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4

GSC400 Series Installation and Wiring

4.1

Safety Information

Generator systems contain high voltage circuits. Working on powered equipment can
cause damage to equipment, injury, or death. The following symbols will be used in this
document to classify information:

The following general safety precautions should be headed:

1.

The GSC400 may carry high Voltage/Current which can cause serious injury or

death. Extreme caution must be exercised when connections are being installed to
or from the controller. All wiring connections must be de-energized before any
installations are performed. Wiring of the GSC400 should be performed by

qualified electricians only.

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 injury or death. Never
unplug an energized connector.

Caution

: This is used to indicate something that

you should take special notice of but that is not
normally a threat to safety.

Danger:

This is used to indicate a potential for

injury or death.

Danger – High Voltage:

This is similar to Danger

above but relates specifically to conditions where
high voltage is encountered.

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Summary of Contents for GSC400 Series

Page 1: ...Revision 2 6 GSC400 Automatic Gen Set Controller Installation and User Manual MAN 0076 Rev2 6 GSC400 User Manual doc May 2010 GSC400 Series Automatic Gen Set Controller Manual ...

Page 2: ...Material Authorization RMA number issued by DynaGen RMA forms are available by contacting DynaGen Technical Support through the contact methods listed below Limited Warranty The GSC400 Gen set controller carries a five year warranty For more 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 plea...

Page 3: ...ds 0 90 KPa 100 2000 RPM Analog Input Input 2 Low Z Gain 1 Input 3 4 Low Z Gain 3 Input 5 7 High Z Gain 3 Input 6 High Z Gain 1 Gnd Fail Open fail 7mA Max Note On LS LX controllers Input 2 is High Z Gain 3 and Input 6 has a gain of 3 Digital Input Input A D Sw to Bat Input E H Sw to Gnd Bat Fail 7mA Max Gnd Fail 7mA Max Digital Output Output A H Extra Relay 200 mA Max 40A Max Exerciser Enable Disa...

Page 4: ...e J1939 20 4 4 2 Current Transformer CT Wiring Note 20 5 GSC400 Operation and Basic User Configuration 21 5 1 Power up 21 5 1 1 Controller Alarming 21 5 2 Remote Start Contacts Emergency Stop 21 5 3 Controller States 22 5 3 1 Locking the GSC400 Screen While in the Run Mode 23 5 4 GSC400 Start Stop Behavior 24 5 5 Idle Mode 25 5 5 1 Cummins Electronic Engine Idle Mode 26 5 6 Generator Starting and ...

Page 5: ...g Inputs 54 6 2 1 Fuel Level Sender Special Case 56 6 2 2 GSC400 Sender Support 57 6 3 Speed Sensing 58 6 3 1 Rated Speed 58 6 4 Generator AC Voltage Current Frequency Setup 59 6 4 1 AC Frequency 59 6 4 2 AC Voltage 59 6 4 3 AC Current 61 6 4 4 AC Current and Voltage Calibration 62 6 5 Engine Logic 62 6 5 1 Startup Sequence 62 6 5 2 Shutdown Sequence 64 6 6 Digital Output Setup 64 6 7 Exerciser Se...

Page 6: ...cessories 78 9 2 GSC400 Programmer Assembly 79 9 3 CT s Current Transformers 80 9 4 Engine Sending Units 81 9 5 GSC400 replaceable 12 24VDC relays 81 9 6 GSC400 Fusing 82 10 Appendix B Modbus Map 83 10 1 Communication Details 83 10 2 Modbus Commands 84 10 3 Register Map 85 11 Appendix C J1939 Old DTC Conversion Methods 103 12 Appendix D Additional Drawings 104 ...

Page 7: ... purposes GSC400 Front View GSC400 Back View arameters se r 85 An RS232 interface is provided that allows communication with the DynaGen GSC400 PC Interface to change settings o display information on the PC An RS4 port is provided for Modbus communications slave only for remote annunciation or communications In addition to the monitoring features the GSC400 controller can be used to automatically...

