Manual Panel C 400

POWER SYSTEMS, INC.

®

PRESS

SENSORLOSS

RPM

OILLOW

NOT IN AUTOMATIC

COOL.TEMP.

HIGH

RESETTEST

SPEEDOVER

CRANKOVER

ER A E

ADJUSTVOLTAGE

NI15-A.FUSE

AUTO

MANUAL

OFFSTOP

START

PREHEAT30-SEC.

MAX.

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RUPTURE

FILLINGBASIN

FUELLOW

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600400

200

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A300

400

100

Hz65

60

Operator’s Manual“C” Option Control Panel

with Sealed Connectors400 kW & Below

This manual should remain with the unit.

Generac® Power Systems, Inc.

Important Safety Instructions“C” Option Control Panel with Sealed Connectors

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to alloperators and potential operators of this equipment.! !

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

Generac cannot possibly anticipate every possible cir-cumstance that might involve a hazard. The warn-ings in this manual, and on tags and decalsaffixed to your equipment, are, therefore, not all-inclu-sive. If you use a procedure, work method, or operatingtechnique Generac does not specifically recommend,you must satisfy yourself that it is safe for you and oth-ers. You also must make sure the procedure, workmethod, or operating technique that you choose doesnot render the equipment unsafe.

GENERAL HAZARDS• For safety reasons, Generac recommends that this

equipment be installed and serviced by a GeneracAuthorized Service Dealer or other qualified electri-cian or installation technician who is familiar withapplicable codes, standards, and regulations. Theoperator also must comply with all such codes, stan-dards, and regulations.

• When working on this equipment, remain alert at alltimes. Never work on the equipment when you arephysically or mentally fatigued.

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

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

ELECTRICAL HAZARDS• Generators produce dangerous electrical voltages

and can cause fatal electrical shock. Avoid contactwith bare wires, terminals, connections, etc., whilethe generator and related equipment are running.Ensure all appropriate covers, guards, and barri-ers are in place before operating the equipment. Ifyou must work around an operating unit, stand onan insulated, dry surface to reduce shock hazard.

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

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

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

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

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

• In case of an accident caused by electric shock,immediately shut down the source of electricalpower. If this is not possible, attempt to free the vic-tim from the live conductor. AVOID DIRECT CON-TACT WITH THE VICTIM. Use a nonconductingimplement, such as, a rope or board, to free the vic-tim from the live conductor. If the victim is uncon-scious, apply first aid and get immediate medicalhelp.

• Never wear jewelry when working on this equipment.Jewelry can conduct electricity, resulting in electricshock, 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 applicablecodes, standards, laws, and regulations. Adherestrictly to local, state, and national electrical andbuilding codes. Comply with regulations theOccupational Safety and Health Administration(OSHA) has established. Also, ensure that theequipment is installed in accordance with the man-ufacturer’s instructions and recommendations.Following proper installation, do nothing thatmight alter a safe installation and render the unitin noncompliance with the aforementioned codes,standards, laws, and regulations.

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Table of Contents“C” Option Control Panel with Sealed Connectors

Generac® Power Systems, Inc. 1

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

Section 1 — General Information ................................21.1 Overview ..............................................................2

1.2 Control Panel Components ..................................2

1.3 Optional Equipment ............................................2

1.3.1 Remote Annunciator Panel......................2

1.3.2 Remote Relay Panel ................................2

1.3.3 Additional Options..................................2

1.4 Panel Face Components ......................................2

1.4.1 AC Voltmeter ..........................................2

1.4.2 AC Ammeter ..........................................2

1.4.3 Frequency Meter ....................................2

1.4.4 Line-Phase Selector Switch ....................2

1.4.5 Voltage Adjust Potentiometer ..................2

1.4.6 Coolant Temperature Gauge ..................2

1.4.7 Oil Pressure Gauge ................................3

1.4.8 DC Voltmeter ..........................................3

1.4.9 Hourmeter ..............................................3

1.4.10 Start/Stop Switch....................................3

1.4.11 Auto/Off/Manual Switch ..........................3

1.4.12 Preheat Switch ........................................4

1.4.13 Panel Fuse ..............................................4

1.5 Engine Monitor Panel ..........................................4

1.5.1 Not in Automatic Start Mode Lamp ........4

1.5.2 Overcrank Lamp ....................................4

1.5.3 High Coolant Temperature Lamp............4

1.5.4 Overspeed Lamp ....................................4

1.5.5 Low Oil Pressure Lamp ..........................4

1.5.6 RPM Sensor Loss Lamp..........................4

1.5.7 Test/Reset Switch ....................................5

1.6 Optional Annunciator Panel ................................5

1.7 Optional Remote Annunciator..............................5

1.8 Standard Alarm Relay..........................................6

1.9 Preparation Before Startup ..................................6

1.9.1 Prior to Initial Startup ............................6

1.9.2 Startup Inspection ..................................6

Section 2 — Operation ....................................................6

2.1 Operating Unit with Manually-OperatedTransfer Switch ..................................................6

2.2 Operating Unit with Automatic Transfer Switch ..6

2.2.1 Manual Startup and Transfer ................6

2.2.2 Manual Retransfer and EngineShutdown ..............................................7

2.2.3 Preventing Automatic Startup ................7

Section 3 – Electrical Data ............................................8

Section 4 – Exploded Views and Parts Lists ..........14

Section 5 – Interconnection Diagram ......................18

AUTHORIZED SERVICEDEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICEDEALER nearest you, please call this number:

1-800-333-1322DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

1.1 OVERVIEWThe “C” option control panel is an analog generatorset control panel designed for Generac’s range ofstandby generators. It allows for either manual (elec-tric) or automatic startup and shutdown.

The panel is housed in a steel sheet metal enclosurethat meets NEMA 1 specifications. The front face ofthe panel includes a number of analog meters andgauges that indicate generator operating conditions,several indicator lamps for annunciation of enginefault shutdowns, and various other generator set con-trols.

1.2 CONTROL PANEL COMPONENTSThe control panel contains one main printed-circuitboard (PCB), the automatic voltage regulator (AVR),various discrete components, and terminal blocks forexternal connections.

To find locations of the circuit board, refer toAppendix 2 for the control panel exploded view. ThePCB has the following defined functions.

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

1.3 OPTIONAL EQUIPMENT1.3.1 REMOTE ANNUNCIATOR PANEL

When connected to the generator via a 19 wire connec-tion link, this multi-light remote indicator panel willdisplay the generator’s status.

1.3.2 REMOTE RELAY PANELThis panel is similar to the remote annunciator, but, inaddition to indicator lights, it provides relay contactclosures for status (e.g., alarms).

1.3.3 ADDITIONAL OPTIONSThe following are some of the more frequently request-ed optional accessories for the “C” option control panel:

• Emergency stop button• Oil temperature gauge• Engine run relay• 100 dBa alarm horn• Over/Under voltage relay• Voltage adjust potentiometer (Standard on all units

that do not use the Marathon alternator.)

1.4 PANEL FACE COMPONENTS(FIGURE 1.1, PAGE 3)

1.4.1 AC VOLTMETERThis meter indicates the generator AC output voltage.(Also see “Line-phase Selector Switch” and “VoltageAdjust Potentiometer” in this section.) To determinethe nominal rated AC voltage of your unit, refer toyour unit’s data plate.

NOTE:Some generators are reconnectable to a variety ofvoltages. Some units may be equipped with arotary “Voltage Selector Switch.” Be sure to readthe “Generator AC Lead Connections” section inyour Owner’s Manual.

1.4.2 AC AMMETERThis meter indicates the current draw of connectedelectrical loads, in amps. Also, see “Line-phaseSelector Switch.” For continuous operation, neverexceed the rated maximum continuous currentcapacity of your generator.

1.4.3 FREQUENCY METERThis meter indicates the generator’s AC output fre-quency in “Hertz” (cycles per second).

1.4.4 LINE-PHASE SELECTOR SWITCHThis four-position switch permits you to select eitherline-to-line or line-to-neutral readings on the panel volt-meter and ammeter. Switch positions are as follows:

1.4.5 VOLTAGE ADJUST POTENTIOMETERThis potentiometer permits the operator to “fine-adjust” the generator’s AC output voltage. Adjustmentrange is plus or minus 5 percent from the midpoint.Turn the knob clockwise to increase voltage, counter-clockwise to decrease voltage.

