Manual Panel D

POWER SYSTEMS, INC.
Operators Manual
D Option Control Panel
GENERAC POWER SYSTEMS
Important Safety Instructions

SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators and potential operators of this equipment.
Study these SAFETY RULES carefully before

installing, operating or servicing this equipment.
Become familiar with this manual and all literature
pertaining to your generator set and related equipment. This equipment can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precautions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warnings in this manual, and on tags and decals
affixed to your equipment are, therefore, not
all-inclusive. If you use a procedure, work method or
operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you
and others. You also must make sure the procedure,
work method or operating technique that you choose
does not render the equipment unsafe.
! GENERAL HAZARDS !
For safety reasons, Generac recommends
that this equipment be installed and serviced by a
Generac Authorized Service Dealer or other competent, qualified electrician or installation technician
who is familiar with applicable codes, standards and
regulations. The operator also must comply with all
such codes, standards and regulations.
When working on this equipment, remain alert at all
times. Never work on the equipment when physically or mentally fatigued.
Inspect the equipment regularly, and promptly repair
or replace all worn, damaged or defective parts using
only factory-approved parts.
Before performing any maintenance on the generator
or any related equipment, disconnect the generators
battery cables to prevent accidental start-up.
Disconnect the cable from the battery post indicated
by a NEGATIVE, NEG or () first. Reconnect that
cable last.
ELECTRICAL HAZARDS
Generators produce dangerous electrical voltages
and can cause fatal electrical shock. Avoid contact
with bare wires, terminals, connections, etc., while
the generator and related equipment are running.
Ensure all appropriate covers, guards and barriers
are in place before operating the equipment. If
work must be done around an operating unit,
stand on an insulated, dry surface to reduce shock
hazard.
Generac Power Systems, Inc.
Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum electrical current (amperage) to which they will be subjected.
Before installing or servicing this equipment, make
sure that all power voltage supplies are positively
TURNED OFF at their source. Failure to do so will
result in hazardous and possibly fatal electrical
shock.
When installed with an automatic transfer switch, the
generator may crank and start anytime without
warning. To prevent injuries cause by sudden startup, disable the generators automatic start circuit
before working on or around the unit. Then, place a
Do Not Operate tag on the generator control panel
and on the transfer switch.
In case of accident caused by electric shock, immediately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
FIRE HAZARDS
For fire safety, the generator and related equipment
must be installed and maintained properly.
Installation always must comply with applicable
codes, standards, laws and regulations. Adhere
strictly to local, state and national electrical and
building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
equipment is installed in accordance with the manufacturers instructions and recommendations.
Following proper installation, do nothing that
might alter a safe installation and render the unit
in noncompliance with the aforementioned codes,
standards, laws and regulations.
Table of Contents
Safety Rules....... ................................Inside Front Cover

General Information ........................................................2
OVERVIEW........ ............................................................2
CONTROL PANEL CIRCUIT BOARDS............................2
PCB 1 Main Central Processor Unit
(CPU) Board ....................................................2
PCB 2 Display Board ........................................2
PCB 3 Interface Board ......................................2
Locations of Circuit Boards ................................2
OPTIONAL EQUIPMENT................................................2
GenLink ............................................................2
Modem... ..............................................................2
Remote Annunciator Panel ..................................2
DIGITAL DISPLAYS ......................................................2
Battery Saver ......................................................2
AC Voltage Display ..............................................3
AC Voltage Indicators ..........................................3
AC Current Display ..............................................3
Frequency Display................................................3
Frequency Indicators............................................3
Power Factor ........................................................3
Power Output ......................................................4
Oil Pressure ........................................................4
Water Temperature ..............................................4
% Fuel.. ..............................................................4
Battery Voltage Display ........................................4
Battery Voltage Indicators ....................................4
Engine Hours ......................................................4
STATUS INDICATORS ALARMS
AND WARNINGS ........................................................4
Oil.......... ..............................................................4
Low Oil Pressure Alarm ......................4
High Oil Temperature Alarm ................4
Pre Low Oil Pressure Warning..............4
Pre High Oil Temperature Warning ........4
Water..... ..............................................................5
High Water Temperature Alarm............5
Low Level Water Alarm ........................5
Pre High Water Temperature
Warning ..............................................5
Low Water Temperature Warning ..........5
Fuel........ ..............................................................5
High Fuel Alarm ..................................5
Critical Low Fuel Alarm ......................5
Low Fuel Warning ................................5
Additional Alarms and Warnings..........................5
Emergency Stop Alarm ........................5
Overcrank Alarm..................................5
General Overspeed Alarm ....................5
Ruptured Basin Alarm ........................6
Not in Auto Alarm ................................6
Main Line Circuit Breaker Warning........6
Remote Access Warning........................6
Program Mode Warning........................6
Spare LEDs..........................................................6
No Equipment Connected ....................6
Remote Annunciator Connected ..........6
KEYPAD........... ..............................................................7
Numeric Keys 0-9 ................................................7
Enter and Clear Keys ..........................................7
Program Key ........................................................7
Alarm Horn Reset Key..........................................7
Alarm Lamp Reset Key ........................................7
Phase Select Key ..................................................7
CONTROLS....................................................................7
Emergency Stop Switch ......................................7
RS-232 Local Communications Port ....................7
Auto-Off-Run Switch ............................................7
Main DC Fuse ......................................................8
Voltage Trim Potentiometer ..................................8
INPUTS............ ..............................................................8
AC Voltage ............................................................8
AC Current ..........................................................8
Fuel Level ............................................................8
Oil Pressure ........................................................8
Water Temperature ..............................................8
Engine Speed Sensor ..........................................8
Coolant Level Sensor ..........................................8
Emergency Stop Contact ......................................8
Transfer Switch/Remote Start ..............................8
Pre High Oil Temperature ....................................8
High Oil Temperature ..........................................9
High Fuel Level ....................................................9
Low Fuel Level ....................................................9
Main Line Circuit Breaker ..................................9
Ruptured Basin....................................................9
Spare Alarms ......................................................9
Spare Warnings ....................................................9
OUTPUTS....... ..............................................................9
Starter Solenoid ..................................................9
Alarm..... ..............................................................9
Load Control........................................................9
Auxiliary ..............................................................9
Preheater..............................................................9
Fuel Control Relay................................................9
COMMUNICATIONS ......................................................9
Front Panel Communications Port ......................9
Modem... ..............................................................9
Remote Communications Port..............................9
Monitored Parameters........................10
Dial Out Option..................................................10
INSTALLATION NOTES ..............................................10
Operation........... ..............................................................11
OPERATION OF DIGITAL GENERATOR
CONTROL PANEL..........................................................11
Using the Keypad.... ..............................................11
Programmable Options ........................................11
Appendix 1 Electrical Data ......................................14

Appendix 2 Notes ......................................................21
Appendix 3 Exploded Views and Parts Lists ......22
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest GENERAC AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
General Information
OVERVIEW
The D option control panel is a microprocessorbased generator set control panel designed for
Generacs range of standby generators. It has a fully
digital user interface and comprehensive communication capabilities.
The panel is housed in a steel sheet metal enclosure
that meets NEMA 1 specifications. The front face of
the panel consists of a number of light-emitting
diodes (LED) display windows showing generator
operating conditions, a tactile keypad, alarm and status LED indicators, a main fuse, an Emergency
Stop switch and other generator set controls.
CONTROL PANEL CIRCUIT BOARDS

The control panel contains three main printed-circuit
boards (PCB), the automatic voltage regulator (AVR),
and terminal blocks for external connections.
To find the location of the circuit boards, refer to
Appendix 3 for the control panel exploded views. The
three main PCBs have the following defined functions:
PCB 1 MAIN CENTRAL PROCESSOR

UNIT (CPU) BOARD
(Part # 0A1053) This board houses the microprocessor, its memory, input and output (I/O) stages and all
communication hardware (including optional modem
for telephone system communications).
PCB 2 DISPLAY BOARD

(Part # 0A1056) This board houses all the LED displays and annunciators, and their respective driver
circuitry.
PCB 3 INTERFACE BOARD

(Part # 0A1054) This board houses all the components necessary to interface the CPU board to the
generator. This board receives high voltage and current signals from the generator output. All control
relays are mounted on this board. Connections to
this board are by screw terminals.
LOCATIONS OF CIRCUIT BOARDS

PCBs 1 and 2 are mounted together on the back of
the hinged front wall of the panel, and PCB 3 is
mounted on the left wall of the panel as viewed from
the front.
The right wall houses the AVR and the optional electronic governor controller. Both of these controls,
which are mounted on a chassis, are accessible externally from the right side of the panel via removable
covers that allow for adjustment.
Remove the 15-amp fuse from the front of the

panel during all engine maintenance to guard
against accidental or remote start-up.
OPTIONAL EQUIPMENT
GENLINK
GenLink is a communications software that allows the
generator to be started and monitored from a remote
PC via a modem. The generator can dial out automatically and inform the PC if it has an active alarm condition.
MODEM
A modem (Part # 0A3557) can be connected to the D
panel to allow the generator to communicate with a
remote PC.
REMOTE ANNUNCIATOR PANEL

When connected to the generator via a simple shielded two-wire link (plus two wires for power), this 20light remote indicator panel will display the generators status.
REMOTE RELAY PANEL

This panel is similar to the remote annunciator, but
instead of indicator lights, it provides relay contact closures for status (e.g., alarms).
DIGITAL DISPLAYS (FIGURE 1.1, PAGE 3)

BATTERY SAVER (SLEEP MODE)
In order to conserve battery power, the display panel
will power down after five minutes when it is not
being used. It will reactivate if any of the following
occurs:
A key is pressed.
The engine is started.
Remote communications occur.
During the power down period, the alarms are
checked for 30 seconds every five minutes; any alarm
that occurs is permanently illuminated.
General Information
Figure 1.1 Digital Displays on D Option Control Panel
AC VOLTAGE DISPLAY (AC VOLTS)

