DynaGen GSC300 User Manual

Installation and User Manual for the GSC300 Auto Start Engine Controller

Auto Start Engine Controller

GSC300

Full Version

File: GSC300rev2.4.doc
Dec. 08, 2005

Thank You For Purchasing This DynaGen Product

Please Read Manual Before Installing Unit

Receipt of Shipment and Warranty Return Information

Upon receipt of shipment, carefully remove the unit from the shipping container and thoroughly examine the
unit for shipping damage. In case of damage, immediately contact the carrier and request that an inspection
report be filed prior to contacting DynaGen.

All returned items are to be shipped prepaid and include a Return Material Authorization (RMA) number issued
by DynaGen. RMA forms are available by contacting DynaGen Technical Support through the contact
methods listed below.

2

Limited Warranty

DynaGen will repair or replace any GSC300 controller which proves to be defective under normal and proper
use within Three Years from the date of shipment. This constitutes the only warranty and no other warranty
shall be implied.

We welcome your comments and suggestions. Please contact us at:

DynaGen Technologies Inc.
Phone: [phone]

[phone]
Fax: [phone]
Email: [e-mail]
WEB SITE: www.dynagen.ca

Operating & Installation Manual for the GSC300 Engine Controller

SPECIFICATIONS FOR THE GSC300

Operating Voltage: 7 to 30VDC continuous, with zero volts cranking dropout protection

Operating Temperature: -40 to +85ºC

Physical Dimensions: 4.5"(H) x 5.5"(W) x 1.25"(D)

Actual Unit Weight: 0.458 lbs

Enclosure: High Impact Resistant, Injection Molded Plastic Enclosure

Front Panel Indications

-High intensity LED’s with regulated brightness

LCD Display:

-Ultra-bright, Backlight LCD display with optimum viewing angle of 0 to -25º from perpendicular

-Display Size (mm): 8 (W) x 32 (H) x 12.8 (D) x 16 characters

Adjustments

Warm-up: 0 - 200 seconds (After Oil Bypass Feature)

Cool-Down: 0 - 255 seconds

Crank Disconnect: 12 to 140Hz (Generator Output Version)

44 to 300Hz (Magnetic Pick-up Version)

Overspeed: 60 - 4156Hz (Generator Output Version)

300 - 8492Hz (Magnetic Pick-up Version)

Crank Rest: 3 - 32 seconds

Delay on Start: 0 – 59 seconds

Crank Tries: 1 to 10

Oil Bypass: 15 – 55 seconds

Low Battery Indication: 7 – 35 VDC

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Operating & Installation Manual for the GSC300 Engine Controller

Timer adjustments

Glow Plug/Preheat: 0 - 255 seconds

Energize To Stop (ETS): Energizes for 15 seconds on failures, or energizes until 5 seconds after

engine speed goes to zero upon removing power from Start/Stop terminal
or removing the unit from manual mode using the front panel buttons.

Inputs

Speed Sensing:

-Optional Generator Output Speed Sensing or Magnetic Pick-Up Model
(Specified by customer at time of order)

Maximum Input Voltage: 300Vrms

Minimum Input Voltage: 0.7Vrms(Generator Output Sensing),

0.1Vrms(Magnetic Pick-Up version)

-60Hz Rejection Filter Included

-Loss of Speed Signal Included

Sender/Failure Inputs:

-Oil Pressure, Coolant Temperature, Fuel Level/Auxiliary Input

-Accepts standard industry low impedance (0-500 ohm) sender inputs
(VDO, Stewart-Warner, Datcom, Murphy, etc.)

-Data entry available for custom sender inputs

-Can be configured to accept a switched gauge failure through the PC interface

-Failure points adjustable

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Operating & Installation Manual for the GSC300 Engine Controller

Protection

-Three on-board replaceable 40A fuses protect Fuel, Crank, and Timer Outputs

-Reverse polarity protected

-Short circuit & overload protection on annunciation outputs

-Inputs are electrostatic discharge protected

-Maximum power supply surge before damage: 1500V for 250us

Outputs

-All outputs positive switched (sourcing)

-Fuel, Crank, and Timer Outputs: 40A each, using standard 40A automotive relays

-Annunciation Outputs: 300mA individually, 350mA combined

Connections

-Removable terminal block for annunciation outputs and low power connections

-0.25" spade terminals for quick connections on all other connections

Programming

-Intuitive windows based software interface utilizing the parallel port of your PC

-Option of programming through 3-button interface (limited parameter adjustment) on the front panel or the
PC Interface that has full parameter programming ability.

