DynaGen GSC400 Series Installation And User Manual
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DynaGen GSC400 Series Installation And User Manual

Automatic gen-set controller
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GSC400 Series
Automatic Gen-Set Controller Manual
Revision 2.6
GSC400 Automatic Gen-Set Controller
Installation and User Manual
MAN-0076 Rev2.6, GSC400 User Manual.doc
, May 2010

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  • Page 1 GSC400 Series Automatic Gen-Set Controller Manual Revision 2.6 GSC400 Automatic Gen-Set Controller Installation and User Manual MAN-0076 Rev2.6, GSC400 User Manual.doc , May 2010...

  • Page 2: Limited Warranty

    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. Limited Warranty The GSC400 Gen-set controller carries a five year warranty.
  • Page 3 3 of 105 GSC400 Specifications VDC Rating 12/24 VDC Standby Current 50 mA @ 12 VDC Consumption Operating Temp -40°C to +85°C (-40°F to +185°F) LCD Operating C to 70 C (-4 F to +158 Temp*** Function Function Selection Range Selection Speed Sensing Generator pickup...

  • Page 4: Table Of Contents

    Table of Contents   GSC400 Controller Series.................... 7 This Manual ......................7 Receiving, Handling, and Storage................8 GSC400 Product Number Identification ..............9 GSC400 Series Installation and Wiring ..............10 Safety Information .................... 10 Mounting Location: ..................11 4.2.1 GSC400 Mounting Dimensions..............12 GSC400 12/24VDC System Operation ............
  • Page 5 5 of 105 5.11.1 Diagnostic Trouble Code Shutdowns ............38 5.11.2 EPS Supplying Load ................. 39 5.12 J1939 ......................... 39 5.12.1 Cummins Idle Speed Control..............39 5.13 J1939 Diagnostic Trouble Code (DTC) Display ..........40 5.13.1 DM1 Messages..................40 5.13.2 DM2 Messages..................
  • Page 6 6 of 105 6.14 Set Dummy Load ....................72 Recommended Maintenance ..................73 Default Configuration Settings................... 74 Appendix A: Accessory List ..................78 GSC400 Controller Harness - Accessories ............78 GSC400 Programmer Assembly............... 79 CT’s (Current Transformers) ................80 Engine Sending Units ..................81 GSC400 replaceable 12/24VDC relays ............

  • Page 7: Gsc400 Controller Series

    ECM via J1939 and u them to control the engine or for display purposes. 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 GSC400 Back View...

  • Page 8: Receiving, Handling, And Storage

    When the GSC400 reaches its destination, the customer should inspect the shipping box and controller for any signs of damage that may have occurred during transportation. Any damage should be reported to a DynaGen representative after a thorough inspection has been completed. A shipping label affixed to the shi pping box includes a variety of product and shipping information, such as items and Customer numbers.

  • Page 9: Gsc400 Product Number Identification

    9 of 105 3 GSC400 Product Number Identification The GSC400 series product numbering scheme (i.e. product number) provides various information – including options selected by the customer – about the un A product number has the format given in Figure 1.

  • Page 10: Gsc400 Series Installation And Wiring

    10 of 105 4 GSC400 Series Installation and Wiring 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:...

  • Page 11: Mounting Location

    11 of 105 Mounting Location: The GSC400 gen-set controller must be properly mounted for safe operation. Caution must be taken at the installation site to make sure the site is free from excessive moisture, fluctuating temperatures, dust, corrosive aterials etc. The controller should be safely mounted in a secure location using the 3 mounting screws provided.

  • Page 12: Gsc400 Mounting Dimensions

    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: Gsc400 12/24Vdc System Operation

    (see section 3 on page 9). Contact DynaGen if replacement relays are required (quote Dynagen Part numbers from Table 23 on page 81). UL Listed relays for 12 or 24VDC system operation are as follows: •...