This is a four-digit LED display for monitoring the
voltage of the selected phase. A keypad command
(PHASE SEL) is used to select which phase is displayed. LEDs indicate the phase that is currently
active. The range is 0 to1,023 volts AC.
When the unit is monitoring a three-phase generator,
the displayed voltage will coincide with one of the following phase selections. A lit LED on the phase indicator will show the active phase.
A-B
B-C
C-A
When the unit is monitoring a single-phase generator,
the displayed voltage will coincide with one of the following phase selections. A lit LED on the phase indicator will show the active phase.
A-Neutral (A - B)
C-Neutral (B - C)
C-A
Selection of single or three phase monitoring is done
through the panels programmable options (see
Programmable Options, Page 11).
AC VOLTAGE INDICATORS (HI, LO)

A pair of LEDs (included in AC VOLTS display) is
used to indicate whether the generators AC output
voltage is low or high. The set points are user programmable. These alarms are latched and cause the
alarm relay to latch.
Either alarm condition will shut down the generator
and cause a modem callout if enabled. This alarm is
enabled after the programmable alarm hold off timer
expires.
Voltage alarm checking is done on all phases. In the

case of single-phase (i.e., 110 volts AC), the C-A
phase selection should coincide with an AC voltage
display of 220 volts AC. The alarm checking is taken
care of by the software, thus the alarm trigger points
only need to be set around the A-N or
C-N reading (i.e., 110 volts AC).
Half a second of bad readings is required before the
alarm will be raised.
AC CURRENT DISPLAY (AC AMPS)

This is a four-digit LED display for monitoring the
current in the selected phase. The range is 0 to 5,000
amps, depending on the selected current transformer
and the setting of the programmable full-scale current range.
FREQUENCY DISPLAY (HERTZ)

This is a three-digit LED display for monitoring the
frequency of the generator output. The range of this
display is 40 to 70 Hertz. Phase A is used for this
measurement.
FREQUENCY INDICATORS (HI, LO)

A pair of LEDs (included in HERTZ display)is used
to indicate whether the generators frequency output
is low or high. The set points are user programmable.
These alarms are latched and cause the alarm relay
to latch.
POWER FACTOR
This is a three-digit LED display for monitoring
the power factor of the selected phase. The range is 0
to 1.00.
General Information
POWER OUTPUT (KILOWATTS/MEGAWATTS)
ENGINE HOURS
This is a three-digit LED display for monitoring the

total power output of the generator. The power output
is the sum of all three phases, taking power factor
into account.
This is a six-digit LED display used to show engine

running time in hours. This display is also used when
entering the password and changing the programmable options (see Operation of Digital Generator
Control Panel, Page 11).
WATER TEMPERATURE
This is a three-digit display used to monitor the engine
water temperature. The range is 0 to 300 F or -18 to
149 C. If the sensor is short circuited,
-S- will display. If the sensor is open circuited,
-0- (or 000) will display. The alarm relay is latched.
If no block heater is fitted to the generator, there can
be a problem in cold climates where temperatures of
less than 25 F (-4 C), can cause the sensor to think
it is open circuited. If this happens, either -0- (or
000) will display.
To avoid this situation, the open circuit detection can
be overridden. To do this, it is necessary to set the
low temperature alarm set point to 1 F or 1 C.
% FUEL
This is a two-digit display that allows users the
option of monitoring the quantity of fuel remaining. If
the display is active, the range is 0 to 99 percent. Fuel
level senders are optional. If a fuel level sender has
not been installed, the % fuel display should be disabled (See Programmable Options on page 13 and
High Fuel Alarm on page 5).
BATTERY VOLTAGE DISPLAY

This is a three-digit LED display for monitoring battery voltage. The range is 0 to 51.1 volts DC.
BATTERY VOLTAGE INDICATORS (HI, LO)

A pair of LEDs (included in Battery Voltage display)
is used to indicate a low or high battery voltage condition. The set points are user programmable. These
alarms are latched and cause the alarm relay to latch.
They do not shut down the generator, but do cause a
modem callout if enabled. The low battery indicator
will be activated after six minutes of a low battery
condition. This allows it to be used as a battery
charger monitor.
4
OIL
Low Oil Pressure Alarm (LO PRES)
A red LED is used to indicate a low oil pressure condition. The set point is user programmable. The alarm is
latched and causes the alarm relay to latch. It shuts
down the generator and causes a modem callout if
enabled. This alarm is enabled after the programmable
alarm hold off timer expires.
This is a three-digit display used to monitor engine

oil pressure. The range is 0 to 100 psi or 0 to 7.03
kg/cm. If the sensor is short circuited, -S- will display. If the sensor is open circuited, -0- will display.
High Oil Temperature Alarm (HIGH TEMP)
A red LED is used to indicate a high oil temperature

switch has been closed. This alarm is latched and
causes the alarm relay to latch. It shuts down the generator and causes the modem to callout if enabled.
This alarm is enabled at all times.
OIL PRESSURE
STATUS INDICATORS ALARMS AND

WARNINGS (SEE FIGURE 1.2)
Pre Low Oil Pressure Warning (PRE LO PRES)
A yellow LED is used to indicate a warning that a low

oil pressure condition exists. The set point is user
programmable. The alarm relay is latched.
For powers greater than 1 megawatt, the display will

show a decimal point after the MW unit, e.g., 900 =
900 kW; 1.10 = 1.1 MW.
Pre High Oil Temperature Warning

(PRE HIGH TEMP)
A yellow LED is used to indicate a warning that a pre

high oil temperature condition exists. The alarm
relay is latched.
Figure 1.2 Status Indicators
General Information
Low Level Water Alarm (LO LEVEL)
A red LED is used to indicate the radiator water level

is low. The alarm is latched and causes the alarm
relay to latch. The alarm shuts down the generator
and causes a modem callout if enabled. This alarm is
enabled after the programmable alarm hold off timer
expires.
Pre High Water Temperature Warning

(PRE HIGH TEMP)
A yellow LED is used to indicate a warning that a high

water temperature condition exists. The set point is
user programmable. The alarm relay is latched.
Low Water Temperature Warning (LO TEMP)
FUEL
1. Percent input from analog sender

2. Switch input on J7-4
If the fuel percent measurement is used, an analog
sensor MUST BE installed and selected via programmable option #2. This allows for percentages to be
programmed for critical low fuel, low fuel and high
fuel. The alarm relay is latched, but the generator will
continue to run. The modem will callout if enabled.
(The switch input will light the LED only.)
NOTE:
The two switch inputs Lo Fuel Level J7-4 and
Hi Fuel Level J7-5 work only if the percentage
input is turned off via programmable option #2.
When the % Fuel measurement is not used, the display is turned off.
ADDITIONAL ALARMS AND WARNINGS
A yellow LED is used to indicate a warning that a low

water temperature exists. The set point is user programmable. The alarm relay is latched.
High Fuel Alarm (HI)
A red LED is used to indicate a high fuel level. The

indicator can be activated in one of two ways:
1. Percent input
2. Switch input on J7-5
If the fuel percent measurement is used, an analog
sensor MUST BE installed and selected via programmable option #2. This allows for percentages to be
programmed for critical low fuel, low fuel and high
fuel. If the percentages are exceeded for high fuel, the
alarm relay will latch, but the generator will continue
to run. The modem will callout if enabled. (The
switch input will light the LED only.)
NOTE:
The two switch inputs LO Fuel Level J7-4 and
HI Fuel Level J7-5 work only if the percentage
input is turned off via programmable option #2.
When the % Fuel measurement is not used, the display is turned off.
Low Fuel Warning (LO)
A yellow LED used to indicate a low fuel level. The

indicator can be activated in one of two ways:
Emergency Stop Alarm (EMG STOP)
A red LED is used to indicate that the emergency stop

switch has been activated. This alarm is latched and
causes the alarm relay to latch. It shuts down the generator and causes a modem callout if enabled. This
alarm is enabled at all times.
A red LED is used to indicate a high water temperature condition. The set point is user programmable.
The alarm is latched and causes the alarm relay to
latch. The alarm shuts down the generator and causes a modem callout if enabled. The alarm is enabled
after the programmable alarm hold off timer expires.
Critical Low Fuel Alarm (CRITICAL LO)
A red LED is used to indicate critical low fuel. This

feature is available only with an analog sender. The
alarm is latched. It does shut down the generator and
causes a modem callout if enabled.
High Water Temperature Alarm (HIGH TEMP)
Overcrank Alarm (OVERCRANK)
A red LED is used to indicate that the engine did not

start after eight starting attempts. The starting cycle
consists of a programmable number of seconds of
cranking followed by five seconds of OFF time. This
alarm is latched and causes the alarm relay to latch.
It shuts down the generator and causes a modem
callout if enabled.
WATER
General Overspeed Alarm (OVERSPEED)
A red LED used to indicate an overspeed condition.