1.4.6 COOLANT TEMPERATURE GAUGEThis gauge indicates the engine coolant temperature.Normal operating temperature should read between185° to 215°F (85° to 102°C). If coolant temperatureexceeds a safe level, the engine shuts down automat-ically.

NOTE:Actual coolant temperature reading may vary dueto variables, such as, ambient temperature,applied load, or cooling system condition.

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Section 1 — General Information“C” Option Control Panel with Sealed Connectors

2 Generac® Power Systems, Inc.

Switch Single-phase Units Three-phase units1 Line E1 to Neutral Line E1 to E22 Line E3 to Neutral Line E2 to E33 Line E1 to E3 Line E3 to E1O No Reading No Reading


1.4.7 OIL PRESSURE GAUGEThis gauge indicates oil pressure during operation.After warm-up, oil pressure should be about 25-90psi. Generac recommends that the operator recordthe normal oil pressure during initial startup.Sudden changes in oil pressure after first startingindicate a possible engine problem.

NOTE:

Engine oil pressure may vary, depending on oilviscosity, oil temperature, engine speed, ambienttemperature, etc. The engine automatically shutsdown if oil pressure drops below a safe level. (10 psi.)

1.4.8 DC AMMETERThe engine is equipped with a belt-driven DC alter-nator, which charges the battery while the unit is run-ning. This ammeter indicates the rate of charge to thebattery during operation. If the needle drops to theleft of zero, battery is discharging. Investigate andcorrect this problem immediately. Erratic movementof the needle should also be corrected immediately.

1.4.9 HOURMETERThe hourmeter provides a continuous indication ofengine/generator operating time, in hours and tenthsof hours. Use the hourmeter with the periodic main-tenance schedule (See “Maintenance” section).

1.4.10 START/STOP SWITCHUse this switch to crank and start the engine manu-ally, or to shut down an operating engine.

• To crank and start engine, first set theAuto/Off/Manual switch to its “Manual” position.

• Hold the Start/Stop switch at “Start.” When theengine starts, release the switch to its center (run)position.

• To shut engine down, set the switch to its “Stop”position.

1.4.11 AUTO/OFF/MANUAL SWITCHThis safety switch should be used to prevent auto-matic startup of the engine when working on theengine/generator. Use the switch as follows:

Auto PositionAlways set switch to AUTO for automatic systemoperation. This means that, when this generator isinstalled with a GTS-type automatic transfer switch,the generator automatically cranks and starts whenthe utility source voltage drops below a preset level,or the unit exercises if programmed to do so.

Off PositionThe engine cannot be started either automatically ormanually. Always set switch to OFF before workingon, or around, the engine-generator.

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Figure 1.1 – “C” Option Panel Components


Manual PositionThe engine can be cranked and started manuallyusing the panel Start/Stop switch. The engine will notstart automatically.

NOTE:

Also see “Engine Monitor Panel.” With switch setto either OFF or MANUAL, a “Not in AutomaticStart Mode” lamp lights up on the panel.

1.4.12 PREHEAT SWITCHThis switch is installed on diesel units only. Whenperforming a manual start, this switch may bepressed for up to 30 seconds (before and duringcranking) to preheat intake air for smoother, cleanerstart-ups. This is important when the engine is cold.

1.4.13 PANEL FUSEThis fuse protects the control console’s DC circuitsagainst overload. If the fuse element melts open dueto an overload, engine cranking and startup will notbe possible. Should fuse replacement become neces-sary, use only an identical 15 amp fuse.

1.5 ENGINE MONITOR PANELThis panel has five advisory shutdown lamps for sep-arate engine fault conditions, plus a “Not inAutomatic Start Mode” lamp. Cranking and startingwill not be possible while any one, or more, of enginefault conditions lamps is lit, with the exception of“Not in Auto” illuminated in the manual mode. Thefollowing apply:

• A “lamp ON” condition indicates that fault condi-tion has been “latched” by DC control/latch-crankcircuit board.

• If any one of the lamps is ON (fault conditionlatched), the engine cannot be cranked either man-ually or automatically.

• To unlatch a fault (that is, to turn a lamp OFF) andpermit cranking, push the Test/Reset switch in.Lamp goes OFF, allowing for additional cranking.

1.5.1 NOT IN AUTOMATIC START MODE LAMPThis lamp comes ON to indicate that automatic start-up of the engine is not possible. The lamp lights upwhenever the Auto/Off/Manual switch is set to OFF orMANUAL.

1.5.2 OVERCRANK LAMPThe control console houses a DC control/latch-crankcircuit board that controls engine startup and shut-down. During automatic startup, the engine cranksfor about five seconds, rests for about five seconds,and so on, until eight of the crank-rest cycles haveoccurred. At the end of eight attempts, crankingstops, and the overcrank lamp goes ON.

1.5.3 HIGH COOLANT TEMPERATURE LAMPThis lamp comes ON if coolant temperature is toohigh or coolant level is too low. The engine shutsdown automatically when such unsafe conditionsoccur. The following apply:

• If the engine is started with an existing high coolanttemperature or low coolant level condition, theengine shuts down, and lamp comes ON whenengine speed reaches about 1000 rpm.

• If the engine starts normally but high tempera-ture/low coolant level develops later, the engineshuts down, and light comes ON immediately.

1.5.4 OVERSPEED LAMPAn engine overspeed above a safe limit causes theengine to automatically shut down, which turns ONthe indicator lamp. The overspeed lamp comes onwhen the unit is run at a 15% faster rpm than rated.

1.5.5 LOW OIL PRESSURE LAMPThis lamp lights up (latches) to indicate low oil pres-sure in the engine as follows:

• During cranking, after engine has reached 800 to1000 rpm, the circuit allows four seconds for oilpressure to build.

• In auto mode, if the unit runs above 800-1000 rpmfor more than four seconds, and oil pressure isbelow a safe level, the engine shuts down, but thelamp does NOT go ON. The system then actuateseight restart attempts; the engine shuts down, andthe lamp goes ON.

• If the engine starts normally with good oil pres-sure, but oil pressure drops later, the system waitsfive seconds for oil pressure to be restored. If pres-sure is still low after a five-second delay, the engineshuts down, and the lamp goes ON immediately.

1.5.6 RPM SENSOR LOSS LAMPUnits with the “C” Option console are equipped withan rpm sensor, which is mounted directly over theengine flywheel gear teeth. This sensor is a magneticpickup that emits an electrical pulse at the passage ofeach flywheel gear tooth. Sensor electrical signals areused by the DC control/latch-crank circuit board asengine speed (rpm) signals. The circuit board usesthese rpm signals (a) to establish a starter lockoutspeed, and (b) to shut down the engine if the engineruns too fast (overspeed). If the rpm signals to thecircuit board are lost, engine shutdown occurs, butthe lamp will not light, (i.e., the condition will notlatch), then, depending on whether the sensor signalloss occurred during a manual or an automatic startattempt, the following events occur:

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▼Section 1 — General Information“C” Option Control Panel with Sealed Connectors


Manual StartupIf the engine starts within two seconds after crankingbegins, shutdown occurs as soon as the Start/Stopswitch is released, but without a lamp ON condition(latching does not occur). If engine does not startwithin two seconds after cranking begins, which dis-ables starting, the rpm sensor loss light goes ON.

Automatic StartupThe engine recranks within about one second after ithas stopped. If sensor loss persists, engine shutsdown, and lamp lights about two seconds aftercranking has restarted.

If engine starts within two seconds after recrank hasbegun, the starter remains engaged until the two-sec-ond delay is over.

1.5.7 TEST/RESET SWITCHTo test all lamps, push this switch in. Following anyfault shutdown with any monitor panel lamp illu-mintaed, engine cranking is inhibited. To reset thesystem (unlatch a fault) and crank the engine again,push the switch in (lamp must go out). If the switchis actuated with the engine running, only the lampswill be tested. The engine will not shut down.

NOTE:

If engine shuts down due to some unmonitoredproblem (such as, out of fuel or failed ignition sys-tem), none of the lamps will come ON. If such anunmonitored shutdown occurs with theAuto/Off/Manual switch set to AUTO, enginerecranks and attempts to start for any of the cyclesremaining in the eight-crank limit. After all eightcrank cycles have been used, the engine shutsdown, and the OVERCRANK lamp goes ON.

