as failure to protect the engine during a fault condition.
9. To verify the operation of engine controller outputs, measure voltage (i.e. meter in volts) when
outputs should be ON.
10. To verify the operation of the Preheat Output, measure the resistance between the Preheat
terminals when the Preheat Output is ON, it should read a closed circuit (i.e. zero ohms). When
the output is OFF there should be an open circuit between the terminals (very high resistance).
11. Speed sensing input terminals (Terminal #’s 9 and 10) do not have polarity sensitivity therefore
the AC generator output leads can be connected in any polarity configuration to the controller
speed sensing terminals. Do not exceed 300VAC on speed sensing input terminals.
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2.3 GSC300 12/24VDC System Operation
!
PRE-HEAT
RELAY
9
10
7
6
3
2
40 A
1
FUEL
RELAY
PRE-HEAT
RELAY
9
10
7
6
5
4
CRANK
RELAY
40 A
40 A
4
12VDC
RELAYS
CRANK
RELAY
8
40 A
5
22
21
20
19
18
17
16
15
14
13
12
11
40 A
40 A
8
!
FUEL
RELAY
24VDC
RELAYS
3
2
1
12VDC RELAYS MUST
BE INSTALLED FOR 12VDC
SYSTEM OPERATION
22
21
20
19
18
17
16
15
14
13
12
11
24VDC RELAYS MUST
BE INSTALLED FOR 24VDC
SYSTEM OPERATION
Figure 1
The GSC300 controller is designed to operate in either 12 or 24VDC system voltages.
When operating in 12VDC systems the Fuel, Crank and Preheat/ETS relays need to be the
12VDC relay type. When operating in 24VDC systems these relays need to be the 24VDC
relay type. Contact the factory if relays are required.
Approved relays for 12 or 24VDC system operation are as follows:


AZETTLER – AZ973-1C-12DC for 12VDC operation
AZETTLER – AZ973-1C-24DC for 24VDC operation
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2.4 Terminal Description
Table 3 – GSC300 Terminals
Term #
1
2,3
4
5,6
7,8
9 , 10
Description
Fuel Output provides 12V/40A or 24V/20A maximum. Fuel Output closes to
+12/24VDC when start signal is received, and opens when either an engine failure
occurs or when Cool Down period has ended.
Auto Terminals. Main +Battery power connection to controller. These terminals are
internally connected together on GSC300 controller.
Crank Output provides 12V/40A or 24V/20A maximum. Crank Output closes to
+12/24VDC during cranking, and opens when the engine has started, or during Crank
Rest.
Main Battery Ground connection for the controller module. A good ground connection,
directly from the battery, is required for proper operation. These terminals are
internally connected together on GSC300 controller.
Preheat/ETS Output provides a set of dry contacts between terminals #7 and #8.
When this output is energized terminals #7 and #8 are connected together. When
output is OFF terminals #7 and #8 have no connection.
Speed. Options: Generator Output (L-Version) or Mag Pickup (H Version)
Generator Output (L-Version)
Speed Signal Input for Crank Disconnect, Engine Run, and Overspeed sensing.
300VAC max input voltage. Speed sensing input terminals (T#9, 10) do not have
polarity sensitivity therefore the AC generator output leads can be connected in any
polarity configuration. Do not exceed 300VAC on speed sensing input terminals.
Mag Pickup (H-Version)
The magnetic pickup only works for frequencies up to 3000Hz (this is max of 100 teeth
at 60Hz)
11
12
13
14
15
16
17
18
General
The GSC300 does not have loss of speed detection. If there is no speed signal during
cranking/run but the genset starts up and runs the starter will remain engaged for the
remainder of the crank cycle.
Overcrank Annunciation Output closes to +12/24VDC on Overcrank Failure. 300mA
max.
Overspeed Annunciation Output closes to +12/24VDC on Overspeed Failure.
300mA max.
High Temp Output closes to +12/24VDC upon High Temp Failure. 300mA max.
Low Oil Output closes to +12/24VDC upon Low Oil Failure. 300mA max.
Low Battery Output closes to +12/24VDC on Low Battery Condition. 300mA max.
When a low battery condition is detected this output turns on immediately. When the
low battery condition is removed this output remains on for 5s before turning off.
Engine Run Output closes to +12/24VDC on Engine Run Condition. 300mA max.
Not In Auto Output closes to +12/24VDC when unit is not in auto. 300mA max.
General Failure Output closes to +12/24VDC on a General Failure. 300mA max.
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19
20
21
22
Start Stop Input (i.e. Remote Start Contacts). Apply +12/24VDC to this terminal while
unit is in Auto Mode to start engine. Remove +12/24VDC to stop engine or enter CoolDown mode.
Maximum distance for the remote start contacts
There is no absolute maximum since this depends on the size and type of the wire
used. There needs to be a minimum voltage of 8VDC at the Start/Stop input for a
start to be detected. The wiring should be rated assuming a maximum 0.1 current
draw.
There could be large voltage drops over long distances. Mounting an external relay
close to the controller and controlling it with the remote switch is a good solution.
Low Oil Pressure sensor input. This sensor can be the resistive type (Sender) or can
be the switch type. The proper type of sensor must be selected during GSC300
controller programming. The sender or switch must be connected to ground for proper
operation. If +Battery is connected to input terminal this can result in damaged to
GSC300 controller. When using a sender, the proper sender manufacturer must be
selected as each sender manufacturer’s characteristics are different; the sender failure
set-point must also be selected. When using a switch NO or NC much be selected from
the programming menu. NO refers to the state of the contacts during normal engine
operation, therefore NO refers to normally open at normal engine run and close to
ground on low oil pressure failure.
High Engine Temperature sensor input. This sensor can be the resistive type
(Sender) or can be the switch type. The proper type of sensor must be selected during
GSC300 controller programming. The sender or switch must be connected to ground
for proper operation. If +Battery is connected to input terminal this can result in
damaged to GSC300 controller. When using a sender, the proper sender manufacturer
must be selected as each sender manufacturer’s characteristics are different; the
sender failure set-point must also be selected. When using a switch the switch must be
the NO type on normal engine run and close to ground on failure.
Fuel Level sensor or Auxiliary failure input. This sensor can be the resistive type
(Sender) or can be the switch type. The proper type of sensor must be selected during
GSC300 controller programming. The sender or switch must be connected to ground
for proper operation. If +Battery is connected to input terminal this can result in
damaged to GSC300 controller. When using a sender, the proper sender manufacturer
must be selected as each sender manufacturer’s characteristics are different. When
using a switch the switch must be the NO type on normal engine run and close to
ground on failure.
2.5 System Wiring Diagram
See below.
Figure 2 – GSC300 System Wiring Diagram
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2.6 Back Panel Layout
7
BATTERY GROUND
6
BATTERY GROUND
5
STARTER OUTPUT
4
BATTERY +
3
BATTERY +
2
FUEL OUTPUT
1
9
22 AUX SWITCH INPUT
21 TEMP. SWITCH INPUT
20 OIL SWITCH INPUT
19 REMOTE START INPUT
18 GENERAL FAIL OUTPUT
17 NOT IN AUTO OUTPUT
16 ENGINE RUN OUTPUT
15 LOW BATTERY OUTPUT
14 LOW OIL OUTPUT
13 HIGH TEMP. OUTPUT
12 OVER-SPEED OUTPUT
11 OVER-CRANK OUTPUT
10
SPEED SIGNAL
INPUTS
CRANK
RELAY
40 A
PRE-HEAT COM
PRE-HEAT
RELAY
40 A
8
40 A
PRE-HEAT NO
FUEL
RELAY
PROGRAMMING
CONNECTOR
ON
MODE SWITCH
Figure 3
OFF
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3. Controller Operation
3.1 Controller Overview
OFF/AUTO/RUN Modes On power up the controller defaults to the mode it was in when power
was last removed (AUTO or OFF). OFF mode can be entered by pressing the OFF button on the
front panel. When the GSC300 is in the OFF mode the “Not In Auto” LED will be lit on the front panel
(NOT IN AUTO below).
When the GSC300 is in the OFF mode, starting – either from the remote start contacts or from the
front panel run button – is disabled. To start the genset the GSC300 needs to be placed in the
AUTO mode by pressing the AUTO button on the front panel.