The set point is user programmable. The alarm is
latched and causes the alarm relay to latch. The
alarm shuts down the generator and causes a modem
callout if enabled. The alarm is enabled after the
engine starts. If the speed sensor fails, then the bottom right (unmarked) yellow LED will light and the
alarm relay will latch. The alarm shuts down the generator and causes a modem callout if enabled.
General Information
Ruptured Basin Alarm (RUPT BASIN)
A red LED is used to indicate the double wall fuel

tank has ruptured. A float switch in the outer tank
closes when a rupture occurs. The alarm latches and
causes the alarm relay to latch. It causes the modem
to callout if enabled, but it does not shut down the
generator. This alarm is enabled at all times.
Not in Auto Alarm (NOT IN AUTO)
A red LED is used to indicate the panel switch is not

set to the Auto start mode.
Main Line Circuit Breaker Warning

(MLCB OPEN)
A yellow LED is used to indicate a main line circuit

breaker is open. This is an optional switch input.
Remote Access Warning (REM ACCESS)
A yellow LED is used to indicate that modem communication is currently active.
ALARMS 1, 2 and the SPECIAL pin can occur only

after the programmable hold off time. When the pin
is shorted to ground, the LED lights, the engine shuts
down, and the alarms relay is latched. The modem
will call out if it is enabled.
The SPECIAL LED also can light and cause an alarm
if there is a speed sensor (tach) loss.
The WARN1 LED will light when its pin is shorted to
ground. The alarm relay will latch, and the modem
will call out if it is enabled.
Remote Annunciator/Remote Relay Panel

Connected
With a Remote Annunciator/Remote Relay Panel fitted

to the D panel (Figure 1.4), the LEDs function as follows:
Figure 1.4 Spare Indicators (With Remote

Annunciator/Remote Relay Panel)
Program Mode Warning (PROG MODE)
A yellow LED is used to indicate that the panel is in

the program mode.
SPARE LEDS
There are four unmarked LEDs on the front panel;

two red and two yellow. These indicators have different functions depending on whether or not a Remote
Annunciator or Remote Relay Panel is connected to
the D-panel.
No Remote Annunciator/Remote Relay

Panel Connected
Without a Remote Annunciator/Remote Relay Panel

connected to the D panel (Figure 1.3), the functions
are as follows:
Figure 1.3 Spare Indicators (Without Remote

Annunciator/Remote Relay Panel Connected)
The BATTERY CHARGER AC FAIL pin is intended to

show that the AC supply to the battery charger has
failed by shorting the pin to ground via an external,
customer supplied relay (Figure 1.5).
Figure 1.5 Battery Charger AC Fail
General Information
The LED will light and latch. The generator will not
shut down, the alarm relay will not operate, and the
modem will not call out. The status will be sent to the
remote annunciator and displayed on its front panel.
GENERATOR POWER will cause the LED to act as an
indicator only. No alarms or shutdowns will occur.
The state of the input will be displayed on the remote
annunciator. It is intended to be connected to an auxiliary contact on a transfer switch to indicate when all
loads are running on generator power. The LED
lights when J7 pin 9 is shorted to ground.
LINE POWER J7 pin 10 acts as above.
PROGRAM KEY (PROG)

This key is used to enter the local programming mode.
After pressing this key, the programming display will
show the word ACCESS, prompting the user for the
password. The password is a six-digit number that is
entered on the numeric keys and is displayed on the
hourmeter/programming display. The default factory
password is always 000000.
ALARM HORN RESET KEY

This key is used to reset the alarm relay contacts.
SPECIAL J7 pin 11 acts as previously described.
ALARM LAMP RESET KEY
KEYPAD
This key is used to reset alarms that have been

latched.
Figure 1.6 Keypad Features
PHASE SELECT KEY (PHASE SEL)

This key is used to select which of three phases is to
be shown in the AC Volts and AC Amps displays.
CONTROLS (FIGURE 1.7, PAGE 8)

EMERGENCY STOP SWITCH
This switch (colored RED) is a normally closed, single-action, latching push button that, when activated,
will immediately cause the generator to shut downand alarm relay to latch.
RS-232 LOCAL COMMUNICATIONS

PORT (COMM. PORT)
Decimal numbers are included on a keypad for entry

of passwords and setting of programmable values.
This connector allows connection of a local computer to the panel for easy programming and diagnostic
checking. The computer needs to have a copy of
GenLink loaded on it to enable communication
with the D panel. A serial cable (part # 0A4042) also
is required to connect to the unit.
ENTER AND CLEAR KEYS
AUTO-OFF-RUN SWITCH
The ENTER key will be used to accept data input

from the numeric keys. The CLEAR key will be used
to remove erroneous entries during programming.
A three-position rotary switch is provided for generator control. In AUTO the generator will wait for a signal, such as from an automatic transfer switch. When
it receives the remote start signal, it will automatically initiate the generator start sequence. This only
occurs assuming no shutdown alarm condition
exists.
NUMERIC KEYS 0-9
When in the OFF position, the generator is inhibited

from starting.
When the switch is in the RUN position, the generator will instantly be commanded to start assuming
that no shutdown alarm condition exists.
General Information
Figure 1.7 Control Switches and Knobs on D Option Control Panel
MAIN DC FUSE (FUSE 15A)
OIL PRESSURE (PCB1: J10-2)
This fuse is rated at 15 amps and is of the 1.25-inches x 0.25-inch glass type (part # 022676). Removal of
this fuse inhibits all control panel functions and is
recommended during all maintenance operations.
An analog input is provided for oil pressure measurement. This input will interface to the standard
Generac sender unit (part # 053666). It is also used
for warning and shutdown situations.
VOLTAGE TRIM POTENTIOMETER

(VOLTAGE ADJUST) (IF EQUIPPED)
WATER TEMPERATURE (PCB1: J10-3)
This control allows adjustment of the generator output voltage in the range +/- 5 percent, if set to the
midpoint.
ENGINE SPEED SENSOR (PCB1: J10-5)
INPUTS
AC VOLTAGE
Four terminals (PCB3: J2-1, J2-2, J2-3, J2-4) are
provided for voltage measurement. Maximum input
voltage is 1000 volts AC.
NOTE
Correct phasing for these terminals is essential
for correct operation (see Appendix 1
Electrical Data for phase schematics).
AC CURRENT
Four terminals (PCB3: J2-7, J2-9, J2-11, J2-10) are
provided for current measurement. The inputs will
interface with current transformers having a five-amp
secondary winding at their rated current.
NOTE
Correct phasing for these terminals is essential
for correct operation (see Appendix 1
Electrical Data for phase schematics).
FUEL LEVEL (PCB1: J10-1)

An optional analog input is provided for fuel level
measurement. This is a 0 to 5 VDC input. An input
signal of 0 volts is equivalent to 0 percent remaining
fuel and 5 volts is equivalent to 99 percent remaining
fuel. The relationship between input voltage and fuel
level is linear.
An analog input is provided for coolant temperature

measurement. This input will interface to the standard Generac thermistor sensor (part # 053667). It
is also used for warning and shutdown situations.
An input is provided for sensing engine speed by

counting teeth on the flywheel via a magnetic proximity probe. The input interfaces to the Generac standard magnetic pickup (part # 082130D).
COOLANT LEVEL SENSOR (PCB1: J10-4)

A dedicated analog input is provided for sensing low
coolant level. The input will interface to the Generac
coolant level sensor (part # 057522).
EMERGENCY STOP CONTACT

(PCB3: TB2-1, TB2-3)
An input is provided for an emergency stop
switch(es). The switch contact is normally closed.
TRANSFER SWITCH/REMOTE START

(PCB1: J7-12)
When the AUTO-OFF-RUN switch is set to AUTO and
this input is grounded, the generator will begin its
start sequence. When the utility voltage drops, the
transfer switch/remote start system will close a contact to ground this input.
PRE HIGH OIL TEMPERATURE (PCB1: J7-7)

An optional input is provided for a pre high oil temperature warning switch. (Switch to ground to
alarm.)
General Information
HIGH OIL TEMPERATURE (PCB1: J7-6)

An optional input is provided for a high oil temperature alarm switch. (Switch to ground to alarm.)
HIGH FUEL LEVEL (PCB1: J7-5)

An input is provided for a high fuel level switch.
(Switch to ground to alarm.) It cannot be used to display fuel percentage.
LOW FUEL LEVEL (PCB1: J7-4)

An input is provided for a low fuel level switch.
(Switch to ground to alarm.) It cannot be used to display fuel percentage.
MAIN LINE CIRCUIT BREAKER (PCB1: J7-2)

An input is provided for a circuit breaker auxiliary
contact to indicate that the main line circuit breaker
is open. (Switch to ground to alarm.)
RUPTURED BASIN (PCB1: J7-3)

An input is provided for a level switch indicating the
fuel tank is ruptured. (Double wall fuel tanks only.)
(Switch to ground to alarm.)
LOAD CONTROL (PCB3: TB1-7(NC),

TB1-8(COM), TB1-9(NO)
A relay contact output is provided for load control.
This contact will not energize unless the generator is
running. It is a form C relay rated at 10 amps at 28
volts DC.
AUXILIARY (PCB3: TB1-1(NC),

A relay contact output is provided for optional use.
This form C relay is rated 10 amps at 28 volts DC.
PREHEATER (PCB3: TB1-9, TB1-1O)

A relay contact output is provided to activate a diesel
preheater. This form A relay is rated at 10 amps at 28
volts DC.
FUEL CONTROL RELAY (PCB3: TB1-14, TB1-15)

A relay contact output is provided to control the fuel
solenoid/valve. This form A relay is rated at 10 amps
at 28 volts DC.
COMMUNICATIONS
SPARE ALARMS (PCB1: J7-1, J7-9)
FRONT PANEL COMMUNICATIONS PORT
Two inputs are provided for spare alarms. (Switch to

ground to alarm.) See Spare LEDs, Page 6.
The front panel includes a connector for RS-232 serial

communication.
See
RS-232
Local
Communications Port, Page 7.
SPARE WARNINGS (PCB1: J7-10, J7-11)

Two inputs are provided for spare warning conditions. (Switch to ground to alarm.) See Spare LEDs,
Page 6.
OUTPUTS
STARTER SOLENOID (PCB3: TB1-12, TB1-13)
A relay contact output is provided to activate the
starter solenoid. This form A relay is rated at 10
amps at 28 volts DC.
ALARM (PCB3: TB1-4(NC),

A relay contact output is provided that will activate
on an alarm condition. This form C relay is rated at
10 amps at 28 volts DC.
MODEM
The unit can optionally be provided with a modem
with AT command set which is FCC part 68
approved. The modem will allow an operator to perform the functions of the front panel at a remote site.
However, the modem functions will not allow remote
control of the engine if the front panel AUTO-OFFRUN switch is in OFF or RUN mode (part # 0A3557).
REMOTE COMMUNICATIONS PORT

(UP TO 1,200 FEET)
The D panel is provided with an RS-485 communications port. This is designed to be connected to
Generacs remote annunciators or remote relay panels (The Time Multiplexed Annunciator CANNOT be
used with a D panel.). Up to one annunciator and
four remote relay panels can be connected together
on this port via a shielded two wire communications
cable (plus two wires for power).
General Information
Monitored Parameters
The remote annunciator panel (RAP) and remote

relay panel (RRP) provide remote monitoring of the
following engine parameters. Remote monitoring is
by illuminated LEDs on the annunciator and relay
contact closures on the relay panel.
1. Generator Run
2. Battery Charger AC Failure
3. Low Battery Voltage
4. High Battery Voltage
5. RPM Sensor Loss
6. Overcrank
7. Overspeed
8. Generator Power
9. Pre Low Oil Pressure
10. Pre High Coolant Temperature
11. Low Coolant Temperature
12. Low Fuel
13. Low Oil Pressure
14. High Coolant Temperature
15. Emergency Stop
16. Not in Auto
17. Line Power
18. Spare
Connection details and a connection harness (excluding the communications cable) are supplied with the
optional panels.
DIAL OUT OPTION (MODEM MUST BE FITTED)

The dial out feature allows the panel to call out to a
PC (computer) running GenLink software when any
alarm (red LEDs) occurs. Once this feature has been
implemented, the GenLink software is placed in
standby mode and waits for calls from any generator
programmed for dial out. The program will then display the alarm responsible for dial out.
10 Generac Power Systems, Inc.
INSTALLATION NOTES
The D option control panel is designed to enhance
the current range of Generac control panels. As such,
this panel can accommodate most Generac standby
generators.
The anti-vibration mountings, fixing centers and
overall dimensions are compatible with existing panels, as are the lower panel connections and most of
the engine electrical connections. All engine temperature and oil pressure alarms and pre-alarms are
derived from the analog signals from engine senders,
so the existing alarm and shutdown switches become
redundant; these should be disconnected or removed
from the engine.
Lower panel connections are identical, and the panel
plugs into the existing lower panel connector. The
only additional lower panel wiring is a separate neutral wire that should be wired from the lower panel
neutral bar to the bullet connector marked 00 (not
used in a delta configuration) which is part of the
lower panel connection harness protruding from the
bottom of the D panel.
Refer to the schematics and wiring diagrams in
Appendix 1 Electrical Data for more installation
information.
Operation
If the correct password is entered, the display will

change to 00. At this time, the program is waiting
for an option (see Programmable Options) to be
entered. Twenty-eight options may be displayed and
changed, if desired. The current setting remains
unchanged if ENTER is pressed, or it can be changed
by entering a new number followed by ENTER. Exit
the keypad routine by pressing ENTER again anytime
the display shows 00.
Program options can be modified in the AUTO, OFF
or RUN mode. However, it is recommended that
the options be changed while the panel is in the OFF
mode.
PROGRAMMABLE OPTIONS
For information on programmable options, refer to

the following text, as well as the chart on Page 13.
1. Select English or Metric Units
Units of measurement will be changed on the panel

for oil pressure and water temperature.
2. Fuel Display On/Off
The fuel display should be turned off when an analog

fuel sensor is not being used. Alarm and warning
LEDs for fuel are activated by either the low and high
fuel switches or the programmed values used with
the analog sensor.
See Status Indicators Alarms and Warnings, Page

4.
7. High Water Temperature

4.
8. Critical Low Fuel
This is used with an analog sensor to turn on a red

alarm LED. See Status Indicators Alarms and
Warnings, Page 4.
Pressing the PROG (Program) key will cause the programming digits to display ACCESS. At this time,
the password must be entered (see Programmable
Option 28 Set User Password). If an invalid password is entered, the program will do nothing.
Additional characters may be entered in an attempt
to log on (only the last six digits are recognized). If a
valid password is not entered and/or no keypad activity has occurred for two minutes, the program will
revert to running time display.
6. Pre High Water Temperature

4.
9. Low Fuel
This is used with an analog sensor to turn on a yellow warning LED. See Status Indicators Alarms
and Warnings, Page 4.
Pressing ALARM HORN RESET turns off only the

alarm relay. Alarm conditions continue to be displayed. Pressing ALARM LAMP RESET clears all
alarm LEDs that are not current.
5. Low Water Temperature

4.
10. High Fuel
This is used with an analog sensor to turn on a red

alarm LED. See Status Indicators Alarms and
Warnings, Page 4.
The use of most keys is self-explanatory, but the operation of some keys requires a brief explanation. (For
additional information, see Keypad on Page 7.)
11. Low AC Voltage
A red LED next to the AC Volts display is used to indicate this alarm. If the generators AC voltage drops
below this set value for more than 0.5 seconds, an
alarm occurs and the engine shuts down. The alarm is
latched and causes the alarm relay to latch and produce a modem callout if enabled. This alarm is activated after the alarm hold off time is complete.
USING THE KEYPAD
4. Low Oil Pressure

4.
12. High AC Voltage
A red LED next to the AC Volts display is used to indicate this alarm. If the generators AC voltage goes above
this set value for more than 0.5 seconds, an alarm
occurs and the engine shuts down. The alarm is latched
and causes the alarm relay to latch and produce a
modem callout if enabled. This alarm is activated after
the alarm hold off time is complete.
OPERATION OF DIGITAL GENERATOR

CONTROL PANEL
A red LED next to the Battery Voltage display is

used to warn that battery voltage is below programmed limits. No shutdown occurs with this warning.
Generac Power Systems, Inc. 11
Operation
A red LED next to the Battery Voltage display is

used to warn that battery voltage is above programmed limits. No shutdown occurs with this warning.
15. Low Frequency Limit
A red LED next to the Hertz display is used to indicate this alarm. If the generators frequency drops
below this set value for more than 1.5 seconds, an
alarm occurs and the engine shuts down. The alarm
is latched and causes the alarm relay to latch and
produce a modem callout if enabled. This alarm is
activated after the alarm hold off time is complete.
Frequency is measured on phase A.
16. High Frequency Limit
22. Load Control
This load control relay output has NO/NC contacts

that can be used to connect the generator to the load
once the generators output voltage and frequency
climb above the preprogrammed low AC voltage and
low frequency limits. This relay can be controlled
from the front panel or through GenLink software
via a modem or RS-232. It is possible to use this output as a generator running signal, but it will be
delayed by the hold off timer. (e.g., Program the output to be ON, see Figure 2.1). See Outputs on Page
9.
Figure 2.1 Load Control as

Generator Running Signal
A red LED next to the Hertz display is used to indicate this alarm. If the generators frequency goes
above this set value for more than 1.5 seconds an
alarm occurs and the engine shuts down. The alarm
is latched and causes the alarm relay to latch and
produce a modem callout if enabled. This alarm is
activated after the alarm hold off time is complete.
Frequency is measured on phase A.
21. Flywheel Teeth
This value is preset at the factory. This is the number

of teeth on the flywheel ring gear.
17. Starting Speed
19. Alarm Hold Off Time
Most alarms are ignored during alarm hold off time.

If an alarm still persists after the hold off time, it will
become active. See Status Indicators Alarms and
Warnings, Page 4, for more information.
20. Crank Cycle On Time
This is the length of time that the starter stays

engaged when given a command to start. There will
be a five second off time after each on time. After
eight unsuccessful tries (each try consisting of one
cycle crank on time and one off time), the overcrank
alarm will latch the engine off, and the alarm LED
will turn on.
23. Set/Reset Auxiliary Output 1
This auxiliary relay output has NO/NC contacts that

can be used as general purpose relay under front
panel control. This relay also can be controlled from
the front panel or through GenLink software via a
modem or RS-232. By selecting Option 3, the relay is
programmed to operate on engine shutdown only.
See Outputs on Page 9.

4.
18. Overspeed
24. Set CT Primary Current
This is the current rating for the primary side of the

CT with the secondary side being five amps. D panels
are set up to use five amp secondaries.
This is the speed at which the engine becomes selfsustaining and causes the starter to disengage. The
alarm hold off timer is started when this rpm has
been reached.
25. Preheat Time On
This is the length of time that the preheat device on a

diesel engine is energized.
Operation
26. Preheat While Cranking
This allows the preheater to be energized while the

engine is cranking.
27. Select Phasing
There are three possible generator configurations.

They are single-phase, three-phase wye and threephase delta.
28. Set User Password
This allows the user to change the default password.

All D panels ship from the factory with the default
password set to zero (000000). If the modified user
password is lost or misplaced, it is possible for a
technician to access the panel through remote software to determine the password. However, in order
for the technician to access the panel and password,
the panel must be capable of remote communication
via a modem.
PROGRAMMABLE OPTIONS
OPTION
1. Select English or
Metric Units
2. Fuel Display On/Off
4. Low Oil Pressure
5. Low Water Temp.
6. Pre High Water Temp.
7. High Water Temp.
8. Critical Low Fuel
9. Low Fuel
10. High Fuel
11. Low AC Voltage
12. High AC Voltage
15. Low Frequency Limit
16. High frequency limit
17. Starting Speed
18. Overspeed
19. Alarm Hold Off Time
20. Crank Cycle On Time
21. Flywheel Teeth
22. Load Control
23. Set/Reset Aux. Output 1
24. Set CT Primary Current
25. Preheat Time On
26. Preheat While Cranking
27. Select Phasing
DEFAULT
1=English
RANGE or ALT
2=Metric
YOUR SETTING
1=OFF
15 psi/1.02 bar.
10 psi/0.68 bar.
90 F/32 C
220 F/104 C
250 F/121.2 C
5%
10%
95%
90 VAC
230 VAC
12.2 VDC
15.0 VDC
57 Hz
63 Hz
500 RPM
2100 RPM
10 SEC
5 SEC
168
1=OFF
1=OFF
150A
0 SEC
2=ON
2=WYE
28. Set User Password
000000
2=ON
0-100 psi/0-6.8 bar.
0-100 psi/0-6.8 bar.
0-300 F/-18-149 C
0-300 F/-18-149 C
0-300 F/-18-149 C
0-99%
0-99%
0-99%
0-1023 VAC
0-1023 VAC
0-51.1 VDC
0-51.1 VDC
40-70 Hz
40-70 Hz
0-3600 RPM
0-3600 RPM
0-60 SEC
5-15 SEC
75-200
2=ON
2=ON/3=Operate on Shutdown
50-5000A
0-30 SEC
1=OFF
1=SINGLE
2=WYE
3=DELTA
000000-999999
Appendix 1 Electrical Data

Phase Schematics Drawing No. 099389-B
VOLTAGE CODE - K + R
SERIES WYE 12-WIRE
VOLTAGE CODE - A + M
SERIES 4-WIRE
S1
AS
11
22 33
NEUTRAL REQD.
00
00
00
00
S15
S1
00
S1
S11
S9
TO
OPTIONAL
EGC
S8
S6
S5
S3
S2
00
S15
S3
57
10
k
58
12
CT2
CT1
l
S1
00
TO
OPTIONAL
S15
EGC
S3
S2
S16
PLUG
CONNECTIONS
TO
CONTROL
PANEL
00
S2
57
k
59
k
CB2
OPTIONAL
CIRCUIT
BREAKER
9
5
11
8
10 PLUG
13 CONNECTIONS
TO
12 CONTROL
PANEL
S1
S3
K
D-OPTION
AS
S10
S12
D-OPTION
5
8
S2
S7
FOR
00
S16
FOR
00
S3
S15
NEUTRAL REQD.
S4
44
CT1
CT3
58
CT2
l
CB2
E1
00
E3
E1
CUSTOMER CONNECTION
120/240V 1-PHASE 60Hz
110/220V 1-PHASE 50Hz
E3
00
VOLTAGE CODE - D,J + P

SERIES DELTA 12-WIRE
(ONLY USED ON 125kW AND

ABOVE, OUTPUT IS 66%
OF 3-PHASE RATING)
S11
S12
S8
S1
SEE
NOTE
ONE
S6
S2
S8
S5
S2
S4
4
AS
S7
7
S7
S6
S9
S11
S3
AS
S10
S10
NEUTRAL REQD.
FOR
00 D-OPTION
00
00
TO
OPTIONAL
S15
EGC
00
S16
00
S1
S3
S16
PLUG
57
TO
CB2
00
E3
CUSTOMER CONNECTION
120/240V 1-PHASE 60Hz
110/220V 1-PHASE 50Hz
CT1
CT3
l
E1
PANEL
S2
8
10
57
58
CT2
CT1
S3
7
9
5
11
S3
S1
S2
59
13
58
12
CB2
E1
PLUG
CONNECTIONS
TO
CONTROL
PANEL
CT2
OPTIONAL
CIRCUIT
BREAKER
00
TO
OPTIONAL
EGC
S2
S1
S15
S15
S15
00
S15
S12
S9
S3
S5
S4
E2
CUSTOMER CONNECTION
277/480V 3-PHASE 60Hz
240/415V 3-PHASE 50/60Hz
VOLTAGE CODE - A + M
PARALLEL ZIG-ZAG
12-WIRE
S1
OPTIONAL
CIRCUIT
BREAKER
E3
CUSTOMER CONNECTION
120/240V 3-PHASE 60Hz
100/200V 3-PHASE 50Hz
E2
OPTIONAL
CIRCUIT
BREAKER
NOTE ONE
PARALLEL WINDING ONLY
FITTED ON D OPTION
ALTERNATORS.J+P OPTION
1-PH MACHINES SHOULD BE
DERATED TO 66% OF THREE
PHASE RATING.

Phase Schematics Drawing No. 099389-B
VOLTAGE CODE - L + S
6-WIRE WYE
EXCITATION POWER OPTIONS

(USE EITHER OPTION A OR OPTION B ONLY)
NEUTRAL REQD.
S1
CONNECT 6 WIRE TO PIN 6 AND
FOR
00
S15
D-OPTION
S4
S3
PANEL PLUG. IN CASE OF TP
FAILURE BYPASS TP BY
TP
CONNECTING 5 WIRE TO PIN 3.
OPTION B - PERMANENT MAGNET GENERATOR
S5
S6
2 WIRE TO PIN 3 IN CONTROL
AS
S15
S15
DPE
S2
S16
00
S1
S3
00
00
S15
S15
57
59
CT1
L
7
9
5
11
8
10
13
S2
k
K
CT3
CT2
CONNECT 6 WIRE TO PIN 6 AND
PME
PMR
2 WIRE TO PIN 3 IN CONTROL

PANEL PLUG.
S2
00
S16
S15
S1
S3
TO
OPTIONAL
EGC
58
2
1
66
PLUG
CONNECTIONS
TO
CONTROL
PANEL
12
BC1
66
CONNECT CHARGE
WINDINGS IN
SERIES FOR
BC2 24V CHARGER
77
66A
77A
66A
BC1
77
CONNECT CHARGE
WINDINGS IN
PARALLEL FOR
12V CHARGER
BC2
77A
EXCITER FIELD OPTIONS

OPTIONAL
CIRCUIT
BREAKER
CB2
OPTION A - UNITS WITH BRUSHES

1
2
CONNECT 1 WIRE FROM BRUSHES
E1
E3
E2
00
TO PIN 2 AND 4 WIRE FROM
AR
CUSTOMER CONNECTION
346/600V 3-PHASE 60Hz
277/480V 3-PHASE 50Hz
BRUSHES TO PIN 4 IN
THE CONTROL PANEL PLUG.
OPTION B - BRUSHLESS UNITS
VOLTAGE CODE - G + N
PARALLEL WYE 12-WIRE
EA
2
CONNECT 1 WIRE TO
S1
NEUTRAL REQD.
S7
S5
S6
589
S8
S3
OPTIONAL CIRCUIT BREAKER STATUS AUXILLIARY CONTACT
S2
S11
TO PIN 4 IN THE
CONTROL PANEL PLUG.
D-OPTION
AS
S12
S9
PIN 2 AND 4 WIRE
FOR
00
S4
EF
AR
589
AUX. CONTACT CLOSED

S1
00
00
S15
S3
S15
00
S16
S1
S3
S2
K
57
59
k 58
CT1
CT3
l
7
9
5
11
8
10
13
CT2
E3
CONTROL PANEL
0
LEGEND
PLUG
CONNECTIONS
TO
CONTROL
PANEL
12
CB2
E1
TO
OPTIONAL
EGC
IN
BREAKER IS OPEN
S2
S15
TO TERMINAL BLOCK
WHEN THE CIRCUIT
00
00
CUSTOMER CONNECTION
120/208V 3-PHASE 60Hz 139/240V 3-PHASE 60Hz
115/200V 3-PHASE 50Hz
OPTIONAL
CIRCUIT
BREAKER
AR
ALTERNATOR ROTOR
AS
ALTERNATOR STATOR
BC
BATTERY CHARGE WINDING
CB2
MAIN CIRCUIT BREAKER (OPTIONAL)
CT
CURRENT TRANSFORMER
DPE
DISPLACED PHASE EXCITATION WINDING
EA
BRUSHLESS EXCITER ARMATURE
EF
BRUSHLESS EXCITER FIELD
EGC
ELECTRONIC GOVERNOR CONTROL
PMR
PERMANENT MAGNET ROTOR
PME
PERMANENT MAGNET EXCITATION WINDING
TP
THERMAL PROTECTOR (AUTO-RESET)
E2
READ THIS DRAWING IN CONJUNCTION WITH
WIRING DIAGRAMS Nos. 099336 & 099491
TS
VR
2
1
4
RA-2
RA-1
00
L3
L2
L1
RA-13
RA-4
J11
RA-10
J12
RA-5
RA-6
RA-11
RA-7
RA-9
RA-8
RA-3
89
1
4
RA-7
RA-8
RA-9
RA-10
162
RA-12
RA-13
29
162
D1
29
R2
CB1
J2
S15
49
14
D2
178
CK
79
RED
R30
13A
49
56
GREEN
BLACK
GREEN
183
567
EEN
89
178
S15
79
589
69
S16
575
150
58
589
S16
69
56
13
14
85
P3
79
68
69
TO
575
567
R15
59
S2
57
S3
S1
58
79
NEUTRAL
589
S15 0
PANEL
10
TO
LOWER
R4
13A
R30
R14
PANEL
FRONT
TO
RED
0
R14
183
68
150
56
14
13A
85
R13
69
575
85
13
R13
TB1-16
13A
R15
R16
RED
R30
R6
R5
567
589
TB1-9
TB1-8
TB1-7
TB1-6
TB1-5
TB1-4
TB1-3
TB1-1
TB1-10
TB1-11
TB1-12
TB1-13
TB1-14
TB1-15
R14 TB1-17
R13
P1-A
RA-11
RA-11
S16
RA-9
RA-9
RA-7
RA-7
RA-8
RA-6
RA-6
89
RA-10
RA-10
13A
PCB3
RA-13
CHASSIS
FRONT PANEL
79
85
79
J10-5
J10-4
J10-3
J10-2
J10-1
J7-12
183
68
J7-8
J7-9
J7-10
J7-11
J7-3
567
R24
RA-5
RA-4
RA-13
J7-1
J7-2
RA-12
589
69
R25
575
RA-4
J5-7
J5-8
R24
R23
J1-12
J1-13
J1-14
J1-15
J5-4
J5-5
R20
R21
J5-1
J5-2
R17
R18
J1-8
J1-9
J1-10
J1-11
J9-2
J9-3
J9-5
J12-4
J11-4
J11-1
13A
13A
J1-5
J1-6
R30
R16
SEE
DETAIL "A"
R15
R5
R27
R28
P2-B
P1-B
R6
J1-1
J1-2
J1-3
J2-8
J2-1
R6
R30
R5
HARNESS
MAIN
TO
575
RA-5
TB3-3
68
RA-12
TB3-2
85
TB3-4
69
TB4-1
RED
TB4-3
TB4-4
COM
CT3
CT2
CT1
0
13A
RA-12
RA-6
RA-5
TB4-2
TB2-5
RA-8
TB3-1
DETAIL "A"
PCB2
PCB1
S16
89
J1
R1
R16
R15
R13
13
13A
13A
R2
R3
J6-1
J6-2
J6-3
J8
11
TO TELCO
R1
J6-4
J4
R4
J3-3
R11
R12
J3-2
R10
J3-1
F1
R14
R13
L2
R13
L1
SW2
R6
R5
LEGEND
R5
R16
SW1 - SWITCH- AUTO/MANUAL/OFF

SW2 - SWITCH- ESTOP
TS1,2- TERMINAL STRIP
VR - VOLTAGE REGULATOR
KP-1 - FRONT PANEL KEY-PAD
R2 - RESISTOR FIELD BOOST

R3 - RESISTOR ENGINE ALTERNATOR
PCB2- CIRCUIT BOARD ENGINE CONTROL DISPLAY

PCB3- CIRCUIT BOARD ENGINE CONTROL I/O
CB1 - CIRCUIT BREAKER- FIELD BOOST

D1 - DIODE 600V 12A
D2 - DIODE- 800V, 2A
DP - DIAGNOSTICS PORT
F - FUEL SENDER
F1 - FUSE-15 AMPS
L1,2 - LIGHT PANEL
P1 - PLUG & CAP 9PIN
P2 - PLUG & CAP 9PIN
P3 - PLUG 15PIN
P4 - PLUG & RECEPTACLE, 3PIN
KP-1
SW1
DIAGNOSTICS PORT

TB2-4
J2-3
J2-1
J2-2
RA-1
TB2-3
RA-2
TB2-2
RA-3
TB2-1
GRAYHILL

Control Panel Wiring Diagram (For Use With Generac Alternator) Drawing No. 021773-E

EXCITER
FIELD
AVR
POWER
AVR
SENSING
S16
S15
178
2-WIRE
START
SIGNAL
183
S3
L3 VOLTS
S1
L1 VOLTS
S2
59
L3 CT
L2 VOLTS
58
L2 CT
57
L1 CT
CT COMMON
NEUTRAL FROM LOWER PANEL
LOWER PANEL CONNECTOR (SEE DRG. 099389 REV-A)
15
14
11
13
12
10
4
D1
FIELD
1
R2
6
VR1
P1-A
P1-B
P1-A
VOLTAGE
REGULATOR
CB1
2
POWER
3
D2
SENSING
EXCITATION
R3
L1
TB4-1
TB4-4
TB4-3
TB4-2
TB3-4
- PH1 CT
J2-6
TB3-3
- PH2 CT
J2-7
TB3-2
J12-1
PH1 CT -
TB3-1
J12-2
PH2 CT -
- PH3 CT
J12-4
P2B
J12-3
PH3 CT COM CT -
- PH3 VOLTS
J2-4
- PH2 VOLTS
J2-3
- PH1 VOLTS
J2-2
- COM CT
J2-5
- N VOLTS
J2-1
P2A
PH1 VOLTS PH2 VOLTS PH3 VOLTS -
J11-1
J11-2
J11-3
J11-4
TB1-17
TB1-16
85
N VOLTS -
R4
TB1-15
14
TB1-14
J9-1
TB1-13
- BAT SENSE
J1-4
TB1-11
- 5VP
J1-3
TB1-12
- COM
TB1-10
RA10
NC
TB1-1
TB1-2
RA9
NO
OPTIONAL INPUTS
- STARTER
J1-5
INTERFACE BOARD
PCB3
- PRE-HEAT
J1-6
TB1-3
N/C
COM
N/0
- SENSE SUPPLY
J1-7
TB1-7
TB1-8
TB1-9
LOAD CONTROL
- LOAD CONTROL
J1-8
AUX O/P
- AUX
J1-9
150
- ALARM
J1-10
56
J9-4
- FUEL
J1-11
J9-5
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
STARTER
PRESOL.
HEAT SOL.
Vbat -
J9-2
COM -
GND STARTER PRE-HEAT SENSE SUPPLY LOAD CONTROL AUX -
FUEL -
J5-8
FUEL
SOL.
J2-1
J7-1
SPARE ALARM 1
P2A
J3-1
J3-3
J2-2
J2-4
J7-9
SPARE ALARM 2
J7-4
LO FUEL LVL.
COOLANT LEVEL
SENSOR
- Vbat
J1-1
P2B
J1-2
L2
J1-3
J3-2
2
3
J2-3
3
4
J7-10
SPARE WARN. 1
J7-5
HI FUEL LVL.
ALARM -
J7-7
PANEL LAMPS
2400 BAUD
MODEM
PORT
RS-232
DIAGNOSTICS
PORT
RS-485
COMMS.
PORT
J9-3
5VP BAT SENSE -
J7-11
SPARE WARN. 2
J7-6
HI OIL TEMP.
PRE-HI OIL TEMP.
PANEL LAMPS -
- E STOP
- MODE SW
J1-14
- PANEL LAMPS
J1-13
TB1-4
TB1-5
TB1-6
COMMON
ALARM
- MODE SW
J1-15
RA7 RA8 RA6

NC COM NO
CPU BOARD
PCB1
P1-A
P1-A
J6-4
SW1-A
P1-B
P1-B
3 RUN
2 OFF
1 AUTO
SW1-B
J6-1
8 OFF
9 RUN
7 AUTO
TB2-1
TB2-2
TB2-3
TB2-4
J7-8
13A
J7-12
P2A
P2A
P2A
P2A
J7-3
FUSED DC
E STOP -
TB2-5
J6-2
J6-3
REM START -
J7-2
J4-11
P2B
P2B
P2B
P2B
FRONT PANEL
KEYPAD
J4-1
J10-1
J10-2
J10-3
J8-8
J8-1
SPARE I/P
RA-13
J12-1
LINE POWER
RA-4
SHIELD
J7-10
RA-12
RA-3
J7-1
RA-1
J2-3
P2A
J2-2
P2B
13
J2-1
SWITCH
N/C
F1
EMERGENCY
J10-4
J10-5
49
RA-2
79
68
RS-485
CHARGER FAIL
RPM SENSOR
COOLANT TEMP. SENSOR
OIL PRESS. SENSOR
FUEL LEVEL SENSOR
69
575
RUPTURED BASIN
567
MLCB OPEN
FUEL LEVEL
SENSOR
575
P4B
P4B
P4B
FUEL
SENDER
589
ON TERM STRIP
TS1
BLACK
E
C
DISPLAY BOARD
PCB2
CHARGE ALT.
WL CONNECTION

Control Panel Schematic Diagram (For Use With Generac Alternator) Drawing No. 021736-E
RA-8
RA-4
RA-3
00
L3
L2
L1
86
87
14A
30
RR
HARNESS FOR
FUEL LEVEL PROBE
RA-13
J11
RA-11
J2
575
220
0
13
79
TO
J9-5
13A
56
589
150
183
178
58
PANEL
LOWER
TO
69
589
P3
13
3
10
79
79
589
TO
575
59
S2
57
S3
S1
58
79
NEUTRAL
68
56
13
68
183
69
150
56
13A
85
R13
14A
0
R14
567
R15
14A
69
R4
68
69
567
85
13A
R14
PANEL
FRONT
TO
575
85
8 9
13A
13
R13
P1-A
RA-10
RA-10
(CONNECT
SHIELD TO
PIN 2 ONLY
AT AVR)
R14
4
R13
RA-6
RA-1
CT2
CT1
RA-11
RA-11
RA-2
RA-9
RA-9
RA-7
RA-8
RA-7
567
589
TB1-9
TB1-8
TB1-7
TB1-6
TB1-5
TB1-4
TB1-3
TB1-1
13A
PCB3
TB3-1
CHASSIS
FRONT PANEL
79
85
J7-12
183
J10-5
J10-4
J10-3
J10-2
J10-1
J7-10
J7-11
RA-4
RA-13
J7-8
J7-3
R24
567
J5-7
J5-8
J5-4
J5-5
J9-1
J9-2
J9-3
J9-4
J5-1
J5-2
J9-5
J12-4
J11-4
J12-1
J11-1
13A
13A
J7-1
J7-2
R16
R15
R14
R13
13
RA-12
589
68
R25
R24
4
7
R5
R6
79
RA-13
R30
R26
R27
R28
R29
R17
R18
R19
R20
R21
R22
R23
SEE
DETAIL "A"
8 9
68
P2-B
P1-B
5 6
69
RA-4
J1-12
J1-13
J1-14
J1-15
J1-11
J1-8
J1-9
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
J2-8
J2-1
R6
R5
TS1-0
TO
HARNESS
MAIN
TO
2 3
575
RA-5
TB3-3
69
RA-12
TB3-2
85
TB3-4
575
TB1-10
TB1-11
TB1-12
TB1-14
TB1-15
R16
13A
R6
R5
TB4-1
TO
AVR
TB4-2
COM
0
13A
RA-1
RA-2
RA-12
TB4-3
J12
RA-9
TB4-4
RA-3
RA-4
RA-7
TB2-5
RA-6
TB2-3
RA-8
TB2-2
J2-3
J2-1
J2-2
RA-1
TB2-1
RA-2

PCB2
PCB1
S16
89
J1
R1
R16
R15
R14
R13
13
13A
R4
R1
R2
R3
J6-4
J6-1
J6-2
J6-3
J8
11
TO TELCO
R12
J3-3
R11
J3-2
J4
R10
J3-1
R14
L2
R6
R5
LEGEND
R5
R15
SW2
R16
SW3 - SWITCH- PRE-HEAT