Page 8: ... been completed A shipping label affixed to the shi information such as items and Customer numbers Make certain that this information matches your order information Each GSC400 controller is packaged in its u Handling As previously mentioned each GSC400 gen set controller is packaged in its own individual box Protect the equipment from impact at all times and do not carelessly ack Once the control...

Page 9: ... in Figure 1 Figure 1 GSC400 product numbering scheme The GSC400 series product numbering scheme i e product number provides various information including options selected by the customer about the un The product number is located on the backside of the GSC400 controller under the bar code ...

Page 10: ... before any installations are performed Wiring of the GSC400 should be performed by qualified electricians only 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 injury or ...

Page 11: ... sure the site is free from excessive moisture fluctuating temperatures dust corrosive aterials etc The controller should be safely e mounting locations m mounted in a secure location using the 3 mounting screws provided See Figure 2 for th Caution Mounting screws must be installed at the recommended torque of 10 inch pounds Figure 2 GSC400 Mounting Locations ...

Page 12: ...12 of 105 4 2 1 GSC400 Mounting Dimensions Figure 3 gives the precise dimensions of the mounting hardware Figure 3 Dimensions of mounting holes ...

Page 13: ... numbers from Table 23 on page 81 UL Listed relays for 12 or 24VDC system operation are as follows HASCO CAR 1A 40 DC12 S for 12VDC operation HASCO CAR 1A 40 DC24 S for 24VDC operation CAUTION The above relays must be installed in the GSC400 for it to meet UL 4 3 3 Relay Fuses CAUTION needs to be taken when connecting relay outputs to an inductive load Due to the inductive nature of certain loads ...

Page 14: ...er and Part Number Terminal Name GSC400 Terminal Type Mating Connector Type For Wiring Harness Digital Inputs Molex 39 28 1123 Molex 39 01 2120 Digital Outputs Molex 39 28 1103 Molex 39 01 2100 AC Current Molex 39 28 1063 Molex 39 01 2060 RS485 Modbus Molex 39 28 1063 Molex 39 01 2060 CAN J1939 Molex 39 28 1043 Molex 39 01 2040 Analog Inputs Molex 39 28 1083 Molex 39 01 2080 RS232 Amp 87227 5 Majo...

Page 15: ...Figure 4 General GSC400 System Wiring Diagram ...

Page 16: ...Figure 5 Digital IO Example ...

Page 17: ...er 3 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 affect the battery related features of the controller Terminal Detail Terminal Location Wire Size AWG Current max Function Ground 1 18 7mA Ground Input 2 2 18 7mA Configurable Low Re...

Page 18: ...active Stop Ground 11 18 7mA Ground Ground 12 18 7mA Ground Digital Inputs 1 Ground input to generate logic high 2 Tie input to battery to generate logic high 3 See Table 15 on page 67 for possible selections Terminal Detail Terminal Location Wire Size AWG Current max Function V Bat 1 18 1 5A Positive Battery Voltage Output A 2 18 200mA Configurable Output B 3 18 200mA Configurable Output C 4 18 2...

Page 19: ...rated AC Voltage Phase C 18 7mA Monitor Generated AC Voltage Neutral 18 7mA AC Voltage Neutral connection AC Voltage Sensing Place 1A fuse between the hot lines and the voltage sensing terminals of GSC400 Terminal Detail Terminal Location Wire Size AWG Current max Function Phase A 1 18 5A Phase A current sensing CT Phase B 2 18 5A Phase B current sensing CT Phase C 3 18 5A Phase C current sensing ...

Page 20: ...istors 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 120Ohms 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 t...

Page 21: ...ote start capability on low battery 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 5 1 1 Controller Alarming If the emergency stop input of the digital input terminal is not connected to ground the controller will alarm and display Emergency Stop when connected Emergency St...

Page 22: ... 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 5 9 2 All of the failures and most of t Off Mode The controller will beep every few seconds to alert the user that the unit is in the Off Mode and cannot automatically start To silence this alarm ...