  • Page 14: Gsc400 Terminals

    Table 18 on page 79 gives the part numbers of the various starter-kit harnesses you can order from DynaGen. Only commonly used circuits on each connector are populated (i.e. connected with a wire on the harness). Table 18 also lists the circuits (i.e.
  • Page 15 Figure 4 – General GSC400 System Wiring Diagram...
  • Page 16 Figure 5 – Digital IO Example...
  • Page 17 17 of 105 Table 2 – GSC400 Terminal Details Quick Fit Terminal Wire Size Current max.* Function Terminals (AWG) Crank Crank Output Terminal Positive Battery Terminal Battery + Negative Battery Terminal Battery - Fuel Fuel Output Terminal Extra Relay Configurable Dry Contact Extra Relay Other side of Configurable Dry Contact...
  • Page 18 18 of 105 Digital Terminal Terminal Wire Current Function Inputs Detail Location Size max. (AWG) 1, 3 Input H - Configurable 1, 3 Input G - Configurable 1, 3 Input F - Configurable 1, 3 Input E - Configurable 2, 3 Input D - Configurable 2, 3...
  • Page 19 19 of 105 RS485 Terminal Terminal Wire Current Function (Modbus) Detail Location Size max. (AWG) RS485-A RS485 Connection High Ground Ground Terminal Connection RS485-B RS485 Connection Low RS485-A RS485 Connection High Ground Ground Terminal Connection RS485-B RS485 Connection Low For safety, it is highly recommended to install a switch on either the RS485 A or B lines locally at the generator.

  • Page 20: Can Wiring Note (J1939)

    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 the last device on the bus. If you are using DWG1375R2-5 this version of the J1939 harness does not have a terminating resistor.

  • Page 21: Gsc400 Operation And Basic User Configuration

    21 of 105 5 GSC400 Operation and Basic User Configuration Power-up The very first time the controller is powered up the unit will go through an initialization where all the configurable settings are set to factory default values. This will happen only on the first power-up.

  • Page 22: Controller States

    22 of 105 The GSC400 also has a dedicated emergency stop input that when open will stop the generator immediately and the controller will enter the OFF Mode (see below for more information on the OFF Mode) and remain in the OFF Mode until the emergency stop input is grounded.

  • Page 23: Locking The Gsc400 Screen While In The Run Mode

    23 of 105 While in Auto Mode the controller will display engine temperature, battery voltage, fuel level, and engine hours. 3. RUN Mode – The controller starts the engine/generator and enters the RUN Mode automatically on certai n triggers (low battery voltage or to exercise the generator) or t user can manually start the engine/generator by pressing...

  • Page 24: Gsc400 Start / Stop Behavior

    24 of 105 5.4 GSC400 Start / Stop Behavior There are three ways to start the generator (start conditions): 1. Modbus – Sending a “Start” using the appropriate register. 2. Remote Start Contacts – Pins 10 and 11 of the digital input connector. 3.

  • Page 25: Idle Mode

    25 of 105 Idle Mode For generators that have the capability of idling at a lower speed than the normal operating speed the GSC400 controller has an Idle Mode feature that suppresses the warnings and failures for under-voltage, under-frequency, and under-speed. The GSC400 displays “Idle Running”...

  • Page 26: Cummins Electronic Engine Idle Mode

    26 of 105 5.5.1 Cummins Electronic Engine Idle Mode For Cummins electronic engines the GSC400 will control the engine using the J1939 speed control feature. Whenever the Idle Mode digital input is active the GSC400 will send a command over J1939 to put the engine into idle. See section 5.12.1 of page 39 for more information.

  • Page 27: Gsc400 Menu System Operation

    27 of 105 GSC400 Menu System Operation The GSC400 incorporates a menu system to allow the end user to adjust basic settings. The menu system will also allow technicians and OEMs to adjust advanced settings (this feature is password protected). With the controller in the Off Mode, the menu system may be selected simply by pressing the Enter key.
  • Page 28 28 of 105 Table 3 - Basic Menu Layout Year Month Date Clock Setup Hour Minute 12/24 Basic Menu Contrast Adj. Page Roll Delay State Roll Dly Basic Setup Sleep Delay Maintenance Not In Auto Off Mode Start Events History...

  • Page 29: Clock Setup

    29 of 105 5.9.1 Clock Setup The Clock Setup menu will allow you to set the clock. The clock is important if you are planning to use the event log (records all failures and warnings and when they occurred) or the exerciser feature (starts the generator for a settable period). Table 4 –...
  • Page 30 30 of 105 The controller can be made to NOT sound the alarm when the controller is not in the AUTO mode. This is controlled by the Not In Auto setting. The OFF Mode Start setting can be set to Enable to allow a manual start from the OFF mode.