1.6 OPTIONAL ANNUNCIATOR PANELSome units may come equipped with a factory-installed annunciator panel having one or two annun-ciated fault conditions displayed. This panel, used ondiesel units equipped with a base tank, will indicatea low fuel condition and, if so equipped, a rupturedbasin condition on a double-walled tank.

Figure 1.2 — Optional Annunciator Panel

1.7 OPTIONAL REMOTE ANNUNCIATORAn optional 18-light REMOTE annunciator panel youcan mount on a wall (Figure 1.3) is also available. Forinformation on the remote annunciator panels, askyour dealer/distributor or consult the factory. Ask forinformation on the Models 9555 and 9556 remoteannunciator panels. The following apply to theremote annunciator panels:

• It is designed for use with installation having aGenerac Power Systems GTS-type transfer switchand a “C” Option control panel.

• The panel is available in both flush-mounted(Model 9556) and surface-mounted (Model 9555)configurations.

• The panel has a built-in audible alarm horn, with areset switch to turn off the horn without disturbingthe lighted indication.

• Remote monitoring of the standby generator setprovides enough information to avoid unnecessarymaintenance trips to the generator site.

Figure 1.3 — Optional 18-Light RemoteAnnunciator

FILLINGBASIN

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1.8 STANDARD ALARM RELAYThe generator’s DC control/latch-crank circuit boardis equipped with an alarm relay “driver”. All unitswith “C” Option control panels are equipped with analarm relay that is connected to the circuit boarddriver (Figure 1.4). If any one or more of the fiveannunciated shutdown faults occur, the circuit boarddriver energizes the optional alarm relay.

A remote-mounted alarm or annunciator device maybe connected across the relay contacts so that a fail-ure will turn on the remote alarm or device. The con-nected alarm device may range from an alarm hornto a warning light to a telephone dialer with a pre-recorded message. The alarm relay normally-open,normally-closed, and common contacts are shown inFigure 1.4.

Figure 1.4 — Standard Alarm Relay

1.9 PREPARATION BEFORE STARTUPThe instructions in this section assume that thestandby generator has been properly installed, serv-iced, tested, adjusted, and otherwise prepared foruse by a competent, qualified installation contractor.Be sure to read RULES FOR SAFE OPERATION onthe inside of the front cover carefully, before attempt-ing to operate this (and related) equipment.

1.9.1 PRIOR TO INITIAL STARTUPBefore starting the generator for the first time, theinstaller must complete the following:

• Properly locate and properly mount the generator,transfer switch, and other standby system compo-nents, in strict compliance with applicable codes,standards, and regulations.

• Make sure the fuel supply system to the generator(a) delivers the correct fuel at the correct pressure,and (b) is properly purged and leak-tested accord-ing to code. No fuel leakage is permitted.

• Have the engine crankcase properly filled to thecorrect level with the recommended oil.

• Have engine cooling system properly filled with rec-ommended coolant mixture. Check the system forleaks and other problems.

• If engine is equipped with a mechanical governor,make sure the governor is properly filled with oil.Use crankcase oil to fill.

• Check engine v-belt tension and belt condition.• Make sure the generator is properly connected to

an approved earth ground.• The generator battery must be fully charged, prop-

erly installed and interconnected, and ready foruse.

1.9.2 STARTUP INSPECTIONA standard, three-part form entitled “StartupInspection for Standby Power Systems” (Part No.67377) should be completed by the installation tech-nician or engineer. As stated on the form, inspectionsare to be performed only by factory-trained person-nel. The installer should complete the form and dis-tribute copies as follows:

• White copy: Mail to Generac Service Department,P.O. Box 310, Eagle, WI 53119.

• Pink copy: For service file of installing dealer.• Yellow copy: For the customer’s records.

2.1 OPERATING UNIT WITH MANUALLYOPERATED TRANSFER SWITCH

If your generator was installed with a transfer switchcapable of manual operation only, the followingapplies. A manually-operated transfer switch is onethat will not provide automatic startup and does notinclude the intelligence circuit.

2.2 OPERATING UNIT WITHAUTOMATIC TRANSFER SWITCH

If your generator has been installed with a Generac“GTS”-type automatic transfer switch, the engine maybe started and stopped either automatically or man-ually.

IMPORTANT: BE SURE TO READ THE APPLICA-BLE AUTOMATIC TRANSFER SWITCH MANUALCAREFULLY. DIFFERENCES EXIST BETWEENTRANSFER SWITCHES.

2.2.1 MANUAL STARTUP AND TRANSFERTo crank and start the engine and to transfer electri-cal loads to the STANDBY power source, proceed asfollows:

• See applicable transfer switch instructions. If soequipped, set the Safety Disconnect Switch toMANUAL.

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36

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DC CONTROL-LATCHCRANK CIRCUIT BOARD

Section 2 — Operation“C” Option Control Panel with Sealed Connectors


• On the generator’s Meter and Control Panel, set theAuto/Off/Manual switch to MANUAL.

The safety disconnect switch and theAuto/Off/Manual switches must be set asinstructed above, or the generator will crankand start as soon as the utility power to thetransfer switch is turned OFF.

• Turn OFF both the NORMAL (utility) and EMER-GENCY (standby) power supplies to the transferswitch, using whatever means is provided (suchas, the main-line circuit breakers).

DO NOT attempt manual operation until allpower voltage supplies to the transfer switchhave been positively turned OFF; otherwise,extremely dangerous---possibly lethal--- elec-trical shock will result.

• Refer to the instructions that correspond to theinstalled transfer switch. Manually actuate theswitch main contacts to their STANDBY (emer-gency) position, as outlined in the correspondingmanual. LOAD circuit must be connected to theSTANDBY power supply before proceeding.

• On the generator console, hold the Start/Stopswitch START to crank the engine. Hold it until itbegins running, then release the switch to its cen-tered (RUN) position.

• Let the engine warm up and stabilize at no-load.• Turn ON the STANDBY power supply to the trans-

fer switch, using whatever means provided (suchas, STANDBY source main-line circuit breaker).

• The generator now powers the load circuits.

2.2.2 MANUAL RETRANSFER AND ENGINE SHUTDOWN

To retransfer LOAD circuits back to the NORMAL(utility) power source and to stop the engine, proceedas follows:

• Turn OFF both the UTILITY and STANDBY powersupplies to the transfer switch, using whatevermeans provided, i.e., the power source main-linecircuit breakers.

DO NOT attempt manual operation until allpower voltage supplies to the transfer switchhave been positively turned OFF; otherwise,extremely dangerous---possibly lethal---elec-trical shock will result.

• Refer to the applicable transfer switch instruc-tions. Manually actuate the transfer switch maincontacts to their utility position (LOAD connectedto UTILITY power supply).

• Turn ON the UTILITY power supply to the transferswitch, using whatever means are provided (suchas, the UTILITY main-line circuit breakers).

• Check that the UTILITY voltage is available to thetransfer switch (see appropriate transfer switchinstructions).

• Let the generator engine run at no-load for a fewminutes. Then, set the generator Start/Stop switchto STOP. Wait for the engine to come to a completestop.

• Reset the system for fully automatic operation.

2.2.3 PREVENTING AUTOMATIC STARTUP

When installed with an automatic transferswitch, Generac standby generators can crankand start suddenly, without warning, whenUTILITY source voltage drops below a presetvalue. To prevent possible injuries caused bysuch sudden starts, disable the automatictransfer switch before working on, or around,the generator. Use any one, or more, of the fol-lowing methods to disable the automatic startfunction:

• Set the generator’s Auto/Off/Manual switch to OFF.Neither a manual nor an automatic start can beaccomplished with this switch set to OFF.

• Remove the fuse from the generator control panel.To remove the fuse, push fuse holder cap in andturn cap counterclockwise. Remove cap and fuseelement.

• Refer to the automatic transfer switch instructions.If the transfer switch is so equipped, set its SafetyDisconnect switch to MANUAL position to preventautomatic startup and transfer.

• Disconnect battery cable from generator batterypost, indicated by a negative, NEG, or (-).