Page 23: ... 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 variou 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 5 on page 30 for more information If normally the value is displayed If the analog...

Page 24: ... in the OFF state 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 The OFF key on the front panel menu can be used to place the GSC400 in OFF regardless of the start condition Preventing a Stop when in Cool Down An exce...

Page 25: ...output to turn on during Idle Mode the Voltage Regulator digital output can be used It is inactive when the controller is in Idle Mode and active when the controller is not in Idle Mode See Table 14 on page 64 for more information on the digital outputs The output is usually used to turn off the generator voltage regulator but can be used for any purpose For users who have engines that idle during...

Page 26: ... whether to preheat and for how long the crank time etc See sections 6 5 1 Startup Sequence and 6 5 2 Shutdown Sequence starting on page 62 for more information on the options for starting and stopping the generator respectively 5 7 Controller Sleep The controller has a low power Sleep Mode that it can enter when in the OFF or AUTO states In this state the LCD screen backlighting is turned off The...

Page 27: ... is called the Basic Menu The following keys perform the menu navigation 1 Scroll up using the up key 2 Scroll down using the down key 3 Enter menus by pressing the enter key 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 5 9 Basic Menu When you pre...

Page 28: ...5 Table 3 Basic Menu Layout Clock Setup Year Month Date Day Hour Minute 12 24 Basic Setup Contrast Adj Page Roll Delay State Roll Dly Sleep Delay Maintenance Not In Auto Off Mode Start Basic Menu Events History ...

Page 29: ...o 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 state i e when the engine generator is running 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...

Page 30: ...rformed when the controller is in the AUTO mode Table 5 Basic Setup Menu Menu SELECTION AND RANGE Contrast Adjust 5 95 Page Roll Delay 1 10 s State Roll Delay 1 10 1 is shortest delay 10 is longest Sleep Delay 10 600s Shorter is ideal to extend the backlighting life Maintenance Read only Displays the amount of hours until next service if this feature is enabled If service is overdue the hours beco...

Page 31: ... 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 or keys located on the GSC400 The event history log can store up to 30 event 30 DTCs and 40 failures entries If these are exceeded t...

Page 32: ...ure occurs repeatedly the unit could be defected EMERGENCY STOP The emergency stop input located on the digital input terminal has been activated EPS LOADS ERROR 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 See section 5 11 2 on page 39 EXERCISER DELAYED TO NEXT RUN If the generator w...

Page 33: ...N key MANUAL STOP Generator stopped manual from the front panel OFF key OFF ENABLE Front panel OFF key pressed to disable automatic starting OPEN ENG TEMP OPEN ENGINE TEMP OPEN FUEL BASIN OPEN FUEL LEVEL OPEN OIL LEVEL OPEN OIL PRES Analog sender always reads the maximum voltage Could indicate that the sender is not connected to the analog input i e broken wire See OVER CRANK The engine RPM was to...

Page 34: ...ese are internal GSC400 failures Try power cycle the GSC400 If the failure occurs repeatedly the unit could be defected UNDER FREQUENCY The generator frequency is too low See section 6 4 1 on page 59 UNDER SPEED The engine speed is too low See section 6 3 on page 58 UNDER VOLTAGE The generator output voltage is too low See section 6 4 2 on page 59 ...

Page 35: ...e 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 Yellow Represents Warning Conditions 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 performed by simulta...

Page 36: ...olid red illuminated LED represents a Low Oil Pressure Failure condition A solid yellow illuminated LED represents a Low Oil Pressure Warning condition Over Speed Red Yellow Solid Red Solid Yellow A solid red illuminated LED represents an Over Speed Failure condition A solid yellow illuminated LED represents an Over Speed Warning condition Low fuel Red Yellow Solid Red Solid Yellow A solid red ill...

