0e2221-J Commercial Study Guide PDF

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Commercial Training
GENERAC SERVICE TRAINING

ii
Chapter Index
Chapter 1 - Electrical Fundamentals......................................................................
Chapter 2 - Generator Set Components.................................................................
Chapter 3 - Generator Configurations....................................................................
Chapter 4 - Voltage Regulation..............................................................................
Chapter 5 - Frequency and Governor Fundamentals...............................................
Chapter 6 - Gaseous Fuel Systems and Spark Ignition Systems.............................
Chapter 7 - Generator Load and Power.................................................................
Chapter 8 - Troubleshooting Fundamentals............................................................
Chapter 9 - Transfer Switch Fundamentals............................................................
Chapter 10 - RTS Series Transfer Switches...........................................................
Chapter 11 - HTS Series Transfer Switches...........................................................
Chapter 12 - R-Series Control Panels....................................................................
Chapter 13 - Nexus Control Panels.......................................................................
Chapter 14 - Introduction to the PM-DCP H-100...................................................
Chapter 15 - H-Panel Inputs and Outputs..............................................................
Chapter 16 - H-Panel Display Screens..................................................................
Chapter 17 - GenLink DCP Configuration and Diagnostic Menus............................
Chapter 18 - H-Panel Voltage Regulation and Current & Voltage Calibration...........
Chapter 19 - Alarm & Event Logs, Reports and Maintenance.................................
Chapter 20 - Remote Trending..............................................................................
Chapter 21 - 21-Light RAP/RRP and HUIO............................................................

iii
Table of Contents
Chapter Index.......................................................... iii Fly Back Diode (DB2)............................................. 65
Section 1 - Generator Basics................................ 1 Brushless Excitation................................................. 66
Chapter 1 - Electrical Fundamentals........................ 1 Problem 4.............................................................. 66
Review of Electrical Fundamentals............................. 2 Voltage Regulator..................................................... 68
Introduction............................................................. 2 Voltage/Frequency Compensation.......................... 68
Ohm’s Law.............................................................. 2 067680 Voltage Regulator...................................... 69
Example 1.......................................................... 3 0G2885 Voltage Regulator..................................... 70
Series and Parallel Circuits.................................. 5  Check Your Knowledge......................................... 71
Digital Inputs Circuits............................................... 8 References................................................................ 71
Raw Values......................................................... 9 Chapter 5 - Frequency and Governor Fundamentals.73
Faraday’s Law......................................................... 9 Frequency................................................................. 74
Magnets............................................................. 9 Mechanical Governor............................................. 77
AC Voltage............................................................. 12 Stepper Motor........................................................ 78
Frequency................................................................. 17 Bosch Governing System....................................... 80
 Check Your Knowledge......................................... 18 Bosch Actuator...................................................... 80
References ............................................................... 19 Testing the Bosch Throttle Body Actuator............... 83
Chapter 2 - Generator Set Components................. 21  Check Your Knowledge......................................... 84
Major Components.................................................... 22 References ............................................................... 84
Prime Mover.......................................................... 24 Chapter 6 - Gaseous Fuel Systems and Spark Ignition
Systems..................................................... 87
Alternator Assembly.............................................. 24
Fuel Systems............................................................ 88
Main Line Circuit Breaker....................................... 31
Fuel Pressure......................................................... 88
Customer Connections.......................................... 34
Example 1............................................................. 90
AC Customer Connections................................ 36
Example 2............................................................. 91
DC Customer Connections................................ 36
Problem 1 ............................................................. 92
Control Panel......................................................... 36
Demand Style Regulator........................................... 93
 Check Your Knowledge......................................... 41
Mixer Assembly..................................................... 93
Chapter 3 - Generator Configurations.................... 43
Fuel Regulator........................................................ 96
Generator Set Identification...................................... 44
R-Panel and H-Panel Fuel Systems.................. 100
QT/Commercial product Model Code Identification. 45
Nexus Fuel System......................................... 101
Industrial Product Model Code Identification........... 46
Ignition Systems..................................................... 102
Alternator Configuration ........................................... 47
Ignition Coil......................................................... 102
Voltage Codes....................................................... 47
Ignition Control Systems...................................... 103
A-Code.................................................................. 48
Nexus Internal Ignition Module (IM)................. 104
D-Code.................................................................. 49
Nexus External Ignition Module (IM)................ 105
J-Code.................................................................. 50
Gaseous Emissions................................................. 110
G-Code.................................................................. 51
Introduction......................................................... 110
K-Code.................................................................. 52
Terms and Terminology........................................ 110
L-Code.................................................................. 53
Component Identification..................................... 110
Fuel Regulator...................................................... 111
References ............................................................... 54
Oxygen Sensor.................................................... 112
Chapter 4 - Voltage Regulation.............................. 57
Description..................................................... 112
Fundamentals........................................................... 58
Air Fuel Ratio Solenoid......................................... 113
Example 1............................................................. 59
Description..................................................... 113
Brushed Voltage Regulation...................................... 60
Operational Analysis............................................ 114
Problem 1.............................................................. 60
Theory of Operation:....................................... 114
Problem 2.............................................................. 61
 Check Your Knowledge....................................... 116
Problem 3.............................................................. 62
References ............................................................ 116
DPE Winding......................................................... 63
Chapter 7 - Generator Load and Power................ 119
Field Flash Resistor................................................ 64
Introduction............................................................. 120
Field Flash Diode................................................... 64
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Table of Contents
Example 1........................................................... 121 Introduction.................................................... 177
AC Resistive Circuits............................................... 121 Load Management Controller.......................... 177
AC Inductor Circuits................................................ 123 Digital Load Module........................................ 179
Power In Resistive and Reactive AC Circuits.......... 126  Check Your Knowledge....................................... 181
AC Capacitor Circuits.............................................. 128 References.............................................................. 182
Real, Reactive, and Apparent Power....................... 129 Chapter 11 - HTS Series Transfer Switches......... 185
Beer Factor.......................................................... 130 HTS Transfer Switch............................................... 186
Example 2........................................................... 132 Remote Start....................................................... 192
Calculating Power Factor........................................ 133 Sequence of Operation......................................... 194
Application to Standby Generators......................... 137 Troubleshooting Tips............................................... 200
Review.................................................................... 138  Check Your Knowledge....................................... 201
 Check Your Knowledge....................................... 138 References.............................................................. 201
References ............................................................. 139 Section 3 - Digital Control Panels..................... 203
Chapter 8 - Troubleshooting Fundamentals......... 141 Chapter 12 - R-Series Control Panels.................. 203
Troubleshooting...................................................... 142 Introduction............................................................. 204
Section 2 - Transfer Switch............................... 147 Components............................................................ 204
Chapter 9 - Transfer Switch Fundamentals.......... 147 Component ID..................................................... 207
General Information................................................ 148 Configuration Settings.......................................... 209
 Check Your Knowledge....................................... 150 R-100 Fault Condition Table............................ 209
References.............................................................. 150 R-200 Fault Condition Table............................ 210
Chapter 10 - RTS Series Transfer Switches......... 153 R-200A Fault Condition Table.......................... 211
Generac RTS Transfer Switch................................. 154 R-200B Fault Condition Table.......................... 212
RTS Transfer Switch Model Identification.............. 155 R-200C Fault Condition Table.......................... 213
Transfer Relay...................................................... 155 R-100 Digital Controller .................................. 214
Customer Connections........................................ 156 R-200 Digital Controller .................................. 215
Terminal Block................................................ 156 R-200A Digital Controller ............................... 216
Fuse Holder.................................................... 157 R-200B Digital Controller................................ 217
“V” Type.............................................................. 158 R-200C Digital Controller................................ 218
“W” Type............................................................. 160 Inputs and Outputs.............................................. 221
Main Closing Coil............................................ 161 Inputs............................................................. 221
Utility and Standby Contacts........................... 161 Analog Inputs.................................................. 224
Bridge Rectifier............................................... 162 Outputs........................................................... 226
LS1 and LS2 Limit Switch............................... 162 Battery Chargers.................................................. 227
LS3 Limit Switch............................................ 162 2 Amp Battery Charger.................................... 227
“Wn” Type........................................................... 165 10 Amp Battery Charger.................................. 228
Main Closing Coil............................................ 166  Check Your Knowledge....................................... 229
Trip Coil.......................................................... 166 References.............................................................. 230
Select Coil...................................................... 166 Chapter 13 - Nexus Control Panels...................... 233
Utility and Standby Contacts........................... 166 Introduction............................................................. 234
Bridge Rectifier............................................... 168 Activation Process............................................... 234
AX-BX Limit Switch......................................... 168 Alarms, Warnings and Run Events. ........................ 235
ATS Limit Switch............................................. 168 Run Log ............................................................. 235
BTS Limit Switch............................................ 168 Switched To Off.............................................. 235
LS Limit Switch.............................................. 168 Running Manually .......................................... 235
Auxiliary Contacts................................................ 171 Stopped In Auto Mode ................................... 235
“W” and “Wn” Type........................................ 171 Running Utility Loss........................................ 235
“V” Type......................................................... 172 Running In Exerciser ..................................... 235
Power Monitor..................................................... 173 Running From Radio....................................... 235
Multiple Transfer Switches................................... 175 Alarms and Warnings.......................................... 235
Digital Load Management..................................... 177 Low Oil Pressure Shutdown Alarm: ................ 235
v
Table of Contents
High Coolant Temperature Shutdown Alarm: ... 236 Digital Inputs........................................................... 277
Over-speed Shutdown Alarm - Latching........... 236 Input Active Level for Digital Input Channels......... 279
RPM Sensor Fail Shutdown Alarm – Latching.. 236 Digital Channel Input Active Level LOW (Inverted).280
Low Fuel Pressure Warning............................. 236 Digital Outputs........................................................ 283
Missing CAM Pulse Shutdown Alarm – Latching......236 Other Digital Output Channels............................... 284
Missing Crank Pulse Shutdown Alarm – Latching.....236 Spare Digital Outputs (Industrial Units Only)......... 285
Governor Sensor Fault Shutdown Alarm – Latching..236 Communication Ports.............................................. 286
Wiring Error Alarm.......................................... 237 RS-232 (Port 0) (Genlink/Modem)....................... 286
Under-Voltage Shutdown Alarm....................... 237 RS-485 (Port 1).................................................. 287
Over-Voltage Shutdown Alarm......................... 237 H-Panel RS-485 Wiring to 4 HTS switches and
Internal Failure Shutdown Alarm...................... 237 21-Light RAP/RRP.......................................... 287
CAN Bus Alarm............................................... 237 Baud Rate, Data Bits, Parity.................................... 289
Check Engine.................................................. 237 Baud rate............................................................. 289
Maintenance Warning..................................... 238 Start bit............................................................... 289
Components............................................................ 238 Data bits.............................................................. 289
Internal Battery Charger ...................................... 238 Parity bit.............................................................. 289
Fuses.................................................................. 239 Stop bits.............................................................. 290
25 Amp Fuse (F1)........................................... 239  Check Your Knowledge....................................... 290
10 Amp Fuse (F2) (If equipped)....................... 239 Chapter 16 - H-Panel Display Screens................. 293
7.5 Amp Fuse (F3) (Not Shown)...................... 239 Introduction............................................................. 294
Nexus AVR.......................................................... 240 Navigation............................................................... 294
Security Access...................................................... 241 Home.................................................................. 294
Security Codes.................................................... 241 Menu................................................................... 294
Level I Password:............................................ 241 Alarms................................................................ 295
Level II Password:........................................... 241 Left Display......................................................... 295
Extended EDIT Menu Options:......................... 241 Engine................................................................. 297
Level I:............................................................ 241 Generator............................................................ 298
Level II:........................................................... 241 Status.................................................................. 299
Programming....................................................... 241 Diagnostic........................................................... 299
Menu Layout........................................................... 242 Maintenance........................................................ 302
 Check Your Knowledge....................................... 243 Exercise/HTS....................................................... 303
Section 4 - DCP H-100 Control Panel................ 245  Check Your Knowledge....................................... 304
Chapter 14 - Introduction to the PM-DCP H-100.. 245 Chapter 17 - GenLink DCP Configuration and
Diagnostic Menus..................................... 307
Introduction............................................................. 246
Configuration and Diagnostic Menus...................... 308
Components............................................................ 247
Introduction......................................................... 308
Component ID..................................................... 252
Diagnostics......................................................... 309
Automatic Voltage Regulator................................ 253
Analog Input........................................................ 310
Governor Control Circuit...................................... 259
Digital Input......................................................... 314
Control Relays (RB1)........................................... 261
Digital Output....................................................... 319
Fuses.................................................................. 262
Digital Output Function......................................... 322
Communications Settings.................................... 325
Chapter 15 - H-Panel Inputs and Outputs............. 265 Engine Settings.................................................... 328
Inputs and Outputs.................................................. 266 Generator Settings............................................... 330
Analog Signal Conditioners .................................... 267 Nameplate Data................................................... 331
4-20mA Analog Inputs from Engine Sensors........ 267 Panel Brand.................................................... 331
Troubleshooting Analog Engine Sensors............... 272 Air/Fuel Settings................................................... 332
H-100 (PM-DCP) Automatic Voltage Regulation... 273 Thermal Protection Settings................................. 333
Current and Voltage Sensing Processing......... 273 Transfer Switch Configuration.............................. 334
Exercise Configuration......................................... 335
HUIO Setup.......................................................... 335
vi
Table of Contents
Governor Settings................................................ 336
Governor PID Control.............................................. 339
Introduction......................................................... 339
PID Governing Principles...................................... 340
References.............................................................. 342
Chapter 18 - H-Panel Voltage Regulation and Current
& Voltage Calibration............................... 345
Introduction............................................................. 346
H-Panel Voltage Regulation and Calibration........... 346
Scaling................................................................ 350
Regulator Settings............................................... 351
H-Panel Voltage Calibration Procedure................... 353
Example 1........................................................... 356
H-Panel Current Calibration.................................... 357
Example 2........................................................... 358
References.............................................................. 359
Chapter 19 - Alarm & Event Logs, Reports and
Maintenance............................................ 361
Introduction............................................................. 362
Alarm Log............................................................... 362
Event Log................................................................ 364
Reports................................................................... 367
Maintenance........................................................... 372
Generator Maintenance Schedules......................... 374
Chapter 20 - Remote Trending............................. 377
Introduction............................................................. 378
Trending.................................................................. 378
Export as CSV..................................................... 385
Chapter 21 - 21-Light RAP/RRP and HUIO........... 389
Introduction............................................................. 390
21-Light Remote Annunciator Panel (RAP)............. 390
The Panel “Configurator” (GUI)............................ 392
H Unit Input/Output (HUIO)..................................... 396
HUIO Digital Input Channels................................. 400
HUIO Digital Output Channels............................... 402
Appendix A - Answers....................................... 405
Index................................................................. 414
vii
viii
1 Electrical Fundamentals
Keywords
●● Magnetism ●● Sine Wave
●● Faraday’s Law ●● RMS Voltage
●● Ohm’s Law ●● Frequency
●● Series Circuits
●● Parallel Circuits
●● Digital Inputs
●● Electromotive Force (EMF)
●● AC Voltage
Contents
Chapter 1 - Electrical Fundamentals........................ 1
Review of Electrical Fundamentals............................. 2
Introduction............................................................. 2
Ohm’s Law.............................................................. 2
Example 1.......................................................... 3
Series and Parallel Circuits.................................. 5
Digital Inputs Circuits............................................... 8
Raw Values......................................................... 9
Faraday’s Law......................................................... 9
Magnets............................................................. 9
AC Voltage............................................................. 12
Frequency................................................................. 17
References ............................................................... 19
1
Chapter 1
Electrical Fundamentals
Review of Electrical Fundamentals

Introduction
●● Ohm’s law defines the relationship between voltage, current and resistance in a circuit.
●● Magnetism can create a current flow in a conductor.
●● Current Flow in a Conductor creates a magnetic field.
Ohm’s Law
Ohm’s Law states that: the amount of current flow (amps) in a circuit is equal to the electromotive force (volts)
divided by the resistance (ohms).
We can illustrate this relationship three different ways.

1. Constant Voltage (E) - In a circuit, if the voltage is held constant and the resistance increases the
current flow through the circuit will decrease; if the resistance decreases the current flow through the
circuit will increase.
2. Constant Resistance (R) – In a circuit, if the resistance is held constant and the voltage increases the
current through the circuit will increases; if the voltage decreases the current through the circuit will
decrease.
3. Constant current (I) – In a circuit, if the current is held constant and the circuit resistance decreases,
the voltage will decrease; if the circuit resistance increases the voltage will increase.
It is important to remember that the voltage is measured across the circuit resistance – so the
measured value is the voltage drop across the circuit.
E
I R
P
I E
Figure 1 – Ohms Law Formulas
Ohm’s Law is also the basis for all of our circuit power formulas. Power (P = Watts) is equal to voltage times
current (E x I). So in any electrical circuit the power can be calculated if the applied voltage and current flow
are known.
2 Section 1 - Generator Basics
Chapter 1
Example 1
What is the current (I) through a wire if the voltage applied is 12 VDC (E) and the resistance is 2 ohms (R)?
+ 2Ω
12V
-
I= 6
Figure 2
If the resistance is higher what happens?
+ 6Ω
12V
-
I= 2
Figure 3
If the resistance is lower what happens?
+ 0.5 Ω
12V
-
I= 24
Figure 4
Section 1 - Generator Basics 3

Chapter 1
If the applied voltage increases what happens?
+ 4Ω
16VDC
-
I= 4
Figure 5
If the applied voltage decreases what happens?
+ 4Ω
4 VDC
-
I= 1
Figure 6

Chapter 1
Series and Parallel Circuits

There are two basic electrical circuits to consider: Series circuits and Parallel circuits. These two circuits can
also be combined to form a circuit with both series and parallel components.
In a series circuit the current flows from one resistive element to the next. Applying Ohm’s law to a series
circuit, the resistance to current flow is the sum of the resistance values – they all add up to equal one total
circuit resistance value.
For example; what is the current flow through a series circuit with three resistors in it and an applied voltage of
12 VDC, where R1 = 25 ohms; R2 = 9.2 ohms; and R3 = 3 ohms?
Figure 7 – Series Circuit
RTotal = R1 + R2 + R3 = 25 ohms + 9.2 ohms + 3 ohms = 37.2 ohms
I (current flow) = V/R V=12, R=37.2
I = 12/37.2 = 0.323 amps

Chapter 1
In a parallel circuit, the total resistance can be found by using the following formula. The R total value will
always be less than the value of the smallest resistor.
Figure 8
Given a parallel circuit with 4 resistors and 24 volts applied, calculate the current flow through the circuit.
Where R1=10 ohms, R2=20 ohms, R3=30 ohms and R4=60 ohms
Figure 9 – Parallel Circuit

Chapter 1
1/10 + 1/20 + 1/30 + 1/60 – first we must find a common denominator – find a value that all of the lower
terms (numbers) have in common. In this case the common denominator is 60. Whatever you multiply the
lower term by to get the common denominator, you must also multiply the upper term by to keep the fraction
the same value – this fraction is really a value of 1.
1 6 6 1 3 3 1 2 2
× = & × = & × =
10 6 60 20 3 60 30 2 60
1 6 3 2 1 1 12
= + + + Thus =
RTotal 60 60 60 60 RTotal 60
Cross Multiply
1 12
= Thus 12( RTotal ) = 60
RTotal 60
So
1 12
= Thus
12( RTotal ) = 60
RTotal 60
Or
1 1
Thus RTotal =
6 3 2 1 12
+ + +
60 60 60 60 60
So
1
RTotal = Thus RTotal = 5 Ohms
.2
24 volts applied to the above circuit results in a total current flow (I = E/R) of I = 24/5 = 4.8 amps

Chapter 1
Ohm’s law also defines our power formulas. P (Watts) = E x I

This enables us to calculate the electrical power output of a generator. Generator sets are typically rated in kW
(kilo-Watts).
The formula for single phase power is: P (kW) = E x I x PF

1000
The formula for three-phase power is: P (kW) = E x I x 1.73 x PF

1000
1.73 is the Root Mean Square value of voltage (instantaneous voltage) used to calculate power in a 3-phase
circuit. PF is the power factor. We will look at voltage, load, power and power factor in a later section.
Digital Inputs Circuits

What if a current limited voltage was applied to a dry contact, which would either connect or disconnect the
signal to ground. A device as simple as a single pole single throw (SPST) switch could be used to accomplish
this. In this type of circuit the current is limited to 0.1 mA (.0001A). Modern day digital inputs circuits use 5
VDC as a reference.
V V= 5VDC
.1 mA
5 VDC
Figure 10 – Digital Input HIGH

With the contact open from ground in Figure 10 the voltage measured cross the contact to ground is 5 VDC.
V V= 0VDC
.1 mA
5 VDC
Figure 11 – Digital Input LOW

With the contact closed to ground, the voltage measured across the contact will be 0 VDC. Although this is a
direct short to ground, the current is limited by the input device, there is no risk of burning out the circuit.
Circuits where you may encounter digital inputs are the key switch of a generator, a rocker switch, push button
switches, high engine temperature switches, low oil pressure switches. Digital input circuits can be used on
any device where it is desired to monitor the position of a dry contact of a switch.
Chapter 1
Raw Values
SIGNAL LOW = CONTACTS CLOSED = 0VDC = ON
SIGNAL HIGH = CONTACTS OPEN = 5VDC = OFF

Faraday’s Law
Generators produce electricity through the application of Faraday’s Law. Faraday’s law states that if a con-
ductor passes through a magnetic field a voltage will be induced in the conductor. So to produce voltage in a
generator set we need three things:
1. Conductor – the conductor in a generator is the Stator Winding(s) (Armature)

2. Magnetic field – the magnetic field in a generator is the Rotor field
3. Relative Motion – the relative motion between the field and the stator is provided by the prime mover
(the engine).
Magnets
Figure 12 – Typical Brushed Rotor

Magnets have a north and south pole; magnetic lines of force, called flux, flow from one pole face to the other.
One measure of the strength of a magnet is called flux density, which is the greatest (the most dense) at the
pole faces. This is the area of flux which cuts the armature coils as the rotor is turned by the prime mover.

