POWER SYSTEMS, INC.

Operators Manual
D Option Control Panel

GENERAC POWER SYSTEMS

 Important Safety Instructions
D 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 all
operators and potential operators of this equipment. !
Study these SAFETY RULES carefully before Do not handle any kind of electrical device while
installing, operating or servicing this equipment. standing in water, while barefoot, or while hands or
Become familiar with this manual and all literature feet are wet. DANGEROUS ELECTRICAL SHOCK
pertaining to your generator set and related equip- MAY RESULT.
ment. This equipment can operate safely, efficiently If people must stand on metal or concrete while
and reliably only if it is properly installed, operated installing, operating, servicing, adjusting or repairing
and maintained. Many accidents are caused by failing this equipment, place insulative mats over a dry
to follow simple and fundamental rules or precau- wooden platform. Work on the equipment only while
tions. standing on such insulative mats.
Generac cannot possibly anticipate every possible Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
circumstance that might involve a hazard. The warn-
trical current (amperage) to which they will be sub-
ings in this manual, and on tags and decals
jected.
affixed to your equipment are, therefore, not
all-inclusive. If you use a procedure, work method or Before installing or servicing this equipment, make
operating technique Generac does not specifically rec- sure that all power voltage supplies are positively
TURNED OFF at their source. Failure to do so will
ommend, you must satisfy yourself that it is safe for you
result in hazardous and possibly fatal electrical
and others. You also must make sure the procedure,
shock.
work method or operating technique that you choose
does not render the equipment unsafe. When installed with an automatic transfer switch, the
generator may crank and start anytime without
! GENERAL HAZARDS ! warning. To prevent injuries cause by sudden start-
up, disable the generators automatic start circuit
For safety reasons, Generac recommends before working on or around the unit. Then, place a
that this equipment be installed and serviced by a Do Not Operate tag on the generator control panel
Generac Authorized Service Dealer or other compe- and on the transfer switch.
tent, qualified electrician or installation technician In case of accident caused by electric shock, imme-
who is familiar with applicable codes, standards and diately shut down the source of electrical power. If
regulations. The operator also must comply with all this is not possible, attempt to free the victim from
such codes, standards and regulations. the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
When working on this equipment, remain alert at all
such as a rope or board, to free the victim from the
times. Never work on the equipment when physical-
live conductor. If the victim is unconscious, apply
ly or mentally fatigued.
first aid and get immediate medical help.
Inspect the equipment regularly, and promptly repair
Never wear jewelry when working on this equipment.
or replace all worn, damaged or defective parts using
Jewelry can conduct electricity resulting in electric
only factory-approved parts.
shock, or may get caught in moving components
Before performing any maintenance on the generator causing injury.
or any related equipment, disconnect the generators
battery cables to prevent accidental start-up.
Disconnect the cable from the battery post indicated FIRE HAZARDS
by a NEGATIVE, NEG or () first. Reconnect that
cable last. For fire safety, the generator and related equipment
must be installed and maintained properly.
Installation always must comply with applicable
ELECTRICAL HAZARDS codes, standards, laws and regulations. Adhere
strictly to local, state and national electrical and
Generators produce dangerous electrical voltages building codes. Comply with regulations the
and can cause fatal electrical shock. Avoid contact Occupational Safety and Health Administration
with bare wires, terminals, connections, etc., while (OSHA) has established. Also, ensure that the
the generator and related equipment are running. equipment is installed in accordance with the man-
Ensure all appropriate covers, guards and barriers ufacturers instructions and recommendations.
are in place before operating the equipment. If Following proper installation, do nothing that
work must be done around an operating unit, might alter a safe installation and render the unit
stand on an insulated, dry surface to reduce shock in noncompliance with the aforementioned codes,
hazard. standards, laws and regulations.

Generac Power Systems, Inc.

 Table of Contents
D Option Control Panel

Safety Rules....... ................................Inside Front Cover CONTROLS....................................................................7

Emergency Stop Switch ......................................7
RS-232 Local Communications Port ....................7
General Information ........................................................2 Auto-Off-Run Switch ............................................7
OVERVIEW........ ............................................................2 Main DC Fuse ......................................................8
CONTROL PANEL CIRCUIT BOARDS............................2 Voltage Trim Potentiometer ..................................8
PCB 1 Main Central Processor Unit INPUTS............ ..............................................................8
(CPU) Board ....................................................2 AC Voltage ............................................................8
PCB 2 Display Board ........................................2 AC Current ..........................................................8
PCB 3 Interface Board ......................................2 Fuel Level ............................................................8
Locations of Circuit Boards ................................2 Oil Pressure ........................................................8
OPTIONAL EQUIPMENT................................................2 Water Temperature ..............................................8
GenLink ............................................................2 Engine Speed Sensor ..........................................8
Modem... ..............................................................2 Coolant Level Sensor ..........................................8
Remote Annunciator Panel ..................................2 Emergency Stop Contact ......................................8
DIGITAL DISPLAYS ......................................................2 Transfer Switch/Remote Start ..............................8
Battery Saver ......................................................2 Pre High Oil Temperature ....................................8
AC Voltage Display ..............................................3 High Oil Temperature ..........................................9
AC Voltage Indicators ..........................................3 High Fuel Level ....................................................9
AC Current Display ..............................................3 Low Fuel Level ....................................................9
Frequency Display................................................3 Main Line Circuit Breaker ..................................9
Frequency Indicators............................................3 Ruptured Basin....................................................9
Power Factor ........................................................3 Spare Alarms ......................................................9
Power Output ......................................................4 Spare Warnings ....................................................9
Oil Pressure ........................................................4 OUTPUTS....... ..............................................................9
Water Temperature ..............................................4 Starter Solenoid ..................................................9
% Fuel.. ..............................................................4 Alarm..... ..............................................................9
Battery Voltage Display ........................................4 Load Control........................................................9
Battery Voltage Indicators ....................................4 Auxiliary ..............................................................9
Engine Hours ......................................................4 Preheater..............................................................9
STATUS INDICATORS ALARMS Fuel Control Relay................................................9
AND WARNINGS ........................................................4 COMMUNICATIONS ......................................................9
Oil.......... ..............................................................4 Front Panel Communications Port ......................9
Low Oil Pressure Alarm ......................4 Modem... ..............................................................9
High Oil Temperature Alarm ................4 Remote Communications Port..............................9
Pre Low Oil Pressure Warning..............4 Monitored Parameters........................10
Pre High Oil Temperature Warning ........4 Dial Out Option..................................................10
Water..... ..............................................................5 INSTALLATION NOTES ..............................................10
High Water Temperature Alarm............5
Low Level Water Alarm ........................5 Operation........... ..............................................................11
Pre High Water Temperature
OPERATION OF DIGITAL GENERATOR
Warning ..............................................5
CONTROL PANEL..........................................................11
Low Water Temperature Warning ..........5
Using the Keypad.... ..............................................11
Fuel........ ..............................................................5
Programmable Options ........................................11
High Fuel Alarm ..................................5
Critical Low Fuel Alarm ......................5
Low Fuel Warning ................................5 Appendix 1 Electrical Data ......................................14
Additional Alarms and Warnings..........................5
Emergency Stop Alarm ........................5
Overcrank Alarm..................................5 Appendix 2 Notes ......................................................21
General Overspeed Alarm ....................5
Ruptured Basin Alarm ........................6
Not in Auto Alarm ................................6 Appendix 3 Exploded Views and Parts Lists ......22
Main Line Circuit Breaker Warning........6
Remote Access Warning........................6
Program Mode Warning........................6
Spare LEDs..........................................................6
No Equipment Connected ....................6
AUTHORIZED SERVICE
Remote Annunciator Connected ..........6 DEALER LOCATION
KEYPAD........... ..............................................................7
Numeric Keys 0-9 ................................................7 To locate the nearest GENERAC AUTHORIZED
Enter and Clear Keys ..........................................7 SERVICE DEALER, please call this number:
Program Key ........................................................7
Alarm Horn Reset Key..........................................7
Alarm Lamp Reset Key ........................................7
1-800-333-1322
Phase Select Key ..................................................7 DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
Generac Power Systems, Inc. 1
 General Information
D Option Control Panel

OVERVIEW The right wall houses the AVR and the optional elec-
The D option control panel is a microprocessor- tronic governor controller. Both of these controls,
based generator set control panel designed for which are mounted on a chassis, are accessible exter-
Generacs range of standby generators. It has a fully nally from the right side of the panel via removable
digital user interface and comprehensive communi- covers that allow for adjustment.
cation capabilities.
The panel is housed in a steel sheet metal enclosure
that meets NEMA 1 specifications. The front face of Remove the 15-amp fuse from the front of the
the panel consists of a number of light-emitting ! panel during all engine maintenance to guard
diodes (LED) display windows showing generator against accidental or remote start-up.
operating conditions, a tactile keypad, alarm and sta-
tus LED indicators, a main fuse, an Emergency OPTIONAL EQUIPMENT
Stop switch and other generator set controls.
GENLINK
CONTROL PANEL CIRCUIT BOARDS GenLink is a communications software that allows the
The control panel contains three main printed-circuit generator to be started and monitored from a remote
boards (PCB), the automatic voltage regulator (AVR), PC via a modem. The generator can dial out automati-
and terminal blocks for external connections. cally and inform the PC if it has an active alarm condi-
To find the location of the circuit boards, refer to tion.
Appendix 3 for the control panel exploded views. The
three main PCBs have the following defined func- MODEM
tions: A modem (Part # 0A3557) can be connected to the D
panel to allow the generator to communicate with a
PCB 1 MAIN CENTRAL PROCESSOR remote PC.
UNIT (CPU) BOARD
(Part # 0A1053) This board houses the microproces- REMOTE ANNUNCIATOR PANEL
sor, its memory, input and output (I/O) stages and all When connected to the generator via a simple shield-
communication hardware (including optional modem ed two-wire link (plus two wires for power), this 20-
for telephone system communications). light remote indicator panel will display the genera-
tors status.
PCB 2 DISPLAY BOARD
(Part # 0A1056) This board houses all the LED dis- REMOTE RELAY PANEL
plays and annunciators, and their respective driver This panel is similar to the remote annunciator, but
circuitry. instead of indicator lights, it provides relay contact clo-
sures for status (e.g., alarms).
PCB 3 INTERFACE BOARD
(Part # 0A1054) This board houses all the compo- DIGITAL DISPLAYS (FIGURE 1.1, PAGE 3)
nents necessary to interface the CPU board to the
generator. This board receives high voltage and cur- BATTERY SAVER (SLEEP MODE)
rent signals from the generator output. All control In order to conserve battery power, the display panel
relays are mounted on this board. Connections to will power down after five minutes when it is not
this board are by screw terminals. being used. It will reactivate if any of the following
occurs:
LOCATIONS OF CIRCUIT BOARDS A key is pressed.
PCBs 1 and 2 are mounted together on the back of The engine is started.
the hinged front wall of the panel, and PCB 3 is Remote communications occur.
mounted on the left wall of the panel as viewed from During the power down period, the alarms are
the front. checked for 30 seconds every five minutes; any alarm
that occurs is permanently illuminated.