-Needs no power to program using the PC Interface –uses power from parallel port of PC

-Specifications May Change Without Notification

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Operating & Installation Manual for the GSC300 Engine Controller

GSC300 Product Number Identification

The GSC300 series product numbering scheme provides significant information pertaining to a
specific model. The Product Number Identification Table (see Table 1) provides the required
interpretation information. An example is offered to initially simplify the process.

A product number GSC300-X-XX-XX would consist of a combination of information from the
following table.

TABLE1: IDENTIFICATION TABLE

Position 1-6

Series

GSC300=GSC300

Position 8

Speed Range

L=Low

H=High

Position 10-11 Position 13-14

DC Voltage

12=12VDC
24=24VDC

LX=Customized

Labeling

LS=Standard

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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

Operating & Installation Manual for the GSC300 Engine Controller

WIRING INSTALLATION GUIDELINES

Danger: Never work on the engine while its power is on. This controller does

not generate a warning signal prior to automatic engine start. Warning signs should
be placed on engine equipment indicating this important safety measure.

INSTRUCTIONS

Following these instructions will help avoid common installation problems during wiring and setup.

• 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.

TYPES AND SIZES

Terminal Wire Size

(AWG)

1 12 40A Fuel Output Terminal
2 12 40A Auto(Battery +) Terminal Connection
3 12 40A Auto(Battery +) Terminal Connection
4 12 40A Crank Output Terminal
5 12 40A Ground Terminal Connection
6 12 40A Ground Terminal Connection
7 12 40A Preheat/ETS Terminal
8 12 40A Preheat/ETS Terminal

9 18 100mA Speed Signal Connection
10 18 100mA Speed Signal Connection
11 18 300mA Overcrank Output
12 18 300mA Overspeed Output
13 18 300mA High Temp Output
14 18 300mA Low Oil Output
15 18 300mA Low Battery Output
16 18 300mA Engine Run Output
17 18 100mA Not in Auto Output
18 18 300mA General Failure Output
19 18 7mA Start/Stop Input
20 18 7mA Oil Pressure Sender/Switch Input
21 18 7mA Temperature Sender/Switch Input
22 18 7mA Fuel Level/Auxiliary Sender/Switch

Current max. Function

Input

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Operating & Installation Manual for the GSC300 Engine Controller

WIRING GUIDELINES

1. DO NOT use wire smaller than 18 AWG.

IMPORTANT: The connections supplying DC power to the GSC300 panel should preferably run directly

2.

from the battery posts with no splices or other connections. Avoid using chassis (aluminum or iron engine
parts), as return conductor for battery negative voltage. Copper wiring is recommended. Failure to follow
the above may result in erratic operation due to large voltage drops across wiring connections. A small fuse
should be placed at the battery terminal to provide 12 volts to the Remote Start Contacts to ensure that a
short along this line will not cause any damage.

3. DO NOT exceed the maximum rated current and voltage on each of the controller outputs. Do not exceed
40A each for the Fuel Output, Crank Output or Preheat Output. Do not exceed 300mA individually, or
350mA combined, for the General Fault Output or Annunciation Outputs.

4. DO NOT short Crank Output or Fuel Output to ground. This will cause damage to the unit.

To verify the operation of engine controller outputs, measure voltage (i.e. meter in volts) when outputs

5.

should be ON.

To verify the operation of the Preheat Output, measure the resistance between the Preheat terminals when

6.

the Preheat Output should be ON. At this time there should be a closed circuit. When the output is
supposed to be OFF there should be an open circuit between the terminals.

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Operating & Installation Manual for the GSC300 Engine Controller

GSC300 12/24VDC SYSTEM OPERATION

9

The GSC300 controller is designed to operate in either 12 or 24 VDC system voltages.
When operating in 12VDC systems the fuel, crank and preheat/ets relays need to be the
proper 12VDC relay type. When operating in 24VDC systems these relays need to be the
proper 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

Operating & Installation Manual for the GSC300 Engine Controller

TERMINAL DESCRIPTION

Term # Description

1 Fuel Output provides 40A maximum. Fuel Output closes to +12/24 VDC when start signal is

actuated, and opens when either an engine failure is detected or when Cool-Down period has

ended.
2 Auto Terminal. Connection point on the unit for +V Battery power connection
3 Auto Terminal. Connection point on the unit for +V Battery power connection
4 Crank Output provides 40A maximum. Crank Output closes to +12/24VDC during cranking,