Chapter 1
N S N S
S N N S
Figure 13 – Magnetic Poles

Faraday’s law also states that current flow in a conductor will produce an electromagnetic field around that
conductor. If the direction of current flow is known, the “Right Hand Rule” will show the direction of the field
flux. If the conductor is wrapped into a coil the flux lines will form through the center of and around the coil.
Figure 14
This is the principle used in a generator set to produce the rotor’s magnetic field. This same principle is used
in solenoids, transformers and motors.

Chapter 1
The theory of electromagnetic induction is applied in a generator set. The magnetic field is passed across
the conductors and results in an electromotive force (EMF – Voltage) being generated in the conductors. The
faster the magnetic field cuts the conductors the greater the amount of EMF induced in the conductor.
Remember there are three things that are required to produce voltage in a generator set.
• A conductor
• A magnetic field
• Relative motion
S N S N
Figure 15 – Electromagnetic Induction
As the magnet moves through the conductor, the magnetic lines of flux cut across the conductor inducing a
voltage. Increase the speed at which the magnet is moving, increase the voltage.
The amount of voltage induced into a conductor is dependent on three things.

1. The number of turns of wire in the coil (stator)
2. The Speed with which the flux lines cut the conductor (stator)
3. The strength of the magnetic field (flux density of the field)

Chapter 1
AC Voltage
The following illustration shows how the current would flow in a single phase generator. This is correctly
called an alternator – because the current flow alternates; first in one direction and then in the other – but it is
more commonly referred to simply as a generator.
Voltage is produced and current flows only when the flux lines are cutting the conductors (stator coils). When
the flux lines are not cutting the conductors, every 90 degrees of rotation, there is no voltage produced and no
current flow. Important Note: Current can only flow when there is a complete circuit and a load.
STEP 1 STEP 2
N S
No current!
+ -
I I
Load Load
STEP 3 STEP 4
S N
No current!
- +
I I
Load Load
Figure 16
If you were to use an oscilloscope or a good quality power analyzer to look at the voltage being produced by
an alternator you would see a sine wave.
Figure 17

Chapter 1
Figure 18
The sine wave illustrates the alternating nature of the voltage being produced in an alternator. The illustration
shows a single phase sine wave developed by a two pole stationary field. One complete revolution of the
conductor in the magnetic field produces a single continuous wave. The voltage starts at a zero value (1)
with the flux lines not cutting the conductor. As the conductor moves through the field the voltage begins to
increase. When the conductor motion is perpendicular to the field flux (3) the voltage is at its maximum, or
peak, value. As the conductor continues to move through the field, the voltage decreases and reaches zero
when the conductor movement is in line with the field flux. As the conductor continues to move through the
field the voltage increases again, but since the conductor is moving the opposite way through the field flux, the
voltage increases in the negative direction. One full rotation of the conductor through the magnetic field (360
degrees) produces one full wave cycle.
Figure 19
This is a 4 pole field. This type of field produces a complete sine wave (360 electrical degrees) every half
revolution of the rotor (180 mechanical degrees).

Chapter 1
Single phase power produces a single sine wave. Three-phase power produces three separate sine waves.
Each sine of a 3 phase alternator is separated by 120 degrees of angular rotation. This is because each
separate winding is physically placed in the stator can 120 degrees apart from the other two.
Three Phase Alternator
Winding
A
Single-Phase Alternator
S S
120° 120°
N N
g
Win B
din
din
Win
120°
C
g
120° 120° 120° 120° 120° 120°
120°
Figure 20
Figure 21
This diagram shows the typical 3 phase sine wave. When any one phase is at zero voltage, the other two are
at .866 of the maximum value and of opposite polarity. This also shows the 1.732 value of the voltage used
in AC power calculations. This is the maximum effective voltage available between any three phases at any
instant in time.
Chapter 1
What voltage does the typical meter read on an AC circuit?

Most meters will read either the average voltage or the True RMS voltage (Root Mean Square). The RMS value
is the average value of all of the instantaneous values of the voltage on the sine wave.
Figure 22
There are 3 ways to quantify the magnitude of a sine wave.
Peak Voltage: Peak voltage is how far the voltage swings, either positive or negative, from the point of
reference (zero).
Peak-Peak Voltage: Rarely used, it is the measure of the voltage from the positive peak to the negative peak.
RMS Voltage: The most common way to measure or quantify AC voltage. Because AC voltage is constantly
changing and is at or near the highest and lowest points in the cycle for only a tiny fraction of the cycle,
the peak voltage is not a good way to determine how much work can be done by an AC power source. DC
voltage is constant and its value can be plugged directly into formulas for power (Ohm’s Law) for an accurate
measure of the work performed. RMS voltage of a pure sine wave is the way we calculate the equivalent work
performed by an AC power source. The RMS value of a pure AC sine wave is approximately .707 of the peak
voltage. If the waveform is not a pure sine wave, you will need a True RMS meter to measure an accurate
RMS value. This type of meter will calculate the RMS value from a set of samples taken at regular intervals.

Chapter 1
In the following diagram, the filled area indicates the work which can be performed by the voltage. The
amount of work performed at any given point in time is determined by the magnitude of the voltage above and
below the reference line (zero)
Figure 23
Since the voltage above and below the reference are the same magnitude, the work performed in each region
is the same. Therefore we can invert the lower sine wave and map the work performed against the equivalent
DC voltage. The diagram below shows the work which can be performed by DC voltage and AC voltage. The
areas are equal.
Figure 24

Chapter 1
Frequency
Frequency refers to the number of cycles per second of a full wave form – called Hertz (Hz). Frequency is
determined by the number of magnetic poles (field poles) and the speed of rotation of the field (RPM). There
are two formulas used that show the relationship between RPM, number of poles and frequency.
RPM × Number of Poles

Frequency =
120
Frequency × 120
RPM =
Number of Poles
The industry standard for frequency in the United States is 60 Hz power. Generac uses two types of rotors; a
two pole and a four pole rotor.
A two pole rotor must turn at 3600 RPM to produce 60 Hz.

A four pole rotor must turn at 1800 RPM to produce 60 Hz.
An important point to remember is that frequency is dependant on RPM. Any change in RPM will result in a
change in frequency because the engine and rotor are mechanically coupled. The prime mover is what drives
the rotor.
Generac uses many different suppliers for prime movers. These can be gaseous or diesel units. Because
one prime mover can provide different horsepower outputs at different RPM ranges, we build gear boxes to
reduce the higher engine RPM to our desired rotor/frequency speed. With a gearbox we can utilize the full
power range capability of one prime mover to provide several different kW output generators. For instance the
QT070, QT100, QT130 & QT150 all use the same 6.8 liter gas engine as the prime mover. The engine rpm
parameters for each generator are listed in their respective specification sheets. The engine rpm for the QT070
is 1800 rpm; the QT100 is 2300 rpm; the QT130 is 3000 rpm; and the QT150 is 3600 rpm. The QT070 uses
a four pole rotor direct drive. The QT100 and QT130 both use four pole rotors turning at 1800 rpm driven
through a gear reduction box. The QT150 is a two pole rotor turning at 3600 rpm direct drive.
You can see that units with prime movers that run at either 1800 or 3600 rpm are direct drive, using a four
pole (1800 rpm) or a two pole rotor (3600 rpm). Any unit with a prime mover that runs greater than 1800 rpm
and less than 3600 rpm will use a gearbox and a four pole rotor which will spin at 1800 RPM.

Chapter 1
 Check Your Knowledge

1. What is the formula for Ohms Law?
2. What does the term “RMS Voltage” represent?
3. What does the term “Frequency” represent?
4. Current flow within a conductor creates a _____________ ____________.
5. What is the total resistance in the circuit?
+
24VDC R1 =40 Ω
R1 R2
R2 =80 Ω
-

Chapter 1
References
Use the following references to gain a better understanding of the concepts found in this section.
J. Wright, “Chapter 7: Electrical Fundamentals,” in On-Site Power Generation, A Reference Book, 4th Edition.
Electrical Generating Systems Association (EGSA), 2006, pp. 55-75.
J. Wright, “Chapter 8: Alternators (Synchronous Generators,” in On-Site Power Generation, A Reference Book,
4th Edition. Electrical Generating Systems Association (EGSA), 2006, pp. 77-135.
T. R. Kuphaldt, “Lessons in Electric Circuits, Volume I – DC, and Volume II – AC,” Open Book Project, July 8,
2008. Available: http://openbookproject.net//electricCircuits/ (Accessed 14 July 2008)
UGLY’S Electrical Reference – a handy electrical resource

20
2 Generator Set Components
Keywords
●● Prime Mover ●● Customer Connections
●● Rotor ●● Circuit Breaker
●● Stator
●● Flywheel
●● Brushed Excitation
●● Brushless Excitation
●● Gearbox
●● Control Panel
Contents
Chapter 2 - Generator Set Components................. 21
Major Components.................................................... 22
Prime Mover.......................................................... 24
Alternator Assembly.............................................. 24
Main Line Circuit Breaker....................................... 31
Customer Connections.......................................... 34
AC Customer Connections................................ 36
DC Customer Connections................................ 36
Control Panel......................................................... 36
21
Chapter 2
Generator Set Components
Major Components
This study guide and the Commercial Training courses focus on the QT/Commercial product series of
generators that Generac manufactures and sells through its distribution network. The QT series are liquid
cooled gaseous generator sets using R control or H control panels.
There are three major component groups that make up the typical generator set:
1. The prime mover and its accessories.

2. The alternator and its associated wiring and components.
3. The control panel and its components, accessories and wiring.
These components are all mounted to a common mounting base and are enclosed by a steel or aluminum
enclosure.
Figure 25 – QT genset with R-Panel
On commercial product the Circuit Breaker/Customer Connection box is mounted below the control panel.

Chapter 2
Figure 26 – Nexus Controlled Genset
Figure 27 – QT 100 Genset with H panel
The CB/customer connection box is mounted beside the alternator with the control panel on top

Chapter 2
Prime Mover
Prime movers are the means used to mechanically power a generator. There are many different types of
prime movers and sources of power. Wind turbines, hydro turbines, steam turbines, gas turbines, and internal
combustion engines are a few. Generac uses diesel and gas engines as prime movers for all of its standby
power applications. The gas engines are mostly automotive engines adapted to use Natural Gas or LP vapor
as the fuel source. The current QT product line uses engines from 1.5 liter to 6.8 liter.
Prime movers are rated by horsepower. Horsepower and electrical power are related by the formula:
kW = Horsepower (bhp) x 0.746
Generators are rated by their power capacity in kW (kilo-Watts), so the prime mover has to be large enough to
provide the rated kW and overcome the friction (power losses) in the drive system – this usually equates to the
prime mover being sized approximately 10% to 20% larger than the kW rating (this applies to standby power
applications).
For example: The QT 045 with the 2.4 liter engine produces 71 horsepower at rated load. 45 kW is equivalent
to approximately 60 HP (45/0.746). The engine produces about 15% more horsepower to drive this load
(60/71 = 0.85). This represents the mechanical loss (due to friction, heat, mechanical resistance) required to
drive the rotor at full load. This is also a measure of efficiency of the engine and generator system.
Alternator Assembly
Generac manufactures all of its own alternator assemblies up to 400 kW. The alternators come in three
different sizes (the size refers to the diameter of the stator housing):
254 mm (10 inch) - Home standby and small QT product
390 mm (15 inch) - QT and Industrial product 25 kW to 150 kW
520 mm (18 inch) - Industrial product 155 kW to 400 kW
The Alternator assembly consists of the rotor and stator, the drive hub and blower, the AC (alternator)
connection box, the CB (circuit breaker) connection/customer connection panel, and all of its associated
wiring.
The rotor is the rotating magnetic field. It is excited (turned into a magnet) by the voltage regulator system.
The excitation power to the rotor is DC voltage. The rotor windings are powered through direct excitation,
using brushes that ride on commutator rings; or brushless excitation, using a stationary exciter field which
powers a rotating three-phase armature winding. The AC power from this exciter armature is then rectified to
DC through a rotating rectifier, which then energizes the rotor field winding.

Chapter 2
Field Windings
Rotor Bearing
Slip Rings
Pole Face and Core Laminations

Figure 28 – Typical Two-Pole Direct Excited Rotor
Rotor Bearing
Slip Rings
Pole Face
Field Windings Laminations
Figure 29 – Typical Four-Pole Direct Excited Rotor
Chapter 2
Form Wound
Field Windings
Figure 30 – Typical Four-Pole Brushless Rotor – with form wound coils
The rotor is connected on the forward end to the engine crankshaft. On gaseous units (QT) the flywheel/fan
assembly is bolted to the rotor and then connected to the engine crankshaft through a flex plate. Generally on
diesel units the flywheel is bolted to the crankshaft and connected to the rotor through a flex plate and drive
hub/fan assembly.
Figure 31 – Typical Rotor Mounted Flywheel and Fan

Chapter 2
The purpose of the rotor mounted blower is to draw air from the back of the alternator across the stator and
rotor windings for cooling. The air is then exhausted through slots or openings in the alternator housing, and
sometimes through an exhaust housing to direct the air flow in one direction.
The back end of the rotor is carried by a bearing mounted in the rear bearing carrier which provides the rear
support and mounting point for the alternator stator housing. The rear bearing carrier also provides the
mounting points for the brush assembly on direct excited units, and is the mounting point for the field exciter
on brushless units. On industrial units with PMG (Permanent Magnet Exciter) the rear bearing carrier is the
mounting point for the PMG assembly.
Field + & - Brush Rigging
Rear bearing pressed into carrier
Figure 32 – Typical Rear Bearing Carrier with Brush Rigging

Chapter 2
Stationary
Exciter Field
Rotating Exciter
Armature
Rotating
Rectifier
Current
Transformers (CT)
Figure 33 – Typical Rear Bearing Carrier with Brushless Excitation
The AC connection box mounts on the rear bearing carrier. The stator power leads, CTs (current transformers),
displaced phase excitation (DPE) leads and field excitation leads are routed through this panel.

Chapter 2
The alternator housing (sometimes referred to as the stator “can”) holds the stator assembly. The stator
assembly contains the power windings. Included in the stator windings on the 10 inch and 390 alternators
is a Displaced Phase Excitation (DPE) winding. The DPE winding provides power (AC, 60Hz) to the voltage
regulator. Some earlier stator windings contain battery charge windings and run windings – these would be
earlier air cooled and pre-pack units.
Figure 34 – Single phase 6 lead stator can
Figure 35 – Three-phase stator assembly – note the skewed core

Chapter 2
The alternator/stator can assembly is held in place between the engine flywheel housing adapter and the rear
bearing carrier by long studs that extend from the flywheel housing adapter to the rear bearing carrier. Larger
assemblies have a machined plate welded to the forward end of the alternator can that bolts directly to the
flywheel adapter housing or the rear face of a gearbox. The rear bearing carrier provides the rear mounting
point for the generator assembly to the mounting base.
Figure 36 – Stator assembly held in place with tie rods
Figure 37 – Stator assembly with welded flange bolted to a gear box

Chapter 2
Main Line Circuit Breaker

On QT units the Main Line Circuit Breaker (MLCB) connections and customer connections are in a separate
box mounted to the base alongside the alternator. Typically the Control Panel is mounted on top of this
connection box.
Figure 38 – Typical R-Panel control box mounted on the MLCB Customer Connection box

Chapter 2
Figure 39 – Typical Nexus control panel mounted on the customer connection box

Chapter 2
Figure 40 – Typical H-Control Panel on top of the MLCB and Customer Connection Box

Chapter 2
Customer Connections
The customer connection panel is the point on the generator where all the customer connections are made.
This includes the connections to the MLCB and neutral/ground, the 2-wire start, the utility sensing wires (N1
& N2 on Nexus and R panels), the transfer switch control wires (R-panel and Nexus Wires 194 & 23), RS-485
communication for HTS and Remote Annunciator Panel (RAP) connections(H-Panel). It is also the location on
QT product where the power for the battery charge and block heater circuit (if used) is connected. Check the
wiring diagram and schematic diagram for the particular unit to identify these connections.
Figure 41 – Typical Customer Connections Terminal Strips
R-Panel on the Left and H-Panel on the Right

Chapter 2
Field Flash Diode Bridge

Resistor and Fly back Diode
AC Customer Connections
DC Customer Connections
Figure 42 – Nexus Customer Connections
DC customer connections in the connection box are separated from the AC connections by the steel shroud to
meet UL and NEC requirements.

Chapter 2
Note: Test Points for meter leads
AC Customer Connections DC Customer Connections

Figure 43
AC Customer Connections
AC Utility Sensing connections from RTS Switch; N1, and N2
AC Power for the battery charger from the RTS switch; T1 and Neutral
DC Customer Connections
Transfer Relay Power (+) Wire 194
Transfer Relay Power (-) Wire 23
Two-Wire start, Wires 178 and 183

The controller must be re-configured to GTS mode before 2-wire start will be come operational.
Note: A ten second Utility lost delay is still enabled in GTS mode, this prevents it from being used in a
NFPA 110 installations.
Control Panel
The control panel mounts in its own box on top of the AC connection box. The control panel enclosure
contains the control panel (Nexus, R-panel or H-panel); auto-off-manual switch; control relays (crank,
run, alarm); voltage regulator (or voltage regulator driver for H panel); governor driver; field boost circuit
components; battery charger; RS-232 connection for the H-panel; and the optional modem available on H
panel units. For gaseous engines using the Generac ignition control module, the ICM is mounted on the
outside of the CB/customer connection box. The Nexus control panel is a sealed component and contains the
auto-off-manual switch, circuitry to control the crank, run and alarm relays, the voltage regulator, the governor
driver and the battery charger.

Chapter 2
Figure 44 – Typical R-Control Panel
Figure 45 – Typical Nexus Control Panel

Chapter 2
Figure 46 – Inside Cover of R-Control panel showing the PC board and connectors
Figure 47 – Inside of R-Control panel enclosure.
Voltage regulator at the upper back left, field boost circuit at the top left, governor driver at the top right, crank
and run relays in the back center, 2 amp battery charger at the bottom right, and the fuse block at the bottom
back left.

Chapter 2
Field Flash Diode Fly-Back Diode
Field Flash Resistor
Figure 48 – Nexus Regulation Components
DPE Breaker Enclosure
J-Connectors on Control Panel
Figure 49

Chapter 2
Figure 50 – Typical H-Control Panel
The key switch, Emergency stop and alarm horn are all part of the H control panel.
Figure 51 – Inside Cover of the H control panel

Chapter 2
Figure 52 – Inside of H control panel enclosure:
Voltage Regulator Driver in the upper back corner, field boost circuit in the top left, Governor Driver in the top
right, 2 amp battery charger in the bottom right, fuse block in the back bottom left, and the control relay board
in the back left center.

1. Name the three major components of a generator?
2. How do we calculate KW using the BHP of a prime mover?
3. What are the wires numbers that make up the customer connections on a Nexus equipped generator?

42
3 Generator Configurations
Keywords
●● Data Tag
●● Voltage Code
●● Model Number
Contents
Chapter 3 - Generator Configurations.................... 43
Generator Set Identification...................................... 44
QT/Commercial product Model Code Identification. 45
Industrial Product Model Code Identification........... 46
Alternator Configuration ........................................... 47
Voltage Codes....................................................... 47
A-Code.................................................................. 48
D-Code.................................................................. 49
J-Code.................................................................. 50
G-Code.................................................................. 51
K-Code.................................................................. 52
L-Code.................................................................. 53
References ............................................................... 54
43
Chapter 3
Generator Configurations
Generator Set Identification

Every Generac generator set has a Data Tag that contains important information pertinent to the generator.
The data tag us normally fixed to the generators AC connection box and lists the unit’s serial number and its
rated voltage, amps, watts capacity, phase, frequency, rpm, power factor, etc. The most important information
you will need for submitting warranty claims or talking to the Generac Service Department is the Serial Number
and Model.
MODEL
PROD DATE SERIAL
KW KVA PHASE HERTZ
VOLT AMP PWR FACT ALT RPM
ENG RPM TYPE CODE
ALT SUBTRANSREACTANCE ALT TRANS REACTANCE
CLASS ROTOR STATOR WINDING INS AT 25°C AMB
MODEL NO (CAT/CUST NO) SERIAL NO
0G2110 REV
Figure 53 – Data Plate
The Type Code is a handy way to obtain important information about the generator.
It is important to know what some of the terms mean in relation to the generator.
• Rated kW – the units maximum power rating in kW

• Rated kVA – the units maximum kVA – this is based on a 0.8 Power Factor (Three-phase)
• Upsize Alt.kW. – represents added capacity to the alternator for running against large inductive loads
• Power Factor – the power factor rating of the unit; this will affect the maximum kVA the unit can
produce.
• Alternator RPM – 1800 or 3600
• Engine RPM – if it is 1800 or 3600 the unit is a direct drive; anything in between will have a gearbox.
• Class – insulation rating for the Rotor and Stator. This indicates the maximum temperature rise
allowed above the ambient temp. This rating is based on an ambient temperature of 40ºC. The
temperature capability of each insulation class is defined as being the maximum temperature at which
the insulation can be operated to yield an average life of 20,000 hours. The rating for 20,000 hours of
average insulation life is shown below.
Class A – 105ºC Class B – 130ºC
Class F – 155ºC Class H – 180ºC

Chapter 3
QT/Commercial product Model Code Identification

QT-045 42 A N S X
●● QT – Identifies the unit as a Quiet Test unit (quiet during exercise)
●● 045 – Identifies the kW rating of the unit
●● 42 – Identifies the engine displacement – QT product uses gaseous engines only
●● A – Identifies the voltage code of the unit (see “Voltage Codes” on page 47)
●● N – Identifies the fuel type. N = Natural Gas, V = Vapor Propane
●● S – Identifies the enclosure type. S = Steel, A = aluminum
●● X – Identifies the Emissions type.
–– N = no catalyst, Y = catalyst & R/F Ratio (Pre-Nexus)
–– X = no catalyst, C = catalyst & R/F Ratio (Nexus)
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

kW Ratings Engine Voltage Fuel Enclosure Emission/Catalytic
e.g. (45 kW = e.g. (6.8L = 68) 120/240 1ø = A Natural Gas = N Steel = S Converter
045) 120/208 3ø = G Propane Vapor = V Aluminum = A No Catalyst = X1
120/240 3ø = J Field Convertible Catalyst &
277/480 3ø = K to LP = * A/F Ratio = C2
22 2.4L @ 1800 RPM A,G,J N* A X
25 1.6L @ 3600 RPM A,G,J N* S X
27 2.4L @ 1800 RPM A,G,J N* A X
ALL 30 1.6L @ 3600 RPM A,G,J N* S X
PRODUCT 363 2.4L @ 1800 RPM A, G, J, K N* A X
CODES 45 2.4L @ 3600 RPM A, G, J, K N* S X, C
BEGIN 48 4.2L @ 1800 RPM A, G, J, K N* A X, C
WITH QT
603 2.4L @ 3600 RPM A, G, J, K N, V S, A X
70 6.8L @ 1800 RPM A, G, J, K N, V A X, C
803 4.6L @ 3600 RPM A, G, J, K N, V A X
100 6.8L @ 2300 RPM Gear Drive A, G, J, K N, V A C
SAMPLE 130 6.8L @ 3000 RPM Gear Drive A, G, J, K N, V A C
150 6.8L @ 3600 RPM A, G, J, K N, V A C
Q T 0 6 0 2 4 G N S X
Q T
PRODUCT CODE (Enter on Order Form)
1 = 22 - 30 kW - CARB emission compliant in State of California and City of Los Angeles and do not require
a catalyst. Emission compliant in State of Massachusetts.
2 = Catalyst & A/F Ratio may not be available for all models required for California and Massachusetts. Contact your
Generac representative for details on these emission requirements.
3 = Not available with catalyst. Units are not CARB Compliant and may not be sold in state of California, City of
Los Angeles, and state of Massachusetts.
* = Units are field convertible through 48 kW and are shipped for use with Natural Gas.
Figure 54

Chapter 3
Industrial Product Model Code Identification

SD-200 – D 1 6 6.8 D 18 H B Y N C
• SD – Standby diesel generator (“SG” indicates a standby gaseous fuel unit).