Page 37: ...Warning condition Pre Heat Green Solid Green A solid green illuminated LED represents an active Pre Heat condition EPS Supplying Load Green Red Solid Green Solid Red A solid green illuminated LED indicates that the generator is supplying load and is operating normally A solid red indicates load is detected on the generator when none should be See section 5 11 2 on page 39 for more information abou...

Page 38: ...RUN mode and goes to 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 it can be reset by pressing the Auto key and then the Off key This returns the controller to t...

Page 39: ...point or if the EPS Supplying Load Switched Input is active 5 12 J1939 This section applies if J1939 is enabled for one or more parameters The parameters will be displayed the same for J1939 as they are for analog inputs The only difference is that when a certain parameter is not 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...

Page 40: ...ontroller 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 the number of times the failure has occurred SPN Suspect Parameter Number The parameter number If one of these DTCs a...

Page 41: ...manent 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 th M2 messages display the same type of information as the DM1 messages e user The follows D The GSC400 controller can support a maximum of 32 messages When previously active DTC messages are requested and received the GSC400 controller...

Page 42: ...ng out the DM2 request an T if ommunication is unsuccessful If the request was successful the GSC400 will show READ DTC SUCCESS and start to display the messages n ECM to power on The GSC re additional 3 times every 1 25 seconds It will then display REQUESTING 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 ...

Page 43: ...rect password number for each selected position by scrolling to the proper number followed by the Enter key The default password is 0 0 0 0 The password may be changed anytime See Password Setup section The Advanced Setup menu on the GSC400 is shown to the right Important For Firmware Versions Below 2 00 After changing any settings on the controller the controller needs to be reset This can be don...

Page 44: ... under frequency warning failures AC Voltage The AC voltage sensing display is contained here as well as the over and under voltage warnings and failures AC Current The CT ratio AC current sensing and display enable are contained in this menu Engine Logic All the basic start and shutdown logic are contained in this menu Outputs Setup This menu allows you to assign a feature action to one of eight ...

Page 45: ...ian can reset the service interval here On reset the service counts down to the next service Set Modbus This sets the modbus slave address and baud rate 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 Set Dummy Load This ...

Page 46: ...ure Level 10 265 F 10 265 C Oil Pressure Input Pin Reserve Analog 2 7 Signal Source J1939 Switch input Sender 1 2 or 3 Bypass Delay 10 60 Seconds Switch Setting GND Fail Open Fail Shorted Sender 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 Fuel Level Input Pin Reserve Analog 2 7 Signal Source Switch inpu...

Page 47: ...itch Setting GND Fail Open Fail Shorted Sender Disable Warning Shutdown Open Sender Disable Warning Shutdown Units Fahrenheit Celsius Warning Level 10 265 F 10 265 C Speed Sensing Signal Source J1939 Mag pickup Gen output Rated Freq 10 9990 Hz Rated RPM 200 4000 RPM Over RPM Warn 100 5000 RPM Over RPM Fail 100 5000 RPM Under RPM Warn 100 5000 RPM Under RPM Fail 100 5000 RPM AC Frequency Disconnect...

Page 48: ...ic Delay to Start 0 60 seconds Glowplug Time 0 60 seconds Crank Time 3 60 seconds MidHeat Time 0 60 seconds Crank Rest Time 1 60 seconds Crank Attempts 1 60 Fuel Crank Rest Disable Enable False Restart Disable Enable Post Heat Time 0 60 seconds ETS On Duration 0 30 seconds Warm up Time 0 600 seconds RPM Disconnect 100 2000 RPM Cool Down Delay 0 600 seconds Crank Oil pres 0 90 Psi Digital Output Se...

Page 49: ...t 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 located at bottom of menu Global Trig Crank Trig Run Trig Crank Run Trig Battery Setup Low Auto Charge Disable Enable Charge Pre Alarm 1 60 minutes Charge Duration 10 240 minutes Recharge Level 7 24 volts Low Warn Level 7 24 volts Low Fail Leve...

Page 50: ...eTemp 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 Warning Table 1 Events Table 1 Failure Table 2 Warning Table 2 Events Table 2 Events Disable EPS Load On Idle Running Service Needed Not In Auto LoBatt InCrank Set...

