manual panel d

POWER SYSTEMS, INC.

®

GENERAC® POWER SYSTEMS

Operator’s Manual“D” Option Control Panel

Generac® Power Systems, Inc.

Important Safety InstructionsD Option Control Panel

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 alloperators and potential operators of this equipment.! !

Study these SAFETY RULES carefully beforeinstalling, operating or servicing this equipment.Become familiar with this manual and all literaturepertaining to your generator set and related equip-ment. This equipment can operate safely, efficientlyand reliably only if it is properly installed, operatedand maintained. Many accidents are caused by failingto follow simple and fundamental rules or precau-tions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warn-ings in this manual, and on tags and decalsaffixed to your equipment are, therefore, not all-inclusive. If you use a procedure, work method oroperating technique Generac does not specifically rec-ommend, you must satisfy yourself that it is safe for youand others. You also must make sure the procedure,work method or operating technique that you choosedoes not render the equipment unsafe.

GENERAL HAZARDS• For safety reasons, Generac recommends

that this equipment be installed and serviced by aGenerac Authorized Service Dealer or other compe-tent, qualified electrician or installation technicianwho is familiar with applicable codes, standards andregulations. The operator also must comply with allsuch codes, standards and regulations.

• When working on this equipment, remain alert at alltimes. Never work on the equipment when physical-ly or mentally fatigued.

• Inspect the equipment regularly, and promptly repairor replace all worn, damaged or defective parts usingonly factory-approved parts.

• Before performing any maintenance on the generatoror any related equipment, disconnect the generator’sbattery cables to prevent accidental start-up.Disconnect the cable from the battery post indicatedby a NEGATIVE, NEG or (–) first. Reconnect thatcable last.

ELECTRICAL HAZARDS• Generators produce dangerous electrical voltages

and can cause fatal electrical shock. Avoid contactwith bare wires, terminals, connections, etc., whilethe generator and related equipment are running.Ensure all appropriate covers, guards and barriersare in place before operating the equipment. Ifwork must be done around an operating unit,stand on an insulated, dry surface to reduce shockhazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while hands orfeet are wet. DANGEROUS ELECTRICAL SHOCKMAY RESULT.

• If people must stand on metal or concrete whileinstalling, operating, servicing, adjusting or repairingthis equipment, place insulative mats over a drywooden platform. Work on the equipment only whilestanding on such insulative mats.

• Wire gauge sizes of electrical wiring, cables and cordsets must be adequate to handle the maximum elec-trical current (amperage) to which they will be sub-jected.

• Before installing or servicing this equipment, makesure that all power voltage supplies are positivelyTURNED OFF at their source. Failure to do so willresult in hazardous and possibly fatal electricalshock.

• When installed with an automatic transfer switch, thegenerator may crank and start anytime withoutwarning. To prevent injuries cause by sudden start-up, disable the generator’s automatic start circuitbefore working on or around the unit. Then, place a“Do Not Operate” tag on the generator control paneland on the transfer switch.

• In case of accident caused by electric shock, imme-diately shut down the source of electrical power. Ifthis is not possible, attempt to free the victim fromthe live conductor. AVOID DIRECT CONTACT WITHTHE VICTIM. Use a nonconducting implement,such as a rope or board, to free the victim from thelive conductor. If the victim is unconscious, applyfirst aid and get immediate medical help.

• Never wear jewelry when working on this equipment.Jewelry can conduct electricity resulting in electricshock, or may get caught in moving componentscausing injury.

FIRE HAZARDS• For fire safety, the generator and related equipment

must be installed and maintained properly.Installation always must comply with applicablecodes, standards, laws and regulations. Adherestrictly to local, state and national electrical andbuilding codes. Comply with regulations theOccupational Safety and Health Administration(OSHA) has established. Also, ensure that theequipment is installed in accordance with the man-ufacturer’s instructions and recommendations.Following proper installation, do nothing thatmight alter a safe installation and render the unitin noncompliance with the aforementioned codes,standards, laws and regulations.

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Table of ContentsD Option Control Panel

Generac® Power Systems, Inc. 1

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

General Information ........................................................2OVERVIEW........ ............................................................2CONTROL PANEL CIRCUIT BOARDS............................2

PCB 1 – Main Central Processor Unit(CPU) Board ....................................................2

PCB 2 – Display Board ........................................2PCB 3 – Interface Board ......................................2Locations of Circuit Boards ................................2

OPTIONAL EQUIPMENT................................................2GenLink™ ............................................................2Modem... ..............................................................2Remote Annunciator Panel ..................................2

DIGITAL DISPLAYS ......................................................2Battery Saver ......................................................2AC Voltage Display ..............................................3AC Voltage Indicators ..........................................3AC Current Display ..............................................3Frequency Display................................................3Frequency Indicators............................................3Power Factor ........................................................3Power Output ......................................................4Oil Pressure ........................................................4Water Temperature ..............................................4% Fuel.. ..............................................................4Battery Voltage Display ........................................4Battery Voltage Indicators ....................................4Engine 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........... ..............................................................7Numeric Keys 0-9 ................................................7Enter and Clear Keys ..........................................7Program Key ........................................................7Alarm Horn Reset Key..........................................7Alarm Lamp Reset Key ........................................7Phase Select Key ..................................................7

CONTROLS....................................................................7Emergency Stop Switch ......................................7RS-232 Local Communications Port ....................7Auto-Off-Run Switch ............................................7Main DC Fuse ......................................................8Voltage Trim Potentiometer ..................................8

INPUTS............ ..............................................................8AC Voltage ............................................................8AC Current ..........................................................8Fuel Level ............................................................8Oil Pressure ........................................................8Water Temperature ..............................................8Engine Speed Sensor ..........................................8Coolant Level Sensor ..........................................8Emergency Stop Contact ......................................8Transfer Switch/Remote Start ..............................8Pre High Oil Temperature ....................................8High Oil Temperature ..........................................9High Fuel Level ....................................................9Low Fuel Level ....................................................9Main Line Circuit Breaker ..................................9Ruptured Basin....................................................9Spare Alarms ......................................................9Spare Warnings....................................................9

OUTPUTS....... ..............................................................9Starter Solenoid ..................................................9Alarm..... ..............................................................9Load Control........................................................9Auxiliary ..............................................................9Preheater..............................................................9Fuel Control Relay................................................9

COMMUNICATIONS ......................................................9Front Panel Communications Port ......................9Modem... ..............................................................9Remote Communications Port..............................9

– Monitored Parameters........................10Dial Out Option..................................................10

INSTALLATION NOTES ..............................................10

Operation........... ..............................................................11OPERATION OF DIGITAL GENERATOR

CONTROL PANEL..........................................................11Using the Keypad.... ..............................................11Programmable Options ........................................11

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

Appendix 2 – Notes ......................................................21

Appendix 3 – Exploded Views and Parts Lists ......22

AUTHORIZED SERVICEDEALER LOCATION

To locate the nearest GENERAC AUTHORIZEDSERVICE DEALER, please call this number:

1-800-333-1322DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

OVERVIEWThe “D” option control panel is a microprocessor-based generator set control panel designed forGenerac’s range of standby generators. It has a fullydigital user interface and comprehensive communi-cation capabilities.

The panel is housed in a steel sheet metal enclosurethat meets NEMA 1 specifications. The front face ofthe panel consists of a number of light-emittingdiodes (LED) display windows showing generatoroperating conditions, a tactile keypad, alarm and sta-tus LED indicators, a main fuse, an “EmergencyStop” switch and other generator set controls.

CONTROL PANEL CIRCUIT BOARDSThe control panel contains three main printed-circuitboards (PCB), the automatic voltage regulator (AVR),and terminal blocks for external connections.

To find the location of the circuit boards, refer toAppendix 3 for the control panel exploded views. Thethree main PCBs have the following defined func-tions:

PCB 1 – MAIN CENTRAL PROCESSOR UNIT (CPU) BOARD

(Part # 0A1053) This board houses the microproces-sor, its memory, input and output (I/O) stages and allcommunication hardware (including optional modemfor telephone system communications).

PCB 2 – DISPLAY BOARD(Part # 0A1056) This board houses all the LED dis-plays and annunciators, and their respective drivercircuitry.

PCB 3 – INTERFACE BOARD(Part # 0A1054) This board houses all the compo-nents necessary to interface the CPU board to thegenerator. This board receives high voltage and cur-rent signals from the generator output. All controlrelays are mounted on this board. Connections tothis board are by screw terminals.

LOCATIONS OF CIRCUIT BOARDSPCBs 1 and 2 are mounted together on the back ofthe hinged front wall of the panel, and PCB 3 ismounted on the left wall of the panel as viewed fromthe front.

The right wall houses the AVR and the optional elec-tronic governor controller. Both of these controls,which are mounted on a chassis, are accessible exter-nally from the right side of the panel via removablecovers that allow for adjustment.

Remove the 15-amp fuse from the front of thepanel during all engine maintenance to guardagainst accidental or remote start-up.

OPTIONAL EQUIPMENTGENLINK™

GenLink is a communications software that allows thegenerator to be started and monitored from a remotePC via a modem. The generator can dial out automati-cally and inform the PC if it has an active alarm condi-tion.

MODEMA modem (Part # 0A3557) can be connected to the Dpanel to allow the generator to communicate with aremote PC.

REMOTE ANNUNCIATOR PANELWhen connected to the generator via a simple shield-ed two-wire link (plus two wires for power), this 20-light remote indicator panel will display the genera-tor’s status.

REMOTE RELAY PANELThis panel is similar to the remote annunciator, butinstead of indicator lights, it provides relay contact clo-sures for status (e.g., alarms).

DIGITAL DISPLAYS (FIGURE 1.1, PAGE 3)

BATTERY SAVER (“SLEEP MODE”)

In order to conserve battery power, the display panelwill power down after five minutes when it is notbeing used. It will reactivate if any of the followingoccurs:

• A key is pressed.• The engine is started.• Remote communications occur.During the power down period, the alarms arechecked for 30 seconds every five minutes; any alarmthat occurs is permanently illuminated.

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General InformationD Option Control Panel

2 Generac® Power Systems, Inc.


AC VOLTAGE DISPLAY (AC VOLTS)This is a four-digit LED display for monitoring thevoltage of the selected phase. A keypad command(“PHASE SEL”) is used to select which phase is dis-played. LEDs indicate the phase that is currentlyactive. 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 fol-lowing phase selections. A lit LED on the phase indi-cator 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 fol-lowing phase selections. A lit LED on the phase indi-cator will show the active phase.

❍ A-Neutral (A - B)

❍ C-Neutral (B - C)

❍ C-A

Selection of single or three phase monitoring is donethrough the panel’s programmable options (see“Programmable Options,” Page 11).

AC VOLTAGE INDICATORS (HI, LO)A pair of LEDs (included in “AC VOLTS” display) isused to indicate whether the generator’s AC outputvoltage is low or high. The set points are user pro-grammable. These alarms are latched and cause thealarm relay to latch.

Either alarm condition will shut down the generatorand cause a modem callout if enabled. This alarm isenabled after the programmable alarm hold off timerexpires.

Voltage alarm checking is done on all phases. In thecase of single-phase (i.e., 110 volts AC), the C-Aphase selection should coincide with an AC voltagedisplay of 220 volts AC. The alarm checking is takencare of by the software, thus the alarm trigger pointsonly 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 thealarm will be raised.

AC CURRENT DISPLAY (AC AMPS)This is a four-digit LED display for monitoring thecurrent in the selected phase. The range is 0 to 5,000amps, depending on the selected current transformerand the setting of the programmable full-scale cur-rent range.

FREQUENCY DISPLAY (HERTZ)This is a three-digit LED display for monitoring thefrequency of the generator output. The range of thisdisplay is 40 to 70 Hertz. Phase “A” is used for thismeasurement.

FREQUENCY INDICATORS (HI, LO)A pair of LEDs (included in “HERTZ” display)is usedto indicate whether the generator’s frequency outputis low or high. The set points are user programmable.These alarms are latched and cause the alarm relayto latch.

POWER FACTORThis is a three-digit LED display for monitoring the power factor of the selected phase. The range is 0to 1.00.

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Figure 1.1 – Digital Displays on D Option Control Panel


POWER OUTPUT (KILOWATTS/MEGAWATTS)This is a three-digit LED display for monitoring thetotal power output of the generator. The power outputis the sum of all three phases, taking power factorinto account.

For powers greater than 1 megawatt, the display willshow a decimal point after the MW unit, e.g., 900 =900 kW; 1.10 = 1.1 MW.

OIL PRESSUREThis is a three-digit display used to monitor engineoil pressure. The range is 0 to 100 psi or 0 to 7.03kg/cm. If the sensor is short circuited, “-S-” will dis-play. If the sensor is open circuited, “-0-” will display.

WATER TEMPERATUREThis is a three-digit display used to monitor the enginewater temperature. The range is 0° to 300° F or -18° to149° 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 canbe a problem in cold climates where temperatures ofless than 25° F (-4° C), can cause the sensor to thinkit is open circuited. If this happens, either “-0-” (or000) will display.

To avoid this situation, the open circuit detection canbe overridden. To do this, it is necessary to set thelow temperature alarm set point to 1° F or 1° C.

% FUELThis is a two-digit display that allows users theoption of monitoring the quantity of fuel remaining. Ifthe display is active, the range is 0 to 99 percent. Fuellevel senders are optional. If a fuel level sender hasnot been installed, the % fuel display should be dis-abled (See Programmable Options on page 13 andHigh Fuel Alarm on page 5).

BATTERY VOLTAGE DISPLAYThis is a three-digit LED display for monitoring bat-tery 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 con-dition. The set points are user programmable. Thesealarms are latched and cause the alarm relay to latch.They do not shut down the generator, but do cause amodem callout if enabled. The low battery indicatorwill be activated after six minutes of a low batterycondition. This allows it to be used as a batterycharger monitor.

ENGINE HOURS This is a six-digit LED display used to show enginerunning time in hours. This display is also used whenentering the password and changing the programma-ble options (see “Operation of Digital GeneratorControl Panel,” Page 11).

STATUS INDICATORS – ALARMS ANDWARNINGS (SEE FIGURE 1.2)

OIL

Low Oil Pressure Alarm (LO PRES)A red LED is used to indicate a low oil pressure condi-tion. The set point is user programmable. The alarm islatched and causes the alarm relay to latch. It shutsdown the generator and causes a modem callout ifenabled. This alarm is enabled after the programmablealarm hold off timer expires.

High Oil Temperature Alarm (HIGH TEMP)A red LED is used to indicate a high oil temperatureswitch has been closed. This alarm is latched andcauses the alarm relay to latch. It shuts down the gen-erator and causes the modem to callout if enabled.This alarm is enabled at all times.

Pre Low Oil Pressure Warning (PRE LO PRES)A yellow LED is used to indicate a warning that a lowoil pressure condition exists. The set point is userprogrammable. The alarm relay is latched.

Pre High Oil Temperature Warning (PRE HIGH TEMP)

A yellow LED is used to indicate a warning that a prehigh oil temperature condition exists. The alarmrelay is latched.

Figure 1.2 – Status Indicators

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WATER

High Water Temperature Alarm (HIGH TEMP)A red LED is used to indicate a high water tempera-ture condition. The set point is user programmable.The alarm is latched and causes the alarm relay tolatch. The alarm shuts down the generator and caus-es a modem callout if enabled. The alarm is enabledafter the programmable alarm hold off timer expires.

Low Level Water Alarm (LO LEVEL)A red LED is used to indicate the radiator water levelis low. The alarm is latched and causes the alarmrelay to latch. The alarm shuts down the generatorand causes a modem callout if enabled. This alarm isenabled after the programmable alarm hold off timerexpires.

Pre High Water Temperature Warning(PRE HIGH TEMP)

A yellow LED is used to indicate a warning that a highwater temperature condition exists. The set point isuser programmable. The alarm relay is latched.

Low Water Temperature Warning (LO TEMP)A yellow LED is used to indicate a warning that a lowwater temperature exists. The set point is user pro-grammable. The alarm relay is latched.

FUEL

High Fuel Alarm (HI)A red LED is used to indicate a high fuel level. Theindicator can be activated in one of two ways:

1. Percent input2. Switch input on J7-5If the fuel percent measurement is used, an analogsensor MUST BE installed and selected via program-mable option #2. This allows for percentages to beprogrammed for critical low fuel, low fuel and highfuel. If the percentages are exceeded for high fuel, thealarm relay will latch, but the generator will continueto run. The modem will callout if enabled. (Theswitch input will light the LED only.)

NOTE:The two switch inputs – LO Fuel Level J7-4 andHI Fuel Level J7-5 – work only if the percentageinput is turned off via programmable option #2.When the % Fuel measurement is not used, the dis-play is turned off.

Critical Low Fuel Alarm (CRITICAL LO)A red LED is used to indicate critical low fuel. Thisfeature is available only with an analog sender. Thealarm is latched. It does shut down the generator andcauses a modem callout if enabled.

Low Fuel Warning (LO)A yellow LED used to indicate a low fuel level. Theindicator can be activated in one of two ways:

1. Percent input from analog sender2. Switch input on J7-4If the fuel percent measurement is used, an analogsensor MUST BE installed and selected via program-mable option #2. This allows for percentages to beprogrammed for critical low fuel, low fuel and highfuel. The alarm relay is latched, but the generator willcontinue 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 andHi Fuel Level J7-5 – work only if the percentageinput is turned off via programmable option #2.When the % Fuel measurement is not used, the dis-play is turned off.

ADDITIONAL ALARMS AND WARNINGS

Emergency Stop Alarm (EMG STOP)A red LED is used to indicate that the emergency stopswitch has been activated. This alarm is latched andcauses the alarm relay to latch. It shuts down the gen-erator and causes a modem callout if enabled. Thisalarm is enabled at all times.

Overcrank Alarm (OVERCRANK)A red LED is used to indicate that the engine did notstart after eight starting attempts. The starting cycleconsists of a programmable number of seconds ofcranking followed by five seconds of OFF time. Thisalarm is latched and causes the alarm relay to latch.It shuts down the generator and causes a modemcallout if enabled.

General Overspeed Alarm (OVERSPEED)A red LED used to indicate an overspeed condition.The set point is user programmable. The alarm islatched and causes the alarm relay to latch. Thealarm shuts down the generator and causes a modemcallout if enabled. The alarm is enabled after theengine starts. If the speed sensor fails, then the bot-tom right (unmarked) yellow LED will light and thealarm relay will latch. The alarm shuts down the gen-erator and causes a modem callout if enabled.

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Ruptured Basin Alarm (RUPT BASIN)A red LED is used to indicate the double wall fueltank has ruptured. A float switch in the outer tankcloses when a rupture occurs. The alarm latches andcauses the alarm relay to latch. It causes the modemto callout if enabled, but it does not shut down thegenerator. 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 notset to the Auto start mode.

Main Line Circuit Breaker Warning (MLCB OPEN)

A yellow LED is used to indicate a main line circuitbreaker is open. This is an optional switch input.

Remote Access Warning (REM ACCESS)A yellow LED is used to indicate that modem com-munication is currently active.

Program Mode Warning (PROG MODE)A yellow LED is used to indicate that the panel is inthe program mode.

SPARE LEDS

There are four unmarked LEDs on the front panel;two red and two yellow. These indicators have differ-ent functions depending on whether or not a RemoteAnnunciator or Remote Relay Panel is connected tothe D-panel.

No Remote Annunciator/Remote Relay Panel Connected

Without a Remote Annunciator/Remote Relay Panelconnected to the D panel (Figure 1.3), the functionsare as follows:

Figure 1.3 – Spare Indicators (Without RemoteAnnunciator/Remote Relay Panel Connected)

ALARMS 1, 2 and the SPECIAL pin can occur onlyafter the programmable hold off time. When the pinis shorted to ground, the LED lights, the engine shutsdown, and the alarms relay is latched. The modemwill call out if it is enabled.

The SPECIAL LED also can light and cause an alarmif there is a speed sensor (tach) loss.

The WARN1 LED will light when its pin is shorted toground. The alarm relay will latch, and the modemwill call out if it is enabled.

Remote Annunciator/Remote Relay PanelConnected

With a Remote Annunciator/Remote Relay Panel fittedto the D panel (Figure 1.4), the LEDs function as fol-lows:

Figure 1.4 – Spare Indicators (With RemoteAnnunciator/Remote Relay Panel)

The BATTERY CHARGER AC FAIL pin is intended toshow that the AC supply to the battery charger hasfailed by shorting the pin to ground via an external,customer supplied relay (Figure 1.5).

Figure 1.5 – Battery Charger AC Fail

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▼General InformationD Option Control Panel


The LED will light and latch. The generator will notshut down, the alarm relay will not operate, and themodem will not call out. The status will be sent to theremote annunciator and displayed on its front panel.

GENERATOR POWER will cause the LED to act as anindicator only. No alarms or shutdowns will occur.The state of the input will be displayed on the remoteannunciator. It is intended to be connected to an aux-iliary contact on a transfer switch to indicate when allloads are running on generator power. The LEDlights when J7 pin 9 is shorted to ground.

LINE POWER – J7 pin 10 acts as above.

SPECIAL – J7 pin 11 acts as previously described.

KEYPADFigure 1.6 – Keypad Features

NUMERIC KEYS 0-9Decimal numbers are included on a keypad for entryof passwords and setting of programmable values.

ENTER AND CLEAR KEYSThe ENTER key will be used to accept data inputfrom the numeric keys. The CLEAR key will be usedto remove erroneous entries during programming.

PROGRAM KEY (PROG)This key is used to enter the local programming mode.After pressing this key, the programming display willshow the word “ACCESS,” prompting the user for thepassword. The password is a six-digit number that isentered on the numeric keys and is displayed on thehourmeter/programming display. The default factorypassword is always 000000.

ALARM HORN RESET KEYThis key is used to reset the alarm relay contacts.

ALARM LAMP RESET KEYThis key is used to reset alarms that have beenlatched.

PHASE SELECT KEY (PHASE SEL)This key is used to select which of three phases is tobe shown in the “AC Volts” and “AC Amps” displays.

CONTROLS (FIGURE 1.7, PAGE 8)

EMERGENCY STOP SWITCHThis switch (colored RED) is a normally closed, sin-gle-action, latching push button that, when activated,will immediately cause the generator to shut dow-nand alarm relay to latch.

RS-232 LOCAL COMMUNICATIONSPORT (COMM. PORT)

This connector allows connection of a local comput-er to the panel for easy programming and diagnosticchecking. The computer needs to have a copy ofGenLink™ loaded on it to enable communicationwith the D panel. A serial cable (part # 0A4042) alsois required to connect to the unit.

AUTO-OFF-RUN SWITCHA three-position rotary switch is provided for genera-tor control. In AUTO the generator will wait for a sig-nal, such as from an automatic transfer switch. Whenit receives the remote start signal, it will automatical-ly initiate the generator start sequence. This onlyoccurs assuming no shutdown alarm conditionexists.

When in the OFF position, the generator is inhibitedfrom starting.

When the switch is in the RUN position, the genera-tor will instantly be commanded to start assumingthat no shutdown alarm condition exists.

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MAIN DC FUSE (FUSE 15A)This fuse is rated at 15 amps and is of the 1.25-inch-es x 0.25-inch glass type (part # 022676). Removal ofthis fuse inhibits all control panel functions and isrecommended during all maintenance operations.

VOLTAGE TRIM POTENTIOMETER(VOLTAGE ADJUST) (IF EQUIPPED)

This control allows adjustment of the generator out-put voltage in the range +/- 5 percent, if set to themidpoint.

INPUTSAC VOLTAGE

Four terminals (PCB3: J2-1, J2-2, J2-3, J2-4) areprovided for voltage measurement. Maximum inputvoltage is 1000 volts AC.

NOTECorrect phasing for these terminals is essentialfor correct operation (see Appendix 1 –Electrical Data for phase schematics).

AC CURRENTFour terminals (PCB3: J2-7, J2-9, J2-11, J2-10) areprovided for current measurement. The inputs willinterface with current transformers having a five-ampsecondary winding at their rated current.

NOTECorrect phasing for these terminals is essentialfor correct operation (see Appendix 1 –Electrical Data for phase schematics).

FUEL LEVEL (PCB1: J10-1)An optional analog input is provided for fuel levelmeasurement. This is a 0 to 5 VDC input. An inputsignal of 0 volts is equivalent to 0 percent remainingfuel and 5 volts is equivalent to 99 percent remainingfuel. The relationship between input voltage and fuellevel is linear.

OIL PRESSURE (PCB1: J10-2)An analog input is provided for oil pressure meas-urement. This input will interface to the standardGenerac sender unit (part # 053666). It is also usedfor warning and shutdown situations.

WATER TEMPERATURE (PCB1: J10-3)An analog input is provided for coolant temperaturemeasurement. This input will interface to the stan-dard Generac thermistor sensor (part # 053667). Itis also used for warning and shutdown situations.

ENGINE SPEED SENSOR (PCB1: J10-5)An input is provided for sensing engine speed bycounting teeth on the flywheel via a magnetic proxim-ity probe. The input interfaces to the Generac stan-dard magnetic pickup (part # 082130D).

COOLANT LEVEL SENSOR (PCB1: J10-4)A dedicated analog input is provided for sensing lowcoolant level. The input will interface to the Generaccoolant level sensor (part # 057522).

EMERGENCY STOP CONTACT(PCB3: TB2-1, TB2-3)

An input is provided for an emergency stopswitch(es). The switch contact is normally closed.

TRANSFER SWITCH/REMOTE START(PCB1: J7-12)

When the AUTO-OFF-RUN switch is set to AUTO andthis input is grounded, the generator will begin itsstart sequence. When the utility voltage drops, thetransfer switch/remote start system will close a con-tact to ground this input.

PRE HIGH OIL TEMPERATURE (PCB1: J7-7)An optional input is provided for a pre high oil tem-perature warning switch. (Switch to ground toalarm.)

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Figure 1.7 – Control Switches and Knobs on D Option Control Panel


HIGH OIL TEMPERATURE (PCB1: J7-6)An optional input is provided for a high oil tempera-ture 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 dis-play 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 dis-play fuel percentage.

MAIN LINE CIRCUIT BREAKER (PCB1: J7-2)An input is provided for a circuit breaker auxiliarycontact to indicate that the main line circuit breakeris open. (Switch to ground to alarm.)

RUPTURED BASIN (PCB1: J7-3)An input is provided for a level switch indicating thefuel tank is ruptured. (Double wall fuel tanks only.)(Switch to ground to alarm.)

SPARE ALARMS (PCB1: J7-1, J7-9)Two inputs are provided for spare alarms. (Switch toground to alarm.) See “Spare LEDs,” Page 6.

SPARE WARNINGS (PCB1: J7-10, J7-11)Two inputs are provided for spare warning condi-tions. (Switch to ground to alarm.) See “Spare LEDs,”Page 6.

OUTPUTSSTARTER SOLENOID (PCB3: TB1-12, TB1-13)

A relay contact output is provided to activate thestarter solenoid. This form A relay is rated at 10amps at 28 volts DC.

ALARM (PCB3: TB1-4(NC),TB1-5(COM), TB1-6(NO)

A relay contact output is provided that will activateon an alarm condition. This form C relay is rated at10 amps at 28 volts DC.

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 isrunning. It is a form C relay rated at 10 amps at 28volts DC.

AUXILIARY (PCB3: TB1-1(NC), TB1-2(COM), TB1-3(NO)

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 dieselpreheater. This form A relay is rated at 10 amps at 28volts DC.

FUEL CONTROL RELAY (PCB3: TB1-14, TB1-15)A relay contact output is provided to control the fuelsolenoid/valve. This form A relay is rated at 10 ampsat 28 volts DC.

COMMUNICATIONSFRONT PANEL COMMUNICATIONS PORT

The front panel includes a connector for RS-232 seri-al communication. See “RS-232 LocalCommunications Port,” Page 7.

MODEMThe unit can optionally be provided with a modemwith “AT” command set which is FCC part 68approved. The modem will allow an operator to per-form the functions of the front panel at a remote site.However, the modem functions will not allow remotecontrol of the engine if the front panel AUTO-OFF-RUN 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 communi-cations port. This is designed to be connected toGenerac’s remote annunciators or remote relay pan-els (The Time Multiplexed Annunciator CANNOT beused with a D panel.). Up to one annunciator andfour remote relay panels can be connected togetheron this port via a shielded two wire communicationscable (plus two wires for power).

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Monitored ParametersThe remote annunciator panel (RAP) and remoterelay panel (RRP) provide remote monitoring of thefollowing engine parameters. Remote monitoring isby illuminated LEDs on the annunciator and relaycontact closures on the relay panel.

1. Generator Run2. Battery Charger AC Failure3. Low Battery Voltage4. High Battery Voltage5. RPM Sensor Loss6. Overcrank7. Overspeed8. Generator Power9. Pre Low Oil Pressure10. Pre High Coolant Temperature11. Low Coolant Temperature12. Low Fuel13. Low Oil Pressure14. High Coolant Temperature15. Emergency Stop16. Not in Auto17. Line Power18. SpareConnection details and a connection harness (exclud-ing the communications cable) are supplied with theoptional panels.

DIAL OUT OPTION (MODEM MUST BE FITTED)The dial out feature allows the panel to call out to aPC (computer) running GenLink™ software when anyalarm (red LEDs) occurs. Once this feature has beenimplemented, the GenLink™ software is placed instandby mode and waits for calls from any generatorprogrammed for dial out. The program will then dis-play the alarm responsible for dial out.

INSTALLATION NOTESThe D option control panel is designed to enhancethe current range of Generac control panels. As such,this panel can accommodate most Generac standbygenerators.

The anti-vibration mountings, fixing centers andoverall dimensions are compatible with existing pan-els, as are the lower panel connections and most ofthe engine electrical connections. All engine tempera-ture and oil pressure alarms and pre-alarms arederived from the analog signals from engine senders,so the existing alarm and shutdown switches becomeredundant; these should be disconnected or removedfrom the engine.

Lower panel connections are identical, and the panelplugs into the existing lower panel connector. Theonly additional lower panel wiring is a separate neu-tral wire that should be wired from the lower panelneutral bar to the bullet connector marked “00” (notused in a delta configuration) which is part of thelower panel connection harness protruding from thebottom of the D panel.

Refer to the schematics and wiring diagrams in“Appendix 1 – Electrical Data” for more installationinformation.

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OPERATION OF DIGITAL GENERATORCONTROL PANEL

USING THE KEYPADThe use of most keys is self-explanatory, but the opera-tion of some keys requires a brief explanation. (Foradditional information, see “Keypad” on Page 7.)

Pressing ALARM HORN RESET turns off only thealarm relay. Alarm conditions continue to be dis-played. Pressing ALARM LAMP RESET clears allalarm LEDs that are not current.

Pressing the PROG (Program) key will cause the pro-gramming digits to display “ACCESS.” At this time,the password must be entered (see ProgrammableOption 28 – “Set User Password”). If an invalid pass-word is entered, the program will do nothing.Additional characters may be entered in an attemptto log on (only the last six digits are recognized). If avalid password is not entered and/or no keypad activ-ity has occurred for two minutes, the program willrevert to running time display.

If the correct password is entered, the display willchange to “00.” At this time, the program is waitingfor an option (see “Programmable Options”) to beentered. Twenty-eight options may be displayed andchanged, if desired. The current setting remainsunchanged if ENTER is pressed, or it can be changedby entering a new number followed by ENTER. Exitthe keypad routine by pressing ENTER again anytimethe display shows “00.”

Program options can be modified in the AUTO, OFFor RUN mode. However, it is recommended that the options be changed while the panel is in the OFFmode.

PROGRAMMABLE OPTIONSFor information on programmable options, refer tothe following text, as well as the chart on .

1. – Select English or Metric UnitsUnits of measurement will be changed on the panelfor oil pressure and water temperature.

2. – Fuel Display On/OffThe fuel display should be turned off when an analogfuel sensor is not being used. Alarm and warningLEDs for fuel are activated by either the low and highfuel switches or the programmed values used withthe analog sensor.

3. – Pre Low Oil PressureSee “Status Indicators – Alarms and Warnings,” Page4.

4. – Low Oil PressureSee “Status Indicators – Alarms and Warnings,” Page4.

5. – Low Water TemperatureSee “Status Indicators – Alarms and Warnings,” Page4.

6. – Pre High Water TemperatureSee “Status Indicators – Alarms and Warnings,” Page4.

7. – High Water TemperatureSee “Status Indicators – Alarms and Warnings,” Page4.

8. – Critical Low FuelThis is used with an analog sensor to turn on a redalarm LED. See “Status Indicators – Alarms andWarnings,” Page 4.

9. – Low FuelThis is used with an analog sensor to turn on a yel-low warning LED. See “Status Indicators – Alarmsand Warnings,” Page 4.

10. – High FuelThis is used with an analog sensor to turn on a redalarm LED. See “Status Indicators – Alarms andWarnings,” Page 4.

11. – Low AC VoltageA red LED next to the “AC Volts” display is used to indi-cate this alarm. If the generator’s AC voltage dropsbelow this set value for more than 0.5 seconds, analarm occurs and the engine shuts down. The alarm islatched and causes the alarm relay to latch and pro-duce a modem callout if enabled. This alarm is activat-ed after the alarm hold off time is complete.

12. – High AC VoltageA red LED next to the “AC Volts” display is used to indi-cate this alarm. If the generator’s AC voltage goes abovethis set value for more than 0.5 seconds, an alarmoccurs and the engine shuts down. The alarm is latchedand causes the alarm relay to latch and produce amodem callout if enabled. This alarm is activated afterthe alarm hold off time is complete.

13. – Low Battery VoltageA red LED next to the “Battery Voltage” display isused to warn that battery voltage is below pro-grammed limits. No shutdown occurs with this warn-ing.

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OperationD Option Control Panel


14. – High Battery VoltageA red LED next to the “Battery Voltage” display isused to warn that battery voltage is above pro-grammed limits. No shutdown occurs with this warn-ing.

15. – Low Frequency LimitA red LED next to the “Hertz” display is used to indi-cate this alarm. If the generator’s frequency dropsbelow this set value for more than 1.5 seconds, analarm occurs and the engine shuts down. The alarmis latched and causes the alarm relay to latch andproduce a modem callout if enabled. This alarm isactivated after the alarm hold off time is complete.Frequency is measured on phase “A.”

16. – High Frequency LimitA red LED next to the “Hertz” display is used to indi-cate this alarm. If the generator’s frequency goesabove this set value for more than 1.5 seconds analarm occurs and the engine shuts down. The alarmis latched and causes the alarm relay to latch andproduce a modem callout if enabled. This alarm isactivated after the alarm hold off time is complete.Frequency is measured on phase “A.”

17. – Starting SpeedThis is the speed at which the engine becomes self-sustaining and causes the starter to disengage. Thealarm hold off timer is started when this rpm hasbeen reached.

18. – OverspeedSee “Status Indicators – Alarms and Warnings,” Page4.

19. – Alarm Hold Off TimeMost alarms are ignored during alarm hold off time.If an alarm still persists after the hold off time, it willbecome active. See “Status Indicators – Alarms andWarnings,” Page 4, for more information.

20. – Crank Cycle On TimeThis is the length of time that the starter staysengaged when given a command to start. There willbe a five second off time after each on time. Aftereight unsuccessful tries (each try consisting of onecycle crank on time and one off time), the overcrankalarm will latch the engine off, and the alarm LEDwill turn on.

21. – Flywheel TeethThis value is preset at the factory. This is the numberof teeth on the flywheel ring gear.

22. – Load ControlThis load control relay output has NO/NC contactsthat can be used to connect the generator to the loadonce the generator’s output voltage and frequencyclimb above the preprogrammed low AC voltage andlow frequency limits. This relay can be controlledfrom the front panel or through GenLink™ softwarevia a modem or RS-232. It is possible to use this out-put as a generator running signal, but it will bedelayed by the hold off timer. (e.g., Program the out-put to be ON, see Figure 2.1). See “Outputs” on Page9.

Figure 2.1 – Load Control as Generator Running Signal

23. – Set/Reset Auxiliary Output 1This auxiliary relay output has NO/NC contacts thatcan be used as general purpose relay under frontpanel control. This relay also can be controlled fromthe front panel or through GenLink™ software via amodem or RS-232. By selecting Option 3, the relay isprogrammed to operate on engine shutdown only.See “Outputs” on Page 9.

24. – Set CT Primary CurrentThis is the current rating for the primary side of theCT with the secondary side being five amps. D panelsare set up to use five amp secondaries.

25. – Preheat Time OnThis is the length of time that the preheat device on adiesel engine is energized.

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▼OperationD Option Control Panel


26. – Preheat While CrankingThis allows the preheater to be energized while theengine is cranking.

27. – Select PhasingThere are three possible generator configurations.They are single-phase, three-phase wye and three-phase delta.

28. – Set User PasswordThis allows the user to change the default password.All D panels ship from the factory with the defaultpassword set to zero (000000). If the modified userpassword is lost or misplaced, it is possible for atechnician to access the panel through remote soft-ware to determine the password. However, in orderfor the technician to access the panel and password,the panel must be capable of remote communicationvia a modem.

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OperationD Option Control Panel

PROGRAMMABLE OPTIONSOPTION DEFAULT RANGE or ALT YOUR SETTING1. Select English or 1=English 2=Metric

Metric Units2. Fuel Display On/Off 1=OFF 2=ON3. Pre Low Oil Pressure 15 psi/1.02 bar. 0-100 psi/0-6.8 bar.4. Low Oil Pressure 10 psi/0.68 bar. 0-100 psi/0-6.8 bar.5. Low Water Temp. 90° F/32° C 0-300° F/-18-149° C6. Pre High Water Temp. 220° F/104° C 0-300° F/-18-149° C7. High Water Temp. 250° F/121.2° C 0-300° F/-18-149° C8. Critical Low Fuel 5% 0-99%9. Low Fuel 10% 0-99%

10. High Fuel 95% 0-99%11. Low AC Voltage 90 VAC 0-1023 VAC12. High AC Voltage 230 VAC 0-1023 VAC13. Low Battery Voltage 12.2 VDC 0-51.1 VDC14. High Battery Voltage 15.0 VDC 0-51.1 VDC15. Low Frequency Limit 57 Hz 40-70 Hz16. High frequency limit 63 Hz 40-70 Hz17. Starting Speed 500 RPM 0-3600 RPM18. Overspeed 2100 RPM 0-3600 RPM19. Alarm Hold Off Time 10 SEC 0-60 SEC20. Crank Cycle On Time 5 SEC 5-15 SEC21. Flywheel Teeth 168 75-20022. Load Control 1=OFF 2=ON23. Set/Reset Aux. Output 1 1=OFF 2=ON/3=Operate on Shutdown24. Set CT Primary Current 150A 50-5000A25. Preheat Time On 0 SEC 0-30 SEC26. Preheat While Cranking 2=ON 1=OFF27. Select Phasing 2=WYE 1=SINGLE

2=WYE3=DELTA

28. Set User Password 000000 000000-999999

CB2 CIRCUITCB2

CUSTOMER CONNECTION120/240V 1-PHASE 60Hz110/220V 1-PHASE 50Hz

E1 00 E3

120/240V 3-PHASE 60Hz100/200V 3-PHASE 50Hz

CUSTOMER CONNECTION

CIRCUITBREAKER

00 E1 E3

BREAKER

PARALLEL WINDING ONLYFITTED ON D OPTIONALTERNATORS.J+P OPTION1-PH MACHINES SHOULD BE

PHASE RATING.DERATED TO 66% OF THREE

E2

NOTE ONE

00

10

12

CB2

(ONLY USED ON 125kW ANDABOVE, OUTPUT IS 66%

S3

S16

0

58

OF 3-PHASE RATING)

lL

LCT1

K

l

k

S7

S1

S10

S4

S15

57

S1S2

0l

CT2

K k

L

AS

00

00

S15

S5

S11 S9

S3

00

CUSTOMER CONNECTION120/240V 1-PHASE 60Hz110/220V 1-PHASE 50Hz

VOLTAGE CODE - A + MPARALLEL ZIG-ZAG12-WIRE

E1

CT1

K

l

k

S2

S8

S6S12

CT2

0

K

E3

0

k

1

SERIES 4-WIREVOLTAGE CODE - A + M

AS

00S1

S1

57

11 22

L

S2

S15

00

9S16

58

S3

85

S3

7

4433

00

8S200

SERIES DELTA 12-WIREVOLTAGE CODE - D,J + P

CUSTOMER CONNECTION277/480V 3-PHASE 60Hz

240/415V 3-PHASE 50/60Hz

S3

S11

PLUG

PANEL

OPTIONAL

1

9

TO

FORNEUTRAL REQD.

D-OPTION

OPTIONAL

00

S15

00 TO

EGCS1

L

K

CT1

k

l

CT3

K

0L

k

l

57

00 S1

S15

S3

S10

S77

S44

CT1

BREAKERCIRCUIT

OPTIONAL

NOTEONE

SEE

E1

S1

E3

0L

K

l

k

CT3L

K

l

k

S2

EGCOPTIONAL

CONTROLPANEL

CONNECTIONS

OPTIONAL

PLUG5

58K

CT2L 0

k

l

S3

59

S2

12

1

10

13

11

8 TO

S2S16

S9S6

ASS12

S15

79

00

TO

OPTIONAL

S5S8

00 E2

L

CT2

K

0

59

57

10

CB2

58

l

k12

13

10CONNECTIONS

CIRCUITBREAKER

PANELCONTROLTO

PLUG

S1

SERIES WYE 12-WIREVOLTAGE CODE - K + R

S4

S10

S7

S12

OPTIONAL

CONNECTIONSPLUG

PANELCONTROLTO

00

S15

TO

EGC

D-OPTION

NEUTRAL REQD.

FOR

S9

S1 S3

S3

S6

NEUTRAL REQD.

D-OPTION

S15

S8

S15

S1S3

S16

00

00

S5

S2

9511

7

S2

00

S11

AS

00

EGC

TOOPTIONAL

FOR


Appendix 1 — Electrical DataD Option Control PanelPhase Schematics – Drawing No. 099389-B


PERMANENT MAGNET ROTOR

ELECTRONIC GOVERNOR CONTROL

THERMAL PROTECTOR (AUTO-RESET)

WIRING DIAGRAMS Nos. 099336 & 099491

READ THIS DRAWING IN CONJUNCTION WITH

PERMANENT MAGNET EXCITATION WINDING

E2

120/208V 3-PHASE 60Hz 139/240V 3-PHASE 60Hz115/200V 3-PHASE 50Hz

E1

CUSTOMER CONNECTION

E3 00

CB2OPTIONALCIRCUITBREAKER PME

TP

EGC

PMR

OPTION B - PERMANENT MAGNET GENERATOR

EXCITATION POWER OPTIONS

(USE EITHER OPTION A OR OPTION B ONLY)

CONNECT CHARGE

OPTION A - UNITS WITH BRUSHES

EXCITER FIELD OPTIONS

OPTION B - BRUSHLESS UNITS

OPTIONAL CIRCUIT BREAKER STATUS AUXILLIARY CONTACT

ALTERNATOR ROTOR

ALTERNATOR STATOR

BATTERY CHARGE WINDING

CURRENT TRANSFORMER

MAIN CIRCUIT BREAKER (OPTIONAL)

BRUSHLESS EXCITER ARMATURE

BRUSHLESS EXCITER FIELD

DISPLACED PHASE EXCITATION WINDING

77TO

CT2

PARALLEL WYE 12-WIREVOLTAGE CODE - G + N

S2

L

CT3

K

CT1l

K k

L 0

S1

00S3

l

k57

0

59

CT2

K

L

S1

S15

S3

S3

S9 S6

S4

S12

00

S15

00

S5

S11

S8

S2

AS

277/480V 3-PHASE 50Hz 346/600V 3-PHASE 60Hz

E1

LCT1

K

l

k

0

CUSTOMER CONNECTION

S1

E3

S7

00

CT3

K

L l

k

0

59

D-OPTION

CONNECTIONS

l

k

0

58

1

10

12

13

S2

S165

118

79

CONTROLPANEL

TO

PLUG

00

S15OPTIONAL

EGC

TO

DPE

EA

EF

CB2

BC

CT

LEGEND

AR

AS

BREAKER IS OPEN

WHEN THE CIRCUIT

AUX. CONTACT CLOSED

NEUTRAL REQD.

FOR00

E2

13

12

CB2

l

K k

L0

58

OPTIONAL

BREAKERCIRCUIT

PANELCONTROL

1

AR

AR

77A

66ABC2

WINDINGS IN

24V CHARGERSERIES FOR

3

VOLTAGE CODE - L + S

S15

S1

S3

S16

S3 00

S1S3

57

S16S16S15

S15

00

00

6-WIRE WYE

S15

S6

S4

S5

S1

OPTIONAL

CONNECTIONS

00

S15

11

10

S2

S2

S2

PLUG

5

8

79

TO

EGC

NEUTRAL REQD.

D-OPTION00

AS

S15FOR

66

BC1

PMR

1

PME

6DPE

5

4

0

589

0

589

4

CONTROL PANEL

TO TERMINAL BLOCK

IN

2

CONNECT 1 WIRE FROM BRUSHES

THE CONTROL PANEL PLUG.

TO PIN 2 AND 4 WIRE FROM

BRUSHES TO PIN 4 IN

EA

4 4

EF

1

1 2

77 77A

BC1 BC2

TO PIN 4 IN THE

PIN 2 AND 4 WIRE

CONTROL PANEL PLUG.

CONNECT 1 WIRE TO

WINDINGS IN

12V CHARGERPARALLEL FOR

3

CONNECT 6 WIRE TO PIN 6 AND

FAILURE BYPASS TP BY

CONNECTING 5 WIRE TO PIN 3.

PANEL PLUG. IN CASE OF TP

2 WIRE TO PIN 3 IN CONTROL

PANEL PLUG.

CONNECT 6 WIRE TO PIN 6 AND

2 WIRE TO PIN 3 IN CONTROL

66

2 3

6 6

66A

TP2 3

6

5

6

CONNECT CHARGE1

Appendix 1 — Electrical DataD Option Control Panel

Phase Schematics – Drawing No. 099389-B


Appendix 1 — Electrical DataD Option Control PanelControl Panel Wiring Diagram (For Use With Generac Alternator) – Drawing No. 021773-E

C

D

A

D

44

64

4

6

641

2

1

0

29

29

14

49

178

162

162

S15

49

6

89

178

58

183

S16

5669

79

0

89 S16

1

01

2

89

0

79S16 69 S150

5614085

7969 68

4

0S

15

058 S1

57 59

183

7969 68

150

561413A0

R14

R13

0

R13

R16

R15

13A

R14

R14

13

R6

R5

R6

R5

P1

-A89 S

16

R6

R5

R16

R15

13A

13A

R16

R15

R13

13A

1313

A

R14

R13

R13

R16

R10

R12R11

R27

R28

R17

R18

R20

R21

R23

R24

R24

R1

R2

R3

R4

69 68 79

R5

R5

R6

S2

S3

183

7968

69

13

R25

85

R30

150

575

575

575

575

575

567

589

589

589

45

6

79

8

32

1

589

567

567

567

L3 L2 L100CT

1C

T2

CT

3C

OM

R13 85

85

85

13A

13A

13A

CK

EENR

15

RED

13A

0

RA-12

RA-8RA-7

RA-6RA-5

RA-10RA-9

RA-13

RA-2

RA-13RA-4

RA-12

RA-3

RA-6RA-8

RA-1

RA-9RA-7

RA-11RA-10

RA-5

RA

-5

RA-9RA-11

RA-10

RA-8RA-6

RA-7

RA

-12

RA

-13

RA

-4

RA-3

RA-1RA-2

J2-3

J2-2J2-1

RA

-5

RA

-13

RA

-4

RA

-12

589

589

J7-1

J7-9

J7-1

0

J7-1

1

RA-11RA-10

RA-6

RA-7RA-8

RA-9

BLA

CK

GR

EE

N

RE

D

RE

D

GR

EE

N

R30

R30

R30

R30

TB

1-16

TB

1-17

TB

1-15

TB

1-14

TB

1-13

TB

1-12

TB

1-11

TB

1-10

TB

1-1

TB

1-3

TB

1-4

TB

1-5

TB

1-6

TB

1-7

TB2-3

TB2-5

TB2-4

TB2-2

TB2-1

J1-1

J1-2

J1-3

J9-2

J9-3

J1-1

3J1

-14

J1-1

5

J1-5

J1-6

J1-8

J1-9

J1-1

0J1

-11

J1-1

2

J5-1

J5-2

J5-4

J5-5

J5-7

J6-4

J6-1

J6-2

J6-3

J7-8

J7-1

2

J10-

2

J10-

3

J10-

4

J10-

5

A

J8

1 81

J4

11

TB4-1

TB4-2

TB4-3

TB4-4

TB3-1

TB3-4

J5-8

J2-1

J2-8

J11-

4

J12-

4

J11-

1

J1

J3-1

J3-2

J3-3

J9-5

TB3-3

TB3-2

J10-

1

632

1

4 7963

J7-3

J7-2

TB

1-8

TB

1-9

4 7

32

1 10

35642 1

S -+

RE

D

F

PA

NE

L

LOW

ER

TO

PA

NE

L

TO FR

ON

T

TO MA

IN

HA

RN

ES

S

FR

ON

T P

AN

EL

CH

AS

SIS

TO

TE

LCO

TO

NE

UT

RA

L

DE

TA

IL"A

"S

EE

DE

TA

IL"A

"