• 100 – Rated output is 100,000 watts (100 kW).
• A – Voltage code (see “Voltage Codes” on page 47).
• 1 – Indicates single-phase unit (3 – indicates three-phase unit).
• 6 – Indicates unit rated 60 Hertz (Hz) (5 – indicates 50 Hz).
• 6.8 – Engine is 6.8 liter.
• D – Unit has diesel fuel system (“N” indicates natural gas; “L” indicates LP Liquid Withdrawal; “V”
indicates LP Vapor Withdrawal).
• 18 – Engine Rated RPM (1,800 rpm); “23” = 2300; “36” = 3,600 rpm.
• H – Unit has an option “H” control panel (option “C”, “D” and “E” and “G” panels also are available).
• B – indicates a brushless unit (“D” indicates a direct excited unit with brushes and slip rings; “P”
indicates permanent magnet excitation).
• Y – Unit is equipped with a standard enclosure (“N” indicates no enclosure; “S” indicates unit has an
acoustic enclosure).
• N – Unit does not have an exhaust muffler (“Y” indicates a muffler has been mounted; “L” indicates a
muffler has been shipped loose with the unit).
• Y – Unit has a main line circuit breaker (“C” indicates unit has a UL-listed circuit breaker; “N” indicates
no circuit breaker has been mounted).

Chapter 3
Alternator Configuration
A generator set produces an alternating current from the armature windings in the alternator. The electrical
characteristics of the unit’s output power are determined by the design and construction of its armature
windings. Generac designs and builds the majority of its alternators, both the rotor and stator, from the small
air cooled units up to the 400 kW liquid cooled units. All of our alternators are of the revolving field, stationary
armature design. Generac provides single phase and three-phase AC alternators in various power ratings
depending on the customer needs.
Single phase AC consists of either a single voltage or two voltages in series with exactly the same phase
relationship. Single phase AC supplies power over two or three lines.
Three-phase AC consists of three separate voltages spaced 120 electrical degrees apart and uses three lines.
The phases are usually given the letter designation, Phase A (S1 or L1), Phase B (S2 or L2), and Phase C (S3
or L3). For a thorough explanation of how the typical armature is constructed see Chapter 8: Alternators, in
the On-Site Power Generation Reference Book (EGSA book).
Voltage Codes
Generac breaks down the various voltage configurations into letter codes. A generator will always have a letter
code which signifies the output voltage of that generator.
A – 120/240 volts, single-phase, four lead, 60 Hz

D – 120/240 volts, single – and three-phase, 12-lead, 60 Hz
G – 120/208 volts, three-phase, 12-lead, 60 Hz
J – 120/240 volts, three-phase, 12-lead, 60 Hz
K – 277/480 volts, three-phase, 12-lead, 60 Hz,
L – 346/600 volts, three-phase, six-lead, 60 Hz
M – 110/220 volts, single-phase, four-lead, 50 Hz
N – 115/200 volts, three-phase, 12-lead, 50 Hz
P – 100/200 volts, three-phase, 12-lead, 50 Hz
R – 231/400 volts, three-phase, 12-lead, 50 Hz
S – 277/480 volts, three-phase, six-lead, 50 Hz

Chapter 3
A-Code
3-LEAD STATOR
1 2 5 6
7 8 3 4
11 22 33 44
S15 S16
S1/L1 S2/00 S3/L3

*** THIS SETUP CANNOT BE REWIRED!!! ***
A-CODE STATOR M-CODE STATOR
120/240 VAC - OR - 110/220 VAC
1 PHASE @ 60 Hz 1 PHASE @ 50 Hz
NOTE 1: (A/M-CODE STATORS ONLY)

- 3 LEAD STATOR.
- 1-PHASE ONLY (CANNOT BE REWIRED FOR OTHER VOLTAGES!!!).
- S15 & S16 ARE ONLY HOOKED UP FOR C, D,
E, Nexus -PANEL UNITS. (NOT USED ON G OR H-PANEL UNITS!!!)
(WIRE NUMBERS MAY BE DIFFERENT ON NEWER UNITS)
Figure 55
A & M Code stators are 3-lead stators. They are single phase only and cannot be rewired for other voltages.
The sensing Wires S-15 & S-16 are the sensing leads on C, D, & E-panel units. On commercial product the
leads coming out are labeled 11, 22, 33, & 44. 11 & 44 are the L1 and L3 leads, and 22 & 33 come out as
the neutral, 00 connection.

Chapter 3
D-Code
12-LEAD STATOR "D"-CODE
S2
L2
3
S12
12
(SEE NOTE 2)
D-CODE STATOR
120/240 VAC
1 OR 3 PHASE
@ 60 Hz 4 11
S5 S9
S8 S6
9 6
"DELTA"
10 5
S11
S15 S16
S3
S1 1 2 S4 S7 7 8 S10
L1 00 L3
NOTE 2: (D-CODE STATORS ONLY)
- 12 LEAD STATOR.
- 120/240VAC IS 1-PHASE OR 3-PHASE. NOT BOTH.
- "L2" IS THE "HIGH" LEG IN 3-PHASE APPLICATIONS.
- D-CODE STATOR CAN RUN 100% FULL LOAD @ 1-PHASE
VOLTAGE.
- CAN BE RECONNECTED TO ALL OTHER VOLTAGES EXCEPT
277/480V (K-VOLTAGE). SEE CONFIGURATIONS UNDER
"12-LEAD BROADRANGE STATORS" FOR WIRING.
- S15 & S16 ARE ONLY HOOKED UP FOR C, D,
E, Nexus PANEL UNITS. (NOT USED ON G OR H-PANEL UNITS!!!)
Figure 56
The D-code stator is a special 12-lead stator with a second set of windings parallel to the L-1 and L-3
windings. This gives it the ability to produce full rated power at 120/240 volts single-phase. L2 is always the
“High” leg on these stators. This high leg is sometimes called the “Crazy” leg, the “Bastard” leg, the “Wild”
leg, and other creative names. If the voltage from L2 to 00 is measured it comes out to be @ 208 volts –
which is about 75% higher than 120 volts. S-15 and S-16 are the voltage sensing leads for C, D, E, Nexus
panel units. Nexus units may use Wires 11,22,33,44 or SA, SB in place of Wires S15, S16.

Chapter 3
J-Code
J-CODE STATOR
120/240 VAC L2
3 PHASE @ 60 Hz S2
3
S12
12
(SEE NOTE 3)
- OR -
P-CODE STATOR
100/200 VAC 4 11
3 PHASE @ 50 Hz S5 S9
(ADJUSTABLE TO 240VAC) S8 S6
9 6
"DELTA"
10 5
S11
S15 S16
S3
S1 1 2 S4 S7 7 8 S10
L1 00 L3
NOTE 3: (ALL BROADRANGE STATORS)

- ALL BROADRANGE CONFIGURATIONS ARE 12 LEAD STATORS.
- "L2" IS THE "HIGH" LEG IN 3-PHASE APPLICATIONS FOR J & P VOLTAGES.
- J & P VOLTAGES CAN RUN 66% OF FULL LOAD UNDER 1-PHASE VOLTAGE.
- ALL BROADRANGE STATORS CAN BE RECONNECTED TO ALL OTHER VOLTAGES AS
SHOWN UNDER THIS SECTION.
- S15 & S16 ARE ONLY HOOKED UP FOR C, D, E, NEXUS PANEL UNITS.
(NOT USED ON G OR H-PANEL UNITS!!!)
Figure 57

Chapter 3
G-Code
L1
L1
G-CODE STATOR S7 S1 S16

120/208 VAC 7 1
3 PHASE @ 60 Hz
- OR -
N-CODE STATOR 8 2
115/200 VAC S10 S4

3 PHASE @ 50 Hz
00
S12 S5
12 4
S6 S11
6 10
11 3
S15 S9 S2
5 9
S3 S8
L3 "LOW WYE" L2
L2
L3
Figure 58
G-Code 12-lead stators are often referred to as a “Low-Wye” configuration because of its shape, and the
voltage output being lower than a “High-Wye” K-Code stator.

Chapter 3
K-Code
L1
S1
S15
K-CODE STATOR 2
S4
277/480 VAC
3 PHASE @ 60 Hz S7
7
- OR -
R-CODE STATOR
231/400 VAC 8
3 PHASE @ 50 Hz
S10
(ADJUSTABLE TO 380V OR 416V)
00
S12 S11
12 10
11 9
S9 S8
S6 S5
6 4
"HIGH WYE"
5 3
S3 S2
S16 L2
L3
Figure 59
K-Code, 12-lead stators are often referred to as a “High-Wye” configuration because of its shape, and the
voltage output being the higher of the two “wye” type stators.

Chapter 3
L-Code
S1
VOLTAGE CODE - L + S
6-WIRE WYE
S15
S4
S15 AS
S6 S5
S15 S3 S2
S16
00 00 TO
OPTIONAL
S15 S15 EGC
S1 S3 00 S2
S16 9
S16 12
Figure 60
The L-Code stator is a dedicated 600 volt, 60 Hz stator. The S-Code would be for 50Hz.

Chapter 3

1. What does the “X” in the QT product code represent?
2. Why are there double windings on the “D” code stator?
3. What voltage will a “G” code alternator produce line-to-line?
References
Use the following references for more information on voltage configuration of generators.
J.Wright, “Chapter 8: Alternators (Synchronous Generators),” in On-Site Power Generation, A Reference Book,
4th Edition. Electrical Generating Systems Association (EGSA), 2006, pp. 77-135

Chapter 3

56
4 Voltage Regulation
Keywords
●● Field Flash Circuit ●● Field Flash Diode
●● DC Field Excitation ●● Fly-Back Diode
●● AC Sensing Circuit ●● V/F Compensation
●● AC Excitation Circuit ●● Voltage Regulator
●● DPE Winding
●● Brushed
●● Brushless
●● Field Flash Resistor
Contents
Chapter 4 - Voltage Regulation.............................. 57
Fundamentals........................................................... 58
Example 1............................................................. 59
Brushed Voltage Regulation...................................... 60
Problem 1.............................................................. 60
Problem 2.............................................................. 61
Problem 3.............................................................. 62
DPE Winding......................................................... 63
Field Flash Resistor................................................ 64
Field Flash Diode................................................... 64
Fly Back Diode (DB2)............................................. 65
Brushless Excitation................................................. 66
Problem 4.............................................................. 66
Voltage Regulator..................................................... 68
Voltage/Frequency Compensation.......................... 68
067680 Voltage Regulator...................................... 69
0G2885 Voltage Regulator..................................... 70
References................................................................ 71
57
Chapter 4
Voltage Regulation
Fundamentals
In an AC generator it is desirable to maintain a constant output voltage. During load changes however,
the output voltage will be affected. As current to a load increases the output voltage of the generator will
decrease; and as current to a load decreases, the output voltage will increase. This is due to the total
impedance in the stator windings of the generator. An Automatic Voltage Regulator (AVR) system is used
to maintain a near constant output voltage regardless of the load, as long as it is within the capacity of the
machine.
The output voltage of an AC generator is dependant on three basic factors:
1. The number of turns of wire in the coil (stator)

2. The Speed with which the flux lines cut the conductor (stator)
3. The strength of the magnetic field (flux density of the field)
The number of turns in the coil cannot be changed, especially when the unit is running. The number of turns
for any alternator is calculated to produce the desired voltage and power output, and once wound cannot be
changed. If you change the speed of the unit the frequency will also change, and since it is also desirable to
maintain a constant frequency, that option for controlling voltage is also out. That leaves only changing the
flux density of the field. By changing the flux density of the field we can change the output voltage in response
to load demands.
The term used to describe changing the flux density is excitation. This process of field excitation and control
for Generac QT and Industrial generator sets can be broken down into three parts.
1. DC Field Excitation (to rotor)

2. AC Sensing (from stator)
3. AC Excitation (from stator)
The rotor is the rotating magnetic field. Typical Generac rotors do not retain a magnetic field after they are
powered down so they need to be flashed at startup to establish the field – this is called field flash or field
boost. The power for the field boost circuit comes from battery voltage on the run wire (Wire 14 – 12 VDC,
Wire 219 - 24 VDC).
The AVR controls the excitation voltage to the field, but requires a power source – this will not be battery
voltage since the excitation voltage at full load can rise well above the typical 12 or 24 volt battery voltage
available. The power source for the Generac AVR used in the commercial product is the Displaced Phase
Excitation winding (DPE), which is a separate coil wound into the stator, 90 degrees out of phase with the
main power windings. Since the DPE is a separate winding in the stator, it needs to be excited by the field to
provide power. Since the rotor does not have enough residual magnetism to excite the main and DPE windings
by itself, it needs to be flashed. This is the purpose of the field flash circuit.

Chapter 4
Voltage Regulation
Once the field is flashed the DPE winding will provide AC, 60 Hz power to the AVR. These two excitation wires
are Wires 2 & 6. The AVR will use this AC voltage to produce a regulated DC output voltage which is used to
excite the rotor field. The DC voltage is delivered to the field circuit through Wires 1 & 4.
The AVR senses single phase voltage through sensing wires. These wires are identified with different numbers
depending on the voltage code of the unit. Single phase 240 volt – Wires 11 & 44; three-phase 208 volts –
S1/11 & S3/44; three-phase 480 volts – S15/11 & S16/44. The H-panel voltage regulator circuit senses all
three-phase voltages, and this regulation circuit is covered in the H panel section.
As the sensed voltage changes because of load, the AVR sees the change and adjusts the DC excitation
voltage to the rotor. As the excitation voltage to the rotor increases, the current through the rotor increases
and the flux density increases proportionally. As the flux density increases, the EMF induced into the power
windings increases and the output voltage increases and carries the load current at the desired voltage. If the
load decreases, the output voltage increases and the AVR responds by reducing the excitation voltage, which
in turn reduces the current flow through the rotor, which reduces the flux density, which causes the output
voltage to decrease and carry the reduced load current at the desired voltage.
Example 1
What is the current which will pass through the below described circuit with an applied voltage of 12 VDC?
12 VDC to R1 + R2 + R3 + R4 to Ground
R1 = 25 W, R2 = 1.5 W, R3 = 9.2 W, R4 = 1.5 W
R Total = 37.2 W
I = E/R, I = 12/37.2 = 0.322 amps
What is the voltage drop across each resistor?
E1 = I x R1 = 0.322 X 25 W = 8.05 volts

E2 = I x R2 = 0.322 X 1.5 W = 0.483 volts
E3 = I x R3 = 0.322 X 9.2 W = 2.96 volts
E4 = I x R4 = 0.322 X 1.5 W = 0.483 volts
Total voltage drop across the circuit is E1 + E2 + E3 + E4 = @ 12 volts (11.98)

Chapter 4
Voltage Regulation
Brushed Voltage Regulation

This represents the field flash circuit on a typical commercial direct excited generator (45 kW).
In the previous example, R1 represents the field boost resistor; R2 represents the positive brush and its
contact with the commutator ring; R3 represents the field winding; R4 represents the negative brush and its
contact with the commutator ring to final ground. During field boost there is a current of 0.322 amps flowing
through the rotor to create the magnetic field. This in turn excites the DPE winding which then powers up the
AVR, which in turn increases the field current to bring the generator output voltage up to its rated value.
TO LOAD
MLB
MLB = MAIN LINE CIRCUIT BREAKER
CB2 = EXCITATION CIRCUIT BREAKER
SENSING
SENSING
1
STATOR STATOR
POWER POWER
FIELD BOOST WINDING WINDING FIELD BOOST
CIRCUIT CIRCUIT
MAGNETIC
FIELD
SA SB
BELT DRIVEN
ENGINE -
ALTERNATOR ROTOR
DIRECT DRIVE NEXUS
ENGINE MOUNT
CONTROLLER
REGULATOR
MAGNETIC 4
FIELD 1
TO BATTERY
2 3 162
STATOR 2 CB2
EXCITATION
(DPE) WINDING
6
Figure 61 – Brushed Operating Diagram
Problem 1
Correctly match the Letter with the correct label.
1:______ A: DC Field Excitation
2:______ B: AC Excitation
3:______ C: AC Sensing

Chapter 4
Voltage Regulation
R4
4
4
AVR
1 1 CB2
29 2 162 2
49 BR1 3 11
14 4 4
5 44
6 6
NOTE 1 BA 1
4
CB1
11 11
44
44 11 2
6
44 5
55
22 66
33
NB STATOR
Figure 62
Problem 2
For the schematic diagram above, list the function for each of the below items:
Wire 14:
Wire 49:
BR1:
Wire 29:
R4:
BA (Brush Assembly):
Wires 4 & 1:
Wires 6 & 2 (162):
CB1:
CB2:
AVR:
Wires 11 & 44:
Wires 22 & 33:

Chapter 4
Voltage Regulation
14 (ORANGE) LVP-2 J2-8
49 (BLUE) LVP-3
49
14 DB1 DB2
29 (WHITE)
4 (YELLOW)
R1 1 (BLACK)
4 (YELLOW)
TB1
BA
1 (BLACK)
4 (RED) 11
10
4 HVP-11 J2-18
1 HVP-12 J2-19
Figure 63
Problem 3
For the schematic diagram above, list the function for each of the below items:
Wire 14:
Wire 49:
DB1:
DB2:
Wire 29:
R1:
BA(Brush Assembly):
Wires 4 & 1:

Chapter 4
Voltage Regulation
DPE Winding
Figure 64 – Bypass Wire
The DPE Winding in the Stator is protected against overload by two separate thermal breakers. The final
protection, or last resort, is an embedded thermal trip in the windings themselves. This is commonly called a
“Klixon” breaker. It is a self resetting breaker. If the breaker fails to reset the stator winding assembly must be
replaced. The purpose of this or any trip or breaker is to protect a circuit against overload (excess current).
Excessive current flow will overheat the windings, leading to insulation damage, shorts and/or open circuits.
Wire ‘5’ is the bypass for the breaker; it can be easily identified by the plastic cap on the end. It is located in
the AC connection box, tied up with Wires 2 & 6. If the alternator output voltage drops to its “flash” value,
and you do not have any DPE output voltage, this would be a circuit you would check. Simply disconnect the
4-pin connector in the AC connection box and check for continuity between 2 & 6. If the resistance is infinite
(Open), check for continuity between 2 & 5. If the resistance between 2 & 5 is infinite (Open) the problem is
likely the Thermal Protector. Check for continuity between 5 & 6; if the resistance between 5 & 6 is normal
DPE resistance (check the rotor/stator tables for the correct resistance value), the problem is most likely the
Thermal Protector. If you have to use this bypass – find out why the protector tripped – and fix the original
problem. Also, if you have to use this bypass order a new stator to replace the one with the problem.
2
CB2
162
Figure 65 – DPE Circuit Breaker
Typical DPE Circuit Breaker. Wire 2 is 60 Hz 170-190 VAC from the DPE winding in the alternator. Wire 162
goes to the AVR. If the main alternator windings are overloaded (too much current demand), the current
demand on the AVR supply voltage also goes up. When this breaker sees the current rise above its rated value
for a certain period of time it will open. This will drop the unit’s output voltage way below rated voltage. CB2
will then “cool off” and reset, allowing the AVR to raise unit voltage back to its normal value.

Chapter 4
Voltage Regulation
Field Flash Resistor

R4
R4
4
4 29

Figure 66 – Field Flash Resistor
This is the Field Flash Resistor. It is used to reduce the voltage (and current) to the rotor during startup when
the field flash is exciting the rotor field. If full battery voltage were allowed to go to the field, on smaller units,
the output voltage could go above the unit rated voltage.
Field Flash Diode

14 BR1
-
(-) 29
29
49 BR1
+
14
49
Figure 67 – Field Flash Diode
This is the typical diode bridge (BR1) used in the field flash circuit. The purpose of the diode bridge is to
“block” the high excitation voltage from the AVR from feeding back into the “run” circuit.
It is important to observe the polarity of the connections to the bridge. Each corner is marked with a symbol:
– for Wire 14; ~ for both Wire 29 and 49; the + terminal is not used. If it is incorrect you will get either,
no field flash (and zero voltage output), or you could feed back excitation voltage to the run circuit. In the
latter case, you could cause the unit to continue to run (even with the E-stop activated), or you could harm
components in the run circuit due to over voltage.
Use the diode check function of your Digital Multi Meter to check a diode bridge. With the Positive lead of
the DMM on the Positive (+) terminal of the Diode Bridge there should be NO continuity (OL) on the meter
when the Negative lead is connected to either of the output terminals (~), or the negative terminal. With the
Positive lead of the meter connected to the Negative (-) terminal of the Diode Bridge there should be a Positive
DC Voltage at each of the output terminals (~) and the Positive (+) terminal. It is very seldom that a Diode
Bridge goes bad in the field flash circuit.