  • Page 31: Event History Log

    31 of 105 5.9.3 Event History Log The GSC400 incorporates an event history logging system. When engine failures, events, or DTCs (Diagnostic Trouble Codes – see section 5.13 on page 40) occur, an entry is created in the GSC400 Event History Log. See Table 6 –...
  • Page 32 32 of 105 Table 6 – Event Log Entries An “*” beside the Event Entry indicates the Event is a GSC400 event. All other events are failures (see page section 5.11 on page 38). Event Entry Description ADC SWITCH FAILURE These are internal GSC400 failures.
  • Page 33 33 of 105 6.5.1.1 on page 63. LOSS OF ECM COMM J1939 messages required by the GSC400 have not been received. The generator has shut down. See section 6.1 on page 51. LOW AIR PRESSURE The low air pressure digital input is active. See Table on page 67.
  • Page 34 34 of 105 SHORT ENGINE TEMP could be caused by a shorted sender. SHORT FUEL BASIN SHORT FUEL LEVEL SHORT OIL LEVEL SHORT OIL PRES TLE6230 FAILURE These are internal GSC400 failures. Try power cycle the GSC400. If the failure occurs repeatedly the unit could be defected.

  • Page 35: Gsc400 Led Status Indicators

    35 of 105 5.10 GSC400 LED Status Indicators Some industry standard failures, warnings, and events on the GSC400 are indicated by a series of LEDs on the left side of the controller. Specific LED indicators will be illuminated depending upon the condition of the controller.
  • Page 36 36 of 105 Table 7 – GSC400 Lamp Indication Meanings LED Color Indication Description Status Over Crank Solid Red A solid red illuminated LED represents an Over Crank condition on the final crank attempt. This is a Failure. Yellow Solid A solid yellow illuminated LED represents an Yellow Over Crank Warning condition when there are...
  • Page 37 37 of 105 Not In Auto Solid Red A solid red illuminated LED represents a Not in Auto condition. Low Coolant Solid Red A solid red illuminated LED represents a Low Coolant (Temperature and/or Level) failure condition. Amber Solid Amber A solid yellow illuminated LED represents a Low Coolant Temperature Warning condition...

  • Page 38: Warnings And Failures

    38 of 105 5.11 Warnings and Failures The GSC400 incorporates many types of warnings and failures. Some are only active in the RUN mode while others are also active in the AUTO and/or OFF modes. Warnings and failures can be triggered from a Digital Input, Analog Input, AC Voltage, AC Current, Speed Signal Input, as well as others.

  • Page 39: Eps Supplying Load

    39 of 105 5.11.2 EPS Supplying Load The GSC400 is often used to control a utility backup generator. When the generator is started and load is detected on the generator when the GSC400 is in the RUN mode the “EPS Supplying Load” LED on the GSC400 front panel will turn green. This indicates that the generator is supply load as normal.

  • Page 40: J1939 Diagnostic Trouble Code (Dtc) Display

    40 of 105 5.13 J1939 Diagnostic Trouble Code (DTC) Display This section applies for electronic generators only (i.e. generators that use J1939) The GSC400 can read J1939 diagnostic trouble codes (DTCs) from an electronic ECM, if enabled (see section 6.1.3 on page 53 for information on how to configure and customize the GSC400 DTC feature).

  • Page 41: Dm2 Messages

    41 of 105 Figure 8 – Five active DTC messages and the 3 one being displayed The user can also manually cycle through the DTC messages by activating either the "UP" or "DOWN" key after the screen has been locked. If the user stops at a specific DTC message the display screen will remain on that message for a period of 10 seconds before it begins scrolling again.

  • Page 42: Dm1 Event Log

    42 of 105 To Trigger a DM2 Request, simultaneously press the "UP" and "DOWN" keys for a period of 3 seconds in either the AUTO, OFF, or RUNNING modes. The controller’s alarm will sound and the controller will send a request to the ECM. A LAMP test will additionally be triggered in the OFF mode.