2 Generac Power Systems, Inc.

 General Information
D Option Control Panel

Figure 1.1 Digital Displays on D Option Control Panel

AC VOLTAGE DISPLAY (AC VOLTS) Voltage alarm checking is done on all phases. In the
case of single-phase (i.e., 110 volts AC), the C-A
This is a four-digit LED display for monitoring the phase selection should coincide with an AC voltage
voltage of the selected phase. A keypad command display of 220 volts AC. The alarm checking is taken
(PHASE SEL) is used to select which phase is dis- care of by the software, thus the alarm trigger points
played. LEDs indicate the phase that is currently only need to be set around the A-N or
active. The range is 0 to1,023 volts AC. C-N reading (i.e., 110 volts AC).
When the unit is monitoring a three-phase generator, Half a second of bad readings is required before the
the displayed voltage will coincide with one of the fol- alarm will be raised.
lowing phase selections. A lit LED on the phase indi-
cator will show the active phase.
AC CURRENT DISPLAY (AC AMPS)
A-B
This is a four-digit LED display for monitoring the
B-C current in the selected phase. The range is 0 to 5,000
C-A amps, depending on the selected current transformer
and the setting of the programmable full-scale cur-
When the unit is monitoring a single-phase generator, rent range.
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.
FREQUENCY DISPLAY (HERTZ)
This is a three-digit LED display for monitoring the
A-Neutral (A - B) frequency of the generator output. The range of this
C-Neutral (B - C) display is 40 to 70 Hertz. Phase A is used for this
measurement.
C-A
Selection of single or three phase monitoring is done FREQUENCY INDICATORS (HI, LO)
through the panels programmable options (see
Programmable Options, Page 11). 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.
AC VOLTAGE INDICATORS (HI, LO) These alarms are latched and cause the alarm relay
A pair of LEDs (included in AC VOLTS display) is to latch.
used to indicate whether the generators AC output
voltage is low or high. The set points are user pro- POWER FACTOR
grammable. These alarms are latched and cause the
alarm relay to latch. This is a three-digit LED display for monitoring
the power factor of the selected phase. The range is 0
Either alarm condition will shut down the generator to 1.00.
and cause a modem callout if enabled. This alarm is
enabled after the programmable alarm hold off timer
expires.

Generac Power Systems, Inc. 3

 General Information
D Option Control Panel

POWER OUTPUT (KILOWATTS/MEGAWATTS) ENGINE HOURS

This is a three-digit LED display for monitoring the This is a six-digit LED display used to show engine
total power output of the generator. The power output running time in hours. This display is also used when
is the sum of all three phases, taking power factor entering the password and changing the programma-
into account. ble options (see Operation of Digital Generator
For powers greater than 1 megawatt, the display will Control Panel, Page 11).
show a decimal point after the MW unit, e.g., 900 =
900 kW; 1.10 = 1.1 MW. STATUS INDICATORS ALARMS AND
WARNINGS (SEE FIGURE 1.2)
OIL PRESSURE
This is a three-digit display used to monitor engine OIL
oil pressure. The range is 0 to 100 psi or 0 to 7.03
Low Oil Pressure Alarm (LO PRES)

kg/cm. If the sensor is short circuited, -S- will dis-
play. If the sensor is open circuited, -0- will display. A red LED is used to indicate a low oil pressure condi-
tion. The set point is user programmable. The alarm is
WATER TEMPERATURE latched and causes the alarm relay to latch. It shuts
down the generator and causes a modem callout if
This is a three-digit display used to monitor the engine enabled. This alarm is enabled after the programmable
water temperature. The range is 0 to 300 F or -18 to alarm hold off timer expires.
149 C. If the sensor is short circuited,
-S- will display. If the sensor is open circuited, High Oil Temperature Alarm (HIGH TEMP)

-0- (or 000) will display. The alarm relay is latched.

A red LED is used to indicate a high oil temperature
If no block heater is fitted to the generator, there can switch has been closed. This alarm is latched and
be a problem in cold climates where temperatures of causes the alarm relay to latch. It shuts down the gen-
less than 25 F (-4 C), can cause the sensor to think erator and causes the modem to callout if enabled.
it is open circuited. If this happens, either -0- (or This alarm is enabled at all times.
000) will display.
Pre Low Oil Pressure Warning (PRE LO PRES)

To avoid this situation, the open circuit detection can

be overridden. To do this, it is necessary to set the A yellow LED is used to indicate a warning that a low
low temperature alarm set point to 1 F or 1 C. oil pressure condition exists. The set point is user
programmable. The alarm relay is latched.
% FUEL Pre High Oil Temperature Warning

This is a two-digit display that allows users the (PRE HIGH TEMP)
option of monitoring the quantity of fuel remaining. If
the display is active, the range is 0 to 99 percent. Fuel A yellow LED is used to indicate a warning that a pre
level senders are optional. If a fuel level sender has high oil temperature condition exists. The alarm
not been installed, the % fuel display should be dis- relay is latched.
abled (See Programmable Options on page 13 and
High Fuel Alarm on page 5). Figure 1.2 Status Indicators

BATTERY VOLTAGE DISPLAY

This 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. 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 Generac Power Systems, Inc.
 General Information
D Option Control Panel

WATER Critical Low Fuel Alarm (CRITICAL LO)

A red LED is used to indicate critical low fuel. This
High Water Temperature Alarm (HIGH TEMP)

feature is available only with an analog sender. The

A red LED is used to indicate a high water tempera- alarm is latched. It does shut down the generator and
ture condition. The set point is user programmable. causes a modem callout if enabled.
The alarm is latched and causes the alarm relay to
Low Fuel Warning (LO)

latch. The alarm shuts down the generator and caus-
es a modem callout if enabled. The alarm is enabled A yellow LED used to indicate a low fuel level. The
after the programmable alarm hold off timer expires. indicator can be activated in one of two ways:
Low Level Water Alarm (LO LEVEL) 1. Percent input from analog sender

A red LED is used to indicate the radiator water level 2. Switch input on J7-4
is low. The alarm is latched and causes the alarm If the fuel percent measurement is used, an analog
relay to latch. The alarm shuts down the generator sensor MUST BE installed and selected via program-
and causes a modem callout if enabled. This alarm is mable option #2. This allows for percentages to be
enabled after the programmable alarm hold off timer programmed for critical low fuel, low fuel and high
expires. fuel. The alarm relay is latched, but the generator will
continue to run. The modem will callout if enabled.
Pre High Water Temperature Warning (The switch input will light the LED only.)

(PRE HIGH TEMP) NOTE:

A yellow LED is used to indicate a warning that a high The two switch inputs Lo Fuel Level J7-4 and
water temperature condition exists. The set point is Hi Fuel Level J7-5 work only if the percentage
user programmable. The alarm relay is latched. input is turned off via programmable option #2.
Low Water Temperature Warning (LO TEMP) When the % Fuel measurement is not used, the dis-

play is turned off.

A yellow LED is used to indicate a warning that a low
water temperature exists. The set point is user pro-
grammable. The alarm relay is latched. ADDITIONAL ALARMS AND WARNINGS
Emergency Stop Alarm (EMG STOP)

FUEL
A red LED is used to indicate that the emergency stop
High Fuel Alarm (HI) switch has been activated. This alarm is latched and

causes the alarm relay to latch. It shuts down the gen-

A red LED is used to indicate a high fuel level. The erator and causes a modem callout if enabled. This
indicator can be activated in one of two ways: alarm is enabled at all times.
1. Percent input
Overcrank Alarm (OVERCRANK)

2. Switch input on J7-5

If the fuel percent measurement is used, an analog A red LED is used to indicate that the engine did not
sensor MUST BE installed and selected via program- start after eight starting attempts. The starting cycle
mable option #2. This allows for percentages to be consists of a programmable number of seconds of
programmed for critical low fuel, low fuel and high cranking followed by five seconds of OFF time. This
fuel. If the percentages are exceeded for high fuel, the alarm is latched and causes the alarm relay to latch.
alarm relay will latch, but the generator will continue It shuts down the generator and causes a modem
to run. The modem will callout if enabled. (The callout if enabled.
switch input will light the LED only.)
General Overspeed Alarm (OVERSPEED)

NOTE:
A red LED used to indicate an overspeed condition.
The two switch inputs LO Fuel Level J7-4 and The set point is user programmable. The alarm is
HI Fuel Level J7-5 work only if the percentage latched and causes the alarm relay to latch. The
input is turned off via programmable option #2. alarm shuts down the generator and causes a modem
When the % Fuel measurement is not used, the dis- callout if enabled. The alarm is enabled after the
play is turned off. engine starts. If the speed sensor fails, then the bot-
tom right (unmarked) yellow LED will light and the
alarm relay will latch. The alarm shuts down the gen-
erator and causes a modem callout if enabled.