Once in AUTO mode the genset can be started by pressing the RUN button. Once crank success is
achieved (i.e. engine has started), the GSC300 enters the RUN mode and the front panel ENGINE
RUNNING LED will be lit.
GENERAL FAILURE CONDITIONS: The following conditions can cause the GSC300
controller to shutdown the engine-generator system unexpectedly:
Auxiliary Failure (“XTR_FAIL”)
Low Oil Pressure
High Coolant Temperature
Overcrank
Overspeed
Loss of Speed (“SPDLOSS”)
Extra failure is indicated by a flashing RED Low oil pressure LED
Low Oil pressure is indicated by a steady on RED Low oil pressure LED
High coolant temperature is indicated by a steady on RED High water
temp LED
Overcrank failure is indicated by a steady on RED Overcrank LED
Overspeed failure is indicated by a steady on RED Overspeed LED
Loss of speed signal is indicated by a flashing RED Overspeed LED
The General Failure output annunciation is triggered during any of the above failure conditions and
is rated 300mA Max.
To reset a failure press the Off key for 3 seconds. This will exit the FAILURE mode and take the
controller back to the OFF mode.
NOT IN AUTO: When the controller is in the OFF Mode, the NOT IN AUTO LED will illuminate
and the NOT IN AUTO Output will be triggered. During this OFF mode Automatic engine starting is
disabled. The LCD display will read “OFF”, and the backlight on the LCD display will be off.
NOTE: + Battery must be permanently connected to the main power terminal for the NOT IN
AUTO feature.
LOW BATTERY VOLTAGE ALARM: When the battery voltage drops below the user defined
set point which can be programmed between 7 and 35VDC, the engine controller displays a Low
Battery Condition. The Low battery warning Led will be illuminated at any time during OFF, AUTO
and Manual run modes. The LCD display will indicate the message: “LOW_BATT”. The LOW battery
warning will be disabled during failure conditions.
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LOW OIL INPUT: The Low Oil Input can be wired to a resistive sender or from a NO or NC type
switch. NO / NC refers to the state of the contacts during normal engine operation (engine oil
pressure ok). When utilizing a resistive sender the display units are fixed in PSI by the PC
programming interface, and a failure set-point must be selected from the programming menu.
Note: The oil input failure is disabled during the Oil Bypass time.
HIGH TEMPERATURE INPUT: The high temperature input can be wired to a resistive sender
or from a NO type switch. For proper operation while using a switch, the switch must be the NO type
which closes to ground upon failure. When utilizing a resistive sender the display units are fixed in
Fahrenheit by the PC programming interface, and a failure set-point must be selected from the
programming menu.
Note: The engine temperature failure is disabled during the Oil Bypass time.
FUEL LEVEL/AUXILIARY INPUT: The Fuel level/Aux input can be wired to a resistive sender
or from a NO type switch. For proper operation while using a switch, the switch must be the NO type
which closes to ground upon failure. If this input is used as a sender, no failure will be indicated.
The sender option is solely for Fuel Level/Auxiliary Level Display on the LCD.
SPEED SIGNAL SENSITIVITY: The controller will accept to a maximum of 300VAC, 60Hz from
direct generator output for speed sensing. The following values are minimal recommended voltages
for speed signal sensing:
Generator Output Option:
20Hz - 0.075V (75mV)
60HZ - 0.6V (600mV)
Magnetic Pickup Option:
1000Hz – 0.6V (600mV)
3000Hz – 0.85V (850mV)
Magnetic Pickup
If using magnetic pickup as the speed sensing source the maximum frequency allowed into the
controller is 3000Hz. Frequencies higher than this will cause the hourmeter and other timings to
become inaccurate. For example at 3500Hz the hourmeter error will be 5%.
Frequency = (Number of teeth * engine speed in RPM) / Generator Output Hz
E.g. Number of teeth = 100, engine speed = 1800RPM, Generator Output Hz at 60Hz the frequency
would be:
(100 * 1800) / 60 = 3000 Hz
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HOUR METER: The controller displays a log of total accumulated generator running hours.
Generator Run times will be displayed on the controllers display screen. The display represents both
hours and minutes in the form 123456:7. The last digit on the hour meter will represent the time in
1/10 of an hour. Please note that although the hour meter displays time in hours and minutes, it will
record up to the nearest second. If the generator was operated for a 3 minute period and then
stopped the running time is stored in permanent memory and then adding to the next running period.