  • Page 43: Advanced Setup

    43 of 105 6 Advanced Setup Important! For Firmware Versions Below 2.00 After changing any settings on the controller, the controller needs to be reset. This can be done one of two ways: 1. Power off, wait for 2s, and power on the controller. 2.
  • Page 44 44 of 105 Table 8 – Advanced Menu Layout Summary Menu Layout Description The J1939 setup contains general Advanced Menu settings for J1939 such as shutdown on J1939 Setup (Password loss of messages. To read parameters Protected) from the J1939 bus please see “Analog Inputs”...
  • Page 45 45 of 105 generator and how long the generator is to remain running. The advanced menu requires a password Set Password for access. The user can change the password here. The default password is 0000. This menu controls the service notification feature for regular maintenance.
  • Page 46 46 of 105 Table 9 – Submenus of the Advanced Menu John Deere, Volvo, Cummins, J1939 Setup Manufacturer Yanmar, Detroit Diesel, Others Loss of ECM Enable, Disable Display Group 1 Enable, Disable Display Group 2 Enable, Disable DTC Display Disable, Enable Active DTC Log Disable, Enable Read Stored DTC...
  • Page 47 47 of 105 Input Pin Reserve, Analog 2-7 Oil Level Signal Source J1939, Switch input, Sender Bypass Delay 10-60 Seconds Switch Setting GND = Fail, Open = Fail Shorted Sender Disable, Warning, Shutdown Open Sender Disable, Warning, Shutdown Units Percentage Warning Level 0-100% Failure Level...
  • Page 48 48 of 105 Over Volt Fail 2 0-700 VAC Under Volt Warn 2 0-700 VAC Under Volt Fail 2 0-700 VAC Over Volt Warn 3 0-700 VAC Over Volt Fail 3 0-700 VAC Under Volt Warn 3 0-700 VAC Under Volt Fail 3 0-700 VAC Over Volt Warn 4 0-700 VAC...
  • Page 49 49 of 105 Under Volt Warn, Over volt warn, Over Amp Warn, Fuel in Basin, Volt Regulator, Low Temp Warn. Back Light, Auxiliary Warn, Maintenance, System Ready, Common Output 1, Common Output 2, Dummy Loads, High Fuel Warn, Current Latch, Config Warn 1, Config Warn 2, Config Fail 1, Config Fail 2.
  • Page 50 50 of 105 Warning Table 1 Locked Rotor, HighEngineTemp, Events Table 1 LowOil Pressure, Over Speed, Low Failure Table 2 Fuel Level, Oil Level, Low Coolant, Warning Table 2 Low Air Pres, Low Hydraulic, Events Table 2 Auxiliary Fail, Low Battery, High Battery, UnderSpeed, Under Voltage, Over Voltage, Over Current, Loss of ECM, EPS Load Fail, Config Fail 1,...

  • Page 51: J1939 Setup

    51 of 105 J1939 Setup The GSC400 will work with any generator as long as it supports the standard messages listed in the SAE J1939 specification. Standard messages include oil pressure, engine temperature, and engine speed. Some engine control modules have proprietary messages that are intended for specialized devices and are not displayed by the GSC400.

  • Page 52: Cummins Idle Speed

    52 of 105 Set Speed (RPM) Barometric Pressure (kPa) ECM Battery (V) Yanmar Fuel Temperature ( Load (%) Oil Temperature ( Fuel Rate (L/min.) Engine Torque (%) Boost Pressure (kPa) Detroit Diesel Friction Torque (%) Oil Temperature ( Load (%) Fuel Rate (L/min) Others - Select this is your engine is not...

  • Page 53: Diagnostic Trouble Codes (Dtcs)

    53 of 105 ECM expects the speed update to be sent continuously and if it is not the ECM thinks there is a problem with the J1939 communications. 6.1.3 Diagnostic Trouble Codes (DTCs) The GSC400 has a DTC feature that when enabled allows the controller to receive currently active DTCs (DM1) messages and display then on the screen as well as optionally store then to the Event Log.

  • Page 54: Analog Inputs

    54 of 105 Analog Inputs The GSC400 has support for the following analog input types: 1. High Engine Temperature 2. Oil Pressure 3. Fuel Level 4. Oil Level 5. Fuel In Basin 6. Low Engine Temperature For each of the analog input types, you can select the pin (2 to 7) to connect to in the Input Pin menu.
  • Page 55 55 of 105 Input Pin Disable Note When the Input Pin is set to disabled it is actually set to a virtual input where the voltage read is 5V, the source is set to a switch, and the switch setting is set to “Closed = Fail”.