Generac Power Systems, Inc. 5

 General Information
D Option Control Panel

Ruptured Basin Alarm (RUPT BASIN) ALARMS 1, 2 and the SPECIAL pin can occur only

after the programmable hold off time. When the pin

A red LED is used to indicate the double wall fuel is shorted to ground, the LED lights, the engine shuts
tank has ruptured. A float switch in the outer tank down, and the alarms relay is latched. The modem
closes when a rupture occurs. The alarm latches and will call out if it is enabled.
causes the alarm relay to latch. It causes the modem
to callout if enabled, but it does not shut down the The SPECIAL LED also can light and cause an alarm
generator. This alarm is enabled at all times. if there is a speed sensor (tach) loss.
The WARN1 LED will light when its pin is shorted to
Not in Auto Alarm (NOT IN AUTO)

ground. The alarm relay will latch, and the modem

A red LED is used to indicate the panel switch is not will call out if it is enabled.
set to the Auto start mode.
Remote Annunciator/Remote Relay Panel

Main Line Circuit Breaker Warning

Connected
(MLCB OPEN) With a Remote Annunciator/Remote Relay Panel fitted
A yellow LED is used to indicate a main line circuit to the D panel (Figure 1.4), the LEDs function as fol-
breaker is open. This is an optional switch input. lows:
Remote Access Warning (REM ACCESS)

Figure 1.4 Spare Indicators (With Remote

A yellow LED is used to indicate that modem com- Annunciator/Remote Relay Panel)
munication is currently active.

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 differ-
ent 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
The BATTERY CHARGER AC FAIL pin is intended to
connected to the D panel (Figure 1.3), the functions
show that the AC supply to the battery charger has
are as follows:
failed by shorting the pin to ground via an external,
customer supplied relay (Figure 1.5).
Figure 1.3 Spare Indicators (Without Remote
Annunciator/Remote Relay Panel Connected) Figure 1.5 Battery Charger AC Fail

6 Generac Power Systems, Inc.

 General Information
D Option Control Panel

The LED will light and latch. The generator will not PROGRAM KEY (PROG)
shut down, the alarm relay will not operate, and the
modem will not call out. The status will be sent to the This key is used to enter the local programming mode.
remote annunciator and displayed on its front panel. After pressing this key, the programming display will
show the word ACCESS, prompting the user for the
GENERATOR POWER will cause the LED to act as an password. The password is a six-digit number that is
indicator only. No alarms or shutdowns will occur. entered on the numeric keys and is displayed on the
The state of the input will be displayed on the remote hourmeter/programming display. The default factory
annunciator. It is intended to be connected to an aux- password is always 000000.
iliary 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. ALARM HORN RESET KEY
This key is used to reset the alarm relay contacts.
LINE POWER J7 pin 10 acts as above.
SPECIAL J7 pin 11 acts as previously described. ALARM LAMP RESET KEY
This key is used to reset alarms that have been
KEYPAD 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, 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 COMMUNICATIONS

PORT (COMM. PORT)
This connector allows connection of a local comput-
er to the panel for easy programming and diagnostic
checking. The computer needs to have a copy of
NUMERIC KEYS 0-9 GenLink loaded on it to enable communication
Decimal numbers are included on a keypad for entry with the D panel. A serial cable (part # 0A4042) also
of passwords and setting of programmable values. 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 A three-position rotary switch is provided for genera-
from the numeric keys. The CLEAR key will be used tor control. In AUTO the generator will wait for a sig-
to remove erroneous entries during programming. nal, such as from an automatic transfer switch. When
it receives the remote start signal, it will automatical-
ly initiate the generator start sequence. This only
occurs assuming no shutdown alarm condition
exists.
When in the OFF position, the generator is inhibited
from starting.
When the switch is in the RUN position, the genera-
tor will instantly be commanded to start assuming
that no shutdown alarm condition exists.

Generac Power Systems, Inc. 7

 General Information
D Option Control Panel

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-inch- An analog input is provided for oil pressure meas-
es x 0.25-inch glass type (part # 022676). Removal of urement. This input will interface to the standard
this fuse inhibits all control panel functions and is Generac sender unit (part # 053666). It is also used
recommended during all maintenance operations. for warning and shutdown situations.

VOLTAGE TRIM POTENTIOMETER WATER TEMPERATURE (PCB1: J10-3)

(VOLTAGE ADJUST) (IF EQUIPPED) An analog input is provided for coolant temperature
This control allows adjustment of the generator out- measurement. This input will interface to the stan-
put voltage in the range +/- 5 percent, if set to the dard Generac thermistor sensor (part # 053667). It
midpoint. is also used for warning and shutdown situations.

INPUTS ENGINE SPEED SENSOR (PCB1: J10-5)

An input is provided for sensing engine speed by
AC VOLTAGE counting teeth on the flywheel via a magnetic proxim-
Four terminals (PCB3: J2-1, J2-2, J2-3, J2-4) are ity probe. The input interfaces to the Generac stan-
provided for voltage measurement. Maximum input dard magnetic pickup (part # 082130D).
voltage is 1000 volts AC.
NOTE
COOLANT LEVEL SENSOR (PCB1: J10-4)
A dedicated analog input is provided for sensing low
Correct phasing for these terminals is essential coolant level. The input will interface to the Generac
for correct operation (see Appendix 1 coolant level sensor (part # 057522).
Electrical Data for phase schematics).
EMERGENCY STOP CONTACT
AC CURRENT (PCB3: TB2-1, TB2-3)
Four terminals (PCB3: J2-7, J2-9, J2-11, J2-10) are
provided for current measurement. The inputs will An input is provided for an emergency stop
interface with current transformers having a five-amp switch(es). The switch contact is normally closed.
secondary winding at their rated current.
NOTE
TRANSFER SWITCH/REMOTE START
(PCB1: J7-12)
Correct phasing for these terminals is essential
for correct operation (see Appendix 1 When the AUTO-OFF-RUN switch is set to AUTO and
Electrical Data for phase schematics). 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 con-
FUEL LEVEL (PCB1: J10-1) tact to ground this input.
An optional analog input is provided for fuel level
measurement. This is a 0 to 5 VDC input. An input PRE HIGH OIL TEMPERATURE (PCB1: J7-7)
signal of 0 volts is equivalent to 0 percent remaining
fuel and 5 volts is equivalent to 99 percent remaining An optional input is provided for a pre high oil tem-
fuel. The relationship between input voltage and fuel perature warning switch. (Switch to ground to
level is linear. alarm.)

8 Generac Power Systems, Inc.

 General Information
D Option Control Panel

HIGH OIL TEMPERATURE (PCB1: J7-6) LOAD CONTROL (PCB3: TB1-7(NC),

An optional input is provided for a high oil tempera- TB1-8(COM), TB1-9(NO)
ture alarm switch. (Switch to ground to alarm.) A relay contact output is provided for load control.
This contact will not energize unless the generator is
HIGH FUEL LEVEL (PCB1: J7-5) running. It is a form C relay rated at 10 amps at 28
An input is provided for a high fuel level switch. volts DC.
(Switch to ground to alarm.) It cannot be used to dis-
play fuel percentage. AUXILIARY (PCB3: TB1-1(NC),
TB1-2(COM), TB1-3(NO)
LOW FUEL LEVEL (PCB1: J7-4) A relay contact output is provided for optional use.
An input is provided for a low fuel level switch. This form C relay is rated 10 amps at 28 volts DC.
(Switch to ground to alarm.) It cannot be used to dis-
play fuel percentage. PREHEATER (PCB3: TB1-9, TB1-1O)
A relay contact output is provided to activate a diesel
MAIN LINE CIRCUIT BREAKER (PCB1: J7-2) preheater. This form A relay is rated at 10 amps at 28
An input is provided for a circuit breaker auxiliary volts DC.
contact to indicate that the main line circuit breaker
is open. (Switch to ground to alarm.) FUEL CONTROL RELAY (PCB3: TB1-14, TB1-15)
A relay contact output is provided to control the fuel
RUPTURED BASIN (PCB1: J7-3) solenoid/valve. This form A relay is rated at 10 amps
An input is provided for a level switch indicating the at 28 volts DC.
fuel tank is ruptured. (Double wall fuel tanks only.)
(Switch to ground to alarm.) COMMUNICATIONS
SPARE ALARMS (PCB1: J7-1, J7-9) FRONT PANEL COMMUNICATIONS PORT
Two inputs are provided for spare alarms. (Switch to The front panel includes a connector for RS-232 seri-
ground to alarm.) See Spare LEDs, Page 6. al communication. See RS-232 Local
Communications Port, Page 7.
SPARE WARNINGS (PCB1: J7-10, J7-11)
Two inputs are provided for spare warning condi- MODEM
tions. (Switch to ground to alarm.) See Spare LEDs, The unit can optionally be provided with a modem
Page 6. with AT command set which is FCC part 68
approved. The modem will allow an operator to per-
form the functions of the front panel at a remote site.
OUTPUTS However, the modem functions will not allow remote
control of the engine if the front panel AUTO-OFF-
STARTER SOLENOID (PCB3: TB1-12, TB1-13) RUN switch is in OFF or RUN mode (part # 0A3557).
A relay contact output is provided to activate the
starter solenoid. This form A relay is rated at 10 REMOTE COMMUNICATIONS PORT
amps at 28 volts DC.
(UP TO 1,200 FEET)
ALARM (PCB3: TB1-4(NC), The D panel is provided with an RS-485 communi-
TB1-5(COM), TB1-6(NO) cations port. This is designed to be connected to
Generacs remote annunciators or remote relay pan-
A relay contact output is provided that will activate els (The Time Multiplexed Annunciator CANNOT be
on an alarm condition. This form C relay is rated at used with a D panel.). Up to one annunciator and
10 amps at 28 volts DC. four remote relay panels can be connected together
on this port via a shielded two wire communications
cable (plus two wires for power).