The same would be true if the controller were to enter a failure mode as the controller would
permanently store the remaining time for the next running cycle.
The maximum hour count is 99,999.9 hours, after which it will continue to display 99,999.9
indefinitely.
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3.2 LED Layout
Front View of GSC300
Figure 4
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3.3 LED Indications
The GSC300 does not have a LED lamp test feature.
Table 4 – Front Panel LED Indications
LED Appearance
Not in Auto LED is ON.
No LED’s ON
Steady Low Oil LED
Flashing Low Oil LED
Steady High Temperature LED
Steady Overcrank LED
Steady Overspeed LED
Flashing Overspeed LED
Steady Engine Running LED
Flashing Engine Running LED
Condition/Failure
Unit is in OFF state, and automatic
starting is disabled
“OFF”, no +12/24VDC to main power
terminal.
Low Oil Pressure Failure
Auxiliary Input Failure
Over Temperature Failure
Engine-generator failed to start after
the specified number of cranking
attempts.
Speed Signal present above
Overspeed setting
The speed signal was Zero while
running.
The engine has stalled (overload or
lack of fuel), or the speed signal has
been lost.
Engine Controller is in running mode of
operation.
Crank Rest period. Cranking will
resume soon.
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4. Programming the GSC300 Settings
4.1 Using the Front Panel Interface
The following table shows the LED’s that correspond to the various settings of the various
parameters. To enter the controller into Program Mode, you need to move the small switch at the
bottom edge of the controller to the Program position (the Program position is to the left). There is a
small viewport in the bottom edge of the controller that is visible with the controller laying flat and
viewed from the bottom (see image below). This Mode Switch can be set using a ballpoint pen or
small tool to allow the controller to be put into Program Mode. The first line on the LCD will display
“PROGMODE” when the switch is in the Program position.
Figure 5
The first three LED’s (3, 2 & 1) on the front of the controller correspond to which Parameter is being
adjusted, and the next three (6, 5 & 4) LED’s show the Value for that particular Parameter.
LED 1 = Low oil pressure
LED 2 = High water temp
LED 3 = Overcrank
LED 4 = Overspeed
LED 5 = Engine Running
LED 6 = Low engine battery
LED7 = Preheat/ETS
LED8 = NOT IN AUTO (starting disabled)
The picture below shows the LED numbering and the location of the Mode Switch.
The highlighted circle in the table refers to the LED being illuminated.
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Table 5 – GSC300 Front Panel Programming Parameter / Value Table
Parameter
LED's 3, 2 & 1
▼ LED's 6, 5 & 4
▼
▼
○○○
○○●
○●○
○●●
●○○
●○●
●●○
●●●
Crank Tries
○○○
1
2
3
4
5
6
7
8
Crank Time
○○●
5
10
15
20
25
30
35
40
Rest Time
○●○
0
5
10
15
20
25
30
35
Preheat Time
○●●
0
5
10
15
20
25
30
35
Cool-Down
●○○
0
32
64
96
128
160
192
224
Preheat/ETS/
Warm-Up
●○●
Preheat
ETS
Warm-Up
N/A
N/A
N/A
N/A
N/A
Warm-Up
●●○
0
28
56
84
112
140
168
196
To scroll through the parameters simply press the Auto button on the front panel of the
GSC300. To scroll through the range of values for that parameter simply press the Manual
Start button. To program the value into the controller’s memory, press the OFF button. In this
manner the settings of the controller can be adjusted by simply using the three buttons on the front
panel of the controller. Be sure to press the OFF button when you have selected the parameter
value wanted.
The current value of the parameter will not be shown by LEDs 4, 5, and 6. LEDs 4, 5, and 6 always
show the first (lowest) value of the parameter (i.e. LED 4, 5, and 6 off). The user then presses the
Manual Start button to scroll up in values if required.
Numbering of LED’s and Location of Mode Switch (new front picture?)
Figure 6
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4.2 Programming Using the PC Interface
The mode switch must be in the normal position. Ensure the LCD does not display
“PROGMODE” when using the PC Interface to program the GSC300.
The GSC300 cannot be powered while using the parallel port or USB programmer. The
GSC300 could be damaged.