  • Page 56: Fuel Level Sender - Special Case

    56 of 105 6.2.1 Fuel Level Sender – Special Case You will need to know the resistance of the sender at 0%, 25%, 75%, and 100% fuel levels. The resistance values must be either monotonically increasing (e.g. 1, 2, 3, 4, 5) or monotonically decreasing (e.g.

  • Page 57: Gsc400 Sender Support

    Pins* 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 into two groups: those that support low resistance senders and those that support high resistance senders.

  • Page 58: Speed Sensing

    58 of 105 Speed Sensing The speed sensing menu allows you to select the source to use for sensing the rotational speed of the engine. There are three options to choose from: 1. J1939 Input – If the engine/generator comes equipped with an engine control module (ECM) that supports the J1939 protocol then the GSC400 can obtain the engine speed from the ECM.

  • Page 59: Generator (Ac Voltage / Current / Frequency) Setup

    59 of 105 Generator (AC Voltage / Current / Frequency) Setup The AC Frequency, AC Voltage, and AC Current menus allow the measurement and display of the AC voltage, current, and frequency from the generator. 6.4.1 AC Frequency In the AC Frequency menu, warnings and failures can be triggered for frequencies under and/or over settable thresholds.
  • Page 60 60 of 105 The GSC400 controller requires a neutral reference. All voltages are measured line to neutral and then converted for display as line to line if required unless Voltage Group 1 is selected with the two wire option in which case only Line to Neutral is displayed. Figure 10 –...

  • Page 61: Ac Current

    61 of 105 Table 13 Voltage Select Inputs Digital Inputs   Voltage Configuration Volt Select 1 Volt Select 2 Voltage Group 1 1 Phase, 3-wire (2-wire option Open Circuit Open Circuit (Single Phase) also selectable) Voltage Group 2 3 Phase, 4-wire Wye ACTIVE Open Circuit Voltage Group 3...

  • Page 62: Ac Current And Voltage Calibration

    62 of 105 from the front panel. On a current latch condition the LCD displays “Over Current Latched.” and “<Up Arrow> + <Down Arrow> for Unlatch”. The current transformers (CTs) negative leads must be terminated individually into the GSC400 AC Current connector. Do not tie the negative leads together to a common eutral.
  • Page 63 63 of 105 Normally the fuel remains off in the AUTO mode until Preheat is entered. For electronic engines some applications require that the ECM (which is powered by the Fuel Relay output) to be powered in the AUTO mode in order to start the generator as quick as possible.

  • Page 64: Shutdown Sequence

    64 of 105 engine logic menu to 0. T he Crank Oil Pressure is the oil press ure usually seen while the engine is cranking. During cra nking if the oil p ressure is below the Crank Oil Pressure parameter (engine logic menu) and if the engi ne speed and AC frequency are both 0 the crank time is shortened to 3s (including...
  • Page 65 65 of 105 activated. See section 6.5.1 for more details. The number of crank attempts is set in the engine logic menu. High Temp Failure This turns on the digital output if the High Engine Temperature Failure is activated. See section 6.2 for more details. High Temp Warning This turns on the digital output if the High Engine Temperature Warning is activated.

  • Page 66: Exerciser Setup

    66 of 105 Warning (section 7.4) is activated. Fuel In Basin Warning This turns on the digital output if the Low Fuel In Basin Warning (section 6.2) is activated. Voltage Regulator This allows the digital output to be controlled by the idle feature. The idle feature also requires a digital input to be set to Idle Mode (see section 6.8).

  • Page 67: Digital Input Setup

    67 of 105 The GSC400 will display a message and sound the buzzer for a set amount of tim e (Pre- Alarm Delay) to alert nearby personnel that the generator is about to start. engine/generator will run for a set period of time (Run Duration) and then shut down. he Start Date and Start Hour determine the date (0 to 31) and time when the ngine/generator will first start.
  • Page 68 68 of 105 modes. Low Oil Pressure This input generates a “Low Oil Pressure” failure when active only when the controller is in the RUN mode. EPS Supplying Load If the generator is starting up but is not running (i.e. the controller is not in the RUN Mode) and if the input is active, the GSC400 will cancel the start sequence and enter the failure state on an EPS load failure.