Generac Power Systems, Inc. 9

 General Information
D Option Control Panel

Monitored Parameters INSTALLATION NOTES

The remote annunciator panel (RAP) and remote The D option control panel is designed to enhance
relay panel (RRP) provide remote monitoring of the the current range of Generac control panels. As such,
following engine parameters. Remote monitoring is this panel can accommodate most Generac standby
by illuminated LEDs on the annunciator and relay generators.
contact closures on the relay panel. The anti-vibration mountings, fixing centers and
1. Generator Run overall dimensions are compatible with existing pan-
2. Battery Charger AC Failure els, as are the lower panel connections and most of
3. Low Battery Voltage the engine electrical connections. All engine tempera-
ture and oil pressure alarms and pre-alarms are
4. High Battery Voltage
derived from the analog signals from engine senders,
5. RPM Sensor Loss so the existing alarm and shutdown switches become
6. Overcrank redundant; these should be disconnected or removed
7. Overspeed from the engine.
8. Generator Power Lower panel connections are identical, and the panel
9. Pre Low Oil Pressure plugs into the existing lower panel connector. The
10. Pre High Coolant Temperature only additional lower panel wiring is a separate neu-
11. Low Coolant Temperature tral wire that should be wired from the lower panel
12. Low Fuel neutral bar to the bullet connector marked 00 (not
13. Low Oil Pressure used in a delta configuration) which is part of the
14. High Coolant Temperature lower panel connection harness protruding from the
bottom of the D panel.
15. Emergency Stop
16. Not in Auto Refer to the schematics and wiring diagrams in
17. Line Power Appendix 1 Electrical Data for more installation
18. Spare information.
Connection details and a connection harness (exclud-
ing 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 dis-
play the alarm responsible for dial out.

10 Generac Power Systems, Inc.

 Operation
D Option Control Panel

OPERATION OF DIGITAL GENERATOR 4. Low Oil Pressure

CONTROL PANEL See Status Indicators Alarms and Warnings, Page
4.
USING THE KEYPAD 5. Low Water Temperature

The use of most keys is self-explanatory, but the opera- See Status Indicators Alarms and Warnings, Page
tion of some keys requires a brief explanation. (For 4.
additional information, see Keypad on Page 7.)
6. Pre High Water Temperature

Pressing ALARM HORN RESET turns off only the
alarm relay. Alarm conditions continue to be dis- See Status Indicators Alarms and Warnings, Page
played. Pressing ALARM LAMP RESET clears all 4.
alarm LEDs that are not current.
7. High Water Temperature

Pressing the PROG (Program) key will cause the pro-
gramming digits to display ACCESS. At this time, See Status Indicators Alarms and Warnings, Page
the password must be entered (see Programmable 4.
Option 28 Set User Password). If an invalid pass-
8. Critical Low Fuel

word is entered, the program will do nothing.
Additional characters may be entered in an attempt This is used with an analog sensor to turn on a red
to log on (only the last six digits are recognized). If a alarm LED. See Status Indicators Alarms and
valid password is not entered and/or no keypad activ- Warnings, Page 4.
ity has occurred for two minutes, the program will
revert to running time display. 9. Low Fuel

If the correct password is entered, the display will This is used with an analog sensor to turn on a yel-
change to 00. At this time, the program is waiting low warning LED. See Status Indicators Alarms
for an option (see Programmable Options) to be and Warnings, Page 4.
entered. Twenty-eight options may be displayed and
10. High Fuel

changed, if desired. The current setting remains

unchanged if ENTER is pressed, or it can be changed This is used with an analog sensor to turn on a red
by entering a new number followed by ENTER. Exit alarm LED. See Status Indicators Alarms and
the keypad routine by pressing ENTER again anytime Warnings, Page 4.
the display shows 00.
11. Low AC Voltage

Program options can be modified in the AUTO, OFF

or RUN mode. However, it is recommended that A red LED next to the AC Volts display is used to indi-
the options be changed while the panel is in the OFF cate this alarm. If the generators AC voltage drops
mode. below this set value for more than 0.5 seconds, an
alarm occurs and the engine shuts down. The alarm is
PROGRAMMABLE OPTIONS latched and causes the alarm relay to latch and pro-
duce a modem callout if enabled. This alarm is activat-
For information on programmable options, refer to ed after the alarm hold off time is complete.
the following text, as well as the chart on Page 13.
12. High AC Voltage

1. Select English or Metric Units

A red LED next to the AC Volts display is used to indi-

Units of measurement will be changed on the panel cate this alarm. If the generators AC voltage goes above
for oil pressure and water temperature. this set value for more than 0.5 seconds, an alarm
occurs and the engine shuts down. The alarm is latched
2. Fuel Display On/Off

and causes the alarm relay to latch and produce a

The fuel display should be turned off when an analog modem callout if enabled. This alarm is activated after
fuel sensor is not being used. Alarm and warning the alarm hold off time is complete.
LEDs for fuel are activated by either the low and high
13. Low Battery Voltage

fuel switches or the programmed values used with

the analog sensor. A red LED next to the Battery Voltage display is
used to warn that battery voltage is below pro-
3. Pre Low Oil Pressure

grammed limits. No shutdown occurs with this warn-

See Status Indicators Alarms and Warnings, Page ing.
4.

Generac Power Systems, Inc. 11

 Operation
D Option Control Panel

14. High Battery Voltage 21. Flywheel Teeth

A red LED next to the Battery Voltage display is This value is preset at the factory. This is the number
used to warn that battery voltage is above pro- of teeth on the flywheel ring gear.
grammed limits. No shutdown occurs with this warn-
22. Load Control

ing.
This load control relay output has NO/NC contacts
15. Low Frequency Limit

that can be used to connect the generator to the load

A red LED next to the Hertz display is used to indi- once the generators output voltage and frequency
cate this alarm. If the generators frequency drops climb above the preprogrammed low AC voltage and
below this set value for more than 1.5 seconds, an low frequency limits. This relay can be controlled
alarm occurs and the engine shuts down. The alarm from the front panel or through GenLink software
is latched and causes the alarm relay to latch and via a modem or RS-232. It is possible to use this out-
produce a modem callout if enabled. This alarm is put as a generator running signal, but it will be
activated after the alarm hold off time is complete. delayed by the hold off timer. (e.g., Program the out-
Frequency is measured on phase A. put to be ON, see Figure 2.1). See Outputs on Page
9.
16. High Frequency Limit

A red LED next to the Hertz display is used to indi- Figure 2.1 Load Control as
cate this alarm. If the generators frequency goes Generator Running Signal
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.

17. Starting Speed

This is the speed at which the engine becomes self-

sustaining and causes the starter to disengage. The
alarm hold off timer is started when this rpm has
been reached.

18. Overspeed

See Status Indicators Alarms and Warnings, Page 23. Set/Reset Auxiliary Output 1

4.
This auxiliary relay output has NO/NC contacts that
19. Alarm Hold Off Time can be used as general purpose relay under front

panel control. This relay also can be controlled from

Most alarms are ignored during alarm hold off time. the front panel or through GenLink software via a
If an alarm still persists after the hold off time, it will modem or RS-232. By selecting Option 3, the relay is
become active. See Status Indicators Alarms and programmed to operate on engine shutdown only.
Warnings, Page 4, for more information. See Outputs on Page 9.
20. Crank Cycle On Time

24. Set CT Primary Current

This is the length of time that the starter stays This is the current rating for the primary side of the
engaged when given a command to start. There will CT with the secondary side being five amps. D panels
be a five second off time after each on time. After are set up to use five amp secondaries.
eight unsuccessful tries (each try consisting of one
cycle crank on time and one off time), the overcrank 25. Preheat Time On

alarm will latch the engine off, and the alarm LED
will turn on. This is the length of time that the preheat device on a
diesel engine is energized.

12 Generac Power Systems, Inc.

 Operation
D Option Control Panel

26. Preheat While Cranking 28. Set User Password

This allows the preheater to be energized while the This allows the user to change the default password.
engine is cranking. All D panels ship from the factory with the default
password set to zero (000000). If the modified user
27. Select Phasing

password is lost or misplaced, it is possible for a

There are three possible generator configurations. technician to access the panel through remote soft-
They are single-phase, three-phase wye and three- ware to determine the password. However, in order
phase delta. for the technician to access the panel and password,
the panel must be capable of remote communication
via a modem.