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Section 2 — Operation“C” Option Control Panel with Sealed Connectors


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E

V

X

RS

C

AB

- 1

2 P

IN B

ULK

HE

AD

CO

NN

EC

TO

R (

BLA

CK

)A

C -

TE

RM

INA

L B

LOC

K/ 1

2 P

OS

.

L1 -

LIG

HT

RP

M S

EN

SO

R L

OS

SA

M-

AM

ME

TE

R

LEG

EN

D

B -

AC

VO

LTA

GE

RE

GU

LAT

OR

G -

RE

SIS

TO

R, F

IELD

BO

OS

T

K -

CIR

CU

IT B

OA

RD

, EN

GIN

E C

ON

TR

OL

N -

SW

ITC

H, A

UT

O/M

AN

UA

L/O

FF

Q -

PO

TE

NT

IOM

ET

ER

, VO

LTA

GE

AD

JUS

T

D -

RE

SIS

TO

R, E

NG

INE

ALT

ER

NA

TO

R

A -

TE

RM

INA

L B

LOC

K/ 2

0 P

OS

.

W -

GU

AG

E, O

IL P

RE

SS

UR

E

S -

SW

ITC

H, P

HA

SE

SE

LEC

TO

R

R -

SW

ITC

H, P

HA

SE

SE

LEC

TO

R

Z -

TE

RM

INA

L B

LOC

K/ 8

PO

S.

Y -

GA

UG

E, W

AT

ER

TE

MP

ER

AT

UR

E

M -

SW

ITC

H, S

TA

RT

/ST

OP

U -

FR

EQ

UE

NC

Y M

ET

ER

V -

AC

AM

ME

TE

R

T -

HO

UR

ME

TE

R

X -

AC

VO

LTM

ET

ER

H -

DIO

DE

J -

PR

EH

EA

T R

ELA

Y

F-

ALA

RM

RE

LAY

49

14/219

85D

2D

D2

- R

ES

IST

OR

, EN

GIN

E A

LTE

RN

AT

OR

P

R2

R2

- R

ES

IST

OR

WA

TE

R T

EM

PE

RA

TU

RE

SW

- S

WIT

CH

, TE

ST

/ RE

SE

T

Z

Z

L2 -

LIG

HT

OV

ER

SP

EE

DL3

- L

IGH

T O

VE

RC

RA

NK

L4 -

LIG

HT

HIG

H T

EM

P/L

OW

LE

VE

L

L7 -

PA

NE

L LI

GH

TL6

- L

IGH

T N

OT

IN A

UT

OM

AT

IC S

TA

RT

MO

DE

L5 -

LIG

HT

LO

W O

IL P

RE

SS

UR

E

86

Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V GasControl Panel Electrical Schematic – Drawing No. 0E1579


Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V Diesel, Less than 400 kW

Control Panel Electrical Schematic – Drawing No. 0E0037-A

= U

SED

FO

R 1

2 VO

LT U

NIT

S O

NLY

= U

SED

FO

R 2

4 VO

LT U

NIT

S O

NLY

15A/

220A

2 - 3

2-7

2-1

1

CO

NTA

CTS

12-7

19 -

14

15 -

1815

- 14

12-1

1

12 -

3

PHAS

E SE

LEC

TOR

SW

ITC

H

C

E0

14/219

GH4

C-N

C-L

C-M

C-A

C-O

C-P

C-D

C-J

C-G

C-F

C-H

C-B C-E

C-C

TO LOWER PANEL

0 1 42

S16

S15

178 657 5958S3S2

1

42

6

1

S16

12

216 18

14/2

19

D2

DS154 6

4 65

4 65

67

S15

0

Q

89

183

315 19 117

89

0

1

U

2 31

31

0

- +V

0

64

X

OFF

PO

SITI

ON

SHO

WN

IN

C-K

S1

R14

S

650

015

/220

503 (J1)

B

0

0

49

0X 00

0X

(J3) K

0

1137

94

9697

98

0 00 00

86

15A/

220A

14/2

19

08579221

183A56229

14/2

19

183

219 69 79

R1

0

85

0

56221

T+ -

860

W

18

15A/

220A

AJ

L7

183A

228

15A/

220A

B

15A/220A

17

R2

0

Y68

0

0

56 85 49796968

9594503

98 96 0 097

15A/

220A

J 47

150

229

M

183

+- AM

015

0

219

J1 6 2

228

(4)

L3

OFF

XXX012

3

0XX

183A

15A/220A

228

OFF

PO

SITI

ON

6 971 43

852

NSH

OW

N IN

15A/220A183

13/2

18A

L7 -

PAN

EL L

IGH

T

L2 -

LIG

HT

OVE

RSP

EED

L3 -

LIG

HT

OVE

RC

RAN

K

D -

RES

ISTO

R, E

NG

INE

ALTE

RN

ATO

R

K -

CIR

CU

IT B

OAR

D, E

NG

INE

CO

NTR

OL

Q -

PO

TEN

TIO

MET

ER, V

OLT

AGE

ADJU

ST

E -

CIR

CU

IT B

REA

KER

, FIE

LD B

OO

STD

2 -

RES

ISTO

R, E

NG

INE

ALTE

RN

ATO

R

AD -

EN

GIN

E M

ON

ITO

R P

CB

ASSE

MBL

Y

R2

- R

ESIS

TOR

WAT

ER T

EMPE

RAT

UR

E

AA -

12 P

IN B

ULK

HEA

D C

ON

NEC

TOR

(GR

EY)

AB -

12 P

IN B

ULK

HEA

D C

ON

NEC

TOR

(BLA

CK)

L6 -

LIG

HT

NO

T IN

AU

TOM

ATIC

STA

RT

MO

DE

N -

SW

ITC

H, A

UTO

/MAN

UAL

/OFF

R -

SW

ITC

H, P

HAS

E SE

LEC

TOR

G -

RES

ISTO

R, F

IELD

BO

OST

AC -

TER

MIN

AL B

LOC

K/ 1

2 PO

S.

L1 -

LIG

HT

RPM

SEN

SOR

LO

SS

Z -

TER

MIN

AL B

LOC

K/ 8

PO

S.Y

- G

AUG

E, W

ATER

TEM

PER

ATU

RE

L4 -

LIG

HT

HIG

H T

EMP/

LOW

LEV

ELL5

- L

IGH

T LO

W O

IL P

RES

SUR

E

C -

23

PIN

BU

LKH

EAD

CO

NN

ECTO

R

A -

TER

MIN

AL B

LOC

K/ 2

0 PO

S.

M -

SW

ITC

H, S

TAR

T/ST

OP

W -

GU

AGE,

OIL

PR

ESSU

RE

SW -

SW

ITC

H, T

EST/

RES

ET

R1

- R

ESIS

TOR

OIL

GAU

GE

B -

AC V

OLT

AGE

REG

ULA

TOR

LEG

END

SW

P -

FUSE

, 15

AMP

F-

ALAR

MR

ELAY

T -

HO

UR

MET

ER

X -

AC V

OLT

MET

ER

AM-

AMM

ETER

V -

AC A

MM

ETER

L -

SWIT

CH

, PR

EHEA

T

J -

PREH

EAT

REL

AY

ZA

AD

13A/

218A

13/2

18

TO ENGINE

L1L2

L4

BA

F174

137L6

L5

1(5)

AC20

9

210

211

5 4

96 137

94228

AC

15A/

220A

PZ


Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V Diesel, Less than 400 kWControl Panel Wiring Diagram – Drawing No. 0E0036-A

Q

N D

P R

XKXX

U

210

211

228

98

137

15A/220A

E

94

95

97

0

0

86

15A/220A

FUEL

LVL

RUPT

TAN

K

PRE-

HEAT

OIL

P S

END

COO

LNT

TEM

P

OIL

TEM

P

7

6

77

6 5 4 3 2 1

M S357

59

T

V

X

N

PQ

S

0

2

41

183

S16S15

S1178

S2

6E

HG

J

LK

F

A

CD

B

WIRE COLOR LEDGEND

162,178,183,S1-3,590

68,69,85,502,509,

2,49,150,A1-8,R1-9

515,523,567,575,589

229

2

14,15,219,220ORANGE FUSED DC

209

210

211

137

98

228

9

10

11

12

5

7

6

98

9413

796

95 97

C

95

94

97

96

AC

1

2

4

Z

CONTROL

AC/MISC

UNIT STATUS

SIGNAL/SENSING

6

7

BLACK

BLUE

YELLOW

86

6

K

0 0 86

0

NEUTRAL

WIRECOLORWHITE

4,13,29,2180,1,R15,591

0

0

14/2

19

AA - 12 PIN BULKHEAD CONNECTOR (GREY)

14/219

209

056

14/2

19

3 4

18221

228

6 7

210

7917

183A

98

85 86

1211

86

228

15A

/220

A

14

S15

228

41

1621

183A6

221

210

NOT USEDNOT USED

NOT USEDNOT USED

NOT USED

NOT USED

86 S15 79

14/2

19 85

S3

S2

S1

1

S16

49

15A

/220

A

15A

/220

A566 41

492

2

162

56 15/22014/219

0

595857

221

689 S154

221

9B 36

228228

183A

221

221

AD - ENGINE MONITOR PCB ASSEMBLY

AB - 12 PIN BULKHEAD CONNECTOR (BLACK)

L4 - LIGHT HIGH TEMP/LOW LEVELL5 - LIGHT LOW OIL PRESSURE

15A/220A

211209

15A

/220

A

162

14/2

19

221

J

A 79B

1436

89

A 7

183

14

AC - TERMINAL BLOCK/ 12 POS.

L1 - LIGHT RPM SENSOR LOSSAM - AMMETER

L2 - LIGHT OVERSPEEDL3 - LIGHT OVERCRANK

150

A

15/220

183A1718

183

1718

14/219

13/2180

69

14/219

89

5758

68

S3

S1

15/220

209211 209

B 1 2

44

211

1

0

00

178 1 79

13/2

18

H

D2

29

G

D

E

85

15/2

20

9

5649 68

13 14

8569 150

18 19 20

211

643 5

97

96

9495

98

137

229

1718

89

S15

210

13796

98

S15

S1597

95

150

ABD - RESISTOR, ENGINE ALTERNATORC - 23 PIN BULKHEAD CONNECTOR

D2 - DIODE, ENGINE ALTERNATOR

N - SWITCH, AUTO/MANUAL/OFF

K - CIRCUIT BOARD, ENGINE CONTROL

Q - POTENTIOMETER, VOLTAGE ADJUST

Y - GAUGE, WATER TEMPERATURE

B - AC VOLTAGE REGULATOR

G - RESISTOR, FIELD BOOST

A - TERMINAL BLOCK/ 20 POS.

F - ALARM RELAY

L - SWITCH, PREHEAT

J - PREHEAT RELAYH - DIODE

P - FUSE, 15 AMP

SW - SWITCH, TEST/ RESET

W - GUAGE, OIL PRESSURE

U - FREQUENCY METER

X - AC VOLTMETER

T - HOURMETER

AA LEGEND

15/220

13/2

18

67

0 0 0

86

14/2

1914

/219

0

000

49

15015/220

56

68523

56150 00

000

575

79

7

86 69 68

6

850

567


Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V Diesel, Less than 400 kW

Control Panel Wiring Diagram – Drawing No. 0E0036-A

0

13/218

14/2

19

14/219

15/220

15A/220A

S16

S16

17

17

17 18

57

57

58

59

59

89

89

98

183A

183

221

221 221

228228

228

228

15/220

69

S15

S15

AMMETER LEADSFROM ENGINE HARNESS

13/218

R

S

14/219

L7

REQUIRED FOR 24V UNITS ONLY

AD

AM

14/219

221

L

0

0

0

0

14/219

228228

57

11

15/220

0 S1

S2

142

7

16

3

18

M0

N

15/2

20 68

0

68

0

P

S3

0

69

19

1218

15

68

0

69

13/218

13A/218AA

14/2

19

14/219

S15S15

R2

0

96

137

98

97

94

95

23

16

514/219

67

0

00

S15

S15

R1

Y

W

S150

S15

0

14/219

+

-

0

67

14/2

19

X

65

64

V

U

89

Q

6968

S16

65 64

13/21813A/218A

14/219

+

-

T

64

S16S16

65

S16

S16

64 65


Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V GasControl Panel Wiring Diagram – Drawing No. 0E1578-A

= USED FOR 24 VOLT UNITS ONLY= USED FOR 12 VOLT UNITS ONLY

KXKK

DN

M

L

QQ

U

W

R

15A/220A

15A/220A

E

0

0

86

COO

LNT

LVL

OIL

P S

END

MLC

B SW

RUPT

TAN

K

FUEL

LVL

97

95

137

98

94

211

210

228

6

7 12

56 34 12

Z

1

C

7

6

AB

5

0 1 79

1 9613

/218

15/2

20

141211

685649

100

H

B

4

3 4 6521

29

4

D

G

D2

E

A16 17

150

85

1569

2056

7

19

76

0 00

14/2

19

CONTROL

BLUE

YELLOW

BLACK

SIGNAL/SENSING

UNIT STATUS

AC/MISC

150

8569

WIRE

ORANGE

WHITE NEUTRAL

515,523,567,575,589

2,49,150,A1-8,R1-9

68,69,85,502,509,

162,178,183,S1-3,590

6

14,15,219,220

0,1,R15,5914,13,29,218

14/2

19

0 0

6

7

4

5

2

1

AC

94

12

11

10

9

2 64 5 7 109 12K

0

0

0

56 1

AA

0

0

0

0

0

0

0

0

0

0

0

0

0

1

1

1

1 4

13/218

13/218

13/2

18

14/2

19

14/2

19

14/2

19 0

0

14/219

14/219

15/220

15/220

15/220

97 4 1

6 3

B 9

A 7

6 34 1

J

F

15A

/220

A15

A/2

20A

15A/220A15A/220A

15A/220A15A/220A

15A

/220

A

15A/220A

15A/220A

2

2

79

150

150

S16

17229

229

18

18

18

18

17

17

17

49

49

49 15/220

14/2

1914

/219

15/220150

150

15/2

20

56

566

56

1

162

89 S15 6

4

6

57

57

5859

58

89

89

89

95

97

96

98

137

211

210

209

228

S15

162

162

97

9594

9698

95

13796

98

9896

13794

9597

178

18318

3A

183

183

183A

183A

183A

209211210

209 211209

211210 210

221

221

221

221

221

228

228 228 228228

56

S3

S2

S1 S3

S1

6968

85 86

86

86

85

85

86

79S15

S15

S15

S15

6869 8586

86

86

079

COLOR

00

H - DIODE

L6 - LIGHT NOT IN AUTOMATIC START MODE

K - CIRCUIT BOARD, ENGINE CONTROL

AB - 12 PIN BULKHEAD CONNECTOR (BLACK)

X - AC VOLTMETER

L5 - LIGHT LOW OIL PRESSURE

L7 - PANEL LIGHT

L4 - LIGHT HIGH TEMP/LOW LEVELL3 - LIGHT OVERCRANKL2 - LIGHT OVERSPEED

Y - GAUGE, WATER TEMPERATUREZ - TERMINAL BLOCK/ 8 POS.

L1 - LIGHT RPM SENSOR LOSS

AC - TERMINAL BLOCK/ 12 POS.AD - ENGINE MONITOR PCB ASSEMBLY

J - PREHEAT RELAY

T - HOURMETER

V - AC AMMETERU - FREQUENCY METER

M - SWITCH, START/STOP

D2 - DIODE, ENGINE ALTERNATOR

F - ALARM RELAY

A - TERMINAL BLOCK/ 20 POS.

C - 23 PIN BULKHEAD CONNECTORD - RESISTOR, ENGINE ALTERNATOR

G - RESISTOR, FIELD BOOST

B - AC VOLTAGE REGULATOR

LEGEND

SP

LIC

E

14/219

14/219


S16

S15

S15

U

S16

X

64

L7V

15 193711

2 14 16 18 12

+

-

+

-

35

62

1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

00

0

13/218

14/219 14/219

14/2

19

14/219

14/2

1914

/219

14/219

15/220

15/2

20

15A/220A

6464

64

65

65

6565

S16

S16

S16

S16

S16

17

17

18

17 18

57

57

5758

59

59

67

67

89

89

89

97

95

137

94

98

96

AD

98

183A

183

228228

228

228

228228

15/220

S1

S2

S3

68

68

6968

69

68

69

69

S15

S15S15S15

S15

S15

13A/218A13/218

13/218

13A/218AA

AMMETER LEADSFROM ENGINE HARNESS

REQUIRED FOR 24V UNITS ONLY

M

N

15/220

13/218 P

R

S

Q

T

AM

W

Y

R2

R1

14/21914/219

14/219

14/219

Section 3 — Electrical Data“C” Option Control Panel with Sealed Connectors 12V & 24V Gas

Control Panel Wiring Diagram – Drawing No. 0E1578-A

UNDERFREQUENCY

E

VOLTAGE ADJUST

E

ADJUST

GA

REGULATOR

R

A A

54

19

7175

76

44

46 53

1

45

59

63

60

66

64

43

67

65

68

68

91

50

5266

64

67

59 60

63

8954 86

5150 41 40

INSIDE.

38 39 50 51

33

A339

2

78

50 52

36

525050 52

92

66

64

90

51

66

8

7

x3

4

5

6059

63 58

60

59

63

67

65

16

17

15

2322

18

82

51

64

67

65

36

80 80

81

6

14

26

28

25

24

6059

63

3

2

34

6059

62

21

10

58

59

27

29

50

20

37

47

88

83

84

48

49

5951

85

61

77

3130 32

57

12

ALL BRUSHLESS & PME MACHINES

OVER 100KW WITH 12 OR 24V DC SYSTEMS

UPTO 100KW WITH 24V DC SYSTEMSALL BRUSHLESS & PME MACHINES

ALL BRUSHLESS & PME MACHINESUPTO 100KW WITH 12V DC SYSTEMS

TABLE A-FIELD BOOST RESISTOR DATA

UPTO 100KW WITH 12 OR 24V DC SYSTEMSALL DIRECTLY EXCITED MACHINES

25 OHM 25W

75 OHM 25WP/N: 086266

P/N: 08336450 OHM 25WP/N: 057405

5 OHM 25WP/N: 048352

TABLE E- OPTION PANEL


TABLE B-AVR POWER(DPE) CIRCUIT BREAKER DATA




ALL DIRECTLY EXCITED MACHINES

UNITS WITH BASE TANKS

UNITS WITHOUT BASE TANKS

OVER 100KW

19 TO 45KW

19 TO 26KW

45 TO 100KW

21 TO 41KW

P/N: 070030

P/N: 0D9750

4.5AP/N: 048476

P/N: 048467

P/N: 054450

P/N: 048467

P/N: 048505

7A

5.5A

6.0A

7A

CONTROL PANEL LEFT SIDE

110/220V 1 PHASE115/200V3 PHASE

231/400V 3 PHASE100/200V 3 PHASE

120/240V 3 PHASE277/480V 3 PHASE

120/208V 3 PHASE

120/240V 1 PHASE

R0-3000A0753260-200A070045 L

0-300A

AMMETER

0-150A

0-1000A0-1600A

0-600A0-800A

0-400A

0-2000A

AMMETER

070056070057

075323075324

070059070060

070058

075325

P/N: RANGEA

N

K

G

VOLT.

070044 0-600V082404600V 3 PHASE 0-750V

070043070043

070043070043

070043070043

070044

METER P/N:VOLTAGE

070043

VOLTAGE

0-300V0-300V0-300V

0-300V0-600V

0-300V0-300V

0-300VMETER RANGEVOLTAGE

VIEW AHINGE ASSEMBLY

SCALE: NONE

++-

GOVERNOR CONTROLBEHIND COVER

AVR BEHIND COVER


Section 4 — Exploded Views“C” Option Control Panel with Sealed Connectors 12V & 24V DieselControl Panel – Drawing No. 0E0035-J


ITEM PART NO. QTY. DESCRIPTION

1 0D9687 1 "C" PANEL BOTTOM/BACK PANEL2 0E0282 1 PANEL FRONT "C" W/SLKSCRN3 0A6322 1 PANEL RIGHT SIDE E4 0A6321 1 PANEL LEFT SIDE E5 0E3550 1 CHASSIS, UNIVERSAL6 0D9720 1 HARNESS SEALED "C" PANEL

STANDARD7 086266 1 RES WW LUG 75R 5% 25W

8 * 025192 1 RECTIFIER MSC 2A 600V 1N506210 023762 3 WASHER SHAKEPROOF EXT #10 STL12 0E6871 1 RECTIFIER ASSEMBLY14 0A3392 1 DECAL TERMINAL BLOCK15 067625 1 SWITCH TOGGLE 3P3T 15/10A16 055867 1 SWITCH TOG SPDT 15A SPD MOM17 055920 1 SWITCH SPST SPADE PANEL MNT18 0D6947 1 HINGE CONTINUOUS19 0C1229 1 DECAL CUST CONN BOX20 084787 1 CABLE RIBBON 16"21 055406 1 GAUGE COOLANT TEMPERATURE22 032300 1 HOLDER FUSE23 022676 1 FUSE 15A X AGC1524 055349 1 INSULATOR25 071361 1 POT 5K 10% 2.25W PNL26 050123 1 KNOB PLASTIC .25 SHAFT27 070081 1 HOURMETER28 061945 1 SWITCH SELECTOR 6A AMP/V29 062304 1 AMMETER 40-0-40 DC30 0E3703 1 LIGHT PANEL WITH LUG31 0C8481 1 BULB-PANEL LIGHT-12V

083288 1 LIGHT 28VDC .17A MIN BAYNT MNT32 070082 1 BLOCKER LIGHT33 0A2275 1 DOOR-STOP RAM PANEL34 030809 1 GROMMET 11/16 X 1/8 X 7/1635 055405 1 GAUGE OIL PRESSURE36 0A2400A 2 TRUNKING 180MM38 0A1441B 1 COVER PLATE, AVR39 0C1127 1 DECAL AVR COVER40 0A1441C 1 COVER PLATE EGOV41 0A3394 1 DECAL ELEC GOVERNOR42 0A5705 REF. FUSE 5A X LTTL215005 (NOT SHOWN)43 066040 1 DECAL TERMINAL STRIP44 0D3471 2 DECAL COVER DEUTSCH (RECT)45 0D3471 2 DECAL COVER DEUTSCH (RECT)

(ELECTRONIC GOVERNOR HARNESS IFEQUIPPED)

46 0C5141 2 CONN DEUTSCH GASKET 8/12POS DT50 022155 14 WASHER LOCK #651 0C2699 14 SCREW PHTT #6-32 X 3/8 ZYC52 0C2428 10 SCREW TAPTITE PH 6-32 X 1/2 Z/YC


53 074908 8 SCREW HHTT M5-0.8 X 10 BP54 022264 8 WASHER LOCK M455 038150 8 WASHER FLAT #8 ZINC58 022158 1 NUT HEX #10-32 STEEL59 022152 14 WASHER LOCK #1060 023897 14 WASHER FLAT #10 ZINC61 024469 2 SCREW TAPTITE #10-32 X 3/8 BP62 033120 1 SCREW HHC #10-32 X 3/863 033121 13 SCREW HHC #10-32 X 1/264 022507 4 SCREW HHC 1/4-20 X 1/2 G565 022097 4 WASHER LOCK M6-1/466 022473 4 WASHER FLAT 1/4 ZINC67 040479 4 VIB MNT 1.0 X 1.0 X 1/4-2068 036261 6 RIVET POP .125 X .129-.133/#3069 0C8243 1 WASHER LOCK HDPDEUTSCH70 0C8244 1 NUT, HDP DEUTSCH-- --------- -- ADDITIONAL PARTS (BASE TANK UNITS)

71 022471 4 NUT HEX #8-32 STEEL75 0E0044 1 HARNESS BASETANK FOR C PNL 24V

0E0044A 1 HARNESS BASETANK FOR C PNL 12V76 0C5141 1 CONN DEUTSCH GASKET 8/12POS DT-- ---------- -- PANEL SPECIAL PARTS

80 064733 2 BRACKET RESISTOR MOUNTNG FOR25W

81 * SEE TABLE A 1 RESISTOR #282 SEE TABLE B 1 FIELD CIRCUIT BREAKER83 SEE TABLE C 1 AMMETER84 SEE TABLE D 1 VOLTMETER AC85 070042 1 METER FREQUENCY 55-65HZ

070042A 1 FREQUENCY METER 240V 45-55HZ86 067680 1 ASSY VOLTAGE REGULATOR 60HZ

092952 1 ASSY VOLTAGE REGULATOR 50HZ37 029187 2 SPACER .19 X .31 X .50 PL47 036908 2 SCREW PPHM #6-32 X 1-1/448 022985 2 WASHER FLAT #6 ZINC49 022188 2 NUT HEX #6-32 STEEL77 SEE TABLE E 1 OPTION PANEL78 083089 1 ASSY PCB "C" CONTROL 12/24V

87 ** 082984 1 RES 120R 10% 2W ASSEMBLY 5540688 ** 082985 1 RES 100R 5% 5W ASSEMBLY 55405

89 024911 8 SCREW HHTT #8-32 X 3/8 CZ90 * 063617 2 RELAY PNL 12VDC DPDT 10A@240VA

** 081767 2 RELAY PNL 24VDC DPDT 10A91 0E1092 1 DECAL 8 POS TS SEALED C PANEL92 0E3783 1 DECAL WARNING REMOVE FUSE

* USED ONLY FOR 12V UNITS.** USED ONLY FOR 24V UNITS.

Section 4 — Exploded Views“C” Option Control Panel with Sealed Connectors 12V & 24V Diesel

Control Panel – Drawing No. 0E0035-J


VOLTAGE ADJUST

E

A A

54

19

7175

76

44

46 53

1

45

59

63

60

66

64

67

65

43

68

68

91

0E10

92

66

64

52

65

67

63

59 60

8954 86

5150 41 40 38 39 50 51

33

+BA

T

GN

D (-

)

A339

2

SPEE

D

PRO

BE

BAT FU

EL

70

78

50 52

36

51

525052

66

64

90

51

51

66

8

7

x3

4

5

6059

63 58

60

59

63

68

67

65

16

17

15

23

92

18

82

51

66

64

67

65

36

80 80

81

6

14

26

28

24

6059

63

3

2

34

6059

62

35

87

10

58

59

27

29

50

20

37

47

88

83

84

48

49

59

85

61

77

3130 32

57

12


OVER 100KW WITH 12 OR 24V DC SYSTEMS

UPTO 100KW WITH 24V DC SYSTEMSALL BRUSHLESS & PME MACHINES

ALL BRUSHLESS & PME MACHINESUPTO 100KW WITH 12V DC SYSTEMS

TABLE A-FIELD BOOST RESISTOR DATA

UPTO 100KW WITH 12 OR 24V DC SYSTEMSALL DIRECTLY EXCITED MACHINES

25 OHM 25W

75 OHM 25WP/N: 086266

P/N: 08336450 OHM 25WP/N: 057405

5 OHM 25WP/N: 048352

TABLE E- OPTION PANEL


TABLE B-AVR POWER(DPE) CIRCUIT BREAKER DATA




ALL DIRECTLY EXCITED MACHINES

UNITS WITH BASE TANKS

UNITS WITHOUT BASE TANKS

OVER 100KW

19 TO 45KW

19 TO 26KW

45 TO 100KW

21 TO 41KW

P/N: 070030

P/N: 0D9750

4.5AP/N: 048476

P/N: 048467

P/N: 054450

P/N: 048467

P/N: 048505

7A

5.5A

6.0A

7A

CONTROL PANEL LEFT SIDE

110/220V 1 PHASE115/200V3 PHASE

231/400V 3 PHASE100/200V 3 PHASE

120/240V 1,3 PHASE

120/240V 3 PHASE277/480V 3 PHASE

120/208V 3 PHASE

120/240V 1 PHASE

TABLE D: VOLTAGE METER

R0-3000A0753260-200A070045 L

0-300A

AMMETER

0-150A

0-1000A0-1600A

0-600A0-800A

0-400A

0-2000A

TABLE C:AMMETER

AMMETER

070056070057

075323075324

070059070060

070058

075325

P/N: RANGEAD

MN

K

GJ

P

CODEVOLT.

070044 0-600V082404600V 3 PHASE 0-750V

070043070043

070043070043

070043070043

070044

METER P/N:VOLTAGE

070043

VOLTAGE

0-300V0-300V0-300V

0-300V0-600V

0-300V0-300V

0-300VMETER RANGEVOLTAGE

VIEW AHINGE ASSEMBLY

SCALE: NONE

++-

GOVERNOR CONTROLBEHIND COVER

AVR BEHIND COVER

Section 4 — Exploded Views“C” Option Control Panel with Sealed Connectors 12V & 24V GasControl Panel – Drawing No. 0E1577-G



1 0D9687 1 "C" PANEL BOTTOM/BACK PANEL2 0E0282 1 PANEL FRONT "C" W/SLKSCRN3 0A6322 1 PANEL RIGHT SIDE E4 0A6321 1 PANEL LEFT SIDE E5 0E3550 1 CHASSIS, UNIVERSAL6 0D9720 1 HARNESS SEALED "C" PANEL

STANDARD7 086266 1 RES WW LUG 75R 5% 25W

8 * 025192 1 RECTIFIER MSC 2A 600V 1N506210 023762 3 WASHER SHAKEPROOF EXT #10 STL12 0E6871 1 RECTIFIER ASSEMBLY14 0A3392 1 DECAL TERMINAL BLOCK15 067625 1 SWITCH TOGGLE 3P3T 15/10A16 055867 1 SWITCH TOG SPDT 15A SPD MOM17 026536 1 PLUG STEEL 0.518 0D6947 1 HINGE CONTINUOUS19 0C1229 1 DECAL CUST CONN BOX20 084787 1 CABLE RIBBON 16"21 055406 1 GAUGE COOLANT TEMPERATURE22 032300 1 HOLDER FUSE23 022676 1 FUSE 15A X AGC1524 055349 1 INSULATOR25 071361 1 POT 5K 10% 2.25W PNL26 050123 1 KNOB PLASTIC .25 SHAFT27 070081 1 HOURMETER28 061945 1 SWITCH SELECTOR 6A AMP/V29 062304 1 AMMETER 40-0-40 DC30 0E3703 1 LIGHT PANEL WITH LUG31 0C8481 1 BULB-PANEL LIGHT-12V

083288 1 LIGHT 28VDC .17A MIN BAYNT MNT32 070082 1 BLOCKER LIGHT33 0A2275 1 DOOR-STOP RAM PANEL34 030809 1 GROMMET 11/16 X 1/8 X 7/1635 055405 1 GAUGE OIL PRESSURE36 0A2400A 2 TRUNKING 180MM38 0A1441B 1 COVER PLATE, AVR39 0C1127 1 DECAL AVR COVER40 0A1441C 1 COVER PLATE EGOV41 0A3394 1 DECAL ELEC GOVERNOR42 0A5705 REF. FUSE 5A X LTTL215005 (NOT SHOWN)43 066040 1 DECAL TERMINAL STRIP44 0D3471 2 DECAL COVER DEUTSCH (RECT)45 0D3471 2 DECAL COVER DEUTSCH (RECT)

(ELECTRONIC GOVERNOR HARNESS IFEQUIPPED)

46 0C5141 2 CONN DEUTSCH GASKET 8/12POS DT50 022155 14 WASHER LOCK #651 0C2699 16 SCREW PHTT #6-32 X 3/8 ZYC52 0C2428 10 SCREW TAPTITE PH 6-32 X 1/2 Z/YC


53 074908 8 SCREW HHTT M5-0.8 X 10 BP54 022264 8 WASHER LOCK M457 0A2284 4 SCREW SWAGE 8-32 X 1/2 Z/YC58 022158 1 NUT HEX #10-32 STEEL59 022152 14 WASHER LOCK #1060 023897 14 WASHER FLAT #10 ZINC61 024469 2 SCREW TAPTITE #10-32 X 3/8 BP62 033120 1 SCREW HHC #10-32 X 3/863 033121 13 SCREW HHC #10-32 X 1/264 022127 4 NUT HEX 1/4-20 STEEL65 022097 4 WASHER LOCK M6-1/466 022473 4 WASHER FLAT 1/4 ZINC67 027831 4 DAMPNER VIBRATION68 036261 6 RIVET POP .125 X .129-.133/#3069 0C8243 1 WASHER LOCK HDP DEUTSCH70 0C8244 1 NUT, HDP DEUTSCH-- --------- -- ADDITIONAL PARTS (BASE TANK UNITS)

71 074908 4 SCREW HHTT M5-0.8 X 10 BP75 0E0044 1 HARNESS BASETANK FOR C PANEL76 0C5141 1 CONN DEUTSCH GASKET 8/12POS DT-- ---------- -- PANEL SPECIAL PARTS

80 064733 2 BRACKET RESISTOR MOUNTNG FOR25W

81 * SEE TABLE A 1 RESISTOR #282 SEE TABLE B 1 FIELD CIRCUIT BREAKER83 SEE TABLE C 1 AMMETER84 SEE TABLE D 1 VOLTMETER AC85 070042 1 METER FREQUENCY 55-65HZ

070042A 1 FREQUENCY METER 240V 45-55HZ86 067680 1 ASSY VOLTAGE REGULATOR 60HZ

092952 1 ASSY VOLTAGE REGULATOR 50HZ-- ---------- --

37 029187 2 SPACER .19 X .31 X .50 PL47 036908 2 SCREW PPHM #6-32 X 1-1/448 022985 2 WASHER FLAT #6 ZINC49 022188 2 NUT HEX #6-32 STEEL77 SEE TABLE E 1 OPTION PANEL78 083089 1 ASSY PCB "C" CONTROL 12/24V

87 ** 082984 1 RES 120R 10% 2W ASSEMBLY 5540688 ** 082985 1 RES 100R 5% 5W ASSEMBLY 55405

89 024911 8 SCREW HHTT #8-32 X 3/8 CZ90 * 063617 2 RELAY PNL 12VDC DPDT 10A@240VA

** 081767 2 RELAY PNL 24VDC DPDT 10A91 0E1092 1 DECAL 8 POS TS SEALED C PANEL92 0E3783 1 DECAL, WARNING REMOVE FUSE

* USED ONLY FOR 12V UNITS.** USED ONLY FOR 24V UNITS.

Section 4 — Exploded Views“C” Option Control Panel with Sealed Connectors 12V & 24V Gas

Control Panel – Drawing No. 0E1577-G


0

525

519

97

22896

95

98

9415/220

15/220

98 98

210

137

97

95

94

209

96

94

137

95

211

14/219

14/219

519

525

15/2209

210

15/220

0

00

0

178

183

211 209

210

220A229

519525

211

BLACK

BLACK

BLA

CK

WH

ITE

GR

EE

N

GREEN

15/220

15/220

15/220

228

A

GENERATOR CONTROL PANEL

00NEUTRAL

94

96

97

98

137

0

CUSTOMER

LOAD

GTS TRANSFER SWITCH

NOTE 5

GENERATOR AC CONNECTIONPANEL W/2-WIRE START

1

4

7

A B

9

6

3

CONTROL CONSOLEWIRING HARNESS

AUXILIARYCONTACTS-NOTE 4

NEUTRALNOTE 1

MODEL 86175 LIGHT - REMOTE

ANNUNCIATOR

18 LIGHT - REMOTE ANNUNCIATORMODELS 9555-9556

ENGINE MONITORCIRCUIT BOARD

RESISTOR

ENGINE COOLANTHEATER

OPTIONALBATTERYHEATER

120 VOLTS AC

BATTERY HEATERTHERMOSTAT

178

183

(POSITIVE TERMINAL)TO BATTERY

(BATTERY NEGATIVE)TO ENGINE GROUND

1 2 3 4 5 6 7 8 9 11 12 13 14 16 17 18 19 20 21

C.

N.C.

N2 N3N1

T1 T3T2

E2 E3E1

UTILITYSUPPLY

178 2-WIRESTART

E1E3 E2

22 24

NOTES:

1. 3-POLE, 1-PHASE & 4-POLE, 3-PHASE TRANSFER SWITCHES GENERALLY NOT EQUIPPED WITH NEUTRAL BLOCK

3. 4.0L & 6.4L UNITS REQUIRE 120 VAC FOR ENGINE COOLANT HEATER. 13.3L UNITS REQUIRE 240 VAC - SEE INSETS

"B" & "C"4. SEE INSETS "D" & "E"5. MODEL 8235 ALARM HORN SHOWN FOR "C"-OPTION UNITS. TB2 TERMINALS 209-210-211 CONNECT TO ALARM RELAY

209 NC CONTACTS OPEN ON ANNUNCIATED SHUTDOWN 211 NO CONTACTS CLOSE ON ANNUNCIATED SHUTDOWN 210 C CONNECT TO FUSE +24V DC CIRCUIT AS SHOWN

CONTACTS.

2. 2 AMP CHARGER WITH 12 VOLTS SINGLE BATTERY SYSTEM SHOWN. FOR OTHER VARIATIONS SEE INSETS "A", "B" & "C".

Section 5 — Interconnection Diagram“C” Option Control Panel 12 Volt GasInterconnection Diagram – Drawing No. 0E2148


Section 5 — Interconnection Diagram“C” Option Control Panel 12 Volt Gas

Interconnection Diagram – Drawing No. 0E2148

2

ENGINECOOLANTHEATER

10 AMP CHARGER

12 V.BATTERY

120 VACUTILITY

ENGINECOOLANT

OPTIONALBATTERYHEATER

GN 1 21 27 28 29 13 34 35 0

INSET "B" 10 AMP 24AF/24MFCHARGER

HEATER

13.3 LITER ENGINES ONLY

UTILITY240V AC

BLACKBLACKGREEN

4.0-6.4 LITERONLY

BATTERY12 V.

FRAMEGROUND

TOUPPERPANEL

218

GR

EE

N

WH

ITE

BLA

CK

218

0

BLA

CK

WH

ITE

GR

EE

N

12 V.BATTERY

GREENBLACKBLACK

240V ACUTILITY

13.3 LITER ENGINES ONLY

HEATER

INSET "C"

HEATERBATTERYOPTIONAL

COOLANTENGINE

UTILITY120 VAC

BATTERY12 V.

HEATERCOOLANTENGINE

TO UPPER PANEL

0

GR

EE

N

WH

ITE

BLA

CK


ENGINE HEATERTHERMOSTAT

CRANKINGCONTACTOR

& THERMOSTAT

CRANKINGCONTACTOR

218218

& THERMOSTAT


ENGINE HEATERTHERMOSTAT

0

24AF/24MF

0

0

0

00

218

GND

1AC 2 2

21AC

27C

28NO

29NC

13+B

34+S

0-B

GR

EE

N

WH

ITE

BLA

CK

SWITCH POSITION

OPEN CLOSED

UTILITY STANDBY4-64-5

STANDARD AUXILIARY CONTACTSGTS 250 VOLT "Y" SERIES

TRANSFER SWITCH

INSET "D"

4

4

5

INSET "E"TRANSFER SWITCH

GTS 600 VOLT "N" SERIESSTANDARD AUXILIARY CONTACTS

4-64-5

UTILITY STANDBYSCLOSED OPENOPEN CLOSEDL

SWITCH POSITIONCONTACTS

MODELS 9555-955618 LIGHT - REMOTEANNUNCIATOR

GTS "Y" SWITCH POSITION INDICATIONTO 18 LIGHT REMOTE ANNUNCIATOR

14 16 17

15/220

AAC

PANEL

210

15/220

AAC

GENERATOR UPPERPANEL

210

MODELS 9555-955618 LIGHT - REMOTEANNUNCIATOR14 15

GTS "N" SWITCH POSITION INDICATIONTO 18 LIGHT REMOTE ANNUNCIATOR

GREENBLACK

BLACK

519525 525

519

GROUNDFRAME

2AMP 24VOLT CHARGER

W/ 12VOLT D.C. ENGINE SYSTEMS10AMP CHARGERINSET "A"

+ - -+

+ --+

ENGINECOOLANTHEATER

12VDCSTANDBYBATTERY

+ -

120 VACUTILITY

C.

N.C.

C.

N.O


Section 6 — Notes“C” Option Control Panel 24 Volt Diesel


Section 6 — Notes“C” Option Control Panel 24 Volt Diesel

Part No. 0E1581

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

WAUKESHA, WI 53187

Revision C (03/15/04) Printed in U.S.A.

Documents

Manual Panel C 400