  • Page 69: Battery Setup

    69 of 105 1. Global –Everywhere 2. Crank – From start of delay-to-start to the end of cranking 3. Run – RUN Mode only 4. Crank+Run – Combination of 2 and 3 above. These settings are located at the bottom of the menu for each input.

  • Page 70: Password Setup

    70 of 105 6.10 Password Setup The GSC400 allows a 4 digit password to be entered to protect the advanced setup menu from any unauthorized changes. This password will be needed to perform any changes to the advanced setup. If the password is entered incorrectly, the controller will allow 3 more tries before the GSC400 returns back to the main menu.

  • Page 71: Set Maintain

    71 of 105 6.11 Set Maintain This menu controls the service feature that is used to alert the user of required generator maintenance and can be enabled or disabled from this menu. If enabled, the count interval menu allows the user to set the number of hours until next service. The number of hours to next service is displayed in the Basic Setup menu under Maintenance (see Table 5 on page 30).

  • Page 72: Set Dummy Load

    72 of 105 6.14 Set Dummy Load The dummy load feature allows the user to turn on an output if the AC current is below a settable threshold (Load On Point). This is useful for applications where the generator must have a minimal load to prevent damage to the generator. Upon crank success (RUN Mode entered), if enabled, the feature waits for a configurable bypass time, then starts to monitor the AC current.

  • Page 73: Recommended Maintenance

    73 of 105 7 Recommended Maintenance The actions in Table 16 should be performed routinely. WARNING: When performing any GSC400 or Engine maintenance be certain controller is in OFF Mode, is isolated from all possible sources of power, and the Crank wire is removed from the Controller. Table 16 –...

  • Page 74: Default Configuration Settings

    74 of 105 8 Default Configuration Settings GSC400’s are factory programmed and shipped with default settings loaded into the controller. Table 17 – GSC400 Default Settings FUNCTION DEFAULT SETTINGS Manufacturer John Deere J1939 Display Group 1 Disable Display Group 2 Disable DTC Display Disable...
  • Page 75 75 of 105 Shorted Sender Disable Open Sender Disable Units Percentage Warning Level Failure Level Input Pin Disable Fuel In Basin Signal Source Switch Bypass Delay 11 Seconds Switch Setting SW Closed = Fail Shorted Sender Disable Open Sender Disable Units Percentage Warning Level...
  • Page 76 76 of 105 Over Volt Fail 4 650 VAC Under Volt Warn 4 570 VAC Under Volt Fail 4 550 VAC Current source Enable A/C Current Turns Ratio 100A:5A Over Current Warn 1 90 A Over Current Fail 1 100 A Over Current Warn 2 80 A Over Current Fail 2...
  • Page 77 77 of 105 Input 8 (Gnd) Disable Disable Low Auto Charge Battery Setup Charge Pre-Alarm 1 minute 91 minutes Charge Duration 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...

  • Page 78: Appendix A: Accessory List

    78 of 105 9 Appendix A: Accessory List GSC400 Controller Harness - Accessories Figure 11 – GSC400 terminal names and layout. View from rear of controller. Table 18 – GSC400 Harness Part Numbers Circuit Numbers Harness Name 5ft Harness (Pins) Populated CAN (J1939) (Rev 3) 1373R3-5 1, 2, 3...

  • Page 79: Gsc400 Programmer Assembly

    79 of 105 The following table identifies all the wiring harnesses as part of the GSC400 controller: Table 19 – GSC400 Wiring Harness Part List Circuit Numbers Harness Stock Code Harness Length Description (Pins) Populated AC Current DWG1375R2-5 5 Feet 1, 2, 3 Sensing* Digital Input*...

  • Page 80: Ct's (Current Transformers)

    80 of 105 CT’s (Current Transformers) Current transformers are required for display of AC current. One CT is required for each phase to be displayed. The wiring for CT’s is as follows: In single phase applications: • Phase A to terminals Phase A* •...