Page 51: ...ne Tmp Negative engine temperatures can be displayed on the GSC400 but any reading below 00 C 320 F is set to 00 C for warning and failure level detection purposes e g low engine temperature 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...

Page 52: ...he 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 read to go when the user desires to start the generator When the controller enters the Auto Mode the ECM Power Delay setting controls the amount of time the GSC400 delays before turning on the fuel output This is useful to pre...

Page 53: ...e package frame J1939 71 2 Multi package frame J1939 21 a BAM b RTS CTS c TP DP 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 rec...

Page 54: ...Attaching Switches to the Sender Inputs The user has the option of connecting either senders or switches to the analog inputs If using switches they 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 Input Type ...

Page 55: ...nput After the bypass period if there are any warnings or failures they will be 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 Each of the analog types support Warnings and or Failures J1939 or senders only In the case of high engine temperature if the data from the sender or J1939 exceeds ...

Page 56: ...ull up Resistance in Ohms and depends on the analog input It is 1000 Ohms for pins 2 3 and 4 and 5110 Ohms for pins 4 6 and 7 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 0V to 1 33V It is recommended to use pin 6 because its 5 11k Ohm pull up w...

Page 57: ...1Ohm VDO 99PSI 136Ohm Murphy 99PSI 237Ohm Sender Part Number Datcon 2505 00 VDO 360 004 Murphy ESP 100 Resistance Type Low Low Low Oil Pressure Supported Analog Input Pins 3 4 3 4 3 4 LSB LXB controllers LS LX controllers pin 2 can also be used Some senders can be supplied by Dynagen Refer to Table 22 Senders Part List on page 81 for the Dynagen stock code The six analog input pins are divided int...

Page 58: ...d failures as well as under speed warnings and failures can be set from the menu in terms of RPM The warnings and failures apply to all three options above 6 3 1 Rated Speed For the magnetic pickup and generator output options you must select the rated frequency and rated speed The GSC400 uses these values together to calculate the engine speed from the magnetic input or generator output The rated...

Page 59: ...se Hi Wye Hi Wye centre tapped 4 Voltage Group 4 Three Phase three or four wire delta Voltage Group 1 has an option the Group 1 Setting under the AC Voltage menu for two wire Hot and Neutral or three wire A B Neutral single phase If two wire single phase is selected the GSC400 display is fixed to L N Voltage Group 2 can be used for 3 wire delta and non center tapped Hi Wye configurations Voltage G...

Page 60: ...ions 6 4 1 Voltage Select Inputs It is e or two of e digital inputs to Volt Select 1 and Volt Select 2 This allows the GSC400 to utomatically re configure its voltage display as well as warning shutdown trip points s and currents This is useful for mobile generators where the oltage selections can be selected via a CAM switch 2 possible to automatically choose between each configuration by setting...

Page 61: ...numbers in this menu are 1000 5A which in turn means the The hese a The current warning and failure e eter second to last entry in the AC Current menu is used to ng 50 selection If this is not desired then the 100 selection e off by the user The Turns Ratio sub menu is used to setup th in terms of 5A For example select 1000 means GSC400 displays 1000A on the screen when the current measured on the...

Page 62: ...rmonic distortion THD D v 6 5 Engine Logic ines the speed that must be attained before the rank output is turned off and the engine is considered to be running T ked R w R The Engine Logic menu contains the 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 determ c he C...

Page 63: ...nce crank success is reached unless the PostHeat is set to a value greater than 0s 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 f...

Page 64: ...ue greater than urned on for the time set one of the digital outputs must b to Energize to Sto he ETS On Duration submenu 6 6 Digital Output Se 200mA dig output dry contact the Ex ure listed is perm tup There are eight ital outputs all switched to ground and one 40A digital tra output all of which are configurable Each feat in Table 14 below itted to be set to only one digital output Table 14 Digi...