F

VR

- V

OLT

AG

E R

EG

ULA

TO

R

R3

- R

ES

IST

OR

EN

GIN

E A

LTE

RN

AT

OR

R2

- R

ES

IST

OR

FIE

LD B

OO

ST

TS

1,2-

TE

RM

INA

L S

TR

IP

PC

B2-

CIR

CU

IT B

OA

RD

EN

GIN

E C

ON

TR

OL

DIS

PLA

YP

CB

3- C

IRC

UIT

BO

AR

D E

NG

INE

CO

NT

RO

L I/O

L1,2

- L

IGH

T P

AN

EL

CB

1 -

CIR

CU

IT B

RE

AK

ER

- F

IELD

BO

OS

T

F1

- F

US

E-1

5 A

MP

S

D1

- D

IOD

E 6

00V

12A

D2

- D

IOD

E-

800V

, 2A

LEG

EN

D

PC

B2

PC

B3

F1

L1

SW

2

SW

1 SW

1 -

SW

ITC

H-

AU

TO

/MA

NU

AL/

OF

FS

W2

- S

WIT

CH

- E

ST

OP

P1

-B

P2-B

PC

B1

KP

-1

KP

-1 -

FR

ON

T P

AN

EL

KE

Y-P

AD

DIA

GN

OS

TIC

S P

OR

T

P3

R4

R1

J11

J12

J2

R2

D2

CB

1

VR

D1

L2

TS

F

- F

UE

L S

EN

DE

RD

P -

DIA

GN

OS

TIC

S P

OR

T

P4

- P

LUG

& R

EC

EP

TA

CLE

, 3P

IN

P1

- P

LUG

& C

AP

9P

IN

P2

- P

LUG

& C

AP

9P

INP

3 -

PLU

G 1

5PIN

1

GRAYHILL

24



Control Panel Schematic Diagram (For Use With Generac Alternator) – Drawing No. 021736-E

J7-1

0

J2-3

J7-1

J2-2

J2-1

LIN

E P

OW

ER

RA

-4

SP

AR

E I/

PR

A-1

3

CH

AR

GE

R F

AIL

SH

IELD

- +

RA

-3

RA

-12

RA

-1

RA

-2

RS

-485

NC

RA

10N

OR

A9

RA

6

NO

CO

MN

CR

A7

RA

8

C

D

D

E

J2-2

J2-3

J2-4

J2-1

J1-7

J1-3

J1-4

J1-5

J1-6

J1-8

J1-1

J1-10

J1-9

J1-11

J1-14

J1-13

J1-15

J11-1

J11-2

J11-3

J11-4

J12-1

J12-2

J12-3

J12-4

J9-4

J9-2

J9-1

J9-3

J5-3

J9-5

J5-1

J5-2

J5-7

J5-4

J5-5

J5-6

J5-8

J7-12

J7-2

J7-8

J7-3

J10-3

J10-1

J10-2

J10-4

J10-5

TB1-13

TB1-16

TB1-17

TB1-14

TB1-12

TB1-11

TB1-15

TB1-10

TB1-2

TB1-1

TB1-3

TB1-7

TB1-8

TB1-9

TB1-4

TB1-5

TB1-6

TB

3-1

TB

3-2

TB

3-3

TB

3-4

TB

4-1

TB

4-4

TB

4-3

TB

4-2

INT

ER

FA

CE

BO

AR

DP

CB

3

CP

U B

OA

RD

PC

B1

RE

GU

LAT

OR

VO

LTA

GE

TB

2-5

TB

2-4

TB

2-3

TB

2-2

TB

2-1

7 4

P2A

P2B

P2A

P2B

EM

ER

GE

NC

Y

SW

ITC

HN

/C

P2A

P2B

5

P2B

P2A

6

L1L2

P2B

1P

2A

P2B

2P

2A

P2B1

P2A

4

1

2

6

3

5

FIELD

POWER

SENSING

J1-2

J1-3

J3-1

J3-2

J3-3

2

3

1

2

3

2400 BAUD

MODEM

PORT

RS-232

DIAGNOSTICS

PORT

R2

R3

D2

D1

EX

CIT

AT

ION

J6-1

J6-3

J6-2

J6-4

C

1 A

UT

O

2 O

FF

3 R

UN

SW

1-A

8 O

FF

9 R

UN

7 A

UT

O

CSW

1-B

COMMS.

1

RS-485

PORT

2

3

J2-1

J2-3

J2-2

4J2-4

8514

5615

0

SE

NS

OR

CO

OLA

NT

LE

VE

LF

UE

L

SO

L.

ST

AR

TE

R

SO

L.

PR

E-

HE

AT

SO

L.

416 2

178

S15

VR

1

183S3S1

S2

595857

0

NE

UT

RA

L F

RO

M L

OW

ER

PA

NE

L

CT

CO

MM

ON

L1 C

T

L2 C

T

L3 C

T

L3 V

OLT

S

L2 V

OLT

S

L1 V

OLT

S

SE

NS

ING

AV

R

SIG

NA

L

2-W

IRE

ST

AR

T

PO

WE

R

AV

R

EX

CIT

ER

FIE

LD

LOWER PANEL CONNECTOR (SEE DRG. 099389 REV-A)

6 3

P1-

A

P1-

B

P1-

A

CB1

R4

13+W

L C

ON

NE

CT

ION

049

CH

AR

GE

ALT

.

-

69 68 79

OIL

PR

ES

S. S

EN

SO

R

CO

OLA

NT

TE

MP

. SE

NS

OR

RP

M S

EN

SO

RP

1-A

9P

1-B

P1-

A8

P1-

B

FU

EL

LEV

EL

SE

NS

OR

575

J7-1

J7-9

J7-10

J7-11

J7-6

J7-5

J7-4

J7-7

SPARE ALARM 1

SPARE ALARM 2

SPARE WARN. 1

SPARE WARN. 2

PRE-HI OIL TEMP.

HI OIL TEMP.

HI FUEL LVL.

LO FUEL LVL.

OP

TIO

NA

L IN

PU

TS

MLC

B O

PE

N

RU

PT

UR

ED

BA

SIN

589

567

J8-1

J8-8

J12-

1

J4-1

J

4-11

FR

ON

T P

AN

EL

KE

YP

AD

- LOAD CONTROL

- Vbat

- COM

- 5VP

- BAT SENSE

- PRE-HEAT

- STARTER

- SENSE SUPPLY

- AUX

- ALARM

- FUEL

- E STOP

- PANEL LAMPS

- MODE SW

- MODE SW

LOAD CONTROL -

PH1 CT -

PH2 CT -

PH3 CT -

COM CT -

PRE-HEAT -

STARTER -

GND -

SENSE SUPPLY -

AUX -

ALARM -

FUEL -

PANEL LAMPS -

E STOP -

REM START -

- N VOLTS

- PH3 VOLTS

- PH2 VOLTS

- PH1 VOLTS

- COM CT

- PH3 CT

- PH2 CT

- PH1 CT J2-6

J2-7

J2-5

N VOLTS -

PH3 VOLTS -

PH2 VOLTS -

PH1 VOLTS -

COM -

5VP -

Vbat -

BAT SENSE -

S16

1 10 12 13 8 115 915 714 3 426

13A

FU

SE

D D

C

F1

-+ S

0O

N T

ER

M S

TR

IPT

S1

575

FU

EL

LEV

EL

SE

NS

OR

BLA

CK

SE

ND

ER

FU

EL

P4B

P4B

P4B

PA

NE

L LA

MP

S

DIS

PLA

Y B

OA

RD

PC

B2

F

AU

X O

/PLO

AD

CO

NT

RO

L N/0

COM

N/C

ALA

RM

CO

MM

ON


Appendix 1 — Electrical DataD Option Control PanelControl Panel Wiring Diagram (For Use With Marathon Alternator) – Drawing No. 0A5798-C

A

B

B

C

VR

- V

OLT

AG

E R

EG

ULA

TO

R

R2

- R

ES

IST

OR

FIE

LD B

OO

ST

TS

1,2-

TE

RM

INA

L S

TR

IP

R1

- P

OT

EN

TIO

ME

TE

R-

VO

LTA

GE

AD

JUS

T

PC

B1-

CIR

CU

IT B

OA

RD

EN

GIN

E C

ON

TR

OL

CP

U

PC

B2-

CIR

CU

IT B

OA

RD

EN

GIN

E C

ON

TR

OL

DIS

PLA

Y

CB

1 -

CIR

CU

IT B

RE

AK

ER

- F

IELD

BO

OS

T

F1

- F

US

E-1

5 A

MP

S

D1

- D

IOD

E 6

00V

12A

D2

- D

IOD

E-

800V

, 2A

LEG

EN

D

0

178

178

58

183

PA

NE

L

LOW

ER

TO

5669

TB

1-15

TB

1-14

TB

1-12

TB

1-11

TB

1-10

TB

1-1

TB

1-3

TB

1-4

TB

1-5

TB

1-6

TB

1-7

TB2-3

TB2-5

TB2-2

TB2-1

79

PA

NE

L

TO FR

ON

T

J1-1

J1-2

J1-3

J1-4

J9-1

J9-2

J9-3

J9-4

J1-1

3J1

-14

J1-1

5

J1-5

J1-6

J1-8

J1-9

J1-1

1

J1-1

2

J5-1

J5-2

J5-4

J5-5

J5-7

J6-4

J6-1

J6-2

J6-3

J7-8

J7-1

2

J10-

2

J10-

3

J10-

4

J10-

5

0

0

7969 680

5614A

085

7969 68

0

0

58

S1

57 59

183

7969 68

150

56

14A

13A0

R144

R13

0

R13

R16

R15

13A

13A

R14

R14

13

R6

R5

R6

R5

PC

B2

PC

B3

L1

L2

SW

2

SW

1

A

SW

1 -

SW

ITC

H-

AU

TO

/MA

NU

AL/

OF

F

SW

3 -

SW

ITC

H-

PR

E-H

EA

T

R4

- R

ES

IST

OR

WT

R. L

VL.