  • Page 81: Engine Sending Units

    81 of 105 Engine Sending Units Senders are required if display of engine parameters, warnings and failures are required. Otherwise switches could be used if only failure indication and shutdown is required. Table 22 – Senders Part List Sender Description Stock Code Part # Description Datcon 102225-00 1/8”...

  • Page 82: Gsc400 Fusing

    82 of 105 GSC400 Fusing Output relays are protected by onboard 40A fuse protection. Smaller amperage fuses from 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.

  • Page 83: Appendix B: Modbus Map

    83 of 105 10 Appendix B: Modbus Map Modbus communications uses master-slave communication in which only the master can initiate a transaction, called a query. The slave addressed by the query will respond by either supplying the requested data to the master or by performing the requested action. A slave device never initiates communications, and will always generate a response to the query unless certain error conditions occur.

  • Page 84: Modbus Commands

    84 of 105 Serial Transmission Details A standard Modbus network offers 2 transmission modes for communication: ASCII or RTU. The GSC400 supports only the RTU (Remote Terminal Unit) mode. Each 8-bit byte in a message contains two 4-bit hexadecimal characters. The message is transmitted in a continuous stream with the LSB of each byte of data transmitted first.

  • Page 85: Register Map

    85 of 105 As an example, a user wanting to read the engine speed and other related parameters (the engine speed holding address is 0x40150), would use the 0x03 command with start address 0x40150 and quantity 20, and a scan rate of 1000ms. The user’s device will continue polling address 0x40150 to 0x40169 at 1000ms duration.
  • Page 86 86 of 105 Events number 6 Emergency Stop bit 14-10 Events number 7 Low Coolant Level bit 4-0 40005 Events number 8 Low Coolant Temperature bit 9-5 Events number 9 Low Fuel Level In Tank bit 14-10 Events number 10 Low Fuel Pressure bit 4-0 40006 Events number 11 Emergency Power Supplying Load bit 9-5 Events number 12 Generator Running bit 14-10...
  • Page 87 87 of 105 bit14: Low coolant level shutdown (red) bit15: Low coolant level warning (amber) bit0: EPS supplying load shutdown (red) 40081 bit1: EPS supplying load (green) bit2: not used bit3 : Glow plug on (green) bit4 : Failure is active (Red Failure LED) bit5 to bit7: (not used) bit8: Crank relay On (no LED) bit9: Fuel relay ON (no LED)
  • Page 88 88 of 105 (this bit will flash) bit10: AC under voltage warning bit11: AC over voltage warning bit12: AC over current warning bit13: Fuel in basin warning bit14: Voltage Regulator Digital Output feature is on. bit15: Low engine temperature warning bit0: Backlight is on 40084 bit1: Auxiliary warning...
  • Page 89 89 of 105 bit14: J1939 Loss of ECM failure bit15: EPS load failure bit0: PGN 61444 EEC1 not available 40086 (engine speed) (f/w bit1: PGN 65263 Fluid level not versions available (oil pressure) 2.02 and bit2: PGN 65262 Engine temperature above) not available bit3: Emergency stop active...
  • Page 90 90 of 105 When 0x5DA2 is written to address 40098 SYSTEM DISABLE 0x5DA2 40098 this places the controller in the (23970) OFF mode (System disabled). The register is read in all controller operating modes (Running, Auto, Failure, Menu/sleep modes). CAUTION – when received in the Running mode the controller immediately goes to the OFF mode (no cool-down is performed).
  • Page 91 91 of 105 Read Only. Allows user to determine current controller mode (and sub-mode). Any active events or warnings will be displayed up to a maximum of 6. The possible controller modes are: 40100 System operating 0x90 R (Read MENU/OFF SLEEP mode 0x90 (144) mode 0x93 Only)