The GSC300 can also be programmed using the PC interface. Detailed instructions on the PC
interface are included with the GSC300 Configurator software. A sample interface screen is
illustrated on the following page.
General Programming Notes
1. The GSC300 must be unpowered when programming. Ensure it is not connected to battery or
other power source.
Parallel Port Programming Note
1. Black wire should face towards center of GSC300.
USB Programming Note
1. Blue wire should face towards centre of GSC300.
2. If the presto ON-LINE LED it not lit and the presto USB cable is plugged in, the USB drivers
did not properly install. Go to the device manager and locate “ASIX PRESTO Programmer”
under “Universal Serial Bus Controllers”. Right click on it and select Update Driver or similar.
The drivers are located in the directory you installed the PC Interface to. For Vista and 7 they
should have been placed on your desktop during installation.
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Sample Screen from PC Interface
NOTE: Factory default settings are outlined in the photo below
Figure 7
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5. Troubleshooting Guidelines
TROUBLE
Unit does not operate when
powered to test mode
Engine starts and
immediately goes into
Overspeed shutdown
Engine does not crank
Engine cranks but does not
start
Engine starts but shuts
down after “Oil BypassTM
period” due to low oil/high
temp/Aux input
POSSIBLE CAUSE
Power leads to unit are reversed
Bad ground connection from engine to
controller unit.
Improper Overspeed setting
Battery is low or terminals are dirty
Crank circuitry wiring improperly
connected
Bad ground connection from engine to
controller
Crank relay damaged. Or on board fuse
is blown
Out of fuel
Ignition control wiring not installed
properly
Fuel relay and or fuse damaged
Oil/Temp/Auxiliary input wiring improperly
connected.
SUGGESTED ACTION
Confirm correct wiring for ground and +bat,
and re-attempt testing.
Run wire directly from battery - to the
ground terminal #11on controller unit.
Verify the Overspeed setting with PC
configuration software. Confirm that
engine’s governor is properly calibrated for
its intended use.
Clean terminals and re-charge battery
Refer to engine control wiring section and
check crank connections
Run wire directly from battery - to the
ground terminal #5 & 6, on controller unit.
Check wiring, in line fuse and slave relay.
Replace fuse, relay and re-test controller.
Check fuel level, add fuel if necessary
Refer to engine control wiring section and
check ignition connections
Check fuel relay and fuse, replace if
damaged or blown.
Check wiring for proper connections.
Incorrect programming of sensor inputs.
Check programming of oil pressure, engine
temperature and aux input. Ensure that the
sensor type is properly programmed to
controller unit (Sender / Switch type)
Flashing Overspeed LED
Speed signal improperly connected,
missing, or damaged.
Crank output damaged, not working, or
fuse blown on starter output
Starter or starter solenoid damaged
Check speed signal wiring; replace
damaged speed signal source.
Check wiring and replace relay of fuse
where necessary.
Replace/repair damaged starter or starter
solenoid.
Steady Oil LED immediately
on start-up, without engine
actually cranking or starting.
False speed signal being detected by
controller. This problem can sometimes
occur in installations where there is AC
power from inverters near generator
output lines connected to the speed
signal cable.
Install a small step down transformer
between the speed sensing wires and the
generator output.
Display Parameter for
Temperature, Oil or Fuel
displayed as >>> or <<<
Parameter is >>> ABOVE or <<< BELOW
specified manufacturer sender range.
If further accuracy is required it may be
necessary to install sender with proper
range specifications.
Warm-Up Feature appears
longer then time setting.
Warm-Up Feature time setting does not
begin until the Oil Bypass Time has
expired.
Re-adjust Oil Bypass and/or Warm-Up
timing.
If the neutral from the generator output is
not grounded, attach it to ground
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6. Technical Notes and FAQ
6.1 Controller Memory Clear Time
The GSC300 needs 10 seconds for its memory to clear. When the power to the controller is turned off and
then back on again without waiting 10 seconds to clear the memory, a loss of speed will may be indicated by
the GSC300 (if controller is in AUTO mode and start signal is activated) because the controller remains in run
mode and senses that the generator has stopped. This would be indicated by a Flashing Overspeed LED. By
leaving the GSC300 main power OFF for 10 seconds before main power is re-applied this allows the clearing
the memory and it will function as intended.