Chapter 4
Voltage Regulation
Fly Back Diode (DB2)

When any magnetic field collapses, there is a kick back voltage that is created. The fly back diode is con-
nected to Wires 1 and 4 only on Nexus controlled product and serves to shunt this kick back voltage to ground
when the magnetic field collapses. The diode is connected to allow current to be blocked during normal opera-
tion and shunt to ground when the polarity reverses during the collapse of the magnetic field. If the diode is
connected improperly and allows current to flow during normal operation, field boost voltage will be shunted to
ground and the output at the breaker will remain minimal.
NOTE 3 14
14 (ORANGE) LVP-2 R1
J2 4 29
49 (BLUE) LVP-3
DB1
DB1 DB2
+ +
49
DB1 - Field Flash Didoe
14 DB2 - Fly Back Diode J2 1
- - R1 - Field Flash Resistor J2 4
DB2
29 (WHITE)
Figure 68 – Nexus Regulation Components

R1
4 (YELLOW)

Chapter 4
Voltage Regulation
Brushless Excitation
TO LOAD
MLB
2
MLB = MAIN LINE CIRCUIT BREAKER N
N = NEUTRAL SENSING
SENSING
STATOR STATOR
1
14 DIODE 29 RESISTOR
POWER POWER
FIELD BOOST
CIRCUIT
WINDING WINDING
EXCITER 4 3
FIELD
MAGNETIC
FIELD 0 SA SB
BELT DRIVEN EXCITER

ENGINE -
ALTERNATOR ROTOR DC AC ARMATURE
DIRECT DRIVE NEXUS
ENGINE MOUNT
CONTROLLER
REGULATOR
MAGNETIC
FIELD DIODE BRIDGE
TO BATTERY
STATOR 2 DPE BREAKER
EXCITATION
WINDING
6
4
Figure 69 – Nexus Brushless Operating Diagram
Problem 4
Correctly match the Letter with the correct number.
1:______ A: DC Field Excitation
2:______ B: AC Sensing
3:______ C: AC Excitation
4:______ D: Field Boost Circuit
Wire 14 is the run wire and is turned on when the unit cranks and runs. This provides power for the field flash
circuit through the field boost resistor and diode and Wire 4. The diode prevents high excitation voltage from
feeding back through the run circuit when the unit is running at rated speed and voltage under load.
When the exciter field is powered up it induces a voltage into the exciter armature. This voltage then goes
through the rotating diode bridge (rotating rectifier) and is rectified to DC which in turn excites the main rotor.
The main rotor then induces a voltage in the Stator DPE winding which provides power to the AVR through
Wires 6 & 2. Wire 2 goes to the DPE circuit breaker which protects the unit from overload by opening if the

Chapter 4
Voltage Regulation
excitation current goes too high. The DPE circuit breaker is a self resetting breaker.
Once the AVR is powered up it provides the full range of excitation voltage to the field circuit. The field circuit
causes the EMF in the Stator Power Windings and the DPE winding to increase. The AVR monitors the Stator
Power Winding voltage through Wires SA and SB. Another good check to make when the start up is finished is
to verify what the unit does with only field flash present, and what it does with no field flash. To do this follow
the procedures listed below. Make all wire disconnects and reconnects with the unit shutdown.
1. To check the voltage output of the unit with only field flash present disconnect Wire 162 from the
DPE breaker. The unit will have only field flash voltage available to the rotor. Record this voltage then
reconnect Wire 162 to the DPE breaker.
2. To check the voltage output of the unit without field flash disconnect Wire 4 from the Field Flash
resistor. Run the unit and measure the output voltage. Without field flash the unit should produce a
very low level of residual voltage (3 to 18 VAC). Record this voltage and reconnect Wire 4 to the field
resistor.
After doing the above two checks you know what the unit produces with only field flash and without field flash.
This will help you in any future voltage regulator troubleshooting efforts.

Chapter 4
Voltage Regulation
Voltage Regulator
Generac has used two different standalone voltage regulators in its commercial (QT) liquid cooled product
line (up to @ 70kW): P/N 067680 & P/N 0G2885. Both of these are self contained, single phase sensing,
automatic voltage regulators. They incorporate voltage adjust, gain, stability (only the 067680), and under-
frequency adjustments.
Voltage/Frequency Compensation
Under-frequency adjustment refers to the ability of the voltage regulator to be voltage/frequency compensated.
This means that the alternator output voltage can be made to vary directly with frequency. If the frequency
drops the voltage can be made to drop so that the load on the engine is reduced. When the frequency rises
the voltage will rise. The point at which the regulator becomes V/F compensated is adjustable.
Voltage remains constant

regardless of frequency
Voltage drops
as freq drops
Voltage
This point is adjustable from 50 to 70 hertz.
Where ever the point is set, the regulator then
becomes a straight line regulator, not a V/F at
any freq above the sert point
58
Frequency
Figure 70
Voltage adjust sets the desired AC output voltage level.
Gain adjust determines how sensitive the voltage regulator is and how fast the voltage regulator will respond
to a change in the alternator output voltage. If the gain is too low, the alternator voltage may recover too
slowly or be too low. If the gain it too high, the alternator voltage may recover too fast (voltage overshoot and
undershoot) and/or become unstable.
Stability adjustment (067680) looks at the type of load and how quickly the measurement samples are taken
to adjust the voltage.

Chapter 4
Voltage Regulation
067680 Voltage Regulator

The three LEDs on these voltage regulators indicate if the regulator is receiving the proper signals and working
properly.
RED Regulator LED: If this light is on, the regulator is working. A signal is being sent to the gate circuits
at the DC output side and the DC output to the rotor is being regulated.
YELLOW Sensing LED: The regulator is receiving voltage from the stator output terminals. The sensing
voltage for these regulators is 200 to 250 volts AC. For 120/208 or 120/240 volt units the sensing
wires come right off the MLCB phase terminals. For 277/480 volt units the sensing is obtained from
the midpoint of the series wye connection between two of the phase legs, which produces 240 volts
AC. Whenever sensing is available the yellow LED is on.
GREEN Excitation LED: This light monitors the incoming excitation voltage (AC). It is this winding that
provides the AC power which is later converted to DC and directed to the rotor field. If excitation
power is available the Green LED is on.
SW 2
SW 3
SW 1
JUMPER
Figure 71 – 067680 Voltage Regulator
This is the backside of the 067680 Automatic Voltage Regulator.

Switch 1 tells the AVR whether the unit is direct excited (Brushes), position 1; or whether the unit is brushless,
position 2.
Switch 2 tells the AVR what its source of excitation is. Standard (STD) is for DPE power (60 Hz). For units
with a PMG (240 Hz) the switch should be set to “PM”.
Switch 3 is for an AVR which uses the 7th wire (“ON”). If the 7th wire is not used, this switch is set to “OFF”.
The Jumper is used to set the V/F droop compensation amount. Position 1 will allow 4 volts per hertz droop;
Position 2 will allow 8 volts per hertz.
Refer to the GENservice website for adjustment procedures.
Chapter 4
Voltage Regulation
0G2885 Voltage Regulator
DIP 1
DIP 2
LEDS
Figure 72 – 0G2885 Automatic Voltage Regulator
Dip 1 is always set to the “STD” position (Down).

Dip 2 is always set to the “HIGH” position (UP).
RED Regulator LED: If this light is on, the regulator is working. A signal is being sent to the gate circuits at the
DC output side and the DC output to the rotor is being regulated.
YELLOW Sensing LED: The regulator is receiving voltage from the stator output terminals. The sensing
voltage for these regulators is 200 to 250 volts AC. For 120/208 or 120/240 volt units the sensing wires
come right off the MLCB phase terminals. For 277/480 volt units the sensing is obtained from the midpoint of
the series wye connection between two of the phase legs, which produces 240 volts AC. Whenever sensing is
available the yellow LED is on.
GREEN Excitation LED: This light monitors the incoming excitation voltage (AC). It is this winding that
provides the AC power which is later converted to DC and directed to the rotor field. If excitation power is
available the Green LED is on.
See Bulletin 0G8616 for set-up and adjustment.

Chapter 4
Voltage Regulation

1. What does DPE stand for?
2. What are Wires 22 and 33 in a single phase generator?
3. What is the purpose of R1 on a Generac generator?
References
Use the following references to gain a better understanding of Generator Voltage Regulation and for adjustment
procedures for the Generac Automatic Voltage Regulators.
Other information can be found on the Generac Service Reference CD set that you received with the Generac
Commercial Training materials.
M. Basler, T Gains, L. Perez, R. Schaefer, and F. Wolf, “Automatic Voltage Regulators,” in On-Site Power
Generation, A Reference Book, 4th Edition. Electrical Generating Systems Association (EGSA), 2006, pp. 257-
287.
G e n e r a c Po w e r S y s t e m s , S e t - u p a n d A d j u s t m e n t o f Vo l t a g e R e g u l a t o r 0 G 2 8 8 5 ,
Publication part number 0G8616
Generac Power Systems, Set-up and Adjustment for Voltage Regulator 67680 and 79801,
Bulletin 0157100SVE

72
5 Frequency and Governor
Fundamentals
Keywords
●● Speed Droop
●● Mechanical
●● Isochronous
●● Magnetic Pickup
●● Stepper Motor
●● Governor Driver
●● Bosch Actuator
Contents
Chapter 5 - Frequency and Governor Fundamentals.73
Frequency................................................................. 74
Mechanical Governor............................................. 77
Stepper Motor........................................................ 78
Bosch Governing System....................................... 80
Bosch Actuator...................................................... 80
Testing the Bosch Throttle Body Actuator............... 83
References ............................................................... 84
73
Chapter 5
Frequency & Governor Fundamentals
Frequency
Frequency refers to the number of alternating current cycles which occur in an alternator (AC generator) in
each second. The frequency an AC generator produces is dependent on two factors: the number of magnetic
poles in the rotor; and the speed of rotation of the rotor (RPM).
The number of poles in the field (N-S), always an even number, determines the number of electrical cycles
produced per revolution of the rotor shaft. A two pole rotor will produce one complete cycle per revolution; a
four pole rotor will produce two complete cycles per revolution. Dividing the number of poles in the alternator
field by two gives the number of complete cycles per revolution of the shaft.
The only control factor in the frequency of an alternator is the RPM of the rotor. The poles are fixed when the
alternator is manufactured. The actual frequency produced will be directly proportional to the speed of the
prime mover. Frequency is measured in hertz (Hz, cycles per second), and rotating speed is measured in
Revolutions Per Minute (RPM). Frequency calculations can be made using the following formulas:
RPM × Number of Poles
Frequency =
120
Frequency × 120
RPM =
Number of Poles
The most common generator operating frequencies are 50 Hz and 60 Hz. The standard in the U.S. and North
America is 60 Hz.
Because the frequency of an AC generator is directly proportional to speed, the control of frequency is handled
by the engine speed governing system. A speed governing system is designed to maintain a speed parameter
within a specific value under all load conditions. There are two basic modes of speed governing: Speed Droop
and Isochronous.
In a speed droop system the speed of the unit is allowed to drop off as the system load increases.
This is done to provide a mechanical or simple electronic control system with stability. It is usually
expressed as a percentage of frequency regulation and can be calculated using the following formula:
No Load RPM - Full Load RPM x 100
% Freq. Reg. =
Full Load RPM
For instance a generator system operating with a No Load speed of 61.5 Hz and a Full Load speed of 58.5 Hz
would have a frequency regulation of 5%.
In an Isochronous system the governor will maintain a constant speed regardless of the load, as long as the
prime mover has the capacity to carry the load. This means there is no droop as the load increases. The
speed will however, temporarily decrease or increase as load increases or decreases, but the governor will
always attempt to return the speed to the desired setting (60 Hz.).

Chapter 5
Speed control governors can be mechanical ball head type governor/actuators or electronic governors with
electrical or hydraulic/mechanical actuators. The governor senses the speed of the unit and positions the fuel
control through an actuator to increase or decrease fuel to the engine to maintain the speed at the given load
condition. As load increases the speed will decrease and the governor will position the actuator to increase
fuel to carry the load at the original desired speed. If load is reduced the speed will increase and the governor
will position the actuator to decrease fuel to carry the reduced load at the original desired speed.
Generac uses a number of different types of governing systems. Some earlier style products use a
mechanical governor driven by belts off the crankshaft pulley. Earlier air cooled products use a mechanical
governor housed inside the crankcase of the engine which moves the fuel control linkage through a lever
and spring assembly. Generac also used Barber Coleman electronic governor and actuator systems, and
the Woodward DPG series of electronic governors with electrical actuators or the Bosch electronic actuators.
Some prime movers have their own speed governing system which requires either a speed control input
or a simple fuel on or fuel off signal. We also use our own electronic governor and stepper motor actuator
fuel control system (found on Pre-packs and some R-panel units). The R-200 series of controls, the Nexus
controller, and the H-panel use an integral governing system built into the PCB. The governor then produces
an output signal which is boosted by a governor driver to position a Bosch throttle body or Bosch linear
actuator. On Nexus units, the governor driver is a built-in component of the controller.
A critical aspect of the speed governing system is the method of sensing speed. All Generac generators use
a magnetic pickup (MPU) which measures the flywheel speed of the prime mover. A magnetic pickup is a
simple AC generator which produces a pulse of voltage each time a flywheel tooth passes the magnetic tip.
Routine maintenance and adjustment of the magnetic pickup is critical to the accurate operation and control
of the speed governing system. The only exception to this is the Power Manager DCP control (H & G panels)
which can use either flywheel (MPU) or frequency sensing for speed reference.
Generac has provided service Product Information Bulletin PIB08-15-S, Adjustment Procedure for Magnetic
Pickups, which specifies the proper adjustment of the magnetic pickup. It is important to note that different
electronic governors require different levels of sensing voltage from the magnetic pickup. If the pickup is not
adjusted properly the governing system will not function as designed. Product information bulletins can be
found on the GENservice website.

Chapter 5
Figure 73 – Magnetic Pickup
The center of the tip is a magnet. It is important to periodically clean and inspect the tip of the pickup.
Tightening the pickup against a flywheel tooth too tightly, or having the tip too close to the rotating flywheel
will damage the tip and make the pickup inoperable. The resistance of the MPU should be approximately 950-
1000 Ohms.
Figure 74 – Magnetic Pickup Breakout harness, P/N 0G41800SRV

Chapter 5
Mechanical Governor
Figure 75 – Generac belt driven mechanical governor/actuator
This unit senses speed through the drive belt and positions the fuel linkage with the output lever.
Figure 76
This is a mechanical governor (droop style) which is integral to the fuel injection pump on a diesel unit. The
fuel injection pump controls the timing of the fuel injection and the mechanical governor controls the amount
of fuel injected. The solenoid controlled lever (outlined) is the fuel run/stop lever.

Chapter 5
Stepper Motor
Figure 77 – Stepper Motor throttle actuator
The stepper motor responds to the governor commands and positions the throttle plate to regulate the fuel/air
mixture to maintain the desired speed (60 Hz)
Figure 78
This is the early style stepper motor and governor control module. These are simple to adjust – set the
frequency switch to the “Off” position for 60 Hz. Set the Gain, Stability & Droop potentiometers to the middle.
The unit will need to have load available – load and unload the unit to see how the governor responds.
Increase the Gain to get faster response. If the unit goes unstable, increase the Stability to smooth it out. With
the unit un-loaded, check the frequency. Load the unit and check the frequency. Adjust the Droop to get the
desired amount of Frequency Droop from no-load to full-load.

Chapter 5
Figure 79
This is the R-100 control board. The connections for the stepper motor are through the J3 plug in the bottom
right corner of the board. The J3 connector is only used with the stepper motor.
STM
1
2
3 W1
4 W2
PCB J3 5 W3
NOT USED 1 6 W4
NOT USED 2
BLACK-W1 3 W1
RED-W2 4 W2
WHITE-W3 5 W3
Figure 80 – Wiring/Schematic Diagrams for the R control panel Stepper Motor Circuit.

Chapter 5
Bosch Governing System

PCB J1
DEG +12V 1 14 DEG
0 1
OX INP RET 2 805
2
DEG GND 3 0
3
COOLANT TEMP 4 85
14 4
GOV 0V 5 767
5
GOV +5V 6 765
6
DISTRIBUTOR 12V 7 SHLDA
7
COOLANT LEVEL 8 573
770 8
CRANK SENSOR IN 9 79
771 9
CRANK SENSE RET. 10 0
768 10
LFP INP 11 601
11
GOV FDBK 12 766
769 12
OX INP 13 804
COIL (+) 14 15R
COIL (A-) 15 25A GOV
771 1
DISTRIBUTOR RET. 16 0
767 2
DISTR. INPUT 17 79A
765 3
DEG PWM 18 769
770 4
DEG ENABLE 19 768
N/C 5
LOW OIL PRESS. 20 86
766 6
CRANK SHIELD 21 SHLD
COIL (C-) 22
COIL (B-) 23 25B
Figure 81 – R-Panel Governor Circuit
Wiring/Schematic Diagram for the R-Series Control Panel with the Bosch Actuator and Governor Driver
Bosch Actuator
1
J2-9 771
J1-18 767
2 GOV
3
J1-19 765
4
J2-1 770
5
N/C
6
J1-20 766
Figure 82 – Nexus Governor Circuit

Chapter 5
Figure 83 – Governor Driver used with R-panels & H-panels
The governor driver is used to produce the current needed to position the
Bosch actuator. The governor is an integral part of the control PCB, and
sends a small signal to the driver module, which then amplifies it and uses
the output to cause the actuator to move the throttle linkage to the new fuel
setting.
Figure 84 – Bosch Throttle Body Actuator
Generac uses the Bosch line of electronic actuators because they have
throttle position feedback. A resistive wiper provides throttle position
feedback to the governor which allows for more accurate speed control.

Chapter 5
Figure 85 – Bosch Throttle Body Actuator on a 6.8L Engine
The Bosch throttle body actuator is mounted in the air intake system. The fuel is
introduced above the throttle plate (butterfly) which then controls the air/fuel flow.
As the throttle plate opens, more air is allowed to flow, this in turn causes more
fuel to be drawn through the fuel regulator and mixed with the intake air.

Chapter 5
Figure 86 – Diesel Linear Actuator
This is a Bosch Linear (horizontal) actuator. The Bosch linear actuators are used on industrial diesel applica-
tions with prime movers that have their own fuel control.
Testing the Bosch Throttle Body Actuator

There is a PIB (Product Information Bulletin) which explains how to check a Bosch Throttle Body actuator:
PIB 05-2-S, Pinouts and Testing of Bosch Actuator Control Systems. (Product information bulletins can be
found on the GENservice website.) The simplest way to connect to the pins is connect to the male pins in the
Governor Driver connector or use piercing probes. If you use piercing probes disconnect the Governor Driver
Connector and make sure you use liquid tape to seal the wires where you pierce them.
For Nexus Units, refer to the Diagnostic manual for proper troubleshooting methods
Use only a 9 volt DC transistor battery to do this check. If you use the generator battery or other large battery
you run the risk of burning up the actuator motor – and that will not be covered under warranty.
Connect the positive lead from the 9 volt battery to Wire 770 going to the actuator and the negative lead to
Wire 771 going to the actuator. The actuator motor will move the throttle to the full open position. When you
remove power the actuator spring (internal) will move the throttle back to the fully closed position.
Measure the feedback resistance through Wires 765, 766, & 767 – look for the resistance values listed in the
PIB across the correct wires when the throttle is fully closed and then fully open.
If the throttle opens and closes and the resistance values match those given in the PIB then the actuator is
good.