and opens when the engine has started, or during Crank Rest.
5

6

7 Preheat/ETS Output closes to terminal 8 during Preheat or ETS period. (Dry contacts between

8 Preheat/ETS Output closes to terminal 8 during Preheat or ETS period. (Dry contacts between

9 Speed 1. Speed Signal Input for Crank Disconnect, Engine Run, and Overspeed sensing. 300

10 Speed 2. Speed Signal Input for Crank Disconnect, Engine Run, and Overspeed sensing. 300

11 Overcrank Annunciation Output closes to +12/24VDC on Overcrank Failure. 300mA max.
12 Overspeed Annunciation Output closes to +12/24VDC on Overspeed Failure. 300mA max.
13 High Temp Output closes to +12/24VDC upon High Temp Failure. 300mA max.
14 Low Oil Output closes to +12/24VDC upon Low Oil Failure. 300mA max.
15 Low Battery Output closes to +12/24VDC on Low Battery Condition. 300mA max.
16 Engine Run Output closes to +12/24VDC on Engine Run Condition. 300mA max.
17 Not In Auto Output closes to +12/24VDC when unit is not in auto. 300mA max.
18 General Failure Output closes to +12/24VDC on a General Failure. 300mA max.
19 Start Stop Input. Apply +12/24VDC to this terminal while unit is in Auto Mode to start engine.

20 Oil pressure sender/switch. This oil pressure sender/switch can be N.O. or N.C., meaning that

21 Temperature sender/switch. For proper operation, this input must be connected to ground via a

22 Fuel Level/Auxiliary Failure Input. For proper operation, this input must be connected to

Battery Ground connection for the controller module. A good ground connection, directly from

the battery, is required for proper operation.

Battery Ground connection for the controller module. A good ground connection, directly from

the battery, is required for proper operation.

terminals 7 & 8)

terminals 7 & 8)

VAC max. input voltage.

VAC max. input voltage.

Remove +12/24VDC to stop engine or enter Cool-Down mode.

for N.O., ground is a failure while +Vbatt is Engine OK, for N.C., ground means engine OK,

and +Vbatt means failure. The operation (failure point) of the output in response to the sender

can be set using the PC Interface.

sender/switch. The operation (failure point) of the output in response to the sender can be set

using the PC Interface.

ground via a sender/switch. The operation (failure point) of the output in response to the sender

can be set using the PC Interface.

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Operating & Installation Manual for the GSC300 Engine Controller

Wiring Connection Diagram

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Operating & Installation Manual for the GSC300 Engine Controller

Back Panel Layout

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Operating & Installation Manual for the GSC300 Engine Controller

CONTROLLER OVERVIEW

The GSC300 Features the Following Functions:

1. Controller Programming Adjustability

2. General Fault Conditions

3. Not In Auto

4. Low Battery Voltage Alarm

5. Oil Pressure Input

6. Coolant Temperature Input

7. Fuel Level/Auxiliary Input

8. Speed Signal Sensing

9. Adjustable Input Programming

10. Magnetic Pick-Up Capability Option

1: CONTROLLER PROGRAMMING ADJUSTABILITY:
Adjustable Parameter Ranges:

Crank Disconnect: 12 to 140Hz (Generator Output Version)

44 to 300Hz (Magnetic Pick-up Version)

Overspeed: 60 - 4156Hz (Generator Output Version) -OR DISABLED BY PC INTERFACE

300 - 8492Hz (Magnetic Pick-up Version) -OR DISABLED BY PC INTERFACE

Crank Tries: 1 to 10

Crank/Rest: 3 to 32 seconds

NOTE: If the engine speed seen by the controller does not go to zero during Crank Rest, the controller will

wait until the speed goes to zero before re-initiating the cranking sequence.

2: GENERAL FAULT CONDITIONS: The following scenarios can cause the unit to enter the

general fault condition:

Low Fuel/Auxiliary Failure (“XTR_FAIL”)
Low Oil
High Coolant Temperature
Overcrank
Overspeed
Loss of Speed (“SPDLOSS”)

The General Fault output is rated 300mA Max.

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Operating & Installation Manual for the GSC300 Engine Controller

14

3: 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 close to +Vbatt, indicating the controller is not in the AUTO Mode. The LCD
display will read “OFF”, however the backlight on the LCD display will not be ON.

NOTE:
and LED indications to function properly.

+ Battery must be permanently connected to the AUTO terminal for the NOT IN AUTO condition

4: LOW BATTERY VOLTAGE ALARM: In the event the battery voltage drops below the user

defined set point which can be between 7 and 35VDC, the engine controller displays a Low Battery Condition.
The Low Battery Voltage condition can occur when the controller is in the AUTO or MANUAL/TEST Mode,
but will only occur in the running state or while in standby in AUTO. The LCD display will show the message:
“LOW_BATT”

5: LOW OIL INPUT: The Low Oil Input can accept data from a sender or signal from a N.O. or N.C. type

switch. N.O. means that ground would be a failure, +5V would be “Engine OK”. N.C. means that ground
would be “Engine OK”, and +5V would be a failure. The operation of the oil input is set in PSI by the PC
Interface and is the only input which has selectable operation in this manner.