6.2 Step Down Transformer Use On Speed Sensing Cable With Inverter Systems
In some applications engine controllers are used on generators where there is no utility connection and
inverters are used to provide AC power instead of a utility. Inverters can produce harmonics that can cause
small AC signals to appear on wires that are near any power lines being fed by the inverter. If the generator
output wires are located close to a line being powered by an inverter, a small AC signal can appear on the
generator output lines when the inverter is on. This signal can cause the engine controller to react as if the
generator is running if the speed sensing wires are connected to the generator output lines. This small AC
signal can cause the controller to appear to have a Low Oil Failure when the remote start contacts are closed
or the controller is put in the manual/test mode. The controller may think the generator is already running and
immediately check to make sure there is oil pressure. Since the engine really hasn’t started yet, there is no oil
pressure and the controller sees a low oil fault. This is seen as the Oil LED turning on steady even before the
engine starts to engage the starter.
Without this false speed signal the controller will not look for oil pressure until the engine has started to run
and the crank disengages if oil verification is disabled. Simply installing a small transformer between the
generator output and the speed sensing terminals on the controller can eliminate this false speed signal. This
transformer should be rated for 120 or 240 volts on the input or primary coil (depending on the generator
output voltage you are using for speed sensing), and have an output voltage of around 12VAC on the
secondary of the transformer. The two wires from the secondary of the transformer are connected to the two
wires of the speed sensing terminals on the GSC300 controller. The step-down transformer acts to reduce the
false speed signal on the line to a level that the engine controller will not recognize as the engine running. A
common size transformer that would serve this purpose would be 24VA.
Step Down Transformer Connections on Speed Sensing Cable
Step Down Transformer
#9
12VAC
Secondary
Winding
#10
Twisted pair of wires connected to
speed sensing terminals on GSC300
120VAC
Primary
Winding
To Generator Output
Line to Neutral 120VAC
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6.3 Pull and Hold Coil
Some fuel pumps have two solenoids instead of the normal one.
1. One is called the pull coil and is used to initially turn the pump on.
2. The other is the hold coil and is used to keep the pump on.
The pull coil uses more battery power as it has to handle the initial inrush current. Once the pump is
on, the hold coil is activated and the pull coil is deactivated to reduce power consumption.
The GSC300 crank output can be attached to the pull coil and the GSC300 fuel output can be
attached to the hold coil. When the engine is started the fuel and crank output will come on
activating both coils but after cranking is successful the crank output will turn off de-energizing the
pull coil.
6.4 Emergency Stop Switch
If the engine does not require an energized output to stop there are a couple of locations the
emergency stop switch can be placed (assuming normally closed switch):
1. Battery + wire going to the GSC300. This would de-energize the GSC300 causing the engine
to shutdown. It has to be able to handle the cranking current.
2. If a lower amperage emergency stop switch is required it is possible to place the emergency
stop switch on the fuel output wire. This would cut power to the fuel causing most engines to
shutdown. A test would have to be performed to ensure that this is the case.
Note: if you have an Energize to Stop engine the above will not work. In this case t he
Emergency Stop switch would have to energize the fuel coil to stop the engine.
6.5 GCP300 Panel (Optional)
The GCP300 is an option that provides AC Voltage and AC current analog gauges with the GSC300
together in an enclosure.
AC Voltage and Current Hookup
The below drawings explain how to connect to the current transformers and AC voltage lines to the
GCP300 in a 3 phase setup. Referring to Figure 9 the hookup is as follows:
1. The neutral from the generator connects to the NEUTRAL terminal.
2. Phase A, B, and C from the generator connects to the L1, L2, and L3 terminals respectively.
3. The white wires of the current transformers connect to the A1 (CTP1), A2 (CTP2), and A3
(CTP3) terminals for Phase A, B, and C current sensing respectively.
4. The black wires of the current transformers connect to the three COM terminals. The COM
terminals are all connected together internally so order is not important.
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Figure 8 – GCP300 Drawing
Figure 9 – GCP300 User Terminal Block Label
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6.6 GSC300 Cutout Template
See below. Not to Scale.
NOT TO SCALE
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Notes:
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