Chapter 5

1. Name two primary types of governing systems?
2. When is the magnetic pickup breakout harness used?
3. Why does Generac use a governor driver on the R-panel and H-panel?
4. What is the maximum battery voltage that can be applied to a Bosch actuator during testing?
5. What does it mean if a generator is designed to run isochronous?
References
Use the following references to gain a better understanding of Generator Frequency and Governor
Fundamentals and for adjustment procedures for the Generac governors and magnetic pickups used on CPL
product.
All of the PIBs and other information can be found on the GENservice website or the Generac Standby Service
Reference CD set (PN 0C3409) that you received with the Generac Commercial Training materials.
T. Hinde, “Governor Fundamentals,” in On-Site Power Generation, A Reference Book, 4th Edition. Electrical
Generating Systems Association (EGSA), 2006, pp. 237-255.
Generac Power Systems, Installation and Adjustment Instructions for the Magnetic Pick-up used as an RPM
sensor for R, H and G controls, Publication part number 0G41790SVE
Generac Power Systems, Installation and Adjustment Instructions for the Magnetic Pick-up used as an RPM
sensor for R, H and G controls, PIB08-15-S
Generac Power Systems, Pin-out and Testing of Bosch Actuator Control Systems,
PIB05-2-S
Chapter 5

86
6 Gaseous Fuel Systems and
Spark Ignition Systems
Keywords
●● Fuel Pressure ●● Fuel Solenoids
●● Inches of Water Column (IN H20) ●● Ignition Coil
●● British Thermal Unit (BTU) ●● Ignition Module
●● Natural Gas ●● Cam Sensor
●● Liquid Propane Vapor ●● Crank Sensor
●● Fuel Regulator ●● Coil Pack
●● Second Stage Regulator ●● Coil Over Plug
●● Mixer Body ●● Oxygen Sensor
●● Cold Start Solenoids ●● Air/Fuel Solenoid
Contents
Chapter 6 - Gaseous Fuel Systems and Spark Ignition Gaseous Emissions................................................. 110
Systems..................................................... 87 Introduction......................................................... 110
Fuel Systems............................................................ 88 Terms and Terminology........................................ 110
Fuel Pressure......................................................... 88 Component Identification..................................... 110
Example 1............................................................. 90 Fuel Regulator...................................................... 111
Example 2............................................................. 91 Oxygen Sensor.................................................... 112
Problem 1 ............................................................. 92 Description..................................................... 112
Demand Style Regulator........................................... 93 Air Fuel Ratio Solenoid......................................... 113
Mixer Assembly..................................................... 93 Description..................................................... 113
Fuel Regulator........................................................ 96 Operational Analysis............................................ 114
R-Panel and H-Panel Fuel Systems.................. 100 Theory of Operation:....................................... 114
Nexus Fuel System......................................... 101  Check Your Knowledge....................................... 116
Ignition Systems..................................................... 102 References ............................................................. 116
Ignition Coil......................................................... 102
Ignition Control Systems...................................... 103
Nexus Internal Ignition Module (IM)................. 104
Nexus External Ignition Module (IM)................ 105
87
Chapter 6
Gaseous Fuel Systems & Spark Ignition Systems
Fuel Systems
Generac uses a variety of manufacturers to provide the prime movers for our generator sets. The majority
of these engines are automotive style engines which we configure to use either Natural Gas (NG) or
Liquid Propane Vapor (LP or LPV) as the fuel source. The re-configuring of these engines involves several
components:
1. The fuel supply system (regulator)

2. The air/fuel intake system (mixer/throttle)
3. The ignition system
Since the fuel supply system is a vapor, and supplied either through a utility provider via a pipe line supply
(NG), or through refillable LP tanks, a way to regulate the supply pressure must be provided. The utility NG
supply pressure can vary widely based on the region of the country and the individual municipalities. Local
fuel/gas codes usually dictate the maximum pressure at which the gas supply can enter a structure. In order
to reduce the gas pressure to that required by law, a Primary Regulator is required. LP tank pressure is
dependant on the ambient temperature and can be as high as 300 psi. A primary regulator is required at the
tank to reduce the pressure to that required at the generator set.
Three basic components of the Gaseous Fuel Systems

1. Fuel Supply Regulator - Provided by the Utility supplying the Natural Gas, or mounted on the LP tank.
2. Demand (secondary) Fuel Regulator - Provided by Generac and mounted on the frame rail of the unit.
3. Fuel Mixer - Mounted above the throttle body (actuator) in the air intake system.
Fuel Pressure
Whether the fuel supply is NG or LP, the fuel pressure at the Generac supplied regulator mounted on the
generator set must be within the following ranges:
11” – 14” H2O for units 70 kW or larger

5” – 14” H2O for units smaller than 70 kW
The fuel supply pressure is measured using an inches of water column (W.C. or In H2O) manometer (low
pressure fuel gage) at the Generac regulator. The fuel pressure must never fall below the minimum required
for the specific unit. Several factors affect the fuel pressure in the supply line while the unit is running.
When the unit is not running (or cranking), the fuel pressure measured will be static. This fuel pressure will be
the same from one end of the supply line to the other.
When the unit is cranking or running the fuel pressure at the generator regulator will be lower than the fuel
pressure at the outlet side of the primary regulator. This is due to the pressure drop caused by the fuel flowing
through the pipe. The longer the run of pipe the greater the pressure drop; the greater the fuel flow the greater
the pressure drop.

Chapter 6
When the unit is running under full load the fuel flow will be at its maximum amount. This is the point at which
the fuel pressure at the secondary regulator must not be have changed more than one inch of water column.
Normally a licensed plumber does the fuel pipe installation. Typically the plumber will want to know the
maximum fuel demand for the unit. Plumbers usually use BTUs per hour to describe how much fuel a piece of
equipment uses. The following are the general conversion factors for NG and LP to BTUs:
NG ft3/hr x 1000 = BTUs/hour

LP ft3/hr x 2520 = BTUs/hour
These are general conversion factors since the actual BTU rating of NG and LP can vary depending on the
region and supplier. The fuel consumption of a specific generator set can be found in the specification sheet
for that particular product on the Generac.com website under the products tab.
It is a best practice to have a
minimum of 8ft between the
regulator and the generator
Primary Regulator Generator Base Gas Actuator

(Supplied by
Installing
Contractor)
Fuel Shutoff/Regulator
Assembly
Flex Fuel Line
(Supplied 11 - 14" Water
with Unit) Column (>= 70 kW)
5 - 14" Water
Column (< 70 kW)
Manual Shutoff
Valve
Figure 87 – Typical Natural Gas Supply System
Manual Shutoff Valves

Generator Base Gas Actuator
It is a best practice to have a

minimum of 8ft between the
regulator and the generator Fuel Shutoff/Regulator
Assembly
Flex Fuel Line
(Supplied 11 - 14" Water
with Unit) Column (>= 70 kW)
11 - 14" Water
Primary Regulator
Column (< 70 kW)
(Supplied by
Installing
Fuel
Contractor)
Tank
Figure 88 – Typical LP Gas Vapor Withdrawal System

Chapter 6
If you suspect that the fuel supply is a problem there are some checks you can make.
First, connect an accurate manometer (PN 0C8013 from Generac) and measure the static pressure at the
Generac regulator.
Second, with the gage connected, observe the supply pressure while the unit is cranking. If the pressure
drops below the minimum required, there is either a blockage in the line, the main fuel supply regulator is not
sized properly or is not functioning correctly, or the line between the primary regulator (Utility provided) and
the unit is improperly sized.
Third, with the gage connected and the unit running under full load, observe the fuel pressure. If it will carry
full load and the pressure is above the minimum required and within 1 inch of the static pressure the problem
is probably not fuel supply related. If however, the unit will not carry full load, or hunts at full load and the
pressure is below the minimum required, or oscillating above and below the minimum pressure, the problem is
likely fuel supply related.
If it appears that there is a problem with the fuel supply pressure and volume, there are tables in the
installation manuals which demonstrate how to size fuel lines for both NG and LP and how to size LP fuel
tanks. The installation manual is part number 0H8218. These same tables and charts can be found in various
other Generac resources including; the Standby Service Reference CD (disc 1); the Generator Sizing Guide
(Bulletin 0172610SBY); and the Automatic Standby Generator Reference slide rule (Bulletin 0174300SBY).
These provide an excellent way to check for proper line sizing.
Example 1
Using the Generator Sizing Guide Bulletin #0172610SBY
1. Use Table 4, for either NG or LPV as appropriate for the unit you are working with.
2. Find the kW rating of the unit you are working with.
3. Determine the length of the supply pipe from the primary regulator (utility provided) to the fuel
connection at the base of the generator frame.
4. Use the appropriate table and cross reference the unit rated kW with the pipe length (in feet).
For example you have a QT045 unit configured for Natural Gas. The length of the pipe from the primary
regulator to the connection at the base of the unit, with bends, is approximately 80 feet. Using Table 4 for
Natural Gas you find you need to use iron pipe with a diameter of 2 inches. If you try to use the 1.5 inch pipe
the unit will not have adequate gas flow to produce its full rated kW.

Chapter 6
Example 2
Using the QT Installation Manual
1. Using the specification sheet for the unit you are working with find the 100% load fuel consumption.
This is given in cubic feet per hour.
2. Measure the distance the pipe will run, with nominal elbows and bends, from the primary regulator to
the fuel connection point at the base of the unit.
3. Cross reference the length of pipe and the flow rate in the table to determine the proper size iron pipe
to use. Always round up when looking for the fuel flow rate.
4. Using the Correction Factors table below the Pipe Size chart calculate the actual flow rate by
multiplying the closest fuel consumption rate by the Multiplier in the table for the type of fuel being
used.
5. If you have a flow rate that is not listed exactly in the table ALWAYS round up to the next higher
number listed and apply the correction factor.
For example you have a QT080 unit configured for Natural Gas. The fuel consumption for this unit at 100%
load (found in the specification sheet on-line at the Generac.com website) is 1154 cubic-feet per hour. The
length of fuel pipe from the primary regulator to the connection point at the base of the unit with a nominal
number of pipe bends (3-4) is 98 feet. Using the table and cross referencing the length of pipe and the flow
rate of 1154, you find that 2-1/2 inch pipe provides 1430 CFH flow rate at 105 feet. Multiply the 1430 x 0.962
the actual flow through the pipe for NG at that length (105 ft) is 1376 CFH. If you try to use 2 inch pipe the
corrected flow rate at 105 feet would be 920 x 0.962 = 885 CFH. If you try to use the 2 inch pipe at 90 feet
the corrected flow rate would be 1000 x 0.962 = 962 CFH. Both of these values are below the required 1154
CFH required for this unit at full load.
Both of these tables will provide a full flow rate from the primary to the secondary with a pressure drop of
approximately 0.5 inches H2O.

Chapter 6
Problem 1
A customer has a QT4842AVAX generator being installed in the central United States. The lowest temperature
in the winter is 20°F (-5.5°C). The owners has stated he would like this unit to run a minimum of 3 days (72
hours) at 100% load before the tank has to be re-filled outage. At the propane tank, a primary regulator that
will deliver the required 11” WC to the generator will be installed approximately 130 ft away from the generator
and will have 2 ninety degree elbows. What size propane tank will the customer need to run the generator for
the required time? What is the correct pipe size for this generator?
Show your work:
Tank Size: _________________

Pipe Size: _________________

Chapter 6
Demand Style Regulator

The secondary fuel regulator provided by Generac and mounted on the frame rail of the generator set, is a
demand style regulator. This type of regulator works off the pressure differential between the bore of the
throttle body and atmospheric pressure, and allows a proportional amount of fuel to flow based on the
changing pressure differential. Instead of a carburetor Generac utilizes a mixer above the throttle body. This
mixer body uses a venturi to create the reduced pressure where the fuel enters the mixer. Bernoulli’s principle
explains how this works.
Figure 89 – Diagram showing effect of Bernoulli’s principle through a venturi
Mixer Assembly
Fuel Entry Slot in Venturi
Figure 90 – Mixer Body
This is the mixer body containing the venturi as used on a 5.4 or 6.8 liter engine intake. The tubes on either
side are the fuel inlets. In smaller applications there would only be one fuel inlet. These are connected to
the outlet ports of the regulator. Venturi’s also come in different bore diameters to match the required power
output of the engine/generator set. The throttle (i.e. Bosch Throttle Body) would be mounted below the mixer.

Chapter 6
Fuel Entry Slot in Venturi
Figure 91
The venturi insert comes in different sizes to accommodate different horsepower requirements.
Figure 92 – Venturi insert and mixer body for a 6.8L engine

Chapter 6
Figure 93 – Venturi insert and mixer body for the 2.4L & 4.2L engines
As the engine speed changes, due to load changes, the governor will open or close the throttle plate
(butterfly). As the throttle plate opens, the air flow passing through the venturi will increase causing more fuel
to be drawn in through the regulator. As the throttle plate closes, the air flow will decrease causing less fuel to
be drawn in through the regulator.

Chapter 6
Fuel Regulator
To Mixer
Fuel Inlet
Atmosphere
Pushes
Diaphram
Negative Pressure
Figure 94

Chapter 6
Fuel Inlet – from the Primary Fuel Solenoid Controlled

Regulator - the pressure here by Wire 14
should not fall below the mini-
mum pressure at full load
Fuel pressure test ports
The upper port is used to
Regulator diaphragm and check supply pressure
regulator poppet valve
The lower port will
As the diaphragm pushes the have pressure when
poppet off its seat fuel is al- the fuel solenoid
lowed to flow to the mixer. opens. It is also
used for the cold
The difference between the start circuit.
atmospheric pressure on the
outside and the low intake It is recommended that you
pressure on the inside of the keep a few 1/8 inch pipe fit- -
diaphragm is what causes it tings – close nipples, tees,
to move. caps, plugs, etc, to facilitate
making connections to these
ports to facilitate connecting
your manometer for pressure
checks.
Figure 95

Chapter 6
Low Fuel Pressure

switch – a normally
open contact that closes
when gas pressure is
greater than 5 In H 2O
Regulated fuel outlet

to intake
Fuel supply inlet from

primary regulator
Orifice jet to convert the

regulator from NG to LP
Cold start Solenoid

Controlled by wire 56 –
the crank circuit.
Figure 96 – Regulator view showing the cold start solenoid and connection
The cold start solenoid is used to prime/purge the fuel system between the regulator and the intake manifold
when the unit is starting. It is controlled by Wire 56, the crank circuit. When the engine is cranking the
solenoid opens, this allows fuel under pressure to flow through the valve and fill/purge the main fuel line to the
intake. The solenoid is connected to the lower port of the regulator which will see fuel supply pressure when
the run/fuel solenoid is turned on. Once the unit reaches crank-disconnect speed (approximately 600 to 800
RPM) the crank circuit will turn off and the cold start solenoid will close. Because the fuel lines are filled, the
unit will continue to smoothly accelerate to its normal run speed, drawing fuel through the regulator.

Chapter 6
Figure 97 – Fuel supply system on a 6.8L engine
As the power requirement for the prime mover is increased the unit will require more fuel. If one regulator
cannot handle the fuel volume needed, two regulators will be installed. In this case there will also be two cold
start solenoids (one on each regulator) to provide for smooth starts.
If during startup, the unit cranks and cranks but won’t start check the fuel supply. If the fuel supply pressure
is good at both the upper and lower test port while cranking it indicates that the fuel solenoid is opening but
fuel is not getting to the intake. One trick is to push one of the regulator diaphragms from the outside while
the unit is cranking. To do this, insert a small allen wrench (or other thin, dull object) through the center hole
in the diaphragm cover. Make sure whatever you use is not sharp so you don’t puncture the diaphragm. With
the unit cranking depress the diaphragm. This will allow fuel under pressure to feed directly into the intake. If
the engine still does not “hit” or fire the next step would be to check the ignition system to make sure each
cylinder is receiving good spark.
Some units can be converted from NG to LP, consult the owner’s manual which was provided with the unit for
procedures and ability to convert the fuel type. Basically the orifice in the regulator needs to be changed and
sometimes the control has to be changed so it knows that the unit is either NG or LP. The specifics for making
the changes to the controls will be covered in the controls section of this study guide.

Chapter 6
R-Panel and H-Panel Fuel Systems
Figure 98 – Typical Schematic and Wiring Diagram of the fuel system on an R control panel unit.
Wire 14 is the “Run” (Fuel) wire. Anytime the unit is cranking or running Wire 14 will be powered and the
main Fuel Solenoid (FS) will be energized and open, allowing fuel to pass to the main regulator body.
Wire 56 is the “crank” wire; anytime the unit is cranking FS2 will be energized and fuel from the secondary
side of the Fuel Solenoid valve will flow directly to the main fuel supply line. When the unit is running, the
crank circuit will turn off (crank disconnect speed) and FS2 will de-energize and close.
Wire 601 is the Low Fuel Pressure signal. When supply fuel pressure drops below 5 In-H2O the control panel
will indicate a low fuel pressure warning.

Chapter 6
Nexus Fuel System

56B
56B
CENTER TERMINAL
NOT USED
FS2
15
14
FS
0
LFP
601
0
FSR
601 1 1 6 6
15 2 2 5 5 56B
0 3 3 4 4 14
0 0
Figure 99 – Nexus Schematic Diagram Fuel System
Wire 14 is the “Run” (Fuel) wire. Anytime the unit is cranking or running Wire 14 will be powered and the
main Fuel Solenoid (FS) will be energized and open, allowing fuel to pass to the main regulator body.
Wire 56B is the “fuel prime” wire; anytime the unit is cranking and engine timing is correct, FS2 will be ener-
gized and fuel from the secondary side of the Fuel Solenoid valve will flow directly to the main fuel supply line.
When the unit is running, the nexus controller will turn off (crank disconnect speed) and FS2 will de-energize
and close.
Wire 601 is the Low Fuel Pressure signal. When supply fuel pressure drops below 5 In-H2O the control panel
will indicate a low fuel pressure warning.

Chapter 6
Ignition Systems
Liquid cooled spark-ignited engines use a variety of ignition timing and spark generating methods. Spark-
ignited refers to the process of igniting the fuel/air mixture in the combustion chamber with a spark from a
spark plug, at the correct time to begin the combustion process in the cylinder which will produce the power
needed to drive the load. Generac has used all the different types of spark ignition over the years and uses the
most current technology available.
The ignition system has to do two basic things for the engine to run and produce power: it must provide a
strong enough spark to ignite the fuel/air mixture and must provide the spark at the correct point in time to
produce the maximum power from each cylinder.
Ignition Coil
The strength of the spark comes from the ignition coil.
High Tension Lead

To Spark Plug or Distributor
Battery Voltage
To Igniton Control
Module
Primary Winding
Secondary Winding
Figure 100
The ignition coil is a simple device -- essentially a high-voltage transformer made up of two coils of wire. One
coil of wire is called the primary coil. Wrapped around it is the secondary coil. The secondary coil normally
has hundreds of times more turns of wire than the primary coil. Current flows from the battery through the
primary winding of the coil. The primary coil’s current can be suddenly disrupted by the breaker points, or by
a solid-state device in an electronic ignition.

Chapter 6
The coil is an inductor. The key to the coil’s operation is what happens when the circuit is suddenly broken by
the points or the solid state switch in the ICM. The magnetic field of the primary coil collapses rapidly. The
secondary coil is engulfed by a powerful and changing magnetic field. This field induces a current in the coils
-- a very high-voltage current (up to 100,000 volts) because of the number of coils in the secondary winding.
The secondary coil feeds this voltage to the distributor or spark plug via a very well insulated, high-voltage
wire.
A single coil can feed all the spark plugs through a distributor, or multiple coils can be controlled by an
electronic ignition module. On some units Generac uses a waste spark ignition system. This is a set of coils,
each of which feeds two spark plugs. The two cylinders that each coil serves are at different points in their
cycle when the coil discharges. One cylinder will be on its compression stroke ready to produce power; the
other will be on its exhaust stroke, discharging the burned fuel out the exhaust. Both cylinders spark plugs
fire at the same time, but only the one on the compression stroke produces power. The other cylinder has a
wasted spark – which is why this system is often called a waste spark ignition system.
Ignition Control Systems

PCB J1
DEG +12V 1 16 14 16
DEG
0 1
OX INP RET 2 805
2
DEG GND 3 16 0
3
COOLANT SENSORS 4 85 16
14 4
DEG 0V 5 767
5
DEG +5V 6 765
6
DISTRIBUTOR 12V 7
7
AFS OUT 8 808
770 8
CRANK SENSOR IN 9 79
771 9
CRANK SENSE RET. 10 0
601 768 10
LFP IN 11
11
DEG FDBK 12 766
769 12
OX INP 13 804
COIL (+) 14 16 15R
COIL (A-) 15 16 25A GOV
771 1 CS
DISTRIBUTOR RET. 16
767 2 1 2
DISTR. INPUT 17
765 3
DEG PWM 18 769
770 4 0
DEG ENABLE 19 768
N/C 5 79
LOW OIL PRESS. 20 86
766 6 CP
CRANK SHIELD 21 SHLD 16
16 15R
COIL (C-) 22 25C 16
25B 3
4
COIL (B-) 23 16 25B 16
25C 6
2
16
25A
1
5
3 6
2 5
1 4
FRONT
Figure 101
This is the schematic diagram for an R-panel which uses a waste spark ignition system. This shows a 6
cylinder engine with a 3 coil pack. Wire 15R provides 12VDC to the coil pack when the ignition portion of the
PCB is turned on (when the unit is cranking or running). Wires 25A, 25B, and 25C are the control wires. The
ignition portion of the R-panel will ground these wires on the control board to “fire” each coil pack. This board
has a crank sensor (CS) which gives the speed reference for the timing of the ignition.
Multiple coils controlled by an ICM can be “coil on plug”, or separate coils with high tension leads to each
spark plug. Each coil has power provided to it from the ICM and a control wire which is controlled by the ICM.
The ICM fires each coil in turn by lifting its control wire from ground. Determining when each spark plug fires
is called timing.

Chapter 6
1
2
3
4 451
5
6
7
8
9
10
11
ICM 12 Primary
13
14
15
16 CYL1
451
17
18 15D
19
20 SP1 Secondary
21 15D
22
23 451
Figure 102
79
0
SHLD N.C.
806
MP1
(CRANK)
56 806
14 SHLD
15 **JMP 0
1 79
ICM 2 453
3 454 454
4 451
454
5 452 453
6 CYL4 CYL3
7
8
9 453
10 SHLDA
11 56
15D
15D
12 14 SP4 SP3
13
14 79
* CYL2 CYL1
15
16 15
451
452
17 0
18 15D
19 806
20 SHLD SP2 SP1
21 0 15D
22
23
0A
79A
MP2 452
(CAM) 451
Figure 103 – R-Panel Ignition System

This is the schematic diagram for an R or an H panel control which uses a separate ignition control module
(ICM). All of the ignition coils get power (12VDC) from Wire 15D which turns on when the ICM is powered
up by Wire 14 (the run circuit). Each coil is controlled by its own wire (451, 452, 453, & 454), which are
grounded by the ICM when each coil is supposed to fire (timing).
Nexus Internal Ignition Module (IM)
The Nexus controller uses a distributor less ignition system. It can control up to 4 cylinders with individual
ignition coils. The ignition system is used to control spark for each cylinder and fire at the proper time. The
ignition Module will utilize both inputs from the crank sensor and the cam sensor to determine the specific
point to ignite a particular cylinder.