Note:

The oil input failure is disabled during the Oil Bypass time.

6: HIGH TEMPERATURE INPUT: For proper operation this must be of the standard N.O. type where

with a switch or sender, a ground would be seen as a failure, and a +5V would be seen as “Engine OK”. This
can be used with a sender or switch and when using a sender the failure point in degree Fahrenheit can be
adjusted using the PC Interface.

7: FUEL LEVEL/AUXILIARY INPUT: For proper operation while using a switch, the switch must

be the N.O. type which closes to ground upon failure. If this input is used as a sender, no failure will be
indicated. The sender option is solely for Fuel Level/Auxiliary Level Display on the LCD.

8: SPEED SIGNAL SENSITIVITY: The controller will accept to a maximum of 300 VAC, 60 Hz from

direct generator output for speed sensing. The following values are minimal recommended voltages for speed
signal sensing:
20 HZ - .075 V (75mV)
60 HZ - .6V (600mV)

9: HOUR METER: The controller can display a log of generator run times. Run times will be displayed on

the controllers display screen. The display represents both hours and minutes in the form 123456:7. The last
digit on the hour meter will represent the time in 1/10 of an hour. Each increment would represent 6 minutes.
For example if the hour meter displays 000010:5 than the generator had ran for 10 hours and 30 minutes.
Please note that although the hour meter displays time in hours and minutes, it will record up to the nearest
second. If the generator was operated for only 3 minutes, the display may not increment but this time would be
stored and added to the next generator run time.

10: MAGNETIC PICK-UP CAPABILITY OPTION: The Magnetic Pick-Up Capability Option can

be provided on the GSC300 upon request. Frequency will not be displayed on the LCD if this option is chosen.

Operating & Installation Manual for the GSC300 Engine Controller

LED LAYOUT

Front View of GSC300

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Operating & Installation Manual for the GSC300 Engine Controller

LED INDICATIONS

FRONT PANEL LED INDICATIONS

LED Appearance Condition/Failure
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

Was Engine Cranking?

Was Engine Running?

Steady Engine Running LED

Flashing Engine Running LED

Unit is in OFF state.
“OFF”, no +12/24VDC to “Auto” terminal.
Low Oil Pressure Failure
Auxiliary Input Failure
Over Temperature Failure
Engine would not start after specified
Crank tries.
Speed Signal present above Overspeed
setting

No speed signal available while Cranking

The speed signal was Zero while running.
The engine has stalled, 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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Operating & Installation Manual for the GSC300 Engine Controller

17

Programming The GSC300 Settings

Using the Front Panel Interface:

The following table shows the LED’s that correspond to the various settings of the various parameters. To
enter the controller into Program Mode, you need to turn the small switch at the bottom edge of the controller to
the program position. This Mode Switch can be set using a ballpoint pen or such to allow the controller to be
put into Program Mode. The first three LED’s (3, 2 & 1) correspond to which parameter is being adjusted, and
the next three (6, 5 & 4) LED’s show the setting for that particular parameter. The picture on the next page
shows the LED numbering and the location of the Mode Switch.

▼ LED's 6, 5 & 4 ▼

Parameter

LED's 3, 2 & 1

▼

○○○ ○○● ○●○ ○●● ●○○ ●○● ●●○ ●●●

Crank Tries

Crank Time

Rest Time

Preheat Time

Cool-Down

Preheat/ETS/

Warm-Up
Warm-Up

○○○ 1 2 3 4 5 6 7 8

○○● 5 10 15 20 25 30 35 40

○●○ 0 5 10 15 20 25 30 35

○●● 0 5 10 15 20 25 30 35

●○○ 0 32 64 96 128 160 192 224

●○●

Preheat ETS Warm-Up

N/A N/A N/A N/A N/A

●●○ 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 set the value into the
controller’s memory, press the OFF button. In this manner the settings of the controller can be adjusted by
simply using the three buttons on the front panel of the controller. Be sure to press the OFF button when you
have selected the parameter value wanted. By not pressing the off button to set the value, the value of that
parameter will not be stored into memory and remain at it’s previous setting.

Operating & Installation Manual for the GSC300 Engine Controller

Numbering Of LED’s and Location of Mode Switch

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Programming Using the PC Interface

The GSC300 can also be programmed using the PC interface. Detailed instructions on the PC interface are
included with the GSC300 Configurator software. A sample interface screen is illustrated on the following
page.