Page 65: ...e is activated See section 6 9 for more details Battery Warning This turns on the digital output if the Low or High Battery Warning is activated See section 6 9 for more details Low Coolant Failure This turns on the digital output if the Low Coolant Failure is activated This is controlled by the Low Coolant Digital Input described in Table 15 in section 6 8 Low Coolant Warning Reserved for future ...

Page 66: ...lt 1 feature is active See section 6 13 for more details Common Fault Output 2 This turns on the output if the Common Fault 2 feature is active See section 6 13 for more details Dummy Load This allows the digital output to be controlled by the Dummy Load feature See section 6 14 for more details High Fuel Level Warning This turns on the output if the High Fuel Level Warning digital input in Table ...

Page 67: ...ek memory storage is availabl in a completely charged cont lly roller clock DC power is required to be supplied continua to the GSC400 for approximately 1 hour to allow for a completely charged clock The remote start contacts 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 ot the GSC400...

Page 68: ...re in Table 14 on page 64 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 5 12 1 on page 39 for more information Start Stop When the digital input is active the generator is started if in the Auto mode If the digital input becomes inactive this places the contro...

Page 69: ...ing 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 6 9 1 Low Battery Recharge The GSC400 can be setup to automatically run the generator if the battery voltage goes below a certain point the Recha...

Page 70: ...lowing Select Password No 1 Digit 1 Enter the desired number 0 9 Select Password No 2 Digit 2 Enter the desired number 0 9 Select Password No 3 Digit 3 Enter the desired number 0 9 Select Password No 4 Digit 4 Enter the desired number 0 9 Remember to write down the password for future reference The default password is all zeros You can only reset the password using the GSC400 PC Interface To reset...

Page 71: ...et from this menu See Appendix B Modbus Map for more communication interface details 6 13 Common Faults Common Fault 1 and Common Fault 2 menus contain tables of all the events warnings and failures available in the GSC400 controller and allows the user to select those to generate a trigger when active The trigger can be used to turn on a digital output store the status of the trigger active inact...

Page 72: ...e 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 digital output is turned on If the AC current rises and remains above a settable threshold Load Off Point for 1 5s the dummy load digital output is turned off A digital...

Page 73: ...ounting location for possible safety issues Inspect mounting location for any safety or fire issues Inspect for dirt wiring damage and mechanical damages Inspect controller for loose fasteners terminals and wiring connections Check all hardware including controller wiring terminals etc for any looseness due to vibrations etc Clean area around controller Periodically inspect and remove any debris d...

Page 74: ... 2 Signal Source Switch 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 Oil Pressure Input Pin Disable Signal Source Switch 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 Fuel Level Input Pin ...

Page 75: ...nal Source Generator Output 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 AC Frequency Frequency Disconnect 22 Hz Over Freq Warn 70 Hz Over Freq Fail 75 Hz Under Freq Warn 50 Hz Under Freq Fail 45 Hz A C Voltage Voltage Source Enable Voltage Display Line Neutral Voltage Group Group 1 Single Over Volt Warn 1...

Page 76: ...ble Post Heat Time 0 seconds ETS On Duration 0 seconds Warm up Time 600 seconds Crank Disconnect 650 RPM Cool Down Delay 0 seconds Crank Oil pres 10 PSI Digital Output Setup All selections apply to each individual output Extra Relay Disable Output 1 Disable Output 2 Disable Output 3 Disable Output 4 Disable Output 5 Disable Output 6 Disable Output 7 Disable Output 8 Disable Exerciser setup Exercis...

Page 77: ...harge 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 Set Password Password No 1 0 Password No 2 0 Password No 3 0 Password No 4 0 ...

Page 78: ...ev 3 1373R3 5 1 2 31 AC Current Sensing Rev 2 1375R2 5 All circuits Digital Outputs Rev 2 1377R2 5 1 2 3 4 Analog Inputs Rev 2 1376R2 5 1 2 3 4 Digital Inputs Rev 2 1378R2 5 4 7 8 9 10 11 12 1 The new Rev 3 of this harness contains a terminating resistor If the GSC400 is not the last device on the network this resistor can be cut out Circuits 9 and 12 are tied together This disables the emergency ...