Chapter 6
J2 - Pinout Chart
PIN WIRE TO FUNCTION
1
2
3
4 451 CYL1 IGNITION COIL DRIVE 1 CYL4 CYL3 CYL2 CYL1
5 452 CYL2 IGNITION COIL DRIVE 2
451
453
452
454
8
9
11 SP4 SP3 SP2 SP1
12
13 15A
14 454
15 J2 453
16 452
17 451
18
19 NOTES
20 5) WIRE #15A IS FUSED +12VDC FOR THE
21
22 AIR/FUEL SOLENOID OPTION AND FOR THE
23 15A EC-3/CYL1-CYL4 NOTE 5 IGNITION COILS.
Figure 104 – Nexus Internal Ignition Systems
Nexus External Ignition Module (IM)
On engines that have 6 cylinders or more it is required that the unit be equipped with an external ignition sys-
tem. The ignition module is controlled by a CAN BUS connection to the Nexus control panel. The CAN BUS
connection will allow the Nexus control panel to set the specific timing as per engine size and fuel type being
used. The CAN BUS will also allow ignition faults to be annunciated on the Nexus control panel display. The
ignition Module will utilize both inputs from the crank sensor and the cam sensor to determine the specific
point to ignite a particular cylinder. Battery voltage is delivered to the ignition module via a fuse protect circuit
and is available through Wire 15B and is present at all times.
1
ICMJ1 2 454
3 456
4 451
5 452
6 455
7
455
8 454
456
9 453 CYL6 CYL5 CYL4

10 SHLD
11
12
13
14 79A
15D
15D
15D
15 SP6 SP5 SP4
16 15B NOTE 6
17 0 NOTE 1 CYL3 CYL2 CYL1
18 15D
19 2
451
453
452
20 SHLDA
21 0A CSS
1 1
22 0
23 450 SP3 SP2 SP1
CAM
2 15D
453
452
451
1 743 743
ICMJ2 2 SHLDC SHLDC J1
3 744
4
5 744
6
7
8
Figure 105 – Nexus External Ignition Systems

Chapter 6
The ignition fails to spark or quits spark-

ing. This indicates the signal relation-
Code 0 Code 21 Coil Short Cylinder 1
ship between the Cam and crank is out
of sync.
Current is detected on the coil high side
Code 10 Code 22 Coil Short Cylinder 2
when none is expected.
Code 11 Coil Open Cylinder 1 Code 23 Coil Short Cylinder 3
Not enough outputs on the ignition. If
Code 19 Coil Open Cylinder 9 Code 50 you setup the Nexus to run a 10 cylinder
with a 6 output ignition module.
Code 20 Coil Open Cylinder 10
Table 1 – Ignition Fault Codes
Engine Block Top View Engine Block Top View
G4.2L
G2.4L
G4.6L G6.8L
G5.4L
G1.5L
Figure 106 – Engine Cylinder Identification

Chapter 6
Figure 107 – Ignition Control Modules used on the 2.4L engine (left) and 4.2L engine (right).
Figure 108 – Individual Ignition Coils on the 4.2L Engine (V-6)

Chapter 6
Figure 109 – Multiple Coil-Pack used on the 2.4L Engine (4 cylinder)
Figure 110 – Individual Coil-on-Plug Ignition Coil used on the 6.8L, 5.4L, 4.6L Engine

Chapter 6
The goal of timing is to ignite the fuel at exactly the right time so that the expanding gases can do the maxi-
mum amount of work. If the ignition system fires at the wrong time, power will fall and gas consumption and
emissions can increase.
When the fuel/air mixture in the cylinder burns, the temperature rises and the fuel is converted to heat energy
and eventually exhaust gas. This transformation causes the pressure in the cylinder to increase dramatically
and forces the piston down.
In order to get the most from the engine, the goal is to maximize the pressure in the cylinder during the power
stroke. Maximizing pressure will also produce the best engine efficiency. There is a small delay from the time
of the spark to the time when the fuel/air mixture is all burning and the pressure in the cylinder reaches its
maximum. If the spark occurs right when the piston reaches the top of the compression stroke, the piston will
have already moved down part of the way into its power stroke before the gases in the cylinder have reached
their highest pressures. To make the best use of the fuel, the spark should occur before the piston reaches
the top of the compression stroke, so by the time the piston starts down into its power stroke the pressures
are high enough to start producing useful work.
Work = Force x Distance

In a cylinder
Force = Pressure x Area of the piston

Distance = Stroke length
So when we’re talking about a cylinder, work = pressure x piston area x stroke length. And because the
length of the stroke and the area of the piston are fixed, the only way to maximize work is by increasing pres-
sure.
The timing of the spark is important, and the timing can either be advanced or retarded depending on condi-
tions. The time that the fuel takes to burn is roughly constant. But the speed of the piston increases as the
engine speed increases. This means that the faster the engine goes, the earlier the spark has to occur. This is
called spark advance: The faster the engine speed, the more advance is required.
However, in a generator application the engine speed is held at a constant to provide a constant frequency of
60Hz. Therefore the need to advance or retard the spark is not required. Generac fixes the spark timing to a
predetermined advance amount based on the power output of the engine required by the generator at the rated
speed (60Hz).

Chapter 6
Gaseous Emissions
Introduction
The purpose of the emission control system is to lower the levels of pollutants in the generator sets exhaust
gas. The system will lower the hydrocarbons, carbon monoxide, and nitrous oxide to levels below the limits
imposed by governing bodies. This is achieved by using an air fuel ratio controller and a catalytic converter.
Terms and Terminology

The following terms are used to describe conditions which affect emissions:
●● Stoichiometric ratio refers to the theoretical mix of fuel and air that will produce complete combustion
for that fuel.
–– Natural Gas: 16.96:1, 16.96 parts air to 1 part fuel
–– LP gas: 15.61:1, 15.61 parts air to 1 part fuel
●● Oxygen Rich condition, refers to the mix of fuel and air where there is a greater amount of fuel to air
(fuel rich). This condition will result in less oxygen in the exhaust stream.
●● Oxygen Lean condition, refers to the mix of fuel and air where there is a greater amount of air to fuel
(fuel lean). This condition will result in more oxygen in the exhaust stream.
●● Atmospheric pressure is the force per unit area exerted against a surface by the weight of air above
that surface in the earth’s atmosphere. Measured at sea level this would be 14.696 PSI.
●● Positive pressure is a pressure within a system that is greater than the atmospheric pressure that sur-
rounds that system.
●● Negative pressure is a pressure within a system that is less than the atmospheric pressure that sur-
rounds that system.
Component Identification
The system will consist of multiple components:
●● The oxygen sensor, or O2 sensor, is a 4 Wire electronic device that measures the proportion of oxygen
(O2) in the exhaust gas flow. It is installed in the exhaust piping between the engine and the catalytic
converter.
●● The catalytic converter is a device placed in the exhaust flow, which converts hydrocarbons, carbon
monoxide and NOx into carbon dioxide, water, and nitrogen using a catalytic element.
●● The primary function of a gas pressure regulator or a demand regulator is to match the flow of gas
through the regulator to the amount of air flowing into the engine. The ratio of gas and air flowing to the
engine will be based on the load placed on the engine and the atmospheric pressure on the regulators
diaphragm.
●● The air fuel ratio solenoid (AFS) is an electrically operated solenoid that will bias the pressure on the
regulators diaphragm. By controlling the pressure on the regulators diaphragm we are able to control
the ratio of gas and air flowing to the engine.
●● The air fuel ratio controller (AFR) is an integrated part of the engine controller that monitors the oxy-
gen in the in the engines exhaust stream. The fuel ratio controller will control the AFS so the exhaust
stream going to the catalytic converter will modulate between an oxygen rich condition and oxygen
lean condition.

Chapter 6
Fuel Regulator
Figure 111 – Emission Regulator
A. Fuel primer solenoid – Wires 56(B) and 0 are active when unit is cranking.
B. Fuel pressure switch – Wires 601, 0 is a normally open contact that closes when gas pressure is above
5 inches H2O.
C. Fuel supply for primer solenoid – Available when main solenoid is active.
D. Pressure port for regulator diaphragm face – Will be at atmospheric pressure or negative pressure.
E. Fuel delivery port from regulator to engine mixer – Will be at negative pressure as per engine load.
Engine will pull fuel from the regulator
F. Air Fuel Ratio Solenoid – Wires 808, 15 will control pressure on regulator diaphragm face. Atmospheric
pressure will be fuel rich, negative pressure will be fuel lean.
G. Negative pressure supply port – This will be at the same negative pressure as fuel delivery port.

Chapter 6
Figure 112 – Emission Regulator (Back)
A. Fuel delivery port from regulator to engine mixer – Will be at negative pressure as per engine load. -1 to
-3 inches of H20 at No load up to -18 inches of H20 at Full load
B. Air Fuel Ratio Solenoid – Wires 808, 15. Will control pressure on regulator diaphragm face. Atmospheric
pressure will be fuel rich, negative pressure will be fuel lean.
C. Fuel primer solenoid – Wires 56(B) and 0 active when unit is cranking.
D. Fuel solenoid – Wires 14, 0 active when unit is cranking and running, allows fuel to enter regulator.
E. Fuel inlet
F. Diaphragm Face chamber
Oxygen Sensor
Description
The oxygen sensor element, or O2 sensor, operates by measuring the difference in oxygen between the exhaust
gas and the external air. It generates a voltage depending on the difference between the two. The oxygen
sensors output wires are 804 and 805. A high voltage (~.6-.9 V) indicates a rich condition in the exhaust flow,
and a low voltage (~.1-.4 V) indicates a lean condition in the exhaust. Wires 14 and 0 are for the O2 sensors
heater circuit, the heater will maintain the O2 sensors temperature allowing the O2 sensor to have a better
resolution.
Chapter 6
Figure 113 – Oxygen Sensor
A. The Oxygen sensor element.

B. 4 Wire plug Wires 804, 805 and 14, 0
C. Wire with high temperature protective sheath.
Air Fuel Ratio Solenoid
Figure 114 – Air/Fuel Ratio Solenoid

A. Connection to regulators negative pressure port.
B. Atmospheric pressure port.
C. Connection to regulators diaphragm face chamber.
D. Electrical connection Wires 15A and 808.
Description
The AFS (Air Fuel Ratio Solenoid) is an electrically operated solenoid. The AFS will control the pressure on the
regulators diaphragm. The AFS is controlled by the air fuel ratio controller through Wire 808, which is normally
open from ground and the solenoid is powered by 15A. When the solenoid is off (closed), atmospheric pres-
sure is present on the face of the regulators diaphragm. This will produce a high output pressure from the
regulator and result in rich operation of the engine.
When the air fuel ratio controller grounds Wire 808 the solenoid will energize. This will allow negative pressure
from the carburetor to bias the regulator diaphragm face, which will reduce the output pressure from the regu-
lator and result in leaner operation of the engine.
Chapter 6
Operational Analysis
Theory of Operation:
The purpose of the emission control system is to reduce the level of emissions in the generators exhaust gas.
It does so through the use of an air fuel ratio controller and a catalytic converter.
1. The air fuel ratio controller receives an input from the exhaust system oxygen sensor.
2. The air fuel ratio controller compares that input to its preset data and adjusts the oxygen content of the
exhaust by adjusting the air fuel ratio going into the engine.
3. The air fuel ratio driver is controlled by the air fuel ratio controller
4. The air fuel ratio driver controls the fuel output of the gas pressure regulator. By controlling the output
of the gas pressure regulator, it is possible to adjust the air fuel ratio into the engine. A modulating fuel
ratio of just above and just below the stoichiometric ratio is the required target output.
5. The AFS will control the fuel output of the gas pressure regulator by controlling the amount of pressure
on the diaphragm face inside the gas pressure regulator. With the AFS in the off mode the diaphragm
face inside the gas pressure regulator will have atmospheric pressure on it allowing more fuel to flow
to the engine. This is a fuel rich condition or Oxygen Lean condition. With the AFS in the on mode the
diaphragm face inside the gas pressure regulator will have less than atmospheric pressure on it allow-
ing less fuel less to flow to the engine. This is a fuel lean condition or Oxygen Rich condition.
6. The catalytic converter uses the modulating oxygen in the exhaust stream to oxidize unburned hydro-
carbons and carbon monoxide, and reduce nitrous oxides.

Chapter 6
Figure 115 – Remote Trending A/F Duty Cycle vs Oxygen Sensors

Chapter 6

1. What is the formula for calculating BTUs on a LP system?
2. When does the low fuel pressure switch trigger and alarm?
3. What is the maximum fuel pressure that a fuel solenoid can handle?
4. What is the purpose of the air/fuel solenoid on emission systems?
References
Use the following references to gain a better understanding of Gaseous Fuel Systems and Spark Ignition
System.
R. Holtgreive, “Chapter 1: Liquid Cooled Spark Ignited Engines,” in On-Site Power Generation, A Reference
Book, 4th Edition. Electrical Generating Systems Association (EGSA), 2006, pp. 3-5.
J. Lang, “Chapter 21: Fuel Systems, Gaseous,” in On-Site Power Generation, A Reference Book, 4th Edition.
Electrical Generating Systems Association (EGSA), 2006, pp. 345-347
K. Nice, “How Automobile Ignition Systems Work, auto.howstuffworks.com.

Available at http://auto.howstuffworks.com/ignition-system.htm (accessed 9 July 2008)

Chapter 6

118
7 Generator Load and Power
Keywords
●● Kilowatts ●● Non-Linear Loads
●● Amperage ●● Power Factor
●● Voltage ●● Real Power (kW)
●● Resistance ●● Apparent Power (kVA)
●● Inductive ●● Reactive Power (kVAR)
●● Capacitive
●● Resistive
●● Linear Loads
Contents
Chapter 7 - Generator Load and Power................ 119
Introduction............................................................. 120
Example 1........................................................... 121
AC Resistive Circuits............................................... 121
AC Inductor Circuits................................................ 123
Power In Resistive and Reactive AC Circuits.......... 126
AC Capacitor Circuits.............................................. 128
Real, Reactive, and Apparent Power....................... 129
Beer Factor.......................................................... 130
Example 2........................................................... 132
Calculating Power Factor........................................ 133
Application to Standby Generators......................... 137
Review.................................................................... 138
References ............................................................. 139
119
Chapter 7
Generator Load and Power
Introduction
The purpose of a Generator is to provide a source of electrical power. Electrical power is described in units of
Watts. In an electrical system Watts can be found by multiplying Volts by Amps.
Power = W = E x I
In single-phase applications In three-phase applications
kW = E x I x PF kW = E x I x PF x 1.732
1000 1000
When a generator is running with no load applied it will have the potential to do work. Until an electrical load
is applied there will be no work performed. Once a load is applied work is performed and current will flow in
the electrical circuit. This work can be measured by calculating the electrical power produced using the above
equations.
There are three distinct types of loads possible in an electrical circuit.
• Resistive load – these types of loads generate heat. Some examples would be; incandescent lighting,
heaters, and general wiring.
• Inductive load – these are loads which operate through inductance. Some examples of inductive load
would be; transformers, motors, solenoids. The effect of inductive load in a circuit is called inductive
reactance (symbol XL) and creates a lagging current condition (Power Factor).
• Capacitive load – these are loads which utilize capacitors to store energy. Some examples of
capacitive loads are: Fluorescent lighting, high intensity discharge lighting, and power factor
correction capacitors. The effect of capacitive load in a circuit is called capacitive reactance (symbol
XC) and creates a leading current condition (Power Factor).
These three types of loads are all considered to be linear electrical loads. The relationship between voltage
and current in a linear load is directly proportional. Both current and voltage display a sinusoidal waveform.
We will be looking at the relationship between the voltage and current sine waves for each of these loads.
There is a fourth type of load which does not fit the above categories because they are considered to be non-
linear. These are loads where the current and voltage relationship is not proportional. Some examples of
non-linear loads are gas discharge lighting with highly saturated ballast coils, variable frequency drives, and
SCR controlled loads (UPS system and other SCR controlled devices).
Resistive loads are those that directly oppose the flow of current in the conductor. This opposition is called
resistance, which causes heat. We use Ohm’s law to measure resistance in a circuit if the applied voltage and
current flow are known. This was previously covered in the electrical fundamentals portion of this course.

Chapter 7
Example 1
QT048, Voltage Code A, Single Phase, 1.0 Power Factor
48,000 watts / 240 VAC = 200 Amps
Connecting a resistive load bank to the unit, load it to 200 amps and the unit runs fine.
QT048, Voltage Code J, Three-phase, .8 Power Factor
48,000 / (240 VAC x 1.73 x .8) = 144 Amps
48,000 / (240 VAC x 1.73 x 1.0) = 115 Amps
You connect a resistive load bank to the unit, load it to 144 amps and the units voltage and frequency fall off
and the unit stalls out.
Why did this happen?
Answer:
The unit was overloaded because at a 1.0 PF the unit can only handle 115 amps
AC Resistive Circuits
If we were to plot the current and voltage for a very simple AC circuit consisting of a source and a resistor
(load) it would look something like Figure 116.
Figure 116 – Voltage and current “in phase” for resistive circuit.
Because the resistor simply and directly resists the flow of electrons at all periods of time, the waveform for
the voltage drop across the resistor is exactly in phase with the waveform for the current through it. We can
look at any point in time along the horizontal axis of the plot and compare those values of current and voltage
with each other (any “snapshot” look at the values of a wave are referred to as instantaneous values, meaning
the values at that instant in time). When the instantaneous value for current is zero, the instantaneous voltage
across the resistor is also zero. Likewise, at the moment in time where the current through the resistor is at
its positive peak, the voltage across the resistor is also at its positive peak, and so on. Where the sine waves
exhibit these simultaneous peaks and zero crossings, the voltage and current are considered “in phase”. At
any given point in time along the waves, Ohm’s Law holds true for the instantaneous values of voltage and
current.
Chapter 7
We can also calculate the power dissipated by this resistor, and plot those values on the same graph: (Figure
117)
Figure 117 – Instantaneous AC power in a pure resistive circuit is always positive.

Note that the power is never a negative value. When the current is positive (above the line), the voltage is also
positive, resulting in a power (P=I x E) of a positive value. Conversely, when the current is negative (below
the line), the voltage is also negative, which results in a positive value for power (a negative number multiplied
by a negative number equals a positive number). This consistent “polarity” of power tells us that the resistor
is always dissipating power, taking it from the source and releasing it in the form of heat energy. Whether the
current is positive or negative, a resistor still dissipates energy.

Chapter 7
AC Inductor Circuits
Inductors do not behave the same as resistors. Whereas resistors simply oppose the flow of electrons through
them (by dropping a voltage directly proportional to the current), inductors oppose changes in current through
them, by dropping a voltage directly proportional to the rate of change of current. In accordance with Lenz’s
Law, this induced voltage is always of such a polarity as to try to maintain current at its present value. That
is, if current is increasing in magnitude, the induced voltage will “push against” the electron flow; if current is
decreasing, the polarity will reverse and “push with” the electron flow to oppose the decrease. This opposition
to current change is called reactance, rather than resistance.
If we were to plot the current and voltage for a very simple purely inductive circuit, it would look something like
this: (Figure 118)
Figure 118 – Pure inductive circuit, waveforms.

Remember, the voltage dropped across an inductor is a reaction against the change in current through it.
Therefore, the instantaneous voltage is zero whenever the instantaneous current is at a peak (zero change, or
level slope, on the current sine wave), and the instantaneous voltage is at a peak wherever the instantaneous
current is at maximum change (the points of steepest slope on the current wave, where it crosses the zero
line). This results in a voltage wave that is 90o out of phase with the current wave. Looking at the graph,
the voltage wave seems to have a “head start” on the current wave; the voltage “leads” the current, and the
current “lags” behind the voltage. (Figure 121 and Figure 119)

Chapter 7
Figure 119 – Current lags voltage by 90° in a pure inductive circuit.
Things get even more interesting when we plot the power for this circuit: (Figure 120)
Figure 120 – In a pure inductive circuit, instantaneous power may be positive or negative

Chapter 7
CURRENT
VOLTAGE
CURRENT VOLTAGE
Figure 121 – Voltage Leading Current
Because instantaneous power is the product of the instantaneous voltage and the instantaneous current (P =
IE), the power equals zero whenever the instantaneous current or voltage is zero. Whenever the instantaneous
current and voltage are both positive (above the line), the power is positive. As with the resistor example the
power is also positive when the instantaneous current and voltage are both negative (below the line). However,
because the current and voltage waves are 90° out of phase, there are times when one is positive while the
other is negative, resulting in equally frequent occurrences of negative instantaneous power.
But what does negative power mean? It means that the inductor is releasing power back to the circuit, while a
positive power means that it is absorbing power from the circuit. Since the positive and negative power cycles
are equal in magnitude and duration over time, the inductor releases just as much power back to the circuit as
it absorbs over the span of a complete cycle. What this means in a practical sense is that the reactance of an
inductor dissipates a net energy of zero, quite unlike the resistance of a resistor, which dissipates energy in the
form of heat. Mind you, this is for perfect inductors only, which have no wire resistance.
An inductor’s opposition to change in current translates to an opposition to alternating current in general,

which is by definition always changing in instantaneous magnitude and direction. This opposition to alternating
current is similar to resistance, but different in that it always results in a phase shift between current and
voltage, and it dissipates zero power. Because of the differences, it has a different name: reactance.
Since inductors drop voltage in proportion to the rate of current change, they will drop more voltage for faster-
changing currents, and less voltage for slower-changing currents. What this means is that reactance in ohms
for any inductor is directly proportional to the frequency of the alternating current.

Chapter 7
Power In Resistive and Reactive AC Circuits

In the previous section, we explored what would happen in simple resistor-only and inductor-only AC circuits.
Now we will mix the two components together in series form and investigate the effects.
As with the purely inductive circuit, the current wave lags behind the voltage wave (of the source), although
this time the lag is not as great: only 37.016o as opposed to a full 90o as was the case in the purely inductive
circuit. (Figure 122)
Figure 122 – Current lags voltage in a series L-R circuit.
Let’s consider an AC circuit with a load consisting of both inductance and resistance in Figure 123.
Figure 123 – AC circuit with both reactance and resistance

We already know that reactive components dissipate zero power, as they equally absorb power from, and
return power to, the rest of the circuit. Therefore, any inductive reactance in this load will likewise dissipate
zero power. The only thing left to dissipate power here is the resistive portion of the load impedance. If we look
at the waveform plot of voltage, current, and total power for this circuit, we see how this combination works in
Figure 124.

Chapter 7
Figure 124
Note: A combined resistive/reactive circuit dissipates more power than it returns to the source. The
reactance dissipates no power; though, the resistor does.
As with any reactive circuit, the power alternates between positive and negative instantaneous values over
time. In a purely reactive circuit that alternation between positive and negative power is equally divided,
resulting in a net power dissipation of zero. However, in circuits with mixed resistance and reactance like this
one, the power waveform will still alternate between positive and negative, but the amount of positive power
will exceed the amount of negative power. In other words, the combined inductive/resistive load will consume
more power than it returns back to the source.
Looking at the waveform plot for power, it should be evident that the wave spends more time on the positive
side of the center line than on the negative, indicating that there is more power absorbed by the load than there
is returned to the circuit. What little returning of power that occurs is due to the reactance; the imbalance of
positive versus negative power is due to the resistance as it dissipates energy outside of the circuit (usually in
the form of heat). If the source were a mechanical generator, the amount of mechanical energy needed to turn
the shaft would be the amount of power averaged between the positive and negative power cycles.
In a purely resistive circuit, all circuit power is dissipated by the resistor(s). Voltage and current are in phase
with each other.
In a purely reactive circuit, no circuit power is dissipated by the load(s). Rather, power is alternately absorbed
from and returned to the AC source. Voltage and current are 90o out of phase with each other.
In a circuit consisting of resistance and reactance mixed, there will be more power dissipated by the load(s)
than returned, but some power will definitely be dissipated and some will merely be absorbed and returned.
Voltage and current in such a circuit will be out of phase by a value somewhere between 0o and 90o.