PROGRAMMABLE OPTIONS
OPTION DEFAULT RANGE or ALT YOUR SETTING
1. Select English or 1=English 2=Metric
Metric Units
2. Fuel Display On/Off 1=OFF 2=ON
3. 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 C
6. Pre High Water Temp. 220 F/104 C 0-300 F/-18-149 C
7. High Water Temp. 250 F/121.2 C 0-300 F/-18-149 C
8. 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 VAC
12. High AC Voltage 230 VAC 0-1023 VAC
13. Low Battery Voltage 12.2 VDC 0-51.1 VDC
14. High Battery Voltage 15.0 VDC 0-51.1 VDC
15. Low Frequency Limit 57 Hz 40-70 Hz
16. High frequency limit 63 Hz 40-70 Hz
17. Starting Speed 500 RPM 0-3600 RPM
18. Overspeed 2100 RPM 0-3600 RPM
19. Alarm Hold Off Time 10 SEC 0-60 SEC
20. Crank Cycle On Time 5 SEC 5-15 SEC
21. Flywheel Teeth 168 75-200
22. Load Control 1=OFF 2=ON
23. Set/Reset Aux. Output 1 1=OFF 2=ON/3=Operate on Shutdown
24. Set CT Primary Current 150A 50-5000A
25. Preheat Time On 0 SEC 0-30 SEC
26. Preheat While Cranking 2=ON 1=OFF
27. Select Phasing 2=WYE 1=SINGLE
2=WYE
3=DELTA
28. Set User Password 000000 000000-999999

Generac Power Systems, Inc. 13

 Appendix 1 Electrical Data
D Option Control Panel
Phase Schematics Drawing No. 099389-B

VOLTAGE CODE - K + R
VOLTAGE CODE - A + M
SERIES WYE 12-WIRE
SERIES 4-WIRE
S1
AS NEUTRAL REQD.
11 22 33 44 S4
FOR
NEUTRAL REQD. 00
S7 D-OPTION
FOR AS
00 00
D-OPTION S10
S12 S11
S9 S8
00 00 TO S6 S5
OPTIONAL
S15 EGC S3 S2
S1 00 S3 00
S15 7 00 00 TO
OPTIONAL
S16 9 S15 S15 EGC
S1 5 S1 S3 S2
S2 8 PLUG S16 7
S3 CONNECTIONS 9
K k 57 10 TO S1 5
K k CONTROL S3 11
58 12
PANEL 00 S2 8
CT2 K k
CT1 57 10 PLUG
L L K k
l
0
l
0 1 59 13 CONNECTIONS
TO
K k
58 12 CONTROL
CT1 CT3 CT2 PANEL
OPTIONAL
CIRCUIT L l L l L l
CB2 0 0 0 1
BREAKER

OPTIONAL
CB2 CIRCUIT
BREAKER
E1 00 E3

CUSTOMER CONNECTION E1 E3 00 E2
120/240V 1-PHASE 60Hz
110/220V 1-PHASE 50Hz CUSTOMER CONNECTION
277/480V 3-PHASE 60Hz
240/415V 3-PHASE 50/60Hz

VOLTAGE CODE - A + M (ONLY USED ON 125kW AND VOLTAGE CODE - D,J + P

PARALLEL ZIG-ZAG ABOVE, OUTPUT IS 66% SERIES DELTA 12-WIRE
12-WIRE OF 3-PHASE RATING) S11
SEE S1 S8
S2 S6 NOTE S5
S8 S12 ONE
S2
S4
4
AS
S7
7 S12
S3 S9
S5 S6
S1 S9 S3
S4 S11
AS NEUTRAL REQD. S10
S15 TO
FOR OPTIONAL
S7 S10
00 00 D-OPTION 00 EGC
00 00 TO S15 7
OPTIONAL S16 9
S15 S15 EGC 00 S1 S3 S2
S15 S1 5 PLUG
S16 9 S3 11 CONNECTIONS
S1 S2 8 TO
S2 PLUG K k CONTROL
S3 57 10
K k PANEL
57 TO K k 59
k 13
K 58
K k
CT2 PANEL 58 12
CT1
L l L l CT1 CT3 CT2
0 0 1
L l L l L l
0 0 1

OPTIONAL
OPTIONAL
CB2 CIRCUIT
CB2 CIRCUIT
BREAKER
BREAKER

NOTE ONE
PARALLEL WINDING ONLY
00 E1 E3 E2 FITTED ON D OPTION
E1 00 E3 ALTERNATORS.J+P OPTION
1-PH MACHINES SHOULD BE
CUSTOMER CONNECTION DERATED TO 66% OF THREE
CUSTOMER CONNECTION PHASE RATING.
120/240V 1-PHASE 60Hz 120/240V 3-PHASE 60Hz
110/220V 1-PHASE 50Hz 100/200V 3-PHASE 50Hz

14 Generac Power Systems, Inc.

 Appendix 1 Electrical Data
D Option Control Panel
Phase Schematics Drawing No. 099389-B

VOLTAGE CODE - L + S EXCITATION POWER OPTIONS

6-WIRE WYE
(USE EITHER OPTION A OR OPTION B ONLY)
S1 NEUTRAL REQD.
FOR CONNECT 6 WIRE TO PIN 6 AND
S15 00 6 6
D-OPTION 2 WIRE TO PIN 3 IN CONTROL
S4 DPE 5 PANEL PLUG. IN CASE OF TP
6 5
S15 AS FAILURE BYPASS TP BY
2 3
S6 S5 TP CONNECTING 5 WIRE TO PIN 3.
OPTION B - PERMANENT MAGNET GENERATOR
S15 S3 S2
S16 6 6
00
00 00 TO CONNECT 6 WIRE TO PIN 6 AND
PME
OPTIONAL PMR 2 WIRE TO PIN 3 IN CONTROL
S15 S15 EGC
S1 S3 PANEL PLUG.
00 S2
S16 7 2 3
S15 9
S1 5 1
66
S3 11
PLUG
S2 8 BC1 1
K k CONNECTIONS 66 66A
57 10 CONNECT CHARGE CONNECT CHARGE
TO 77
K k 59 13 WINDINGS IN WINDINGS IN
CONTROL SERIES FOR BC1 BC2 PARALLEL FOR
K k PANEL 66A
58 12 BC2 24V CHARGER 12V CHARGER
77 77A
3
CT1 CT3 CT2 77A
3
L l L l L l
0 0 0 1
EXCITER FIELD OPTIONS
OPTIONAL
CIRCUIT
OPTION A - UNITS WITH BRUSHES
CB2
BREAKER
1 2

CONNECT 1 WIRE FROM BRUSHES

E1 E3 00 E2 TO PIN 2 AND 4 WIRE FROM
AR
BRUSHES TO PIN 4 IN
CUSTOMER CONNECTION 4 4 THE CONTROL PANEL PLUG.
346/600V 3-PHASE 60Hz
277/480V 3-PHASE 50Hz OPTION B - BRUSHLESS UNITS
VOLTAGE CODE - G + N EA
1 2
PARALLEL WYE 12-WIRE
CONNECT 1 WIRE TO

NEUTRAL REQD. EF PIN 2 AND 4 WIRE

S1 S7 AR
TO PIN 4 IN THE
FOR
00 CONTROL PANEL PLUG.
D-OPTION
S4
AS 4 4

S12 S5
OPTIONAL CIRCUIT BREAKER STATUS AUXILLIARY CONTACT
S9 S6 S11 S2

S3 S8 589 589

AUX. CONTACT CLOSED TO TERMINAL BLOCK

S1 00 WHEN THE CIRCUIT IN
BREAKER IS OPEN CONTROL PANEL
00 00 TO
OPTIONAL
S15 S15 EGC 0 0
S3 00 S2
S15 7
S16 9 LEGEND
S1 5 PLUG
S3 11 CONNECTIONS AR ALTERNATOR ROTOR
S2 8 TO AS ALTERNATOR STATOR
K k 57 10 CONTROL BC BATTERY CHARGE WINDING
K k PANEL
59 13 CB2 MAIN CIRCUIT BREAKER (OPTIONAL)
K k 58 12 CT CURRENT TRANSFORMER
CT1 CT3 CT2 DPE DISPLACED PHASE EXCITATION WINDING
L l L l L l EA BRUSHLESS EXCITER ARMATURE
0 0 0 1
EF BRUSHLESS EXCITER FIELD
OPTIONAL EGC ELECTRONIC GOVERNOR CONTROL
CB2 CIRCUIT PMR PERMANENT MAGNET ROTOR
BREAKER PME PERMANENT MAGNET EXCITATION WINDING
TP THERMAL PROTECTOR (AUTO-RESET)

E1 E3 00 E2

CUSTOMER CONNECTION READ THIS DRAWING IN CONJUNCTION WITH

120/208V 3-PHASE 60Hz 139/240V 3-PHASE 60Hz
WIRING DIAGRAMS Nos. 099336 & 099491
115/200V 3-PHASE 50Hz

Generac Power Systems, Inc. 15

 C

F
89 3 2 1
DETAIL "A" 6 5 4
S16
+
RED F 9 8 7
S
GREEN P1-A 3
TO 89
SW2
COM R5
J12 CT3 6 S16
CT2 J2 BLACK FRONT
CT1 R6
- PANEL 9 R6
R13

00 R14 1 2 3 P1-B
TO R5 R1
L3
J11 L2 6
L1 MAIN
R15 HARNESS 13A 13A
13
13 2 4
13A 13A
R13 R13
R13 13A
R16

4 R15 R15
RED
GREEN 7 R16 R16
L1

CK
D

EEN
RED
P2-B F1
R30 R30

16 Generac Power Systems, Inc.

R14 R13
RED
L2
13A 13A
TS R15
R5
R16
R6
0 0
D Option Control Panel

0 R30
R14

0
69 R4
13A 56 J11-1

13A
85 R13 TB1-16 SEE
D J2-1

RA-5
RA-12
RA-13

RA-6
RA-7
RA-8
RA-9
RA-10
DETAIL "A"

TB2-5
TB2-4
TB2-3
TB2-2
TB2-1
R14 TB1-17 J11-4 DIAGNOSTICS PORT
150 567
R30 85 J2-8 J12-4 J3-1 R10
0
13A TB1-15
14 14 TB1-14 J3-2 R11
Appendix 1 Electrical Data

R30 J9-5
589 575 TB1-13 J1-1
56 56 TB1-12 J1-2 J9-2 J3-3 R12
R27
13 TB1-11 J1-3 R28 J9-3
567
150 TB1-10
575 J1-5 R17 J5-1
TB1-1 PCB3 J1-6 J5-2
SW1
0 R18 J6-4 R4
J6-1 R5
1

S16 R1
TB1-3 J1-8 R20 J5-4
69 69 J1-9 R21 J5-5 J6-2 R2 A
TB1-4 R5
GRAYHILL

79 J1-10
68 TB1-5 J1-11 J5-7 J6-3 R3
2 162 R23
79 79 TB1-6 J5-8 R6
1 1 589

RA-10
1 PCB1
4 TB1-7
VR 4 S15 S15
0 TB1-8 J1-12 R24

RA-11
162

RA-7
6 6 1
TO J1-13 R25
TB1-9 1
5 89 J1-14
0 NEUTRAL

RA-9
J1-15

RA-8
3 89 TO
2 LOWER 575
J4
KP-1

RA-6
PANEL 589
49

TB4-1
TB4-2
TB4-3
TB4-4
TB3-1
TB3-2
TB3-3
TB3-4
CB1
2 1 0 S15 0 79 68 69 85 RA-12 J7-1
589 11
J7-2

178
58 567 J7-3

589
P3 R24 J7-8
49 S16 3 2 1 567 RA-5 J7-9 LEGEND
0 RA-4 J7-10
4
RA-13 J7-11 A
S1 CB1 - CIRCUIT BREAKER- FIELD BOOST
7 183 J7-12 D1 - DIODE 600V 12A
6 58 S2
1 D2 - DIODE- 800V, 2A
6 10 57
D2 DP - DIAGNOSTICS PORT
S3
85 F - FUEL SENDER
F1 - FUSE-15 AMPS
4 R2 183
59 J8 L1,2 - LIGHT PANEL
575 575 J10-1 P1 - PLUG & CAP 9PIN
178
69 69 J10-2 P2 - PLUG & CAP 9PIN
29 P3 - PLUG 15PIN
14 68 J10-3

RA-10
4 68 8
P4 - PLUG & RECEPTACLE, 3PIN
29 79 J10-4
85
J1

RA-11
183 J10-5 PCB2- CIRCUIT BOARD ENGINE CONTROL DISPLAY
79
RA-12 PCB3- CIRCUIT BOARD ENGINE CONTROL I/O
RA-5
J2-3
J2-1
J2-2

RA-9

RA-1
RA-4 R2 - RESISTOR FIELD BOOST
RA-13 PCB2 R3 - RESISTOR ENGINE ALTERNATOR

RA-7
RA-9
4

RA-2
D1
SW1 - SWITCH- AUTO/MANUAL/OFF

RA-8
RA-11
RA-7

TO TELCO

RA-3
SW2 - SWITCH- ESTOP
RA-6

TS1,2- TERMINAL STRIP

RA-6
RA-10
4 4 VR - VOLTAGE REGULATOR

RA-13
RA-8

RA-4
6
RA-1

KP-1 - FRONT PANEL KEY-PAD

RA-12
RA-2

RA-5
CHASSIS FRONT PANEL
RA-3
Control Panel Wiring Diagram (For Use With Generac Alternator) Drawing No. 021773-E
Generac Power Systems, Inc. 17
LOWER PANEL CONNECTOR (SEE DRG. 099389 REV-A)
2-WIRE

FIELD
EXCITER
SIGNAL

SENSING
L3 VOLTS
L2 VOLTS
L1 VOLTS

START
L3 CT
L2 CT
L1 CT

AVR
AVR

POWER
CT COMMON
NEUTRAL FROM LOWER PANEL

183
178

S16
S15
59
58
57

S3
S2

4
2
6
0

S1

4
2
3
6
9
7
8
5
1

15
14
13
12
10

11

4
FIELD
D1

1
CB1
2
POWER
6
R2
VR1

VOLTAGE
REGULATOR
3
6

P1-A
P1-B
P1-A

3
SENSING
D2

5
EXCITATION
R3
L1
L2

PH1 CT - J12-1 J2-6 - PH1 CT

TB4-1
TB4-4
TB4-3
TB4-2
TB3-4
TB3-3
TB3-2
TB3-1
PANEL LAMPS

PH2 CT - J12-2 J2-7 - PH2 CT

2400 BAUD 2 J1-2 PH3 CT - J12-3 - PH3 CT
P2B
P2B

MODEM
PORT 3 J1-3 COM CT - J12-4 J2-5 - COM CT
2
1

P2A
P2A

1 J3-1 PH1 VOLTS - J11-1 J2-2 - PH1 VOLTS

RS-232
DIAGNOSTICS 2 J3-2 PH2 VOLTS - J11-2 J2-3 - PH2 VOLTS TB1-17
PORT
3 J3-3 PH3 VOLTS - J11-3 J2-4 - PH3 VOLTS TB1-16
85

N VOLTS - J11-4 J2-1 - N VOLTS

SENSOR

R4
COOLANT LEVEL

1 J2-1
RS-485 2 J2-2 TB1-15
COMMS.
14

PORT 3 J2-3 TB1-14

SOL.
FUEL

4 J2-4 Vbat - J9-1 J1-1 - Vbat TB1-13

56

COM - J9-2 - COM TB1-12

SOL.
STARTER

5VP - J9-3 J1-3 - 5VP TB1-11

BAT SENSE - J9-4 J1-4 - BAT SENSE TB1-10
150
PRE-
HEAT SOL.

SPARE ALARM 1 J7-1 GND - J9-5

SPARE ALARM 2 J7-9 STARTER - J5-1 J1-5 - STARTER TB1-1
NC
RA10

SPARE WARN. 1 J7-10 PRE-HEAT - J5-2 J1-6 - PRE-HEAT TB1-2

AUX O/P

PCB3

SPARE WARN. 2 J7-11 SENSE SUPPLY - J5-3 J1-7 - SENSE SUPPLY TB1-3
NO
RA9

LO FUEL LVL. J7-4 LOAD CONTROL - J5-4 J1-8 - LOAD CONTROL

OPTIONAL INPUTS
INTERFACE BOARD

HI FUEL LVL. J7-5 AUX - J5-5 J1-9 - AUX TB1-7 N/C

D

HI OIL TEMP. J7-6 ALARM - J5-6 J1-10 - ALARM TB1-8 COM

LOAD CONTROL

PRE-HI OIL TEMP. J7-7 FUEL - J5-7 J1-11 - FUEL TB1-9 N/0
PANEL LAMPS - J5-8 - E STOP
J1-13 - PANEL LAMPS TB1-4
J1-14 - MODE SW TB1-5
ALARM
COMMON

J1-15 - MODE SW TB1-6

NC COM NO
RA7 RA8 RA6

J6-4
P1-A
P1-A

9
8

C
SW1-A
PCB1
P1-B
P1-B

CPU BOARD
C
SW1-B

3 RUN
1 AUTO

2 OFF
J6-1
J6-2
TB2-2
TB2-3
TB2-4
TB2-5

TB2-1

9 RUN
7 AUTO

8 OFF
J6-3 E STOP - J7-8
REM START - J7-12
13A
FUSED DC

J7-3
P2A
P2A
P2A
P2A

J7-2
4
7
5
6

J4-1
P2B
P2B
P2B
P2B

J10-1

J4-11

KEYPAD
J10-2

FRONT PANEL
J10-3
J10-4
N/C
F1

J10-5
SWITCH

J8-8
J8-1
1

J7-1
J2-3
J2-2
J2-1
P2B P2A

J7-10
+

EMERGENCY
13
-

J12-1
49
CHARGE ALT.
WL CONNECTION

0
BLACK

79
68
69
575
589
567
575
E

RA-4
RA-3
RA-1
RA-2

RA-13
RA-12
C

PCB2
-

+
P4B

P4B
P4B

TS1

SHIELD
SENSOR
-
+

DISPLAY BOARD
S
FUEL

SPARE I/P
MLCB OPEN
FUEL LEVEL

RPM SENSOR

RS-485
SENDER

LINE POWER
ON TERM STRIP

CHARGER FAIL
RUPTURED BASIN

D
OIL PRESS. SENSOR
FUEL LEVEL SENSOR
F

COOLANT TEMP. SENSOR

Control Panel Schematic Diagram (For Use With Generac Alternator) Drawing No. 021736-E
D Option Control Panel
Appendix 1 Electrical Data
 DETAIL "A" 1 2 3 SW2
89
TO 1 4 5 6 S16
AVR 2 7 8 9 R6
(CONNECT
COM SHIELD TO P1-B
J12 PIN 2 ONLY
CT2 AT AVR) TO R5 R1
CT1
MAIN
J2
HARNESS 13A
P1-A
13 13 2 4
00 TO 13A 13A
L3 R5
J11 L2 R13 R13 R13
FRONT
L1 R6 3 2 1 R15 R16
R14 R14
PANEL
R13
6 5 4 R15 R15
C
L1
R14 1 9 8 7 R16 R16
HARNESS FOR 575
220
FUEL LEVEL PROBE
B 0 P2-B
R15 7 8 9 13
TO L2

18 Generac Power Systems, Inc.

R14 R13
13A R13 13A TS1-0

13A 13A

R5
R16
R6
0 0
D Option Control Panel

87 RR
R14

0
30 69 R4
13 13A 56 J11-1

13A
85 R13 SEE
B 86 J2-1

RA-3
RA-4
RA-13

RA-1
RA-2
RA-6
RA-7
RA-8
RA-9
RA-11
RA-10
DETAIL "A"

TB2-5
TB2-3
TB2-2
TB2-1
R14
4 J11-4
TO
J12-1
J9-5 150 567
0 85 J2-8 J3-1 R10
J12-4 1

3
0 13A TB1-15
14A 14A 14A TB1-14 J3-2 R11
J9-5
Appendix 1 Electrical Data

R30
589
J1-1 R26 J9-1
56 56 TB1-12 J1-2 J9-2 J3-3 R12
R27
13 TB1-11 J1-3 R28 J9-3
567
150 J1-4 R29 J9-4
TB1-10
575 J1-5 R17 J5-1
TB1-1 SW1
PCB3 J1-6 R18 J5-2 J6-4 R4
0
R19 J6-1 R5
R1
TB1-3 J1-8 R20 J5-4
2

69 69 J1-9 R21 J5-5 J6-2 R2 A

TB1-4 R5
7

79 R22
68 68 TB1-5 J1-11 J5-7 J6-3 R3
R23
79 79 TB1-6 J5-8 R6
589

RA-10
PCB1
TB1-7

0 TB1-8 J1-12 R24

RA-11
RA-7
TO J1-13 R25
TB1-9 1
J1-14
0 NEUTRAL

RA-9
J1-15

RA-8
TO
575
LOWER J4
KP-1

RA-6
PANEL 589

TB4-1
TB4-2
TB4-3
TB4-4
TB3-1
TB3-2
TB3-3
TB3-4
0 0 79 68 69 85 RA-12 J7-1
589 11
J7-2

178
58 567 J7-3

P3 589
R24 J7-8
1 567
LEGEND
0 RA-4 J7-10
4 RA-13 J7-11 A
S1 CB1 - CIRCUIT BREAKER- FIELD BOOST
183 J7-12 D1 - DIODE 600V 12A
58 S2
1 D2 - DIODE- 800V, 2A
10 57
F1 - FUSE-15 AMPS
S3
13
3 85
183 PCB1- CIRCUIT BOARD ENGINE CONTROL CPU
59 J8
PCB2- CIRCUIT BOARD ENGINE CONTROL DISPLAY
575 575 J10-1
178
69 69 J10-2 R1 - POTENTIOMETER- VOLTAGE ADJUST
68 J10-3 R2 - RESISTOR FIELD BOOST

RA-10
68 8
79 85 J10-4
J1 R4 - RESISTOR WTR. LVL. SENSE

RA-11
183 J10-5
79 SW1 - SWITCH- AUTO/MANUAL/OFF
RA-12
RA-5
J2-3
J2-1
J2-2

RA-9

RA-1
RA-4 SW3 - SWITCH- PRE-HEAT
RA-13 PCB2 TS1,2- TERMINAL STRIP

RA-7
RA-9
VR - VOLTAGE REGULATOR

RA-2
KP-1 - FRONT PANEL KEY-PAD

RA-8
RA-11
RA-7
TO TELCO

RA-3
RA-6

RA-10
RA-8

RA-4
RA-1

RA-12
RA-2

CHASSIS FRONT PANEL

RA-3
Control Panel Wiring Diagram (For Use With Marathon Alternator) Drawing No. 0A5798-C
Generac Power Systems, Inc. 19
LOWER PANEL CONNECTOR (SEE DRG. 99389 REV-A)
2-WIRE

SIGNAL
L3 VOLTS
L2 VOLTS
L1 VOLTS

START
L3 CT
L2 CT
L1 CT

AVR
TO
CT COMMON
NEUTRAL FROM LOWER PANEL

183
178
59
58

S3
S2

2
0

S1

1
8
5
1

15
14
13
12
10

11

VR1

3
6

P1-A
P1-B
P1-B
P1-A
L1
L2

PH1 CT - J12-1 J2-6 - PH1 CT

TB4-1
TB4-4
TB4-3
TB4-2
TB3-4
TB3-3
TB3-2
TB3-1
PANEL LAMPS

PH2 CT - J12-2 J2-7 - PH2 CT

2400 BAUD 2 J1-2 PH3 CT - J12-3 J2-8 - PH3 CT
P2B
P2B

MODEM
PORT 3 J1-3 COM CT - J12-4 J2-5 - COM CT
2

1
P2A
P2A

1 J3-1 PH1 VOLTS - J11-1 J2-2 - PH1 VOLTS

RS-232
DIAGNOSTICS 2 J3-2 PH2 VOLTS - J11-2 J2-3 - PH2 VOLTS TB1-17
PORT
3 J3-3 PH3 VOLTS - J11-3 J2-4 - PH3 VOLTS TB1-16
85

N VOLTS - J11-4 J2-1 - N VOLTS

SENSOR

R4
COOLANT LEVEL

1 J2-1
RS-485 2 J2-2 TB1-15
COMMS.
PORT 3 J2-3
4 J2-4 Vbat - J9-1 J1-1 - Vbat TB1-13
56

COM - J9-2 J1-2 - COM TB1-12

SOL.
STARTER

5VP - J9-3 J1-3 - 5VP TB1-11

BAT SENSE - J9-4 J1-4 - BAT SENSE TB1-10
150
PRE-
HEAT SOL.

SPARE ALARM 1 J7-1 GND - J9-5

SPARE ALARM 2 J7-9 STARTER - J5-1 J1-5 - STARTER TB1-1
NC
RA10

SPARE WARN. 1 J7-10 PRE-HEAT - J5-2 J1-6 - PRE-HEAT TB1-2

AUX O/P

PCB3

SPARE WARN. 2 J7-11 SENSE SUPPLY - J5-3 J1-7 - SENSE SUPPLY TB1-3
NO
RA9

LO FUEL LVL. J7-4 LOAD CONTROL - J5-4 J1-8 - LOAD CONTROL

OPTIONAL INPUTS
INTERFACE BOARD

HI FUEL LVL. J7-5 AUX - J5-5 J1-9 - AUX TB1-7 N/C

HI OIL TEMP. J7-6 ALARM - J5-6 J1-10 - ALARM TB1-8 COM
LOAD CONTROL

PRE-HI OIL TEMP. J7-7 FUEL - J5-7 J1-11 - FUEL TB1-9 N/0
PANEL LAMPS - J5-8 J1-12 - E STOP
J1-13 - PANEL LAMPS TB1-4
NC
RA7

J1-14 - MODE SW TB1-5

ALARM
COMMON

J1-15 - MODE SW TB1-6

NO
RA6

J6-4
P1-A
P1-A
B

9
8

C
SW1-A
PCB1
P1-B
P1-B

CPU BOARD
C
SW1-B

3 RUN
1 AUTO

2 OFF
J6-1
TB1-14

J6-2
TB2-2
TB2-3
TB2-4
TB2-5

TB2-1

9 RUN
7 AUTO

8 OFF
J6-3 E STOP - J7-8
REM START - J7-12
13A
FUSED DC

86

J7-3
P2A
P2A
P2A
P2A

J7-2
4
7
5
6

J4-1
A

RR
P2B
P2B
P2B
P2B

J10-1

J4-11

KEYPAD
J10-2

FRONT PANEL
J10-3
J10-4

N/C
F1

15A

STOP
J10-5

SWITCH

J8-8
J8-1
3

85

J7-9
J7-1
J2-3
J2-2
J2-1
P2B P2A

J7-11
J7-10
+

EMERGENCY
13
-

0
DC POWER

J12-1
30

0
RR

79
68
69
589
567
575
13A
87

0
A

575
220
14

PCB2
RA-4
RA-5
RA-3
RA-1
RA-2
FUEL

RA-13
RA-12
-DC
SIG.
+DC

MLCB OPEN
SOLENOID

RPM SENSOR

DISPLAY BOARD
RUPTURED BASIN

OIL PRESS. SENSOR

C

SHIELD
SENSOR

SPARE I/P
COOLANT TEMP. SENSOR

RS-485

LINE POWER
FUEL LEVEL

GEN. POWER
CHARGER FAIL

B
Control Panel Schematic Diagram (For Use With Marathon Alternator) Drawing No. 0A5799-C
D Option Control Panel
Appendix 1 Electrical Data
 Appendix 1 Electrical Data
D Option Control Panel
Typical Engine Schematic Diagram Drawing No. 021737

20 Generac Power Systems, Inc.

Appendix 2 Notes
D Option Control Panel

Generac Power Systems, Inc. 21

 1 47

38,63,48 74
60,44,59,52 9
69 51 11
72
28
29 71 30 31 63 66 41 2
45 10
34 33 64
38,63,48 7 56
54 56
65
VIEW "A"

22 Generac Power Systems, Inc.

75
63
42 48
D Option Control Panel

58 49,50,51,52
8 49
44 67
50 9
43 70 19
20
37 24
68
21 13,50,43
12 32
Appendix 3 Exploded Views and Parts Lists

3
23 44,50,43 44,50,52
6 39,55 22
5 4
76
Control Panel (Units Less Than 400 kW) Drawing No. 0A3103-H

See View
TABLE A-FIELD BOOST RESISTER DATA TABLE B-AVR POWER (DPE) CIRCUIT BREAKER DATA TABLE C-AVR/ELECTRONIC GOVERNOR CONTROLLER DATA
ALL DIRECTLY EXCITED MACHINES 5 OHM 25W ALL DIRECTLY EXCITED MACHINES 7A. ALL 60HZ MACHINES WITH GENERAC
UP TO 100KW WITH 12 OR 24V DC SYSTEMS P/N-48352 19 TO 45KW P/N-48467 ALTERNATORS USE VOLTAGE REGULATOR P/N-67680
ALL BRUSHLESS MACHINES 25 OHM 25W ALL BRUSHLESS MACHINES 5.5A ALL 50HZ MACHINES WITH GENERAC
UP TO 100KW WITH 12V DC SYSTEMS P/N-57405 19 TO 25KW P/N-54450 ALTERNATORS USE VOLTAGE REGULATOR P/N-92952
ALL BRUSHLESS MACHINES 50 OHM 25W ALL BRUSHLESS MACHINES 6.0A BARBER COLMAN 12V 2500-5000HZ
UP TO 100KW WITH 24V DC SYSTEMS P/N-83364 29 TO 41KW P/N-48505 ELECTRONIC GOVERNOR CONTROLLER P/N-67709
ALL BRUSHLESS MACHINES 75 OHM 25W ALL BRUSHLESS MACHINES 4.5A BARBER COLMAN 24V 2500-5000HZ
OVER 100KW WITH 12 OR 24V DC SYSTEMS P/N-86266 45 TO 100KW P/N-48476 ELECTRONIC GOVERNOR CONTROLLER P/N-67710
ALL MACHINES 4.5A BARBER COLMAN 12V 5000-9500HZ
OVER 100KW P/N-48476 ELECTRONIC GOVERNOR CONTROLLER P/N-67711
 Appendix 3 Exploded Views and Parts Lists
D Option Control Panel
Control Panel (Units Less Than 400 kW) Drawing No. 0A3103-H