Operating & Installation Manual for the GSC300 Engine Controller

Sample Screen From PC Interface

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Operating & Installation Manual for the GSC300 Engine Controller

TROUBLESHOOTING GUIDELINES

TROUBLE POSSIBLE CAUSE SUGGESTED ACTION

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

Power leads to unit are reversed Confirm correct wiring for ground and +bat,

and re-attempt testing.
Bad ground connection from engine to
controller unit.
Improper speed range Check to ensure that the speed sensing

Battery is low or terminals are dirty Clean terminals and re-charge battery
Crank circuitry wiring improperly
connected
Bad ground connection from engine to
controller
Crank relay damaged. Or on board fuse is
blown

Out of fuel Check fuel level, add fuel if necessary
Ignition control wiring not installed
properly
Fuel relay damaged Check fuel relay and replace if damaged.

Run wire directly from battery - to the

ground terminal #11on controller unit.

wires of the controller are connected to the

generator output.

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

again

Refer to engine control wiring section and

check ignition connections

20

Engine starts but shuts

down after “Oil Bypass

period” due to low oil/high
temp/Aux input

Fault LED works OK, but
general fault output does not
activate
Flashing Overspeed LED

Flashing Run LED & Solid
Oil LED

Solid Oil LED immediately
on start-up, without engine
actually cranking or starting.

Display Parameter for
Temperature, Oil or Fuel
displayed as >>> or <<<

TM

Oil/Temp/Auxiliary input wiring improperly
connected.

Fault (short or overload) on general fault
output.

Speed signal improperly connected,
missing, or damaged.
Crank output damaged, not working Check wiring and replace controller if

Starter or starter solenoid damaged Replace/repair damaged starter or starter

Oil switch not closed as it should be Check oil switch wiring and switch to make

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.

Parameter is >>> ABOVE or <<< BELOW
specified manufacturer sender range.

Check wiring for proper connections.

Check for fault, once fault is corrected then

output operation resumes.

Check speed signal wiring; replace

damaged speed signal source.

necessary

solenoid.

sure the switch is closing when there is no

oil pressure

Install a small step down transformer

between the speed sensing wires and the

generator output.

If the neutral from the generator output is

not grounded, attach it to ground

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.

Operating & Installation Manual for the GSC300 Engine Controller

Re-adjust Oil Bypass and/or Warm-Up

timing.

21

TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS

1. Controller Memory Clear Time

The GSC300 needs 10 seconds for its memory to clear. When the power to the controller is turned off and then back on
again without waiting a few seconds to clear the memory, a loss of speed will be indicated by the GSC300 because the
controller remains in run mode and senses that the generator has stopped. This would be indicated by a Flashing
Overspeed LED. By leaving the GSC300 OFF for 10 seconds before it is returned to the Auto setting the memory will be
cleared and it will function as intended.

2. Step-Down Transformer Use On Speed Sensing Cable With Inverter Systems

In some applications engine controllers are used on generators where there is no utility connection and inverters are used
to provide AC power instead of a utility. Inverters can produce harmonics that can cause small AC signals to appear on
wires that are near any power lines being fed by the inverter. If the generator output wires are located close to a line being
powered by an inverter, a small AC signal can appear on the generator output lines when the inverter is on. This signal
can cause the engine controller to react as if the generator is running if the speed sensing wires are connected to the
generator output lines. This small AC signal can cause the controller to appear to have a Low Oil Failure when the remote
start contacts are closed or the controller is put in the manual/test mode. The controller may think the generator is already
running and immediately check to make sure there is oil pressure. Since the engine really hasn’t started yet, there is no oil
pressure and the controller sees a low oil fault. This is seen as the Oil LED turning on solid even before the engine starts
to engage the starter.

Without this false speed signal the controller will not look for oil pressure until the engine has started to run and the crank
disengages if oil verification is disabled. Simply installing a small transformer between the generator output and the
speed sensing terminals on the controller can eliminate this false speed signal. This transformer should be rated for 120 or
240 volts on the input or primary coil (depending on the generator output voltage you are using for speed sensing), and
have an output voltage of around 12VAC on the secondary of the transformer. The two wires from the secondary of the
transformer are connected to the two wires of the speed sensing terminals on the GSC300 controller. The step-down
transformer acts to reduce the false speed signal on the line to a level that the engine controller will not recognize as the
engine running. A common size transformer that would serve this purpose would be 24VA

.

Operating & Installation Manual for the GSC300 Engine Controller