Chapter 7
AC Capacitor Circuits
Capacitors do not behave the same as resistors. Whereas resistors allow a flow of electrons through them
directly proportional to the voltage drop, capacitors oppose changes in voltage by drawing or supplying
current as they charge or discharge to the new voltage level. The flow of electrons “through” a capacitor is
directly proportional to the rate of change of voltage across the capacitor. This opposition to voltage change is
another form of reactance, but one that is precisely opposite to the kind exhibited by inductors.
If we were to plot the current and voltage for this very simple circuit, it would look something like this: (Figure
125)
Figure 125 – Pure capacitive circuit waveforms

Remember, the current through a capacitor is a reaction against the change in voltage across it. Therefore,
the instantaneous current is zero whenever the instantaneous voltage is at a peak (zero change, or level slope,
on the voltage sine wave), and the instantaneous current is at a peak wherever the instantaneous voltage is
at maximum change (the points of steepest slope on the voltage wave, where it crosses the zero line). This
results in a voltage wave that is -90o out of phase with the current wave. Looking at the graph, the current
wave seems to have a “head start” on the voltage wave; the current “leads” the voltage, and the voltage “lags”
behind the current. (Figure 126)
Figure 126 – Voltage lags current by 90° in a pure capacitive circuit.

Chapter 7
As you might have guessed, the same unusual power wave that we saw with the simple inductor circuit is
present in the simple capacitor circuit, too: (Figure 127)
Figure 127 – In a pure capacitive circuit, the instantaneous power may be positive or negative.
As with the simple inductor circuit, the 90 degree phase shift between voltage and current results in a power
wave that alternates equally between positive and negative. This means that a capacitor does not dissipate
power as it reacts against changes in voltage; it merely absorbs and releases power, alternately.
A capacitor’s opposition to change in voltage translates to an opposition to alternating voltage in general,

which is by definition always changing in instantaneous magnitude and direction. For any given magnitude of
AC voltage at a given frequency, a capacitor of given size will “conduct” a certain magnitude of AC current.
Just as the current through a resistor is a function of the voltage across the resistor and the resistance offered
by the resistor, the AC current through a capacitor is a function of the AC voltage across it, and the reactance
offered by the capacitor.
Since capacitors “conduct” current in proportion to the rate of voltage change, they will pass more current
for faster-changing voltages (as they charge and discharge to the same voltage peaks in less time), and less
current for slower-changing voltages. What this means is that reactance in ohms for any capacitor is inversely
proportional to the frequency of the alternating current.
Real, Reactive, and Apparent Power

We know that reactive loads such as inductors and capacitors dissipate zero power, yet the fact that they drop
voltage and draw current gives the deceptive impression that they actually do dissipate power. This “phantom
power” is called reactive power, and it is measured in a unit called Volt-Amps-Reactive (VAR), rather than
watts. The mathematical symbol for reactive power is the capital letter Q. The actual amount of power being
used, or dissipated, in a circuit is called true power or real power, and it is measured in watts (symbolized by
the capital letter P). The combination of reactive power and true power is called apparent power, and it is the
product of a circuit’s voltage and current, without reference to phase angle. Apparent power is measured in the
unit of Volt-Amps (VA) and is symbolized by the capital letter S.

Chapter 7
Beer Factor
One way of looking at the relationship between real power, reactive power and apparent power is the beer
factor. In the typical pint, you have the real beer - liquid; the foam (not very satisfying); and the total or
apparent beer. You pay for the apparent beer – no matter how much foam there is.
Foam
Apparent Beer
Real Bear
Figure 128
If we apply the electrical concepts to the pint of beer, we see Apparent power, Reactive power and Real power.
Reactive Power
(kVAR)
Apparent Power
(kVA)
Real Power
(kW)
Figure 129

Chapter 7
There are several power equations relating the three types of power to resistance, reactance, and impedance.
X = total circuit reactance; inductive (XL); capacitive (XC).
Z = total circuit impedance (sum of R + XL + XC).
E2
P = Real Power P=I R 2
P=
R
Measured in units of Watts
E2
Q= Reactive Power Q = I X 2
Q=
X
Measured in units of Volt-Amps-Reactive (VAR)
E2
S= Apparent Power S = I Z 2
S= S = IE
Z
Measured in units of Volt-Amps (VA)
Figure 130
Please note that there are two equations each for the calculation of true and reactive power. There are three
equations available for the calculation of apparent power, P= I x E being useful only for that purpose.

Chapter 7
Example 2
QT060 Voltage Code K, Three-phase,
What would the current output be with resistive load (PF = Unity = 1.0)
I = (kW x 1000) / (E x 1.73 x 1.0)
I = 60000 / (480 x 1.73 x 1.0)
I = 6000 / 830.4
I = 72 Amps
What would the current output be with restive and inductive load with a power factor of .8?
I = (kW x 1000) / (E x 1.73 x 0.8)
I = 60000 / (480 x 17.3 x 0.8)
I = 60000 / 664.3
I = 90 Amps

Chapter 7
Calculating Power Factor

These three types of power -- true, reactive, and apparent -- relate to one another in trigonometric form. We
call this the power triangle: (“Figure 131 - Power triangle relating apparent power to real power and reactive
power”).
The “Power Triangle”
Apparent Power (S)

Measured in VA
Reactive Power (Q)
measured in VAR
Impedence
Phase Angle
Real Power (P)

Measured in Watts
Figure 131 – Power triangle relating apparent power to real power and reactive power
+ A B C D E F
kVAR - Reactive Power

wer
Po
nt
re
Amperes
pa
Ap
45°
—
0
A
kV
45° 45°
Volts kW — True Power
- 90° 180° 270°
Power factor determined by degree volts are “out of

phase” with amperes.
Figure 132 – Power Triangle Vs Sine Wave
Using the laws of trigonometry, we can solve for the length of any side (amount of any type of power), given
the lengths of the other two sides, or the length of one side and an angle.
The angle of this “power triangle” graphically indicates the ratio between the amount of dissipated (or
consumed) power and the amount of absorbed/returned power. When expressed as a fraction, this ratio
between true power and apparent power is called the power factor for this circuit. Because true power and
apparent power form the adjacent and hypotenuse sides of a right triangle, respectively, the power factor ratio
is also equal to the cosine of that phase angle.
Chapter 7
kVA 2 = kVAR2 + kW 2
Real Power
Power Factor = PF = kW/kVA
Apparent Power
PF = Cos(θ )
It should be noted that power factor, like all ratio measurements, is a unit less quantity.
For the purely resistive circuit, the power factor is 1 (perfect or unity), because the reactive power equals zero.
Here, the power triangle would look like a horizontal line, because the opposite (reactive power) side would
have zero length.
kVA
kW
Unity Power Factor is 1,
kVA and kW are the same
Figure 133
For the purely inductive circuit, the power factor is zero, because true power equals zero. Here, the power
triangle would look like a vertical line, because the adjacent (true power) side would have zero length.

Chapter 7
With purely inductive load

the power factor would be
kVAR
zero
Figure 134
The same could be said for a purely capacitive circuit. If there are no dissipative (resistive) components in the
circuit, then the true power must be equal to zero, making any power in the circuit purely reactive. The power
triangle for a purely capacitive circuit would again be a vertical line (pointing down instead of up as it was for
the purely inductive circuit).
Power factor can be an important aspect to consider in an AC circuit because any power factor less than 1
means that the circuit’s wiring has to carry more current than what would be necessary with zero reactance in
the circuit to deliver the same amount of (true) power to the resistive load. The poor power factor makes for an
inefficient power delivery system.
What happens to the angle θ

(power factor) if the load
(resistive) increases?
kVA
kVAR
θ
kW
Figure 135
Poor power factor can be corrected, paradoxically, by adding another load to the circuit drawing an equal
and opposite amount of reactive power, to cancel out the effects of the load’s inductive reactance. Inductive
reactance can only be canceled by capacitive reactance, so we have to add a capacitor in parallel to our circuit
as the additional load. The effect of these two opposing reactances in parallel is to bring the circuit’s total
impedance equal to its total resistance (to make the impedance phase angle equal, or at least closer, to zero).
Chapter 7
kW
θ
kVAR
kVA
Figure 136
This is what Capacitive load would look like on a power triangle plot. The power factor is represented on the
negative side of the graph, but since power factor is an angle it always represents as a positive number (0 to
1.0). Capacitive load can be used to offset Inductive load – the two power factors would sum to a total power
factor. Large manufacturers running a low power factor (large inductive load) would add “power factor cor-
rection” capacitors to offset the low power factor, bringing the total power factor closer to “1.0”.

Chapter 7
Application to Standby Generators

How do these types of loads affect standby generator sets? Standby generators are typically rated to produce
a certain amount of kW, at a specified voltage level, down to a specific power factor. The power factor and the
output of the generator will be determined by the types of load it sees. We have seen that some loads reduce
the power factor, and this is acceptable to a point. Standby generators are rated to produce a certain kVA
down to typically, a 0.8 power factor. If the system loads cause the power factor to drop below the 0.8 rating,
we can cause the system to draw more current than the alternator windings are capable of carrying. This will
lead to overheat of the windings and other conductors in the system.
Generators will not operate satisfactorily against capacitive loads and leading current conditions. This is
because the nature of the capacitor is to keep the voltage propped up – this leads to unstable voltage regula-
tion and possible voltage runaway.
Generators operating against non-linear loads must be properly sized to be able to absorb the non-linear har-
monic distortion found on the voltage sine wave. Typically this involves up-sizing or over sizing the alternator
windings by some percentage. Non-linear harmonic distortion is caused by AC loads where the current is not
proportional to the voltage.
Three-phase @ .8 Power Factor Single Phase

kVA kW 208V 240V 480V kVA 120/240
6.3 5 17.5 15.2 7.6 5 20.8
9.4 8 27.8 24 12 8 33.3
12.5 10 34.7 30.1 15 10 41.6
18.7 15 52 45 22.5 15 62.5
25 20 69.5 60 30 20 83.3
31.3 25 87 75.5 37 25 104
37.5 30 104 90 45 30 125
43.7 35 121 105 52 35 145
50 40 139 120 60 40 166
56.25 45 156 135 67 45 187
62.5 50 173 152 76 50 208
75 60 208 181 91 60 250
81.25 65 225 195 97 65 270
93.8 75 261 226 113 75 312
100 80 278 240 120 80 333
125 100 347 301 150 100 416
156 125 433 375 188 125 520
187 150 520 450 225 150 625
Table 2

Chapter 7
Review
• Power dissipated by a load is referred to as true power or real power. True power is symbolized by the
letter P and is measured in the unit of Watts (W).
• Power merely absorbed and returned by load due to its reactive properties is referred to as reactive
power. Reactive power is symbolized by the letter Q and is measured in the unit of Volt-Amps-Reactive
(VAR).
• Total power in an AC circuit, both dissipated and absorbed/returned is referred to as apparent power.
Apparent power is symbolized by the letter S and is measured in the unit of Volt-Amps (VA).
• These three types of power are trigonometrically related to one another. In a right triangle, P =
adjacent length, Q = opposite length, and S = hypotenuse length. The opposite angle is equal to the
circuit’s impedance (Z) phase angle.

1. What is the amperage rating for a QT08046JNAN at .8 PF?
2. When running at .8 PF how many degrees are the current and voltage sine separated by?
3. In a purely inductive circuit, what is the power consumed by the load?
4. In a purely resistive load, what is the power consumed by the load?

Chapter 7
References
Use the following references to gain a better understanding of the concepts found in this section.
J. Wright, “Chapter 7: Electrical Fundamentals,” in On-Site Power Generation, A Reference Book, 4th Edition.
J. Wright, “Chapter 8: Alternators (Synchronous Generators,” in On-Site Power Generation, A Reference Book,
4th Edition. Electrical Generating Systems Association (EGSA), 2006, pp. 77-135.
T. R. Kuphaldt, “Lessons in Electric Circuits, Volume II – AC,” Open Book Project, July 8, 2008. Available:
http://openbookproject.net//electricCircuits/ (Accessed 14 July 2008)

140
8 Troubleshooting Fundamentals
Keywords
●● KIS
Contents
Chapter 8 - Troubleshooting Fundamentals......... 141
Troubleshooting...................................................... 142
141
Chapter 8
Troubleshooting Fundamentals
Troubleshooting
Troubleshooting is the act (art) of pinpointing and correcting problems in any kind of system.
The following are some general questions to ask when you start troubleshooting a system:
●● Has the system ever worked before?
●● If yes, has anything happened since then that might have caused the problem?
●● Has this system proven itself prone to a certain type of failure?
●● How urgent is the need for repair?
●● What are the Safety Concerns before I start troubleshooting?
●● What are possible quality concerns before I start troubleshooting? (Like dropping utility and transfer-
ring power without notifying anyone!)
All Generac generators are run at the factory under full rated load (kW – some are full rated kVA – that would
be against a reactive load bank). So, during a startup you know that the particular unit has operated correctly
at least once. When asking yourself, “What has happened since the last time the unit ran?” it could be
damaged or loose connections during transport. This is one reason that during the startup you should check
‘ALL’ the connections on the generator set to make sure they are tight and secure in their terminal connections.
Other things that can happen would be; did you just load a new configuration file (.xml)? If the unit ran with
the old configuration file, but does not with the new one – try reloading the old file and see if the unit runs. If
it does, then the problem could be a corrupt ‘new’ configuration file. Contact service if you need to get a new
configuration file to replace the corrupt one.
Who was the last person to work on the system and what did they do? Did you just change a component
and now the machine does not work? Re-check the component you replaced. Did you have to disconnect
anything to install the new component? Did you reconnect what was disconnected to the proper place? For
example: the 1.6 liter engine (CHERY) has a cam pickup sensor that connects to the back end of the Cam
housing. Just below that cam sensor connection is a water coolant sensor with the exact same connection
plug. If the cam sensor is connected to the water coolant sensor the unit will not run – no cam position for
ignition timing. There are many possibilities for this type of incorrect connection.
There are many other instances of, “what was the last thing done to the unit or system,” that may cause it to
not function correctly. It is important to ask enough questions of the owner or operator to find the information
you need. For instance: If the unit is hard to start and won’t carry the load check the fuel pressure. If the
fuel pressure is dropping excessively since the startup did something change? Did the customer add some
load to the gas system? Has the plumber changed the system? A new primary regulator installed by the gas
company? If the unit appears to be overloaded, did the customer add some load? Some new machinery or
branch circuits added to the system? These are things that you have to consider when troubleshooting the
system.
Service, Product, Training, and Warranty Information Bulletins (PIBs, SIBs, TIBs and WIBs) provide the means
for Generac to communicate with the service technicians common problems with the units. It is a good
practice to have the PIBs , SIBs, TIBs, and WIBs printed and kept in a binder. Organize them any way you
wish, but be familiar with the information they contain. If you have a problem with a particular machine, ask
some of your other service techs if they have encountered similar problems. This is exactly what the Generac
service technicians do with each other.
Chapter 8
How urgent is the need for repair? This addresses mainly the customer concern that the unit be up and
running. If it is a transfer switch that has faulted, can it be switched manually so the customer has power, and
then repaired after the outage is over? Again, this is up to the customer needs and you have to try to meet
their needs.
Safety concerns would be such things as unit accessibility for repair. Weather conditions can present safety
concerns (electricity and water don’t mix). Powering the system with the generator for testing; make sure you
give people warning and get permission to start and transfer power. Most customers appreciate the warning
and give the permission, especially since you are trying to fix their system.
Another aspect of troubleshooting is to divide the system up into what works and what does not work. For
instance, if you call service and say, “This unit doesn’t run.” The tech will probably ask if it will crank. If the
unit doesn’t run because it will not crank, you need to get it cranking first. If it does crank but does not run,
start breaking the system down into what does work: Fuel supply good? Ignition - spark? Power to the run
circuit? This way you don’t try to fix something that is already working correctly.
Use the diagnostic and troubleshooting manuals wherever they are provided. It also helps to have a thorough
understanding of how the system works. This is what the training and new training manuals are for. Use the
appropriate schematic and wiring diagrams for the unit you are working on.
If you narrow the problem down to a component and you replace it and still have the problem, put the original
component back in – it is probably not the problem. There can be a cascade effect – one component fails and
that failure takes out another component. This can happen but generally does not – except for a high voltage
surge (lightning strike). A lightning strike on a communications wire can take out anything on that wire. A
strike on a customer configurable relay panel (H-Panel) can take out the relay panel and the H-Panel.
Divide the system into sections and check each section. In a system with multiple sections or stages,
carefully measure the variables going in and out of each section until you find a section where things are not
right. For instance – an H-Panel has low voltage on one phase and the other two are not correct – is it the
sensing wiring to the voltage interface? Or is it the voltage interface? Or is it the wiring to the H-panel? By
checking the voltage at the MLCB, and then in and out of the IFT, you will be able to tell if those sections have
a problem. If they have good voltages then check the sensing voltage to the H-Panel. Wiring harnesses lend
themselves to this method – check for continuity between connectors; check pins for loose fit and proper
crimp. Using the wiring diagram allows you to check wire continuity without ripping a harness apart – so use
the wiring diagrams.
Simplify – apply the KIS method – Keep It Simple! If you aren’t getting anywhere re-evaluate and don’t be
afraid to ask for help. Start with your senior tech or the IDC Master Technician. If they are not available or
can’t help then call the Generac Service Department and follow the guidelines for making a service call:
●● Provide your Name
●● Provide your Dealer Name and Dealer Number
●● Provide the Serial Number of the Unit
●● Provide what the problem is and what you have checked so far
●● Have the tech pubs and schematic and wiring diagrams available and use them
There can also be operator error problems. Was the key switch in the Auto position? Was the transfer switch
in Auto? The most common cause of failure of a standby system to operate is that it is in the OFF position.
There are ways to keep track of the key switch position in the H-panel through event logging – use it. Are their
Chapter 8
programming errors or errors in setting the configuration? Did you make changes to things that you should
not have (scaling factors, coefficients, alarm set points, etc.).
Wiring problems break down into two categories; short circuits, and open circuits. An open circuit is literally
that, a circuit that has an open and is not continuous. These can be found by checking the resistance or
continuity on the wire or circuit. A short circuit is one which has contact with ground or with another circuit
(or it’s own circuit). Shorts and opens can be caused by many things; environmental conditions (moisture,
vibration, dirt, corrosion). The two most common causes of shorts are water and vibration. Electricity and
water do not mix – and vibration can cause connection points to loosen or break. If connections are not made
properly to begin with they can eventually fail due to vibration or moisture. Insulation breakdown is caused
by heat, often due to overload, over-current, and over-voltage conditions as well as vibration and moisture.
In a high voltage circuit (AC & DC) the loose connections tend to cause severe arcing which often leads to
a completely open circuit. In low voltage applications, loose connections can be the source of intermittent
problems as the connection opens and then closes – like a switch. A common case of shorted wiring is the
ground fault, where a conductor accidentally makes contact with either earth or chassis ground. This may
change the voltage(s) present between other conductors in the circuit and ground, thereby causing bizarre
system malfunctions and/or personnel hazard.
Active components (amplification devices) tend to fail with greater regularity than passive (non-amplifying)
devices, due to their greater complexity and tendency to amplify over-voltage & over-current conditions.
Semiconductor devices are notoriously prone to failure due to electrical transient (voltage/current surge)
overloading and thermal (heat) overloading.
Passive components are non-amplifying components and are the most rugged of all, their relative simplicity
granting them a statistical advantage over active devices. The following list gives an approximate relation of
failure probabilities (again, top being the most likely and bottom being the least likely):
●● Diodes open (rectifying diodes) or shorted (Zener diodes).
●● Inductor and transformer windings open or shorted to conductive core. Failures related to overheating
(insulation breakdown) are easily detected by smell.
●● Resistors open, almost never shorted. Usually this is due to over-current heating, although it is less
frequently caused by over-voltage transient (arc-over) or physical damage (vibration or impact).
Resistors may also change resistance value if overheated!
Finally there are manufacturing errors or defects. These can be broken down into;
●● Wiring problems
●● Defective components
●● Improper configuration
●● Improper installation
On the technician side these defects show up as:
●● Trusting that a brand-new component will always be good - While it is generally true that a new
component will be in good condition, it is not always true.
●● Not periodically checking your test equipment - This is especially true with battery-powered meters,
as weak batteries may give spurious readings. When using meters to safety-check for dangerous
voltage, remember to test the meter on a known source of voltage both before and after checking the
circuit to be serviced, to make sure the meter is in proper operating condition. Also use a meter with
all the functions you need: we have received numerous calls from technicians saying the unit is not
running at the correct speed. Their meter does not display frequency or RPM, so how do they know it
is not running at the correct speed?
Chapter 8
●● Assuming there is only one failure to account for the problem - Single-failure system problems are
ideal for troubleshooting, but sometimes failures come in multiple numbers. In some instances, the
failure of one component may lead to a system condition that damages other components. Sometimes
a component in marginal condition goes undetected for a long time, then when another component
fails the system suffers from problems with both components.
●● Mistaking coincidence for causality - Just because two events occurred at nearly the same time does
not necessarily mean one event caused the other! They may be both consequences of a common
cause, or they may be totally unrelated! If possible, try to duplicate the same condition suspected to be
the cause and see if the event suspected to be the coincidence happens again. If not, this may mean
there is no causal relationship between the two events whatsoever, or that there is a causal relation-
ship, but just not the one you expected.
The above are just some general troubleshooting guidelines; whatever system you use, if it is effective,
keep using it. Always be willing to change and learn additional or new ways. There are many electrical
troubleshooting papers and tools on the internet. The EGSA book has a whole chapter dedicated to system
troubleshooting – read it during your next load bank test.
It is also important that you know how the system works and what voltages to expect on each part of the
control circuit. Use the Schematic and Wiring diagrams to help you understand how the system works.
Remember a schematic diagram shows the function of the system components and how the whole system
works; the wiring diagram shows the form of the components and where the wires connect. Our step by step
operational descriptions for the various controls and transfer switches tell you how the system works and
are keyed to the schematic diagrams. Learn how to read the diagrams and use the operational descriptions.
The homework assignments in the Commercial training are designed to help you understand how to read the
diagrams and how the different systems work.
Last, you need good tools to work with. The following is a list of tools it is recommended you have to perform
troubleshooting and adjustment on our generators:
●● Calibrated meter with Hz capability
●● Different types of meter probes – (clamp, needle, piercing)
●● Various jumper wires with clips, pins, clamps, etc.
●● A 1000 Ohm resistor (H-panel sensors)
●● Pressure gage - Manometer (in H2O)
●● 1/8 inch pipe fittings – tee, nipple, plug
●● ELECTRICAL SAFETY EQUIPMENT! Voltage rated Face shield, gloves, FR clothing, etc. The require-
ments for Electrical Safety in the Work Place can be found in NFPA-70E.