  • Page 92 92 of 105 4 CRANK FAILURE 5 Charger 2 Fault 6 Custom Warning 1 7 Custom Warning 2 8 CRANK SUCCESS 9 Empty Space 11 REQUESTING DTC 14 LAMP TEST 15 High Fuel Level 16 Warning 17 Low AC Voltage 18 Over Cur Latched 19 ↑+↓...
  • Page 93 93 of 105 47 Low Speed Warn 48 Locked Rotor 49 Fuel In Basin 50 Low Battery 51 High Battery 52 AUTO FOR SILENCE 53 AUTO FOR ALARM 54 Low Engine Temperature warning 55 Open Engine Temperature sender 56 Short Engine Temperature sender 57 Open Oil Pressure sender 58 Short Oil Pressure sender 59 Open Fuel Level sender...
  • Page 94 94 of 105 15 LOW BATTERY 16 LOW COOLANT 17 OVER CRANK 18 OVER VOLTAGE 19 UNDER VOLTAGE 20 OVER CURRENT 21 EPS LOADS ERROR 22 LOW AIR PRESSURE 23 LOW HYDRAULIC 24 LOW OIL LEVEL 25 LOCKED ROTOR 26 HIGH BATTERY 27 LOSS OF ECM COMMUNICATION 28 OPEN ENG TEMP (applies to both High and Low Engine Temperature)
  • Page 95 95 of 105 CRANKING WARMUP CRANK REST COOLDOWN IDLE COOL (COOLDOWN IN IDLE) LOW BATTERY PRELARM LOW DC BATTERY CHARGING EXERCISER PREALARM EXERCISER RUNNING 4. DIGITAL I/O AND ANALOG INPUTS (Read Only) Allows the status of the digital inputs and outputs to be read. Digital I/O and Analog Input will update every 1 second once.
  • Page 96 96 of 105 start signal active or not active, please read the register 40100 for system state. Status of controller outputs. 0 40111 Digital Output 0~2047 R (Read corresponds to output OFF or NOT Only) ACTIVE, while a 1 corresponds to output ON or ACTIVE.
  • Page 97 97 of 105 1 bit equal 0.1 RPM 40150 Engine Speed 0 ~ 6553.0 Reading 18000 corresponds to 1800RPM 1 bit equal 0.1 unit 40151 High Engine 0 ~ 250.0 Reading 1000 corresponds Temperature to 100.0C 1 bit equal 0.1 unit 40153 Low Engine 0 ~ 250.0...
  • Page 98 98 of 105 Reading 318 corresponds to 31.8V 1 bit 0.1C 40175 PCB Board -55 ~ 130 Reading 1000 corresponds Temperature Signed to 100.0C Integer 16 bit Positive or negative values can be identified by reading the high byte of MSB.
  • Page 99 99 of 105 0x6C93 Write control command to holding 40130 Read Previous Entry (27795) register address. 0x639C Read Next Entry (25500) The controller will check the log request every 1 second. Each time a new command is received, the controller will scroll either down or up one message (until it reaches either the bottom or top of the message log), one message and update the log content in address 40131 to 40141.
  • Page 100 100 of 105 30 OPEN OIL PRESSURE 31 SHORT OIL PRESSURE 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 44 POWER ON 45 AUTO ENABLE...
  • Page 101 101 of 105 Low 4-bit ones 0 ~ 9 Lowest byte of SPN (bit 8 MSB) 40136 0 ~ 255 Log DTC code. Only Middle byte of SPN (bit 8 MSB) 40137 0 ~ 39 valid if entry contains 3 highest bits of SPN and the FMI (bit 8 40138 0 ~ 31 is SPN MSB and bit 5 is FMI MSB)
  • Page 102 102 of 105 40117 ~ Registers 40117 to 40126 not shown. They 40126 contain Active DTC No. 2 to 6 and are in the same format as above. Bit 8~7 malfunction indicate lamp status 40180 Previous Active DTC 0~65536 Bit 6~5 red stop lamp status lamp status and Bit 4~3 amber warning lamp status reserved lamp status...

  • Page 103: Appendix C: J1939 Old Dtc Conversion Methods

    103 of 105 11 Appendix C: J1939 Old DTC Conversion Methods This appendix was created to assist the user in decoding the information contained in the modbus DTC (DM1 and DM2) registers if the generator ECM does not support the newest DTC conversion method.

  • Page 104: Appendix D: Additional Drawings

    104 of 105 12 Appendix D: Additional Drawings The follow pages include various drawings that may be of benefit. Hardy Diesel & Equipment Inc 15749 Lyons Valley Rd Jamul, CA 91935 800-341-7027 HardyDiesel.com...
  • Page 105 105 of 105...

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