GSC300 Auto Start Engine Controller Revision 2.11 Installation and User Manual for the GSC300 Auto Start Engine Controller File: MAN-0039 R2.11, GSC300 User Manual.
of 28 Thank You For Purchasing This DynaGen Product Please Read Manual Before Installing Unit Receipt of Shipment and Warranty Return Information Upon receipt of shipment, carefully remove the unit from the shipping container and thoroughly examine the unit for shipping damage. In case of damage, immediately contact the carrier and request that an inspection report be filed prior to contacting DynaGen.
of 28 GSC300 Specifications Operating Voltage Current Consumption Operating Temperature Physical Dimensions 7 to 30VDC continuous. Zero volts operation for 100mS (assumes supply was 12VDC before initiating starting). Standby current: 40mA. Actual Unit Weight 0.
of 28 -Fuel, Crank, and Timer Outputs: 12V/40A or 24V/20A each, using standard automotive relays -Annunciation Outputs: 300mA individually, 350mA combined Connections -Removable terminal block for annunciation outputs and low power connections -0.
of 28 Table of Contents 1. 2. GSC300 Product Number Identification ......................................................................................... 6 Wiring Installation Guidelines ........................................................................................................ 7 2.1 Mounting .................................................................................................................................. 7 2.2 General .....................................................
of 28 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.
of 28 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 Mounting See section 6.7 on page 26 for the GSC300 mounting dimensions. The maximum torque is 7in-lbs for the three GSC300 mounting screws. 2.
of 28 1. Battery must be disconnected before any wiring connections are made. 2. Wire length from the engine to the controller should not exceed 6 meters (20 feet). 3. 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. 4. WARNING: Relays are rated for maximum 40A at 12V. If relays are being used at 24V maximum rating is 20A. Relays are rated for resistive ratings.
of 28 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 2.
of 28 9 , 10 Speed. Options: Generator Output (L-Version) or Mag Pickup (H Version) Generator Output (L-Version) Speed Signal Input for Crank Disconnect, Engine Run, and Overspeed sensing. 300VAC max input voltage. Speed sensing input terminals (#9, #10) do not have polarity sensitivity therefore the AC generator output leads can be connected in any polarity configuration. Do not exceed 300VAC on speed sensing input terminals. The following values are minimal recommended voltages: 20Hz - 0.
of 28 14 15 16 17 18 19 20 - 22 Low Oil Output closes to +12/24VDC upon Low Oil Failure. Low Battery Output closes to +12/24VDC on Low Battery Condition. When a low battery condition is detected this output turns on immediately. When the low battery condition is removed this output remains on for 5s before turning off. Engine Run Output closes to +12/24VDC on Engine Run Condition. Not In Auto Output closes to +12/24VDC when unit is not in auto.
of 28 21 22 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.
Figure 2 – GSC300 System Wiring Diagram
of 28 2.6 Back Panel Layout PRE-HEAT COM 7 BATTERY GROUND 6 BATTERY GROUND 5 STARTER OUTPUT 4 BATTERY + 3 BATTERY + 2 1 40 A FUEL OUTPUT PRE-HEAT RELAY 9 22 21 20 19 18 17 16 15 14 13 12 11 10 SPEED SIGNAL INPUTS 40 A 8 40 A PRE-HEAT NO CRANK RELAY PROGRAMMING CONNECTOR FUEL RELAY ON MODE SWITCH Figure 3 OFF AUX SWITCH INPUT TEMP.
of 28 3. Controller Operation 3.1 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.
of 28 and Manual run modes. The LCD display will indicate the message: “LOW_BATT”. The LOW battery warning will be disabled during failure conditions. LOW OIL INPUT: The Low Oil Input can be wired to a resistive sender or from a NO or NC type switch. NO / NC refers to the state of the contacts during normal engine operation (engine oil pressure ok).
of 28 3.
of 28 3.6 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.
of 28 4. Programming the GSC300 Settings The GSC300 cannot be powered while using the parallel port or USB programmer. The GSC300 could be damaged. Programming the GSC300 requires a special USB programmer supplied by Dynagen. The part number is GSC300-USB-PGMR. Detailed instructions on the PC interface are included with the GSC300 Configurator software. A sample interface screen is illustrated on the following page. General Programming Notes 1. The GSC300 must be unpowered when programming.
of 28 Sample Screen from PC Interface NOTE: Factory default settings are outlined in the photo below Figure 5
of 28 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 TM down after “Oil Bypass 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.
of 28 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.
of 28 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.
of 28 6.6 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 7 the hookup is as follows: 1. The neutral from the generator connects to the NEUTRAL terminal. 2.
of 28 Figure 7 – GCP300 User Terminal Block Label
of 28 6.7 GSC300 Cutout Template See below. Not to Scale.
NOT TO SCALE
of 28 Notes:
