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
installing, operating or servicing this equipment.
Become familiar with this manual and all literature
pertaining to your generator set and related equip-
ment. This equipment can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precau-
tions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals
affixed to your equipment are, therefore, not
all-inclusive. If you use a procedure, work method or
operating technique Generac does not specifically rec-
ommend, you must satisfy yourself that it is safe for you
and others. You also must make sure the procedure,
work method or operating technique that you choose
does not render the equipment unsafe.
! GENERAL HAZARDS !
For safety reasons, Generac recommends
that this equipment be installed and serviced by a
Generac Authorized Service Dealer or other compe-
tent, qualified electrician or installation technician
who is familiar with applicable codes, standards and
regulations. The operator also must comply with all
such codes, standards and regulations.
When working on this equipment, remain alert at all
times. Never work on the equipment when physical-
ly or mentally fatigued.
Inspect the equipment regularly, and promptly repair
or replace all worn, damaged or defective parts using
only factory-approved parts.
Before performing any maintenance on the generator
or any related equipment, disconnect the generators
battery cables to prevent accidental start-up.
Disconnect the cable from the battery post indicated
by a NEGATIVE, NEG or () first. Reconnect that
cable last.
ELECTRICAL HAZARDS
Generators produce dangerous electrical voltages
and can cause fatal electrical shock. Avoid contact
with bare wires, terminals, connections, etc., while
the generator and related equipment are running.
Ensure all appropriate covers, guards and barriers
are in place before operating the equipment. If
work must be done around an operating unit,
stand on an insulated, dry surface to reduce shock
hazard.
Generac Power Systems, Inc.
!
Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum elec-
trical current (amperage) to which they will be sub-
jected.
Before installing or servicing this equipment, make
sure that all power voltage supplies are positively
TURNED OFF at their source. Failure to do so will
result in hazardous and possibly fatal electrical
shock.
When installed with an automatic transfer switch, the
generator may crank and start anytime without
warning. To prevent injuries cause by sudden start-
up, disable the generators automatic start circuit
before working on or around the unit. Then, place a
Do Not Operate tag on the generator control panel
and on the transfer switch.
In case of accident caused by electric shock, imme-
diately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
FIRE HAZARDS
For fire safety, the generator and related equipment
must be installed and maintained properly.
Installation always must comply with applicable
codes, standards, laws and regulations. Adhere
strictly to local, state and national electrical and
building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
equipment is installed in accordance with the man-
ufacturers instructions and recommendations.
Following proper installation, do nothing that
might alter a safe installation and render the unit
in noncompliance with the aforementioned codes,
standards, laws and regulations.

Safety Rules....... ................................Inside Front Cover
General Information ........................................................2
OVERVIEW........ ............................................................2
CONTROL PANEL CIRCUIT BOARDS............................2
PCB 1 Main Central Processor Unit
(CPU) Board ....................................................2
PCB 2 Display Board ........................................2
PCB 3 Interface Board ......................................2
Locations of Circuit Boards ................................2
OPTIONAL EQUIPMENT................................................2
GenLink ............................................................2
Modem... ..............................................................2
Remote Annunciator Panel ..................................2
DIGITAL DISPLAYS ......................................................2
Battery Saver ......................................................2
AC Voltage Display ..............................................3
AC Voltage Indicators ..........................................3
AC Current Display ..............................................3
Frequency Display................................................3
Frequency Indicators............................................3
Power Factor ........................................................3
Power Output ......................................................4
Oil Pressure ........................................................4
Water Temperature ..............................................4
% Fuel.. ..............................................................4
Battery Voltage Display ........................................4
Battery Voltage Indicators ....................................4
Engine Hours ......................................................4
STATUS INDICATORS ALARMS
AND WARNINGS ........................................................4
Oil.......... ..............................................................4
Low Oil Pressure Alarm ......................4
High Oil Temperature Alarm ................4
Pre Low Oil Pressure Warning..............4
Pre High Oil Temperature Warning ........4
Water..... ..............................................................5
High Water Temperature Alarm............5
Low Level Water Alarm ........................5
Pre High Water Temperature
Warning ..............................................5
Low Water Temperature Warning ..........5
Fuel........ ..............................................................5
High Fuel Alarm ..................................5
Critical Low Fuel Alarm ......................5
Low Fuel Warning ................................5
Additional Alarms and Warnings..........................5
Emergency Stop Alarm ........................5
Overcrank Alarm..................................5
General Overspeed Alarm ....................5
Ruptured Basin Alarm ........................6
Not in Auto Alarm ................................6
Main Line Circuit Breaker Warning........6
Remote Access Warning........................6
Program Mode Warning........................6
Spare LEDs..........................................................6
No Equipment Connected ....................6
Remote Annunciator Connected ..........6
KEYPAD........... ..............................................................7
Numeric Keys 0-9 ................................................7
Enter and Clear Keys ..........................................7
Program Key ........................................................7
Alarm Horn Reset Key..........................................7
Alarm Lamp Reset Key ........................................7
Phase Select Key ..................................................7
Table of Contents
D Option Control Panel
CONTROLS....................................................................7
Emergency Stop Switch ......................................7
RS-232 Local Communications Port ....................7
Auto-Off-Run Switch ............................................7
Main DC Fuse ......................................................8
Voltage Trim Potentiometer ..................................8
INPUTS............ ..............................................................8
AC Voltage ............................................................8
AC Current ..........................................................8
Fuel Level ............................................................8
Oil Pressure ........................................................8
Water Temperature ..............................................8
Engine Speed Sensor ..........................................8
Coolant Level Sensor ..........................................8
Emergency Stop Contact ......................................8
Transfer Switch/Remote Start ..............................8
Pre High Oil Temperature ....................................8
High Oil Temperature ..........................................9
High Fuel Level ....................................................9
Low Fuel Level ....................................................9
Main Line Circuit Breaker ..................................9
Ruptured Basin....................................................9
Spare Alarms ......................................................9
Spare Warnings ....................................................9
OUTPUTS....... ..............................................................9
Starter Solenoid ..................................................9
Alarm..... ..............................................................9
Load Control........................................................9
Auxiliary ..............................................................9
Preheater..............................................................9
Fuel Control Relay................................................9
COMMUNICATIONS ......................................................9
Front Panel Communications Port ......................9
Modem... ..............................................................9
Remote Communications Port..............................9
Monitored Parameters........................10
Dial Out Option..................................................10
INSTALLATION NOTES ..............................................10
Operation........... ..............................................................11
OPERATION OF DIGITAL GENERATOR
CONTROL PANEL..........................................................11
Using the Keypad.... ..............................................11
Programmable Options ........................................11
Appendix 1 Electrical Data ......................................14
Appendix 2 Notes ......................................................21
Appendix 3 Exploded Views and Parts Lists ......22
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest GENERAC AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
Generac Power Systems, Inc. 1
 General Information
D Option Control Panel
OVERVIEW
The D option control panel is a microprocessor-
based generator set control panel designed for
Generacs range of standby generators. It has a fully
digital user interface and comprehensive communi-
cation capabilities.
The panel is housed in a steel sheet metal enclosure
that meets NEMA 1 specifications. The front face of
the panel consists of a number of light-emitting
diodes (LED) display windows showing generator
operating conditions, a tactile keypad, alarm and sta-
tus LED indicators, a main fuse, an Emergency
Stop switch and other generator set controls.
CONTROL PANEL CIRCUIT BOARDS
The control panel contains three main printed-circuit
boards (PCB), the automatic voltage regulator (AVR),
and terminal blocks for external connections.
To find the location of the circuit boards, refer to
Appendix 3 for the control panel exploded views. The
three main PCBs have the following defined 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 all
communication hardware (including optional modem
for telephone system communications).
PCB 2 DISPLAY BOARD
(Part # 0A1056) This board houses all the LED dis-
plays and annunciators, and their respective driver
circuitry.
PCB 3 INTERFACE BOARD
(Part # 0A1054) This board houses all the compo-
nents necessary to interface the CPU board to the
generator. This board receives high voltage and cur-
rent signals from the generator output. All control
relays are mounted on this board. Connections to
this board are by screw terminals.
LOCATIONS OF CIRCUIT BOARDS
PCBs 1 and 2 are mounted together on the back of
the hinged front wall of the panel, and PCB 3 is
mounted on the left wall of the panel as viewed from
the front.
2 Generac Power Systems, Inc.
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 removable
covers that allow for adjustment.
Remove the 15-amp fuse from the front of the
! panel during all engine maintenance to guard
against accidental or remote start-up.
OPTIONAL EQUIPMENT
GENLINK
GenLink is a communications software that allows the
generator to be started and monitored from a remote
PC via a modem. The generator can dial out automati-
cally and inform the PC if it has an active alarm condi-
tion.
MODEM
A modem (Part # 0A3557) can be connected to the D
panel to allow the generator to communicate with a
remote PC.
REMOTE ANNUNCIATOR PANEL
When connected to the generator via a simple shield-
ed two-wire link (plus two wires for power), this 20-
light remote indicator panel will display the genera-
tors status.
REMOTE RELAY PANEL
This panel is similar to the remote annunciator, but
instead 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 panel
will power down after five minutes when it is not
being used. It will reactivate if any of the following
occurs:
A key is pressed.
The engine is started.
Remote communications occur.
During the power down period, the alarms are
checked for 30 seconds every five minutes; any alarm
that occurs is permanently illuminated.

Figure 1.1 Digital Displays on D Option Control Panel
AC VOLTAGE DISPLAY (AC VOLTS)
This is a four-digit LED display for monitoring the
voltage of the selected phase. A keypad command
(PHASE SEL) is used to select which phase is dis-
played. LEDs indicate the phase that is currently
active. The range is 0 to1,023 volts AC.
When the unit is monitoring a three-phase generator,
the displayed voltage will coincide with one of the 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 done
through the panels programmable options (see
Programmable Options, Page 11).
AC VOLTAGE INDICATORS (HI, LO)
A pair of LEDs (included in AC VOLTS display) is
used to indicate whether the generators AC output
voltage is low or high. The set points are user pro-
grammable. These alarms are latched and cause the
alarm relay to latch.
Either alarm condition will shut down the generator
and cause a modem callout if enabled. This alarm is
enabled after the programmable alarm hold off timer
expires.
General Information
D Option Control Panel
Voltage alarm checking is done on all phases. In the
case of single-phase (i.e., 110 volts AC), the C-A
phase selection should coincide with an AC voltage
display of 220 volts AC. The alarm checking is taken
care of by the software, thus the alarm trigger points
only need to be set around the A-N or
C-N reading (i.e., 110 volts AC).
Half a second of bad readings is required before the
alarm will be raised.
AC CURRENT DISPLAY (AC AMPS)
This is a four-digit LED display for monitoring the
current in the selected phase. The range is 0 to 5,000
amps, depending on the selected current transformer
and the setting of the programmable full-scale cur-
rent range.
FREQUENCY DISPLAY (HERTZ)
This is a three-digit LED display for monitoring the
frequency of the generator output. The range of this
display is 40 to 70 Hertz. Phase A is used for this
measurement.
FREQUENCY INDICATORS (HI, LO)
A pair of LEDs (included in HERTZ display)is used
to indicate whether the generators frequency output
is low or high. The set points are user programmable.
These alarms are latched and cause the alarm relay
to latch.
POWER FACTOR
This is a three-digit LED display for monitoring
the power factor of the selected phase. The range is 0
to 1.00.
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
total power output of the generator. The power output
is the sum of all three phases, taking power factor
into account.
For powers greater than 1 megawatt, the display will
show a decimal point after the MW unit, e.g., 900 =
900 kW; 1.10 = 1.1 MW.
OIL PRESSURE
This is a three-digit display used to monitor engine
oil pressure. The range is 0 to 100 psi or 0 to 7.03
This is a six-digit LED display used to show engine
running time in hours. This display is also used when
entering the password and changing the programma-
ble options (see Operation of Digital Generator
Control Panel, Page 11).
STATUS INDICATORS ALARMS AND
WARNINGS (SEE FIGURE 1.2)
OIL
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.
WATER TEMPERATURE
This is a three-digit display used to monitor the engine
water temperature. The range is 0 to 300 F or -18 to
149 C. If the sensor is short circuited,
-S- will display. If the sensor is open circuited,
A red LED is used to indicate a low oil pressure condi-
tion. The set point is user programmable. The alarm is
latched and causes the alarm relay to latch. It shuts
down the generator and causes a modem callout if
enabled. This alarm is enabled after the programmable
alarm hold off timer expires.
High Oil Temperature Alarm (HIGH TEMP)

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

If no block heater is fitted to the generator, there can
be a problem in cold climates where temperatures of
less than 25 F (-4 C), can cause the sensor to think
it is open circuited. If this happens, either -0- (or
000) will display.
A red LED is used to indicate a high oil temperature
switch has been closed. This alarm is latched and
causes the alarm relay to latch. It shuts down the 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)

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.

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 to
latch. The alarm shuts down the generator and caus-
es a modem callout if enabled. The alarm is enabled
after the programmable alarm hold off timer expires.
Low Level Water Alarm (LO LEVEL)
A red LED is used to indicate the radiator water level
is low. The alarm is latched and causes the alarm
relay to latch. The alarm shuts down the generator
and causes a modem callout if enabled. This alarm is
enabled after the programmable alarm hold off timer
expires.
Pre High Water Temperature Warning
(PRE HIGH TEMP)
A yellow LED is used to indicate a warning that a high
water temperature condition exists. The set point is
user programmable. The alarm relay is latched.
Low Water Temperature Warning (LO TEMP)
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.
FUEL
High Fuel Alarm (HI)
A red LED is used to indicate a high fuel level. The
indicator can be activated in one of two ways:
1. Percent input
2. Switch input on J7-5
If the fuel percent measurement is used, an analog
sensor MUST BE installed and selected via program-
mable option #2. This allows for percentages to be
programmed for critical low fuel, low fuel and high
fuel. If the percentages are exceeded for high fuel, the
alarm relay will latch, but the generator will continue
to run. The modem will callout if enabled. (The
switch input will light the LED only.)
NOTE:
The two switch inputs LO Fuel Level J7-4 and
HI Fuel Level J7-5 work only if the percentage
input is turned off via programmable option #2.
When the % Fuel measurement is not used, the dis-
play is turned off.
General Information
D Option Control Panel
Critical Low Fuel Alarm (CRITICAL LO)
A red LED is used to indicate critical low fuel. This
feature is available only with an analog sender. The
alarm is latched. It does shut down the generator and
causes a modem callout if enabled.
Low Fuel Warning (LO)
A yellow LED used to indicate a low fuel level. The
indicator can be activated in one of two ways:
1. Percent input from analog sender
2. Switch input on J7-4
If the fuel percent measurement is used, an analog
sensor MUST BE installed and selected via program-
mable option #2. This allows for percentages to be
programmed for critical low fuel, low fuel and high
fuel. The alarm relay is latched, but the generator will
continue to run. The modem will callout if enabled.
(The switch input will light the LED only.)
NOTE:
The two switch inputs Lo Fuel Level J7-4 and
Hi Fuel Level J7-5 work only if the percentage
input is turned off via programmable option #2.
When the % Fuel measurement is not used, the dis-
play is turned off.
ADDITIONAL ALARMS AND WARNINGS
Emergency Stop Alarm (EMG STOP)
A red LED is used to indicate that the emergency stop
switch has been activated. This alarm is latched and
causes the alarm relay to latch. It shuts down the gen-
erator and causes a modem callout if enabled. This
alarm is enabled at all times.
Overcrank Alarm (OVERCRANK)
A red LED is used to indicate that the engine did not
start after eight starting attempts. The starting cycle
consists of a programmable number of seconds of
cranking followed by five seconds of OFF time. This
alarm is latched and causes the alarm relay to latch.
It shuts down the generator and causes a modem
callout if enabled.
General Overspeed Alarm (OVERSPEED)
A red LED used to indicate an overspeed condition.
The set point is user programmable. The alarm is
latched and causes the alarm relay to latch. The
alarm shuts down the generator and causes a modem
callout if enabled. The alarm is enabled after the
engine starts. If the speed sensor fails, then the 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
tank has ruptured. A float switch in the outer tank
closes when a rupture occurs. The alarm latches and
causes the alarm relay to latch. It causes the modem
to callout if enabled, but it does not shut down the
generator. This alarm is enabled at all times.
Not in Auto Alarm (NOT IN AUTO)
is shorted to ground, the LED lights, the engine shuts
down, and the alarms relay is latched. The modem
will call out if it is enabled.
The SPECIAL LED also can light and cause an alarm
if there is a speed sensor (tach) loss.
The WARN1 LED will light when its pin is shorted to

ground. The alarm relay will latch, and the modem

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

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

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.


The LED will light and latch. The generator will not
shut down, the alarm relay will not operate, and the
modem will not call out. The status will be sent to the
remote annunciator and displayed on its front panel.
GENERATOR POWER will cause the LED to act as an
indicator only. No alarms or shutdowns will occur.
The state of the input will be displayed on the remote
annunciator. It is intended to be connected to an aux-
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.
LINE POWER J7 pin 10 acts as above.
SPECIAL J7 pin 11 acts as previously described.
KEYPAD
Figure 1.6 Keypad Features
NUMERIC KEYS 0-9
Decimal numbers are included on a keypad for entry
of passwords and setting of programmable values.
ENTER AND CLEAR KEYS
The ENTER key will be used to accept data input
from the numeric keys. The CLEAR key will be used
to remove erroneous entries during programming.
General Information
D Option Control Panel
PROGRAM KEY (PROG)
This key is used to enter the local programming mode.
After pressing this key, the programming display will
show the word ACCESS, prompting the user for the
password. The password is a six-digit number that is
entered on the numeric keys and is displayed on the
hourmeter/programming display. The default factory
password is always 000000.
ALARM HORN RESET KEY
This key is used to reset the alarm relay contacts.
ALARM LAMP RESET KEY
This key is used to reset alarms that have been
latched.
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
GenLink loaded on it to enable communication
with the D panel. A serial cable (part # 0A4042) also
is required to connect to the unit.
AUTO-OFF-RUN SWITCH
A 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. 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)
This fuse is rated at 15 amps and is of the 1.25-inch-
es x 0.25-inch glass type (part # 022676). Removal of
this fuse inhibits all control panel functions and is
recommended 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 the
midpoint.
INPUTS
AC VOLTAGE
Four terminals (PCB3: J2-1, J2-2, J2-3, J2-4) are
provided for voltage measurement. Maximum input
voltage is 1000 volts AC.
NOTE
Correct phasing for these terminals is essential
for correct operation (see Appendix 1
Electrical Data for phase schematics).
AC CURRENT
Four terminals (PCB3: J2-7, J2-9, J2-11, J2-10) are
provided for current measurement. The inputs will
interface with current transformers having a five-amp
secondary winding at their rated current.
NOTE
Correct phasing for these terminals is essential
for correct operation (see Appendix 1
Electrical Data for phase schematics).
FUEL LEVEL (PCB1: J10-1)
An optional analog input is provided for fuel level
measurement. This is a 0 to 5 VDC input. An input
signal of 0 volts is equivalent to 0 percent remaining
fuel and 5 volts is equivalent to 99 percent remaining
fuel. The relationship between input voltage and fuel
level is linear.
8 Generac Power Systems, Inc.
OIL PRESSURE (PCB1: J10-2)
An analog input is provided for oil pressure meas-
urement. This input will interface to the standard
Generac sender unit (part # 053666). It is also used
for warning and shutdown situations.
WATER TEMPERATURE (PCB1: J10-3)
An analog input is provided for coolant temperature
measurement. This input will interface to the stan-
dard Generac thermistor sensor (part # 053667). It
is also used for warning and shutdown situations.
ENGINE SPEED SENSOR (PCB1: J10-5)
An input is provided for sensing engine speed by
counting 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 low
coolant level. The input will interface to the Generac
coolant level sensor (part # 057522).
EMERGENCY STOP CONTACT
(PCB3: TB2-1, TB2-3)
An input is provided for an emergency stop
switch(es). The switch contact is normally closed.
TRANSFER SWITCH/REMOTE START
(PCB1: J7-12)
When the AUTO-OFF-RUN switch is set to AUTO and
this input is grounded, the generator will begin its
start sequence. When the utility voltage drops, the
transfer switch/remote start system will close a 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 to
alarm.)

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 auxiliary
contact to indicate that the main line circuit breaker
is open. (Switch to ground to alarm.)
RUPTURED BASIN (PCB1: J7-3)
An input is provided for a level switch indicating the
fuel tank is ruptured. (Double wall fuel tanks only.)
(Switch to ground to alarm.)
SPARE ALARMS (PCB1: J7-1, J7-9)
Two inputs are provided for spare alarms. (Switch to
ground 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.
OUTPUTS
STARTER SOLENOID (PCB3: TB1-12, TB1-13)
A relay contact output is provided to activate the
starter solenoid. This form A relay is rated at 10
amps at 28 volts DC.
ALARM (PCB3: TB1-4(NC),
TB1-5(COM), TB1-6(NO)
A relay contact output is provided that will activate
on an alarm condition. This form C relay is rated at
10 amps at 28 volts DC.
General Information
D Option Control Panel
LOAD CONTROL (PCB3: TB1-7(NC),
TB1-8(COM), TB1-9(NO)
A relay contact output is provided for load control.
This contact will not energize unless the generator is
running. It is a form C relay rated at 10 amps at 28
volts DC.
AUXILIARY (PCB3: TB1-1(NC),
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 diesel
preheater. This form A relay is rated at 10 amps at 28
volts DC.
FUEL CONTROL RELAY (PCB3: TB1-14, TB1-15)
A relay contact output is provided to control the fuel
solenoid/valve. This form A relay is rated at 10 amps
at 28 volts DC.
COMMUNICATIONS
FRONT PANEL COMMUNICATIONS PORT
The front panel includes a connector for RS-232 seri-
al communication. See RS-232 Local
Communications Port, Page 7.
MODEM
The unit can optionally be provided with a modem
with AT command set which is FCC part 68
approved. The modem will allow an operator to per-
form the functions of the front panel at a remote site.
However, the modem functions will not allow remote
control of the engine if the front panel AUTO-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 to
Generacs remote annunciators or remote relay pan-
els (The Time Multiplexed Annunciator CANNOT be
used with a D panel.). Up to one annunciator and
four remote relay panels can be connected together
on this port via a shielded two wire communications
cable (plus two wires for power).
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 OF DIGITAL GENERATOR
CONTROL PANEL
USING THE KEYPAD
The use of most keys is self-explanatory, but the opera-
tion of some keys requires a brief explanation. (For
additional information, see Keypad on Page 7.)
Pressing ALARM HORN RESET turns off only the
alarm relay. Alarm conditions continue to be dis-
played. Pressing ALARM LAMP RESET clears all
alarm 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 Programmable
Option 28 Set User Password). If an invalid pass-
word is entered, the program will do nothing.
Additional characters may be entered in an attempt
to log on (only the last six digits are recognized). If a
valid password is not entered and/or no keypad activ-
ity has occurred for two minutes, the program will
revert to running time display.
If the correct password is entered, the display will
change to 00. At this time, the program is waiting
for an option (see Programmable Options) to be
entered. Twenty-eight options may be displayed and
changed, if desired. The current setting remains
unchanged if ENTER is pressed, or it can be changed
by entering a new number followed by ENTER. Exit
the keypad routine by pressing ENTER again anytime
the display shows 00.
Program options can be modified in the AUTO, OFF
or RUN mode. However, it is recommended that
the options be changed while the panel is in the OFF
mode.
PROGRAMMABLE OPTIONS
For information on programmable options, refer to
the following text, as well as the chart on Page 13.
1. Select English or Metric Units
Units of measurement will be changed on the panel
for oil pressure and water temperature.
2. Fuel Display On/Off
The fuel display should be turned off when an analog
fuel sensor is not being used. Alarm and warning
LEDs for fuel are activated by either the low and high
fuel switches or the programmed values used with
the analog sensor.
3. Pre Low Oil Pressure
See Status Indicators Alarms and Warnings, Page
4.
Operation
D Option Control Panel
4. Low Oil Pressure
See Status Indicators Alarms and Warnings, Page
4.
5. Low Water Temperature
See Status Indicators Alarms and Warnings, Page
4.
6. Pre High Water Temperature
See Status Indicators Alarms and Warnings, Page
4.
7. High Water Temperature
See Status Indicators Alarms and Warnings, Page
4.
8. Critical Low Fuel
This is used with an analog sensor to turn on a red
alarm LED. See Status Indicators Alarms and
Warnings, Page 4.
9. Low Fuel
This is used with an analog sensor to turn on a yel-
low warning LED. See Status Indicators Alarms
and Warnings, Page 4.
10. High Fuel
This is used with an analog sensor to turn on a red
alarm LED. See Status Indicators Alarms and
Warnings, Page 4.
11. Low AC Voltage
A red LED next to the AC Volts display is used to indi-
cate this alarm. If the generators AC voltage drops
below this set value for more than 0.5 seconds, an
alarm occurs and the engine shuts down. The alarm is
latched and causes the alarm relay to latch and pro-
duce a modem callout if enabled. This alarm is activat-
ed after the alarm hold off time is complete.
12. High AC Voltage
A red LED next to the AC Volts display is used to indi-
cate this alarm. If the generators AC voltage goes above
this set value for more than 0.5 seconds, an alarm
occurs and the engine shuts down. The alarm is latched
and causes the alarm relay to latch and produce a
modem callout if enabled. This alarm is activated after
the alarm hold off time is complete.
13. Low Battery Voltage
A red LED next to the Battery Voltage display is
used to warn that battery voltage is below pro-
grammed limits. No shutdown occurs with this warn-
ing.
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-
cate this alarm. If the generators frequency drops
below this set value for more than 1.5 seconds, an
alarm occurs and the engine shuts down. The alarm
is latched and causes the alarm relay to latch and
produce a modem callout if enabled. This alarm is
activated after the alarm hold off time is complete.
Frequency is measured on phase A.
16. High Frequency Limit
once the generators output voltage and frequency
climb above the preprogrammed low AC voltage and
low frequency limits. This relay can be controlled
from the front panel or through GenLink software
via a modem or RS-232. It is possible to use this out-
put as a generator running signal, but it will be
delayed by the hold off timer. (e.g., Program the out-
put to be ON, see Figure 2.1). See Outputs on Page
9.

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

24. Set CT Primary Current

This is the length of time that the starter stays
engaged when given a command to start. There will
be a five second off time after each on time. After
eight unsuccessful tries (each try consisting of one
cycle crank on time and one off time), the overcrank
This is the current rating for the primary side of the
CT with the secondary side being five amps. D panels
are set up to use five amp secondaries.
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.
They are single-phase, three-phase wye and three-
phase delta.
technician to access the panel through remote soft-
ware to determine the password. However, in order
for the technician to access the panel and password,
the panel must be capable of remote communication
via a modem.

PROGRAMMABLE OPTIONS
OPTION 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.