Page 79: ...hased together as a starter kit Stock Code ACC0086 See section 12 on page 104 for the drawing 1 Circuits 9 and 12 are tied together This disables the emergency stop input For users who desire this feature cut this wire 2 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 termin...

Page 80: ...inals Phase A Phase B to terminals Phase B Phase C to terminals Phase C In center tap delta applications Phase A to terminals Phase A Phase B to terminals Phase B Phase C to terminals Phase C White wire assumed positive Black wire assumed negative Table 21 Current Transformers Part List CT Description Stock Code Manufacturer s Part No 100A 5A ACC0045 PC S 546 100 L 200A 5A ACC0046 PC S 546 200 L 3...

Page 81: ...ature 3 8 ACC0098 DATCON 02024 00 3 8 18 NPTF Datcon Temperature 1 2 ACC0099 DATCON 02025 00 1 2 14 NPTF 9 5 GSC400 replaceable 12 24VDC relays 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 T...

Page 82: ...om many automotive stores may be used in place of the higher current 40A If installing lower amperage fuse protection be certain that current draw does not exceed the fuse current limit Table 24 GSC400 fuse part list Fuse Description Stock Code Part Description 40A 32VDC Auto Fast Action FUS0012 Littlefuse 257040 ...

Page 83: ... the Data Block and the Error Check field Query Response Message Structure Device Address Function Code Eight Bit Data Bytes Error Check Device Address Field The Device Address field contains the unique Modbus address of the slave being queried The addressed slave will repeat its address in the Device Address field of the response message This field is 1 byte Function Code Field The Function Code ...

Page 84: ...SC400 controller goes from the Run to OFF mode or Menu to OFF mode modbus communications will be unavailable until the controller is in the OFF mode 10 2 Modbus Commands GSC400 supports two Modbus commands 0x03 Read Holding Register 4x and 0x06 Write Single Register To make the communication work user need to setup something in GSC400 setting to corresponding with the RSA unit In the GSC400 Advanc...

Page 85: ...e updated by controller once every 250ms 40001 Highest Severity Event Read only bit 16 Alarm State bit 15 14 Severity Bits 13 10 Reserved Bits 9 1 Event 40002 Previous Highest Severity Event R bit 16 Alarm State bit 15 14 Severity Bits 13 1 Event 40003 40010 Read Only Each event uses 5bits b4 b3 b2 b1 b0 where b0 is the least significant bit b0 The event status warning or shutdown occurring 0 Not ...

Page 86: ... 18 Locked Rotor bit 14 10 40009 Events number 19 Common Fault 1 Warning Shutdown bit 4 0 Events number 20 Common Fault 2 Warning Shutdown bit 9 5 Events number 21 Reserved bit 14 10 40010 Reserved 2nd generation Modbus register support Basic Modbus Functions 1 CONTROLLER INFORMATION Read Only 40080 GSC400 Front Panel LED Status 0 OFF 1 ON R bit0 Over Crank Failure red bit1 Over Crank Warning ambe...

Page 87: ...ngine 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 speed freq warning bit13 Low fuel level failure bit14 Low fuel level warning bit15 Battery low and high level failure 40083 Events Warnings Status 0 OFF 1 ON R bit0 Battery low and high...

Page 88: ...re warning and failure bit6 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 40085 bit0 to bit4 Reserved bit...

Page 89: ...Version format is X YY Decimal format where X represents a number from 1 9 and is stored in the high byte of 40090 YY represents a decimal number from 00 to 99 and is stored in the lower byte of 40090 40092 40095 GSC400 serial number 4 to 7 characters R The serial number is stored in 7 digit decimal format with the high byte of register 40092 containing the high MSB and the low byte of register 40...

Page 90: ... all other operating modes START 0x9768 38760 W 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 W When 0x57A8 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 an...