SE

NS

E

P1-

A

P1-

B

P2-

B

TO MA

IN

HA

RN

ES

S

PC

B1

J8

1 8

KP

-1

1

J4

11

KP

-1 -

FR

ON

T P

AN

EL

KE

Y-P

AD

89 S16

R6

R5

R14

R16

R15

R13

13A

1313

A

R14

R16

R15

R13

13A

13

R15

R14

R13

R13

R16

R10

R12R11

R26

R27

R28

R29

R17

R18

R19

R20

R21

R22

R23

R24

R24

R1

R2

R3

R4

69 68 79

R5

R5

R6

TB4-1

TB4-2

TB4-3

TB4-4

TB3-1

S2

S3

183

7968

69

13

P3

FR

ON

T P

AN

EL

CH

AS

SIS

TO

TE

LCO

TO

NE

UT

RA

L

TB3-4

R25

J5-8

85

J2-1

J2-8

DE

TA

IL"A

"S

EE

TO TS

1-0

R30

J11-

4

J12-

4

J11-

1

J12-

1

J1

J3-1

J3-2

J3-3

J9-5

TB3-3

TB3-2

150

575

575

J10-

1

575

575

567

589

589

589

R4

98

71

2

7

1

3

45

6

79

8

32

198

745

632

1

R1

24

J7-3

J7-2

589

567

567

567

TO

J9-5

J11

J12

L3 L2 L100CT

1C

T2

CO

M

DE

TA

IL"A

"

J2

R13

TB

1-8

TB

1-9

85

85

85

13A

13A

13A

TO

AV

R21

(CO

NN

EC

T

SH

IELD

TO

PIN

2 O

NLY

AT

AV

R)

13

0

14AR

R

RA-4

13A

0

RA-3

RA-1RA-2

RA-8RA-7

RA-6

RA-10

RA-11

RA-9

RA-13

RA-2

RA-4

RA-12

RA-3

RA-8

RA-1

RA-9RA-7

RA-11RA-10

RA

-5

RA-9RA-11

RA-10

RA-8RA-6

RA-7

RA

-12

RA

-13

RA

-4

RA-3

RA-1RA-2

J2-3

J2-2J2-1

RA

-13

RA

-4

RA

-12

589

589

J7-1

J7-1

0

J7-1

1

RA-11RA-10

RA-6

RA-7RA-8

RA-9

41 13310

8687

30

022

057

5H

AR

NE

SS

FO

RF

UE

L LE

VE

L P

RO

BE



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

A

A

B

B

CJ2-2

J2-3

J2-4

J2-1

J1-7

J1-2

J1-3

J1-4

J1-5

J1-6

J1-8

J1-1

J1-10

J1-9

J1-12

J1-11

J1-14

J1-13

J1-15

J11-1

J11-2

J11-3

J11-4

J12-1

J12-2

J12-3

J12-4

J9-4

J9-2

J9-1

J9-3

J5-3

J9-5

J5-1

J5-2

J5-7

J5-4

J5-5

J5-6

J5-8

J7-12

J7-2

J7-8

J7-3

J10-3

J10-1

J10-2

J10-4

J10-5

TB1-13

TB1-16

TB1-17

TB1-12

TB1-11

TB1-15

TB1-10

TB1-2

TB1-1

TB1-3

TB1-7

TB1-8

TB1-9

TB1-4

TB1-5

TB1-6

TB

3-1

TB

3-2

TB

3-3

TB

3-4

TB

4-1

TB

4-4

TB

4-3

TB

4-2

INT

ER

FA

CE

BO

AR

DP

CB

3

CP

U B

OA

RD

PC

B1

TB

2-5

TB

2-4

TB

2-3

TB

2-2

TB

2-1

7 4

P2A

P2B

P2A

P2B

EM

ER

GE

NC

YS

TO

PS

WIT

CH

N/C

P2A

P2B

5

P2B

P2A

6

L1L2

PA

NE

L LA

MP

SP

2B2

P2A

P2B

1P

2A

P2B3

P2A

J1-2

J1-3

J3-1

J3-2

J3-3

2

3

1

2

3

2400 BAUD

MODEM

PORT

RS-232

DIAGNOSTICS

PORT

J6-1

J6-3

J6-2

J6-4

C

1 A

UT

O

2 O

FF

3 R

UN

SW

1-A

8 O

FF

9 R

UN

7 A

UT

O

CSW

1-B

COMMS.

1

RS-485

PORT

2

3

J2-1

J2-3

J2-2

4J2-4

8556

150

SE

NS

OR

CO

OLA

NT

LE

VE

LS

TA

RT

ER

SO

L.

PR

E-

HE

AT

SO

L.

DIS

PLA

Y B

OA

RD

PC

B2

178

1

VR

1

183S3S1

S2

5958

0

NE

UT

RA

L F

RO

M L

OW

ER

PA

NE

L

CT

CO

MM

ON

L1 C

T

L2 C

T

L3 C

T

L3 V

OLT

S

L2 V

OLT

S

L1 V

OLT

S

AV

R

TO

SIG

NA

L

2-W

IRE

ST

AR

T

LOWER PANEL CONNECTOR (SEE DRG. 99389 REV-A)

6 3

P1-

B

P1-

A

P1-

B

P1-

A

R4

13+

DC

PO

WE

R

0-

69 68 79

OIL

PR

ES

S. S

EN

SO

R

CO

OLA

NT

TE

MP

. SE

NS

OR

RP

M S

EN

SO

RP

1-A

9P

1-B

P1-

A8

P1-

B

575

J7-1

J7-9

J7-10

J7-11

J7-6

J7-5

J7-4

J7-7

SPARE ALARM 1

SPARE ALARM 2

SPARE WARN. 1

SPARE WARN. 2

PRE-HI OIL TEMP.

HI OIL TEMP.

HI FUEL LVL.

LO FUEL LVL.

OP

TIO

NA

L IN

PU

TS

MLC

B O

PE

N

RU

PT

UR

ED

BA

SIN

589

567

J8-1

J8-8

J12-

1

J4-1

J

4-11

FR

ON

T P

AN

EL

KE

YP

AD

- LOAD CONTROL

- Vbat

- COM

- 5VP

- BAT SENSE

- PRE-HEAT

- STARTER

- SENSE SUPPLY

- AUX

- ALARM

- FUEL

- E STOP

- PANEL LAMPS

- MODE SW

- MODE SW

LOAD CONTROL -

PH1 CT -

PH2 CT -

PH3 CT -

COM CT -

PRE-HEAT -

STARTER -

GND -

SENSE SUPPLY -

AUX -

ALARM -

FUEL -

PANEL LAMPS -

E STOP -

REM START -

- N VOLTS

- PH3 VOLTS

- PH2 VOLTS

- PH1 VOLTS

- COM CT

- PH3 CT

- PH2 CT

- PH1 CT J2-6

J2-7

J2-8

J2-5

N VOLTS -

PH3 VOLTS -

PH2 VOLTS -

PH1 VOLTS -

COM -

5VP -

Vbat -

BAT SENSE -

2

1 10 12 13 8 115 1514

13A

FU

SE

D D

C

F1

15A

TB

1-14

RR

8586

SO

LEN

OID

14

FU

EL

3087

RR

J7-1

0

J7-1

1

J2-3

J7-9

J7-1

J2-2

J2-1

LIN

E P

OW

ER

RA

-4

SP

AR

E I/

PR

A-1

3

GE

N. P

OW

ER

CH

AR

GE

R F

AIL

SH

IELD

- +

RA

-3

RA

-5

RA

-12

RA

-1

RA

-2

RS

-485

NC

RA

10AU

X O

/PLO

AD

CO

NT

RO

L

NO

RA

9

N/0

COM

N/C

RA

6

NO

NC

ALA

RM

RA

7CO

MM

ON

013A

220

575

0

+D

C

SIG

.

-DC

FU

EL

LEV

EL

SE

NS

OR


Appendix 1 — Electrical DataD Option Control PanelTypical Engine Schematic Diagram – Drawing No. 021737


Appendix 2 — NotesD Option Control Panel


VIEW

"A"

51

45

54

292860,4

4,59

,52

69

7

11

102

1

20

3

21

4

2223

1213

,50,

43

6

5

9

47

74

3433

64 56 8

75 49,5

0,51

,52

38,6

3,48

24

4131

30

943

44

42

39,5

544

,50,

43

50

58

65

56 44,5

0,52

See

View

71

38,6

3,48

72

6770

1949

63 48

66

32

68

37

63

76

TABL

E A-

FIEL

D B

OO

ST R

ESIS

TER

DAT

AAL

L D

IREC

TLY

EXC

ITED

MAC

HIN

ESU

P TO

100

KW W

ITH

12

OR

24V

DC

SYS

TEM

S

UP

TO 1

00KW

WIT

H 1

2V D

C S

YSTE

MS

ALL

BRU

SHLE

SS M

ACH

INES

ALL

BRU

SHLE

SS M

ACH

INES

UP

TO 1

00KW

WIT

H 2

4V D

C S

YSTE

MS

ALL

BRU

SHLE

SS M

ACH

INES

OVE

R 1

00KW

WIT

H 1

2 O

R 2

4V D

C S

YSTE

MS

5 O

HM

25W

P/N

-483

52

25 O

HM

25W

P/N

-574

05

50 O

HM

25W

P/N

-833

64

75 O

HM

25W

P/N

-862

66P/

N-4

8476

4.5A

P/N

-485

056.

