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Packing More Capability into a Small Package

DynaGen Technologies Inc. has introduced the second generation of its GSC400 genset controller. The new unit offers significant enhancements from the original version launched in 2006, the company said, while maintaining the initial goal of creating a small, but powerful and versatile generator set control.

“The second generation product builds on the success of the original GSC400 by adding more value in advanced gen-set control features,” explained Paul Wareham, director of business development for the Dartmouth, Nova Scotia-based company. Citing its compact dimensions - 4.5 in. high x 5.5 in. wide x 1.25 in deep – Wareham said that the GSC400 “has the smallest space footprint in the genset controls market, yet does not sacrifice things like the display screen size, buttons or lamp indicators.

“This is extremely valuable where control panel real estate is at a premium, especially for mobile, trailer-mounted or vehicle-based gen-sets where space and weight are always at a premium.”

The GSC400 genset controller incorporates front panel indicators for a range of conditions, including overcrank, high engine temperature, low oil pressure, overspeed, low fuel, battery status, not in auto, low coolant, EPS supplying load and preheat. The unit, which can be used with either electronically controlled or mechanical engines, offers eight programmable digital inputs, eight programmable digital outputs, six sensor inputs and a wide variety of adjustable settings and parameters.

“Most genset controllers are limited to three analog sensor inputs, for measuring parameters such as engine temperature, oil pressure and fuel level,” Wareham said. “The GSC400 can accommodate up to six different analog sensors at the same time, allowing customers to configure other types of sensors for certain monitoring functions that would otherwise require external devices.”

That flexibility and its ease of setup, quick plug-in installation and reliability in even the harshest conditions makes the GSC400 controller extremely attractive to gen-set manufacturers, Wareham said.

The GSC400 controller has an operating voltage range of 7 to 32 Vdc, a controller operating temperature range of -40 to 185°F (-40 to 85°C) and an LCD temperature range of -4 to 158°F (-20 to 70°C). The 128 x 64 white-on-blue graphic LCD screen is designed for high readability in all conditions and the unit is housed in a high impact ABS UV-resistant enclosure.

The GSC400’s second-generation enhancements include improved functionality for mobile applications, diagnostics code display, Modbus communications and programmable inputs.

“For mobile applications, the GSC400 now has a service interval timer, automatic voltage reconfiguration and idle mode functions, all of which are valuable attributes for rental generator sets to enhance the serviceability, fuel savings and flexibility of the fleet,” Wareham said. “The new Diagnostic Trouble Code displays allow customers to view codes from electronic engines through the J1939 protocol, which eliminates the need to install a secondary display device.”

Wareham added that an enhanced Modbus communications protocol enables customers to connect remote annunciator panels and to interface the controller with various devices to display sensor information at remote locations and perform remote control functions. “We can even extend this capability via the Internet or GSM cell phone to any location in the world, Wareham said.

“Our engineering team has also enhanced the flexibility in programming the GSC400 to allow such things as user-defined text for extra warning or failure inputs so customers can create their own unique events.”

The GSC400 is designed to be manually programmed manually through the front panel buttons or with a simple PC-based software package that allow the user to customize screen messages, languages, sender selectors, control settings, etc.

The newly enhanced GSC400 control is targeted toward both mobile gen-sets applications as well as continuous-duty prime power installations.

A good example of the latter is at Frontier Power Products Ltd., a multi-line engine and generator set distributor headquartered in Delta, British Columbia. Frontier Power also manufactures its own gen-set and pump set packages using Kubota, Deere and Mitsubishi diesel engines.

“We are using the GCS400 in our prime power applications,” said Rick Byzitter, service manager for Frontier. “Most of our prime power activity is in the oil and gas industry, as well as remote village power and other off-grid locations in Canada, thus the remote start function is something we use quite frequently.

“We have been using DynaGen products for a long time. For example, we’ve been using their ES52 autostart engine controller, which they build to our specifications.

"The GCS400 decreases the complexity of controlling our prime power gen-sets and it is a very versatile controller. We also like the fact that we can just upload it from a laptop computer, so if we ever need to replace a unit in the field, we could easily pre-program the unit, send it to the field and then it’s plug and play from that point.”

A primary design goal for the GSC400, Wareham said, was to package the controller into the same compact footprint package as the company’s GSC300 controller. That goal was achieved as DynaGen’s engineering staff developed the circuit and mechanical component design in such a way that physical package was identical.

“The small size of the GCS400 controller is something that really works for us,” Byzitter noted. “We already have our own in-house control panels for prime power applications, so it’s quite easy for us to retrofit this small unit into our existing panels without having to design a whole new control unit. All we have to do is leave a 6 in. by 6 in. blank in our panel and it can fit right in.”