TS1,2- TERMINAL STRIP
VR - VOLTAGE REGULATOR
KP-1 - FRONT PANEL KEY-PAD
SW1 - SWITCH- AUTO/MANUAL/OFF
R4 - RESISTOR WTR. LVL. SENSE
R1 - POTENTIOMETER- VOLTAGE ADJUST

R2 - RESISTOR FIELD BOOST
PCB1- CIRCUIT BOARD ENGINE CONTROL CPU

PCB2- CIRCUIT BOARD ENGINE CONTROL DISPLAY
CB1 - CIRCUIT BREAKER- FIELD BOOST

D1 - DIODE 600V 12A
D2 - DIODE- 800V, 2A
F1 - FUSE-15 AMPS
KP-1
R13
L1
SW1
R13
RA-3
DETAIL "A"

Control Panel Wiring Diagram (For Use With Marathon Alternator) Drawing No. 0A5798-C
178
RA-7
RA-8
RA-9
RA-10
RA-11
RA-10
RA-6

178
2-WIRE
START
SIGNAL
S3
L3 VOLTS
TO
AVR
S2
L2 VOLTS
183
S1
59
L3 CT
L1 VOLTS
58
L2 CT
L1 CT
CT COMMON
NEUTRAL FROM LOWER PANEL
LOWER PANEL CONNECTOR (SEE DRG. 99389 REV-A)
15
14
11
13
12
10
VR1
P1-A
P1-B
P1-B
P1-A
L1
TB4-1
TB4-4
TB4-3
TB4-2
TB3-4
- PH1 CT
TB3-3
J2-6
J12-1
PH1 CT -
TB3-2
J2-7
J12-2
TB3-1
J2-8
J12-3
PH2 CT -
- PH2 CT
- PH3 CT
P2B
J2-5
J12-4
PH3 CT COM CT -
P2B
J1-2
L2
J1-3
- COM CT
1
P2A
J3-1
PH1 VOLTS PH2 VOLTS PH3 VOLTS -
J2-1
J11-4
J2-4
J11-3
J2-3
J11-2
J2-2
J11-1
- PH1 VOLTS
- PH2 VOLTS
TB1-17
- PH3 VOLTS
TB1-16
85
N VOLTS -
- N VOLTS
R4
J2-1
TB1-15
Vbat -
J1-2
J9-2
J1-1
J9-1
TB1-12
- COM
TB1-13
- Vbat
- 5VP
TB1-11
OPTIONAL INPUTS
J1-7
J5-3
J1-6
J5-2
J1-5
J5-1
- BAT SENSE
- STARTER
- PRE-HEAT
- SENSE SUPPLY
- LOAD CONTROL
TB1-10
TB1-1
TB1-2
TB1-3
- AUX
TB1-7
- ALARM
N/C
TB1-8
- FUEL
COM
TB1-9
N/0
LOAD CONTROL
J1-8
J5-4
RA9
NO
J1-9
J5-5
RA10
NC
J1-10
J5-6
AUX O/P
INTERFACE BOARD
PCB3
J1-3
J9-3
J1-11
J5-7
150
J1-4
J9-4
J9-5
AUX -
J1-12
J5-8
56
GND STARTER PRE-HEAT SENSE SUPPLY LOAD CONTROL -
FUEL -
- E STOP
TB1-4
- PANEL LAMPS
J1-13
RA6
NO
TB1-5
- MODE SW
J1-14
TB1-6
COMMON
ALARM
- MODE SW
J1-15
RA7
NC
CPU BOARD
PCB1
P1-A
P1-A
SW1-A
P1-B
P1-B
3 RUN
2 OFF
1 AUTO
SW1-B
8 OFF
9 RUN
7 AUTO
TB1-14
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
J7-8
13A
J7-12
86
P2A
P2A
P2A
P2A
J7-3
FUSED DC
E STOP -
STARTER
PRESOL.
HEAT SOL.
J7-1
SPARE ALARM 1
COOLANT LEVEL
SENSOR
J3-3
J2-2
J2-4
J7-9
J7-4
LO FUEL LVL.
P2A
J3-2
2
3
J2-3
3
4
J7-10
SPARE WARN. 1
SPARE ALARM 2
J7-5
HI FUEL LVL.
ALARM -
J7-7
PANEL LAMPS
2400 BAUD
MODEM
PORT
RS-232
DIAGNOSTICS
PORT
RS-485
COMMS.
PORT
COM 5VP BAT SENSE -
J7-11
SPARE WARN. 2
J7-6
HI OIL TEMP.
PRE-HI OIL TEMP.
PANEL LAMPS -
J6-4
J6-1
J6-2
J6-3
REM START -
J7-2
J4-11
RR
P2B
P2B
P2B
P2B
FRONT PANEL
KEYPAD
J4-1
J10-1
J10-2
J10-3
F1
15A
RA-4
RA-13
J7-10
J7-11
J8-8
GEN. POWER
RA-5
J7-9
J8-1
CHARGER FAIL
RA-12
P2A
J7-1
J2-3
J2-2
J2-1
85
13
P2B
DC POWER
+
-
EMERGENCY
STOP
SWITCH
N/C
J10-4
J10-5
J12-1
DISPLAY BOARD
PCB2
30
SPARE I/P
LINE POWER
RS-485
SHIELD
RPM SENSOR
RA-3
COOLANT TEMP. SENSOR
79
RA-1
OIL PRESS. SENSOR
68
RA-2
MLCB OPEN
69
FUEL LEVEL
SENSOR
589
-DC
SIG.
+DC
RUPTURED BASIN
575
220
14
567
575
87
13A
RR
FUEL
SOLENOID

Control Panel Schematic Diagram (For Use With Marathon Alternator) Drawing No. 0A5799-C

Typical Engine Schematic Diagram Drawing No. 021737
Appendix 2 Notes
23
44,50,52
P/N-67710
P/N-67711
BARBER COLMAN 12V 5000-9500HZ

ELECTRONIC GOVERNOR CONTROLLER
P/N-67709
P/N-92952
P/N-67680
4.5A
P/N-48476
ALL 50HZ MACHINES WITH GENERAC

ALTERNATORS USE VOLTAGE REGULATOR
ALL 60HZ MACHINES WITH GENERAC

ALTERNATORS USE VOLTAGE REGULATOR
ALL MACHINES
OVER 100KW
ALL BRUSHLESS MACHINES

UP TO 100KW WITH 24V DC SYSTEMS
7A.
P/N-48467
5.5A
P/N-54450
6.0A
P/N-48505

TABLE C-AVR/ELECTRONIC GOVERNOR CONTROLLER DATA
44,50,43
4.5A
P/N-48476
22

45 TO 100KW
32
20
24
68
13,50,43
19
49,50,51,52
49
75
56
75 OHM 25W
P/N-86266
See View
39,55
12
21
63
48
8
33 64
56
65

OVER 100KW WITH 12 OR 24V DC SYSTEMS
34
10

29 TO 41KW
76
37
67
70
31 63 66 41
ALL DIRECTLY EXCITED MACHINES

19 TO 45KW
19 TO 25KW
42
30
5 OHM 25W
P/N-48352
25 OHM 25W
P/N-57405
50 OHM 25W
P/N-83364
44
58
38,63,48
71
11
74
ALL DIRECTLY EXCITED MACHINES

UP TO 100KW WITH 12 OR 24V DC SYSTEMS
UP TO 100KW WITH 12V DC SYSTEMS
43
50
VIEW "A"
54
45
72
TABLE B-AVR POWER (DPE) CIRCUIT BREAKER DATA
28
29
51
38,63,48
47
TABLE A-FIELD BOOST RESISTER DATA
69
60,44,59,52
Appendix 3 Exploded Views and Parts Lists

Control Panel (Units Less Than 400 kW) Drawing No. 0A3103-H

Control Panel (Units Less Than 400 kW) Drawing No. 0A3103-H
ITEM PART NO.
QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
19
0A1053
0A1056
0A2274
0A1057A
0A2277
0A1054
0A1436
0A1438
0A1440
SEE TABLE C
SEE TABLE C
0A2275
----071361
1
1
1
1
1
1
1
1
1
1
1
20
032300
022676
0A3033
0A3034
098426A
098426C
1
1
1
1
1
1
24
28
29
30
31
32
33
34
35
0A3035
055444
049939
SEE TABLE A
044213
025192
0A1441B
0A1441A
0A1666
2
1
1
1
1
1
1
1
1
36
37
38
0A1667
0A2566A
057335
1
1
2
21
22
23
SCH ASSEMBLY "D-PANEL" CPU

PCB ASSEMBLY "D" DISPLAY
FRONT PANEL RAM
OVERLAY 'D' OPT PANEL
RAM PANEL LEFT SIDE
INTERFACE BOARD
D PANEL BOTTOM-LG GENS
RAM PANEL RIGHT SIDE
CHASSIS AVR & E-GOV
AVR ASSEMBLY
ELECTRONIC GOVERNOR
DOOR-STOP RAM PANEL
SEE TABLE B
POTENTIOMETER PNL 5K +/-10%
2.25W
FUSE HOLDER
FUSE 15A X AGC15 (NOT SHOWN)
SWITCH AUTO/OFF/MAN
CONNECTOR RS-232
SWITCH EMERG PB HEAD
SWITCH EMERG PB N.C. (NOT
SHOWN)
LAMP PANEL ILLUM.
HEATSINK (DIODE)
RECTIFIER MSC 12A 600V 1N1206R
FIELD BOOST RESISTOR
RESISTOR 10R 5% 12W
RECTIFIER MSC 2A 600V 1N5062
COVER PLATE AVR
COVER PLATE E-GOVERNOR
HARNESS 'D' PANEL FRONT (NOT
SHOWN)
HARNESS 'D' PANEL MAIN
HARNESS D INTERCONNECTING
BLOCK TERM 20A 20 X 6 X 1100V
ITEM PART NO.

39
40
41
42
43
44
45
46
47
48
49
50
51
52
54
55
56
58
59
60
61
63
64
65
66
67
68
69
70
71
72
73
74
75
76
0A2273
0A2400
0A2400A
020752
033121
023897
022097
057405
084543A
022155
022188
022152
022287
022158
022473
036261
0C6225
023364
023762
030468
034616
036909
036918
038150
039271
047246
064733
070370
040479
0C8474
0A3392
0441140156
0A5062F
0A2284
0C1229
QTY. DESCRIPTION
1
1
1
5
16
17
4
1
9
14
4
16
4
2
4
4
4
8
1
1
1
6
4
4
1
8
4
2
4
1
1
1
9
4
1
HINGE, RAM PANEL

TRUNKING 320MM
TRUNKING 180MM
SCREW PPM 4-40 X 1/4 ZINC
SCREW HHC #10-32 X 1/2
WASHER FLAT #10 ZINC
WASHER LOCK M6-1/4
RESISTOR 25R 5% 25W
SCREW PHM M3-0.5 X 12MM
WASHER LOCK #6
NUT HEX #6-32 STEEL
WASHER LOCK #10
SCREW HHC 1/4-20 X 3/4 G5
NUT HEX #10-32 STEEL
WASHER FLAT 1/4 ZINC
RIVET POP .125 X .129-.133/#30
SCREW HHTT #6-32 X 1/4 CZ
WASHER SHAKEPROOF INT #6
WASHER SHAKEPROOF EXT #10 STL
WASHER STEP NYLON .20
FITTING STRAIGHT 3/4
SCREW PPHM #6-32 X 1-3/8
SCREW PPHM #8-32 X 1/2
WASHER FLAT #8 ZINC
FITTING 90D 3/4
FLAT WASHER SPECIAL 1/4
RESISTOR MOUNTING BRACKET
WASHER MICA .203
VIB MOUNT 1.0 X 1.0 X 1/4-20
DECAL 20 LITE AN CON
DECAL TERMINAL BLOCK
WIRE ASSY 18AWG #0
PCB EDGEHOLD MOUNT
SCREW SWAGE 8-32 X 1/2 Z/YC
DECAL CUST CONN BOX
43
50
44
51
VIEW "A"
54
58
45
75
42
37
70
67
50
12
41
52
See View
"A"
39,55
46
74
61
NOTE: SMOKE LIMITING RELAY (0C14110)

IS FOUND ON 1350, 1825, & 2000KW
GENERATORS ONLY.
38,63,48
71
44
38,63,48
26
23
72
11
44
22
25
50
52
33
44,50,43
34
40,36
63
48
64
56
65
53
62
24
20
19
43,44,50,52
68
21
49
76
49,50,51,52
47

Control Panel (Units 400 kW and Larger) Drawing No. 0A5793-E

Control Panel (Units 400 kW and Larger) Drawing No. 0A5793-E
ITEM PART NO. QTY.

1
2
3
4
5
6
7
8
9
11
12
19
0A1053
0A1056
0A2274
0A1057A
0A2277
0A1054A
0A9294
0A1438
0A1440
067710
0A2275
071361
1
1
1
1
1
1
1
1
1
1
1
1
20
032300
022676
0A3033
0A3034
098426A
098426C
1
1
1
1
1
1
24
25
26
33
34
35
0A3035
0C4110
SEE NOTE:
0A1441B
0A1441A
0A1666
2
1
1
1
1
1
36
37
38
39
40
0A5800
0A2566A
057335
0A2273
0A2400
1
1
2
1
1
21
22
23
DESCRIPTION
SCH ASSEMBLY "D-PANEL" CPU
PCB ASSEMBLY "D" DISPLAY
FRONT PANEL RAM
OVERLAY 'D' OPT PANEL
RAM PANEL LEFT SIDE
INTERFACE BOARD
D PANEL BOTTOM-LG GENS
RAM PANEL RIGHT SIDE
CHASSIS AVR & E-GOV
CONTROLLER GOVERNOR 24V 1800
DOOR-STOP RAM PANEL
POTENTIOMETER PNL 5K +/-10%
2.25W
FUSE HOLDER
FUSE 15A X AGC15 (NOT SHOWN)
SWITCH AUTO/OFF/MAN
CONNECTOR RS-232
SWITCH EMERG PB HEAD
SWITCH EMERG PB N.C. (NOT
SHOWN)
LAMP PANEL ILLUM.
RELAY 24V 50A W/DIODE
RELAY SMOKE LIMITING 24V
COVER PLATE AVR
COVER PLATE E-GOV
HARNESS 'D' PANEL FRONT (NOT
SHOWN)
WIRING HARNESS D PANEL
HARNESS D INTERCONNECTING
BLOCK TERM 20A 20 X 6 X 1100V
HINGE RAM PANEL
TRUNKING 320MM
ITEM PART NO. QTY.

41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
58
61
62
63
64
65
66
67
68
70
71
72
73
74
75
76
0A2400A
020752
033121
023897
022097
057405
084543A
022155
022188
022152
022507
022158
0C6225
022473
036261
022264
023364
034616
0A5062F
036909
036918
038150
0A9234
047246
064733
040479
0C8474
0A3392
0441140156
036906
0C1229
0A2284
1
5
6
3
4
1
9
12
2
3
4
4
4
4
4
4
5
1
9
6
4
4
1
8
2
4
1
1
1
2
1
4
DESCRIPTION
TRUNKING 180MM
SCREW PPM 4-40 X 1/4 ZINC
SCREW HHC #10-32 X 1/2
WASHER FLAT #10 ZINC
WASHER LOCK M6-1/4
RESISTOR 25R 5% 25W
SCREW PHM M3-0.5 X 12MM
WASHER LOCK #6
NUT HEX #6-32 STEEL
WASHER LOCK #10
SCREW HHC 1/4-20 X 1/2 G5
NUT HEX #10-32 STEEL
SCREW HHTT #6-32 X 1/4 CZ
WASHER FLAT M6-1/4 ZINC
RIVET POP .125 X .129-.133/#30
WASHER LOCK M4
WASHER SHAKEPROOF INT #6
FITTING STRAIGHT 3/4
PCB EDGEHOLD MOUNT
SCREW PPHM #6-32 X 1-3/8
SCREW PPHM #8-32 X 5/8
WASHER FLAT #8 ZINC
GEDNEY CONN 1IN 90
FLAT WASHER SPECIAL 1/4
RESISTOR MTG BRACKET
VIB MNT 1.0 X 1.0 X 1/4-20
DECAL 20 LITE AN CON
DECAL TERMINAL BLOCK
WIRE ASSEMBLY 18AWG #0
SCREW PPHM #6-32 X 1
DECAL CUST CONN BOX
SCREW SWAGE 8-32 X 1/2 Z/YC
GENERAC POWER SYSTEMS, INC.

P.O. BOX 8
WAUKESHA, WI 53187
Part No. A3303
Revision C (11/25/02)
Printed in U.S.A.

Manual Panel D

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Manual Panel D

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POWER SYSTEMS, INC.

GENERAC POWER SYSTEMS

Important Safety Instructions

Study these SAFETY RULES carefully before

Do not handle any kind of electrical device while

Safety Rules....... ................................Inside Front Cover

Appendix 1 Electrical Data ......................................14

CONTROL PANEL CIRCUIT BOARDS

PCB 1 MAIN CENTRAL PROCESSOR

PCB 2 DISPLAY BOARD

PCB 3 INTERFACE BOARD

LOCATIONS OF CIRCUIT BOARDS

Generac Power Systems, Inc.

Remove the 15-amp fuse from the front of the

REMOTE ANNUNCIATOR PANEL

REMOTE RELAY PANEL

DIGITAL DISPLAYS (FIGURE 1.1, PAGE 3)

Figure 1.1 Digital Displays on D Option Control Panel

AC VOLTAGE DISPLAY (AC VOLTS)

AC VOLTAGE INDICATORS (HI, LO)

Voltage alarm checking is done on all phases. In the

AC CURRENT DISPLAY (AC AMPS)

FREQUENCY DISPLAY (HERTZ)

FREQUENCY INDICATORS (HI, LO)

Generac Power Systems, Inc.

POWER OUTPUT (KILOWATTS/MEGAWATTS)

This is a three-digit LED display for monitoring the

This is a six-digit LED display used to show engine

BATTERY VOLTAGE DISPLAY

BATTERY VOLTAGE INDICATORS (HI, LO)

Generac Power Systems, Inc.

This is a three-digit display used to monitor engine

High Oil Temperature Alarm (HIGH TEMP)

A red LED is used to indicate a high oil temperature

STATUS INDICATORS ALARMS AND

Pre Low Oil Pressure Warning (PRE LO PRES)

A yellow LED is used to indicate a warning that a low

For powers greater than 1 megawatt, the display will

Pre High Oil Temperature Warning

A yellow LED is used to indicate a warning that a pre

Figure 1.2 Status Indicators

Low Level Water Alarm (LO LEVEL)

A red LED is used to indicate the radiator water level

Pre High Water Temperature Warning

A yellow LED is used to indicate a warning that a high

Low Water Temperature Warning (LO TEMP)

1. Percent input from analog sender

ADDITIONAL ALARMS AND WARNINGS

A yellow LED is used to indicate a warning that a low

High Fuel Alarm (HI)

A red LED is used to indicate a high fuel level. The

Low Fuel Warning (LO)

A yellow LED used to indicate a low fuel level. The

Emergency Stop Alarm (EMG STOP)

A red LED is used to indicate that the emergency stop

Critical Low Fuel Alarm (CRITICAL LO)

A red LED is used to indicate critical low fuel. This

High Water Temperature Alarm (HIGH TEMP)

Overcrank Alarm (OVERCRANK)

A red LED is used to indicate that the engine did not

General Overspeed Alarm (OVERSPEED)

A red LED used to indicate an overspeed condition.

Ruptured Basin Alarm (RUPT BASIN)

A red LED is used to indicate the double wall fuel