Page 91: ...enable command 40098 40101 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 36 EXERCISER RUNNING 0 None of the above 0 corresponds to none of th...

Page 92: ...nk 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 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 WAITI...

Page 93: ... sender 70 EMERGENCY STOP 71 Auxiliary Warn 72 Under Frequency warning 73 Over Frequency warning 255 0xFF Empty No message in queue 40108 Active Failure 0 44 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 In...

Page 94: ...SHORT OIL PRES 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 CONFIG FAIL 2 255 0xFF Empty No failure message 40109 System Sub state delay countdown 0 65535 R The value of register 40109 corresponds to the count down delay for one of the below m...

Page 95: ...110 Digital Input 0 1023 R Read Only Status of controller digital inputs OFF means the input is not active or not connected Bit0 Input A BAT 0 OFF 1 ACTIVE Bit1 Input B BAT 0 OFF 1 ACTIVE Bit2 Input C BAT 0 OFF 1 ACTIVE Bit3 Input D BAT 0 OFF 1 ACTIVE Bit4 Input E GND 1 OFF 0 ACTIVE Bit5 Input F GND 1 OFF 0 ACTIVE Bit6 Input G GND 1 OFF 0 ACTIVE Bit7 Input H GND 1 OFF 0 ACTIVE Bit8 Start Stop 1 OF...

Page 96: ...F 1 ACTIVE Bit6 Output G 0 OFF 1 ACTIVE Bit7 Output H 0 OFF 1 ACTIVE Bit8 Extra Relay 0 OFF 1 ACTIVE Bit9 Fuel Relay 0 OFF 1 ACTIVE Bit10 Crank Relay 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 0xFF0...

Page 97: ...orresponds to 100 0 40157 Fuel In Basin 0 100 0 R 1 bit equal to 0 1 Reading 1000 corresponds to 100 0 40160 Line Voltage A B R V 40161 Line Voltage B C R V 40162 Line Voltage C A R V 40163 Phase Voltage A R V 40164 Phase Voltage B R V 40165 Phase Voltage C 0 999 9 R 1 bit 0 1V Reading 9999 corresponds to 999 9 V V 40167 Phase A Current R A 40168 Phase B Current R A 40169 Phase C Current 0 999 9 R...

Page 98: ... 1 hour 65535 corresponds to 6553 5Hs Hours 40177 40178 Engine Hours old way use registers 40172 40173 instead 0 255999 9 R Total Accumulated running hours the reading in 40177 1 bit equal to 0 1 hour The reading in 40178 1 bit equal to 1000 hours So the total hours 40178 1000 40177 10 Hours 40145 Maintenance Time 1000 1000 Signed Integer 16 bit R The unit is 0 1 hour 1 bit 0 1 hour Positive value...

Page 99: ...Entry command is received After 20s of receiving further commands in register 40130 all registers are cleared i e set to 0 40131 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 ...

Page 100: ...EDED 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 2 233 0xE9 DTC 40132 Log Time stamp Minutes Decimal 0 59 Decimal format High 4 bit tens 0 5 Low 4 bit ones 0 9 Minute 40133 Log Time stamp Hours Decimal 0 23 Decimal format High 4 bit tens 0 2 Low 4 bit ones 0 9 Hour 40134 Log Time sta...

Page 101: ...mp status and reserved lamp status 0 65536 R 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 Bit 1 0 protect lamp status Low byte reserved for lamp status 40115 0 65536 R 40116 Active DTC No 1 Each DTC code will be stored in 2 holding register High Byte of the first register is Byte 1 Low byte is byte 2...

Page 102: ...n 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 40181 0 65536 R 40182 Previous Active DTC No 1 Same format as Active DTC registers above 0 65536 R 40183 40244 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 Activ...

Page 103: ...nificant 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 b...

Page 104: ...104 of 105 12 Appendix D Additional Drawings The follow pages include various drawings that may be of benefit ...

Page 105: ...105 of 105 ...

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