0A

P/N

-544

505.

5A

P/N

-484

677A

.19

TO

45K

W

45 T

O 1

00KW

ALL

BRU

SHLE

SS M

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P/N

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N-6

7711

Appendix 3 — Exploded Views and Parts ListsD Option Control PanelControl Panel (Units Less Than 400 kW) – Drawing No. 0A3103-H


ITEM PART NO. QTY. DESCRIPTION

1 0A1053 1 SCH ASSEMBLY "D-PANEL" CPU2 0A1056 1 PCB ASSEMBLY "D" DISPLAY3 0A2274 1 FRONT PANEL RAM4 0A1057A 1 OVERLAY 'D' OPT PANEL5 0A2277 1 RAM PANEL LEFT SIDE6 0A1054 1 INTERFACE BOARD7 0A1436 1 D PANEL BOTTOM-LG GENS8 0A1438 1 RAM PANEL RIGHT SIDE9 0A1440 1 CHASSIS AVR & E-GOV

10 SEE TABLE C - AVR ASSEMBLY11 SEE TABLE C - ELECTRONIC GOVERNOR12 0A2275 1 DOOR-STOP RAM PANEL13 ----- - SEE TABLE B19 071361 1 POTENTIOMETER PNL 5K +/-10%

2.25W20 032300 1 FUSE HOLDER

022676 1 FUSE 15A X AGC15 (NOT SHOWN)21 0A3033 1 SWITCH AUTO/OFF/MAN22 0A3034 1 CONNECTOR RS-23223 098426A 1 SWITCH EMERG PB HEAD

098426C 1 SWITCH EMERG PB N.C. (NOTSHOWN)

24 0A3035 2 LAMP PANEL ILLUM.28 055444 1 HEATSINK (DIODE)29 049939 1 RECTIFIER MSC 12A 600V 1N1206R30 SEE TABLE A 1 FIELD BOOST RESISTOR31 044213 1 RESISTOR 10R 5% 12W32 025192 1 RECTIFIER MSC 2A 600V 1N506233 0A1441B 1 COVER PLATE AVR34 0A1441A 1 COVER PLATE E-GOVERNOR35 0A1666 1 HARNESS 'D' PANEL FRONT (NOT

SHOWN)36 0A1667 1 HARNESS 'D' PANEL MAIN37 0A2566A 1 HARNESS D INTERCONNECTING38 057335 2 BLOCK TERM 20A 20 X 6 X 1100V


39 0A2273 1 HINGE, RAM PANEL40 0A2400 1 TRUNKING 320MM41 0A2400A 1 TRUNKING 180MM42 020752 5 SCREW PPM 4-40 X 1/4 ZINC43 033121 16 SCREW HHC #10-32 X 1/244 023897 17 WASHER FLAT #10 ZINC45 022097 4 WASHER LOCK M6-1/446 057405 1 RESISTOR 25R 5% 25W47 084543A 9 SCREW PHM M3-0.5 X 12MM48 022155 14 WASHER LOCK #649 022188 4 NUT HEX #6-32 STEEL50 022152 16 WASHER LOCK #1051 022287 4 SCREW HHC 1/4-20 X 3/4 G552 022158 2 NUT HEX #10-32 STEEL54 022473 4 WASHER FLAT 1/4 ZINC55 036261 4 RIVET POP .125 X .129-.133/#3056 0C6225 4 SCREW HHTT #6-32 X 1/4 CZ58 023364 8 WASHER SHAKEPROOF INT #659 023762 1 WASHER SHAKEPROOF EXT #10 STL60 030468 1 WASHER STEP NYLON .2061 034616 1 FITTING STRAIGHT 3/463 036909 6 SCREW PPHM #6-32 X 1-3/864 036918 4 SCREW PPHM #8-32 X 1/265 038150 4 WASHER FLAT #8 ZINC66 039271 1 FITTING 90D 3/467 047246 8 FLAT WASHER SPECIAL 1/468 064733 4 RESISTOR MOUNTING BRACKET69 070370 2 WASHER MICA .20370 040479 4 VIB MOUNT 1.0 X 1.0 X 1/4-2071 0C8474 1 DECAL 20 LITE AN CON72 0A3392 1 DECAL TERMINAL BLOCK73 0441140156 1 WIRE ASSY 18AWG #074 0A5062F 9 PCB EDGEHOLD MOUNT75 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC76 0C1229 1 DECAL CUST CONN BOX

Appendix 3 — Exploded Views and Parts ListsD Option Control Panel

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


7

11

21

20

3

21

4

2223

12

6

5

9

47

62

3433

64 56 8

49,5

0,51

,52

38,6

3,48

24

41

40,3

6

43

44

42

39,5

544

,50,

43

50

58

65

53 43,4

4,50

,52

See

View

"A"

VIEW

"A"

51

45

54

71

38,6

3,48

72

46

67

70

19

25

NO

TE:

SMO

KE L

IMIT

ING

REL

AY (0

C14

110)

IS F

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ND

ON

135

0, 1

825,

& 2

000K

WG

ENER

ATO

RS

ON

LY.

4450

52

49

6348

26

4450

52

616

3768

74

75

76

Appendix 3 — Exploded Views and Parts ListsD Option Control PanelControl Panel (Units 400 kW and Larger) – Drawing No. 0A5793-E



1 0A1053 1 SCH ASSEMBLY "D-PANEL" CPU2 0A1056 1 PCB ASSEMBLY "D" DISPLAY3 0A2274 1 FRONT PANEL RAM4 0A1057A 1 OVERLAY 'D' OPT PANEL5 0A2277 1 RAM PANEL LEFT SIDE6 0A1054A 1 INTERFACE BOARD7 0A9294 1 D PANEL BOTTOM-LG GENS8 0A1438 1 RAM PANEL RIGHT SIDE9 0A1440 1 CHASSIS AVR & E-GOV

11 067710 1 CONTROLLER GOVERNOR 24V 180012 0A2275 1 DOOR-STOP RAM PANEL19 071361 1 POTENTIOMETER PNL 5K +/-10%

2.25W20 032300 1 FUSE HOLDER

022676 1 FUSE 15A X AGC15 (NOT SHOWN)21 0A3033 1 SWITCH AUTO/OFF/MAN22 0A3034 1 CONNECTOR RS-23223 098426A 1 SWITCH EMERG PB HEAD

098426C 1 SWITCH EMERG PB N.C. (NOTSHOWN)

24 0A3035 2 LAMP PANEL ILLUM.25 0C4110 1 RELAY 24V 50A W/DIODE26 SEE NOTE: 1 RELAY SMOKE LIMITING 24V33 0A1441B 1 COVER PLATE AVR34 0A1441A 1 COVER PLATE E-GOV35 0A1666 1 HARNESS 'D' PANEL FRONT (NOT

SHOWN)36 0A5800 1 WIRING HARNESS D PANEL37 0A2566A 1 HARNESS D INTERCONNECTING38 057335 2 BLOCK TERM 20A 20 X 6 X 1100V39 0A2273 1 HINGE RAM PANEL40 0A2400 1 TRUNKING 320MM


41 0A2400A 1 TRUNKING 180MM42 020752 5 SCREW PPM 4-40 X 1/4 ZINC43 033121 6 SCREW HHC #10-32 X 1/244 023897 3 WASHER FLAT #10 ZINC45 022097 4 WASHER LOCK M6-1/446 057405 1 RESISTOR 25R 5% 25W47 084543A 9 SCREW PHM M3-0.5 X 12MM48 022155 12 WASHER LOCK #649 022188 2 NUT HEX #6-32 STEEL50 022152 3 WASHER LOCK #1051 022507 4 SCREW HHC 1/4-20 X 1/2 G552 022158 4 NUT HEX #10-32 STEEL53 0C6225 4 SCREW HHTT #6-32 X 1/4 CZ54 022473 4 WASHER FLAT M6-1/4 ZINC55 036261 4 RIVET POP .125 X .129-.133/#3056 022264 4 WASHER LOCK M458 023364 5 WASHER SHAKEPROOF INT #661 034616 1 FITTING STRAIGHT 3/462 0A5062F 9 PCB EDGEHOLD MOUNT63 036909 6 SCREW PPHM #6-32 X 1-3/864 036918 4 SCREW PPHM #8-32 X 5/865 038150 4 WASHER FLAT #8 ZINC66 0A9234 1 GEDNEY CONN 1IN 9067 047246 8 FLAT WASHER SPECIAL 1/468 064733 2 RESISTOR MTG BRACKET70 040479 4 VIB MNT 1.0 X 1.0 X 1/4-2071 0C8474 1 DECAL 20 LITE AN CON72 0A3392 1 DECAL TERMINAL BLOCK73 0441140156 1 WIRE ASSEMBLY 18AWG #074 036906 2 SCREW PPHM #6-32 X 175 0C1229 1 DECAL CUST CONN BOX76 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC

Appendix 3 — Exploded Views and Parts ListsD Option Control Panel

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

Part No. A3303

GENERAC® POWER SYSTEMS, INC.P.O. BOX 8

WAUKESHA, WI 53187

Revision C (11/25/02) Printed in U.S.A.

manual panel d

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