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

1 0A1053 1 SCH ASSEMBLY "D-PANEL" CPU 39 0A2273 1 HINGE, RAM PANEL

2 0A1056 1 PCB ASSEMBLY "D" DISPLAY 40 0A2400 1 TRUNKING 320MM
3 0A2274 1 FRONT PANEL RAM 41 0A2400A 1 TRUNKING 180MM
4 0A1057A 1 OVERLAY 'D' OPT PANEL 42 020752 5 SCREW PPM 4-40 X 1/4 ZINC
5 0A2277 1 RAM PANEL LEFT SIDE 43 033121 16 SCREW HHC #10-32 X 1/2
6 0A1054 1 INTERFACE BOARD 44 023897 17 WASHER FLAT #10 ZINC
7 0A1436 1 D PANEL BOTTOM-LG GENS 45 022097 4 WASHER LOCK M6-1/4
8 0A1438 1 RAM PANEL RIGHT SIDE 46 057405 1 RESISTOR 25R 5% 25W
9 0A1440 1 CHASSIS AVR & E-GOV 47 084543A 9 SCREW PHM M3-0.5 X 12MM
10 SEE TABLE C - AVR ASSEMBLY 48 022155 14 WASHER LOCK #6
11 SEE TABLE C - ELECTRONIC GOVERNOR 49 022188 4 NUT HEX #6-32 STEEL
12 0A2275 1 DOOR-STOP RAM PANEL 50 022152 16 WASHER LOCK #10
13 ----- - SEE TABLE B 51 022287 4 SCREW HHC 1/4-20 X 3/4 G5
19 071361 1 POTENTIOMETER PNL 5K +/-10% 52 022158 2 NUT HEX #10-32 STEEL
2.25W 54 022473 4 WASHER FLAT 1/4 ZINC
20 032300 1 FUSE HOLDER 55 036261 4 RIVET POP .125 X .129-.133/#30
022676 1 FUSE 15A X AGC15 (NOT SHOWN) 56 0C6225 4 SCREW HHTT #6-32 X 1/4 CZ
21 0A3033 1 SWITCH AUTO/OFF/MAN 58 023364 8 WASHER SHAKEPROOF INT #6
22 0A3034 1 CONNECTOR RS-232 59 023762 1 WASHER SHAKEPROOF EXT #10 STL
23 098426A 1 SWITCH EMERG PB HEAD 60 030468 1 WASHER STEP NYLON .20
098426C 1 SWITCH EMERG PB N.C. (NOT 61 034616 1 FITTING STRAIGHT 3/4
SHOWN) 63 036909 6 SCREW PPHM #6-32 X 1-3/8
24 0A3035 2 LAMP PANEL ILLUM. 64 036918 4 SCREW PPHM #8-32 X 1/2
28 055444 1 HEATSINK (DIODE) 65 038150 4 WASHER FLAT #8 ZINC
29 049939 1 RECTIFIER MSC 12A 600V 1N1206R 66 039271 1 FITTING 90D 3/4
30 SEE TABLE A 1 FIELD BOOST RESISTOR 67 047246 8 FLAT WASHER SPECIAL 1/4
31 044213 1 RESISTOR 10R 5% 12W 68 064733 4 RESISTOR MOUNTING BRACKET
32 025192 1 RECTIFIER MSC 2A 600V 1N5062 69 070370 2 WASHER MICA .203
33 0A1441B 1 COVER PLATE AVR 70 040479 4 VIB MOUNT 1.0 X 1.0 X 1/4-20
34 0A1441A 1 COVER PLATE E-GOVERNOR 71 0C8474 1 DECAL 20 LITE AN CON
35 0A1666 1 HARNESS 'D' PANEL FRONT (NOT 72 0A3392 1 DECAL TERMINAL BLOCK
SHOWN) 73 0441140156 1 WIRE ASSY 18AWG #0
36 0A1667 1 HARNESS 'D' PANEL MAIN 74 0A5062F 9 PCB EDGEHOLD MOUNT
37 0A2566A 1 HARNESS D INTERCONNECTING 75 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC
38 057335 2 BLOCK TERM 20A 20 X 6 X 1100V 76 0C1229 1 DECAL CUST CONN BOX

Generac Power Systems, Inc. 23

 26
44
50
52
25

44 1
50 47
52
62
38,63,48

51 9 11
41 72
71 2

24 Generac Power Systems, Inc.

74 6
45 34 64
7 61 33 53
D Option Control Panel

54 38,63,48 56
65
76
VIEW "A" 49,50,51,52
63
48
42 8
58 49
67 19
70 20
Appendix 3 Exploded Views and Parts Lists

44
50 24
43 46
37 68
40,36 21
12 43,44,50,52
Control Panel (Units 400 kW and Larger) Drawing No. 0A5793-E

23 3
22 44,50,43
39,55
6

5 4
See View
"A"
75
NOTE: SMOKE LIMITING RELAY (0C14110)
IS FOUND ON 1350, 1825, & 2000KW
GENERATORS ONLY.
 Appendix 3 Exploded Views and Parts Lists
D Option Control Panel
Control Panel (Units 400 kW and Larger) Drawing No. 0A5793-E

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
1 0A1053 1 SCH ASSEMBLY "D-PANEL" CPU 41 0A2400A 1 TRUNKING 180MM
2 0A1056 1 PCB ASSEMBLY "D" DISPLAY 42 020752 5 SCREW PPM 4-40 X 1/4 ZINC
3 0A2274 1 FRONT PANEL RAM 43 033121 6 SCREW HHC #10-32 X 1/2
4 0A1057A 1 OVERLAY 'D' OPT PANEL 44 023897 3 WASHER FLAT #10 ZINC
5 0A2277 1 RAM PANEL LEFT SIDE 45 022097 4 WASHER LOCK M6-1/4
6 0A1054A 1 INTERFACE BOARD 46 057405 1 RESISTOR 25R 5% 25W
7 0A9294 1 D PANEL BOTTOM-LG GENS 47 084543A 9 SCREW PHM M3-0.5 X 12MM
8 0A1438 1 RAM PANEL RIGHT SIDE 48 022155 12 WASHER LOCK #6
9 0A1440 1 CHASSIS AVR & E-GOV 49 022188 2 NUT HEX #6-32 STEEL
11 067710 1 CONTROLLER GOVERNOR 24V 1800 50 022152 3 WASHER LOCK #10
12 0A2275 1 DOOR-STOP RAM PANEL 51 022507 4 SCREW HHC 1/4-20 X 1/2 G5
19 071361 1 POTENTIOMETER PNL 5K +/-10% 52 022158 4 NUT HEX #10-32 STEEL
2.25W 53 0C6225 4 SCREW HHTT #6-32 X 1/4 CZ
20 032300 1 FUSE HOLDER 54 022473 4 WASHER FLAT M6-1/4 ZINC
022676 1 FUSE 15A X AGC15 (NOT SHOWN) 55 036261 4 RIVET POP .125 X .129-.133/#30
21 0A3033 1 SWITCH AUTO/OFF/MAN 56 022264 4 WASHER LOCK M4
22 0A3034 1 CONNECTOR RS-232 58 023364 5 WASHER SHAKEPROOF INT #6
23 098426A 1 SWITCH EMERG PB HEAD 61 034616 1 FITTING STRAIGHT 3/4
098426C 1 SWITCH EMERG PB N.C. (NOT 62 0A5062F 9 PCB EDGEHOLD MOUNT
SHOWN) 63 036909 6 SCREW PPHM #6-32 X 1-3/8
24 0A3035 2 LAMP PANEL ILLUM. 64 036918 4 SCREW PPHM #8-32 X 5/8
25 0C4110 1 RELAY 24V 50A W/DIODE 65 038150 4 WASHER FLAT #8 ZINC
26 SEE NOTE: 1 RELAY SMOKE LIMITING 24V 66 0A9234 1 GEDNEY CONN 1IN 90
33 0A1441B 1 COVER PLATE AVR 67 047246 8 FLAT WASHER SPECIAL 1/4
34 0A1441A 1 COVER PLATE E-GOV 68 064733 2 RESISTOR MTG BRACKET
35 0A1666 1 HARNESS 'D' PANEL FRONT (NOT 70 040479 4 VIB MNT 1.0 X 1.0 X 1/4-20
SHOWN) 71 0C8474 1 DECAL 20 LITE AN CON
36 0A5800 1 WIRING HARNESS D PANEL 72 0A3392 1 DECAL TERMINAL BLOCK
37 0A2566A 1 HARNESS D INTERCONNECTING 73 0441140156 1 WIRE ASSEMBLY 18AWG #0
38 057335 2 BLOCK TERM 20A 20 X 6 X 1100V 74 036906 2 SCREW PPHM #6-32 X 1
39 0A2273 1 HINGE RAM PANEL 75 0C1229 1 DECAL CUST CONN BOX
40 0A2400 1 TRUNKING 320MM 76 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC

Generac Power Systems, Inc. 25

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