146
9 Transfer Switch Fundamentals
Keywords
●● Utility Power
●● Standby Power
●● Contactor
Contents
Chapter 9 - Transfer Switch Fundamentals.......... 147
General Information................................................ 148
References.............................................................. 150
147
Chapter 9
Transfer Switch Fundamentals
General Information
Transfer switches are used to provide power to a load from two different sources. In standby power
applications the normal source would be the utility supply and the standby source would be the standby
generator set. Some applications use two generators, one as the normal source and one as the standby
source. Two different utility supply sources could also be used, one would be the normal supply and the other
would be the standby source. Whatever combination is used, the automatic transfer switch is the means used
to connect either the normal source or the standby source to the load.
Automatic transfer switches include controls to monitor the normal source power and detect when the power
fails. They also include controls to start the generator when the power failure is detected. Then when the
generator reaches the proper voltage and frequency the switch will transfer the load circuits from the normal
source to the standby (generator) source. When the normal source returns and is at the proper voltage and
frequency the switch will transfer the load circuits back to the normal supply source and then shut down the
generator source.
For the following diagrams, the open lines (white with black outline) indicate voltage present. The solid black
lines indicate no voltage present
Figure 137
Utility voltage is available and the transfer switch is in its “normal” position with utility source feeding the
loads.
148 Section 2 - Transfer Switches

Chapter 9
Figure 138
Utility voltage has failed. The transfer switch gave a start command to the generator which started and
ramped up to acceptable voltage and frequency levels. When the transfer switch sees that the standby source
voltage and frequency are acceptable it transfers to the “standby’ or “emergency” position and the standby
source feeds the loads.
This is the basic function of an Automatic Transfer Switch (ATS). There are several factors to consider when
selecting and sizing an ATS for a particular application. The purpose of an ATS in a standby application is to
transfer power to the load when the normal source fails and the standby power source becomes available. If
you think this through, that means that when the utility fails the customer will be without power for a short
period of time. This is normal when the power fails. However, when power returns what does the customer
expect or need to happen. This will help determine which type of transfer switch to use for a particular
application.
Transfer switches come in two basic types – open transition and closed transition. An open transition transfer
switch will see a momentary loss of power to the load when transferring from one live source to another. A
closed transition transfer switch will not see any loss of power to the load when transferring from one live
source to another. The important thing to note is that if both sources are available, only the closed transition
switch will provide constant power to the load. Whenever utility fails the lights are going to go out – unless the
generator is already running and the transfer has already occurred.
Generac provides several different styles of transfer switches. These can be found on the Generac.com
website under the product tab and specification sheet listing. These types are the RTS, GTS, HTS, MTS, and
CTTS switches.
Section 2 - Transfer Switches 149

Chapter 9

1. What does it mean for a switch to be a “closed transition” transfer switch?
2. What does it mean for a switch to be a “open transition” transfer switch?
References
Use the following references to gain a better understanding of automatic transfer switches and for operation,
maintenance, and adjustment procedures for the Generac Automatic Transfer Switches. The owner’s manuals
for the various switches and other information can be found on the Generac Service Reference CD set that you
received with the Generac Commercial Training materials.
H. Daugherty, “Automatic Transfer Switches,” in On-Site Power Generation, A Reference Book, 4th Edition.
Generac Power Systems, RTS “V” Style Transfer Switch Technical Manual, PN 0G0399
Generac Power Systems, RTS “W” Style Transfer Switch Technical Manual, PN 0F6139
Generac Power Systems, GTS “W” Type Automatic Transfer Switch Owner’s Manual, PN 0E1978
Generac Power Systems, HTS “W” Type Automatic Transfer Switch Owner’s Manual, PN 0F5574
Generac Power Systems, Diagnostic Repair Manual, Sections 3.1 to 3.4, “W/V” Type Transfer switches, PN
0G4338
Generac Power Systems, Commercial Supplement, PN 0E2223
The above referenced Technical Manuals and Owner’s Manuals can be found on the Generac Power Systems
Service Reference CD (Disc 1), PN 0C3409
The Owner’s Manual or Technical Manuals for the switch you are working with.

Chapter 9

152
10 RTS Series Transfer Switches
Keywords
●● RTS ●● Wire 194
●● “Wn” Type ●● Wire 23
●● “W” Type ●● Fuses
●● “V” Type ●● Limit Switches
●● Timers ●● Coils
●● Power Monitor ●● Digital Load Management
●● Auxiliary Contacts
●● Transfer Relay
Contents
Chapter 10 - RTS Series Transfer Switches......... 153 Utility and Standby Contacts........................... 166
Generac RTS Transfer Switch................................. 154 Bridge Rectifier............................................... 168
RTS Transfer Switch Model Identification.............. 155 AX-BX Limit Switch......................................... 168
Transfer Relay...................................................... 155 ATS Limit Switch............................................. 168
Customer Connections........................................ 156 BTS Limit Switch............................................ 168
Terminal Block................................................ 156 LS Limit Switch.............................................. 168
Fuse Holder.................................................... 157 Auxiliary Contacts................................................ 171
“V” Type.............................................................. 158 “W” and “Wn” Type........................................ 171
“W” Type............................................................. 160 “V” Type......................................................... 172
Main Closing Coil............................................ 161 Power Monitor..................................................... 173
Utility and Standby Contacts........................... 161 Multiple Transfer Switches................................... 175
Bridge Rectifier............................................... 162 Digital Load Management..................................... 177
LS1 and LS2 Limit Switch............................... 162 Introduction.................................................... 177
LS3 Limit Switch............................................ 162 Load Management Controller.......................... 177
“Wn” Type........................................................... 165 Digital Load Module........................................ 179
Main Closing Coil............................................ 166  Check Your Knowledge....................................... 181
Trip Coil.......................................................... 166 References.............................................................. 182
Select Coil...................................................... 166
153
Chapter 10
RTS Series Transfer Switches
Generac RTS Transfer Switch

Generac RTS automatic transfer switches are designed to operate with the Generac R-Series, Nexus air and
liquid cooled along with earlier generations of air-cooled. All standard and load center transfer switches are
UL and CUL Listed and suitable for use as optional standby systems (NEC 702). The 2 pole single phase RTS
switches are also available with a service entrance rated breaker.
There are a number of impor tant points to remember when selecting/sizing the RTS switches for an
application.
●● The voltage rating of the switch and generator must match the utility supply voltage.
●● The transfer switch current rating must be equal to or greater than the utility supply breaker.
●● On service entrance rated switches, the rating of the service breaker on the transfer switch must
match the utility current rating.
●● The generator supply breaker must be equal to or less than the utility supply breaker.
●● All wiring must conform to the guidelines found in the NEC and local codes.
The RTS switches work only with the R series and Nexus control panels. The switch contains no logic to
monitor power, start the generator, or transfer. All of the control logic is performed by the R control and Nexus
panel. The typical sequence of operation and time delays are as follows:
●● Line Interrupt – Utility Loss Delay – 15 seconds

●● Engine Warm up timer – 10 seconds
●● Return to Utility Delay – 15 seconds
●● Engine Cool down timer – 1 minute
All of these timers, the voltage set-points, and the delays are explained in detail in the Technical Manual for
the applicable R-panel or Nexus panel. We will cover these timers and set points in the R control and Nexus
sections of this study guide.

Chapter 10
RTS Transfer Switch Model Identification

HTS Switch Identification would be similar to what is shown for the RTS.
TRANSFER SWITCHES
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5
SELECTION Transfer Switch Used With Switch Type Amp Rating Voltage Enclosure Type
CRITERIA Generator Controller DLM Load Shedding= X1 e.g. (200 Amp = 200) 120/240 1ø = A NEMA 3R= 3
R Controller or Service Entrance Rated 120/208 3ø = G
Nexus Controller = RTS DLM Load Shedding= D1 120/240 3ø = J
16 Circuit Load Shedding = J2 277/480 3ø = K3
All 3ø = N
For Standby
Generators RTS X, D, J, N 100, 1504, 200, 400, A, G, J, K 3
22 - 150 kW 600, 800
SAMPLE R T S X 2 0 0 A 3
PRODUCT NUMBER
(Enter on Order Form)
1 = 120/240 1ø, 100 - 400 Amp NEMA 3R Only

2 = 120/240 1ø, 200 Amp service entrance rated NEMA 3R
3 = 277/480 3ø phase only for 36-150 kW
4 = 150 Amp only available in RTSD150A3 configuration
Figure 139
Transfer Relay
Figure 140
Power to transfer the switch is controlled by a transfer relay coil and contacts. The transfer relay is controlled
by the R control board or Nexus Panel. Wire 194 is 12VDC power from the control board when the generator
control switch is in the Auto or Manual position. Wire 23 is the control ground for the relay. When the control
board takes Wire 23 to ground (low) the relay will energize and the contacts will change states (From Normally
Open to Normally Closed). When the control board lifts Wire 23 from ground (high) the relay will de-energize
and the contacts will change back to their normal de-energized position.

Chapter 10
Figure 141
Customer Connections
0
CUSTOMER CONNECTIONS
DC COMMON
194
+12VDC
23
TRANSFER
N1 N2 T1
WARNING UTILITY LOAD
NOTE WIRE ORIENTATION SENSE
240VAC
CUSTOMER CONNECTION
Figure 142 – Customer Connections
Terminal Block
During system installation, this 6-point terminal block must be properly connected with an identically labeled
terminal block in the generator customer connection area.
Terminals used on the terminal block are identified as: 194, 23, 0, T1, N1 and N2.
Note: On some generators, Wire 194 may be marked as 15B in the generator. Wires 194 and 15B serve the
same function. During installation, these wires should be connected together.

Chapter 10
Utility N1 and N2
Wires N1 and N2 are connected with identically labeled terminals in the Generator customer connection area.
This is the Utility sensing voltage to the circuit board. The signal is delivered to the Generator and on some
older models is stepped down to 16 VAC using a transformer. N1 and N2 voltage is used by the circuit board
as follows:
If Utility source voltage should drop below a preset level, circuit board logic will initiate automatic cranking and
startup, followed by automatic transfer to the standby source.
Terminal 0, 194, 23
These terminals connect to the transfer relay and if equipped, the Digital Load Management system.
Note: These terminals and wire numbers vary depending on the production date of the transfer switch. Always
consult the owner’s manual supplied with the unit to ensure accurate information.
Load T1
Wire T1 is connected with an identically labeled terminal in the Generator customer connection area. This
Load voltage is delivered to the generator to supply 120 VAC to the control board for battery charging. On
some older models, this voltage is delivered to a charger external of the printed circuit board.
Fuse Holder
The fuse holder holds three fuses, designated as fuses F1, F2, and F3. Each fuse is rated at 5 amperes.
Fuses F1 and F2
These two fuses protect the Utility N1 and Utility N2 circuit against overload.
Fuse F3
The F3 is installed inline with Wire T1; it protects the battery charger circuit from overload.

Chapter 10
“V” Type
Figure 143 – RTS “V” type two-pole contactor.
RTS “V” type two-pole contactor. Note that the “V” type switch has two contactor closing coils: one to trans-
fer to Utility position and one to transfer to the generator (standby) position. The two limit switches, XA1 and
XB1, are mechanically actuated by the load contacts. When the switch is in the utility position the XA1 con-
tacts are open and the XB1 contacts are closed. When the switch is in the standby position the XA1 contacts
are closed and the XB1 contacts are open. The limit switches serve two functions: they set the switch up for
transfer to the next live source, and they disconnect the source that is performing the transfer when the trans-
fer is complete.

Chapter 10
STANDBY UTILITY
LOAD
Figure 144 RTS “V” type switch in the Utility position.
STANDBY UTILITY
LOAD
Figure 145 – RTS “V” Type switch in the Standby position.
There is no controlled “neutral” position in this switch – it “breaks” the contact with one source and then
“makes” the contract with the other source. The time it takes for the contactor to change positions is the time
delay in neutral.

Chapter 10
“W” Type
The Generac RTS switch with the “W” style contactor is designed to meet the need of three-phase applications
in 120/240, 120/208 and 277/480 volts. Because of the 3-phase sensing this style switch uses a Power
Monitor which monitors all 3 phase voltages.
Utility
A1 B1
T1 T2
LS1 2 3 5 6
LS3
RED
WHITE C
1 4
Load
LS2
A2 B2
Generator
Figure 146

Chapter 10
Transfer Relay
Power Monitor
Auxiliary Contacts
Fuses
Terminal Block
Figure 147
Typical “W” style RTS switch showing the main contactor (3-pole), the Transfer Relay, Power Monitor, Sensing
Fuses, Terminal Board, and Auxiliary Contacts. This switch is wired to the R panel or Nexus panel the same
as the V-style RTS switch. N1 & N2 are the sensing wires leading from the Power Monitor, through the fuses,
to the sensing transformer on a R-Panel and directly to the controller on a Nexus. The terminal board is where
the connections to/from the generator are made for the N1 & N2 sensing, and 23 & 194.
Main Closing Coil
The coil (C1) energizes utilizing rectified AC voltage to actuate the contacts from either the “Utility” or the
“Standby” position. Internal to the CONTACT, when C1 energizes, the switch mechanically trips to the
“Neutral” position. C1 must remain energized in order for it to remain in neutral. When the contactor is in the
“Neutral” position, limit switch (LS3) contacts will open removing the AC voltage from the closing coil.
Utility and Standby Contacts
Figure 146 shows the UTILITY contacts in the “Utility” position supplying voltage to the load.

Chapter 10
Bridge Rectifier
The bridge rectifier receives AC voltage from either Utility or Generator. This voltage is rectified into a usable
DC voltage that is capable of energizing the closing coil. It also acts a terminal block for incoming wires.
Figure 148 – Bridge Rectifier

LS1 and LS2 Limit Switch
The limit switches (LS1 and LS2) are internal to the switch and are located between the coil housing and the
arc chute. LS1 and LS2 mechanically connect to the CONTACTOR and change states when the CONTACTOR
switches from one source to the other. When the switch is in the “Utility” position, the limit switch provides a
path for current to flow to the coil utilizing Generator voltage. Vice-versa when the switch is in the “Standby”
position, the limit switch provides a path for current to flow to the coil with Utility voltage. This is based on the
principal that the switch’s contacts will always “arm” itself for the next transfer.
LS3 Limit Switch

When the switch is in the “Neutral” position the LS3 limit switch opens removing the source voltage that ener-
gized the coil, allowing the Contactor spring to pull the switch to the next position.

Chapter 10
Figure 149 – “W” type contactor shown in the utility position.
Figure 150 – “W” type contactor shown in the neutral position
“W” type contactor shown in the “neutral” position. In an RTS application the neutral position is not
adjustable. When the closing coil pulls the contactor to the neutral position the LS3 contact opens, this opens
the power feeding the closing coil (de-energizing the coil) which allows the contactor spring to pull the switch
the next position.

Chapter 10
Figure 151 – “W” type contactor shown in the “Emergency” or “Standby” position.

Chapter 10
“Wn” Type
The Generac RTS “Wn” style automatic transfer switch is used in commercial applications. They are available
in single and three-phase applications and current ratings from 600 to 800 amp. “Wn” style switches are
open transition switches. The Wn style mechanism has a de-energized Neutral meaning that when the switch
is Neutral position the internal actuator coils will not be powered. They are provided with automatic operation
through the control of the generator set’s controller.
There are several major components in a RTS “Wn” switch: the transfer switch contactor mechanism; transfer
relay; customer connection terminal strip; F1 through F4 fuses and on 3 phase switches a phase monitor relay.
Switches that are 480 volts will have 2 transformers TR1 and TR2 to power the mechanism. The “Wn” mecha-
nisms power for actuation is 208 or 240 VAC.
The transfer mechanism houses the main current carrying contacts, the mechanical and spring switching
mechanism, the closing, trip, select coils and there rectifier circuitry, the ATS1, ATS2 control contacts (micro
switch), LS1 & LS2 limit switches, AX, BX control contacts (micro switches), and the auxiliary contacts,
all required for operating the switch. The main contacts are tripped open by a single solenoid (trip coil), are
closed by a single solenoid (closing coil) they are electrically opened and mechanically held closed. As in
our other transfer switches, power for the coils operation is taken from the side to which the load is being
transferred. Therefore, transfer to any power source cannot occur unless that power source is available to the
switch. The ATS1 & ATS2, BTS1 & BTS2, LS1, LS2 and AX & BX micro switches are mechanically actuated
by the transfer mechanism. These micro switches are key to the operation of the switch. Refer to “Table 3” on
page 169
AT2 AT1 A2 A1
ATS2 LS AX
N1 N2 N3
ATS1 COM COM
LS
NC NO
AUX
C
T1 T2 T3
TC SC COM COM
NC NO
BTS2 BTS1 BX
BT2 BT1 B2 B1 AUX E1 E2 E3
Figure 152

Chapter 10
Main Closing Coil

The coil (C) energizes utilizing rectified AC voltage to actuate the contacts from either the “Utility” or the
“Standby” position. The (C) coil can only energize to the “Standby” or “Utility” position when the CONTACTOR
is in the “Neutral” position.
Trip Coil
The Wn style CONTACTOR’S need to mechanically trip out of a given position. When the CONTACTOR is in
the “Utility” position, the ATS limit switch is in the closed position. When the TR relay energizes it allows
Generator voltage to energize the trip coil mechanically tripping the CONTACTOR to the “Neutral” position.
When the CONTACTOR is in the “Standby” position the BTS limit switch is in the closed position. When the
TR relay de-energizes it allows Utility voltage to energize the trip coil mechanically tripping the CONTACTOR to
the “Neutral position.
Select Coil
The select coil (SC) provides the electrical and mechanical connection to allow the CONTACTOR to transfer to
the “Standby” position. With the CONTACTOR in the “Neutral position” the AX and BX limit is in the closed
position. When BX is in the closed position Generator voltage will be made available to the coil when the TR
relay energizes. TR relay energized, Generator voltage energizes the SC coil and connects the LS limit switch
to Generator voltage energizing the main coil. At the same time the SC is energized it mechanically changes
the roller position of the CONTACTOR allowing it to transfer to the “Standby” position.
Note: If the SC coil never energized, the CONTACTOR will never transfer to the “Standby” position.
Utility and Standby Contacts
Figure 153 shows the UTILITY contacts in the “Utility” position supplying voltage to the load. The trip coil is
responsible for disconnecting the CONTACTOR from either the “Utility” or the “Standby” position.
Figure 153

Chapter 10
Figure 154 shows both the UTILITY contacts and the STANDBY contacts disconnected from the load. In RTS
family, the “Neutral” position is not adjustable. When the closing coil pulls the CONTACTOR to either the
“Standby” or “Utility” positions, limit switch AX and BX contacts will open. This removes the voltage feeding
the closing coil (de-energizing the coil).
Figure 154
Figure 155 shows the contactor now in the “Standby” position supplying voltage to the load.
Figure 155

Chapter 10
Bridge Rectifier
The bridge rectifier receives AC voltage from either Utility or Generator. This voltage is rectified into a use able
DC voltage that is capable of energizing the closing coil. It also acts as terminal block for incoming wires.
Figure 156
AX-BX Limit Switch
The AX-BX limit switch (Refer to Figure 157) is internal to the CONTACTOR and is located on the left side of the
CONTACTOR. Mechanically connected to the CONTRACTOR, it is only closed in the “Neutral” position. Refer
to Table 3 for limit switch positions.
ATS Limit Switch
The ATS limit switch is internal to the CONTACTOR and is located between the arc chute and the main coil.
Refer to Figure 157. Mechanically connected to the CONTACATOR, it is only closed in the “Standby” position.
Refer to Table 3 for limit switch positions.
BTS Limit Switch
The BTS limit switch is internal to the CONTACTOR and is located between the arc chute and the main coil.
Refer to Figure 157. Mechanically connected to the CONTRACTOR, it is only closed in the “Utility” position.
Refer to Table 3 for limit switch positions.
LS Limit Switch
The LS limit switch is mechanically connected to the SC. When the SC coil energizes it allows Generator volt-
age to energize the main coil and transfer to the “Standby” position.

Chapter 10
Limit Switch Positions

“Utility” “Neutral” “Standby”
ATS1 CLOSED OPEN OPEN
ATS2 CLOSED OPEN OPEN
BTS1 OPEN OPEN CLOSED
BTS2 OPEN OPEN CLOSED
AX OPEN CLOSED OPEN
BX OPEN CLOSED OPEN
Table 3
Coils
Trip Coil Select Coil Main Coil
“Utility to Standby” “1 “2 “3
Terminals AT1, AT2” B1, B2” B1, B2”
“Standby to Utility” “1 “3
Terminals” BT1, BT2” A1, A2”
Table 4

Chapter 10
Select Coil
LS1 & LS2
Trip Coil
Transfer Relay Limit Switch
Power Monitor ATS1 & ATS2
Limit Switch
Fuse Block
Closing Coil
Terminal Block AX & BX
Limit Switch BTS1 & BTS 2
Limit Switch
Figure 157

Chapter 10
Auxiliary Contacts
Auxiliary contacts are available for the contractors used on Generac Transfer Switches. These contacts can
be used to indicate switch position or they can be used to lock-out a control circuit while the switch is in the
standby position only. An example of this would be to lock-out a large air conditioner using the thermostat cir-
cuit. This would prevent it from starting any time the switch is in the standby position.
“W” and “Wn” Type
100-200 Amp
400-800 Amp
Figure 158

Chapter 10
Figure 159
“V” Type
COMMON
NORMALLY OPEN
Kit # 0E97950ESV
NORMALLY CLOSED
VIEW "A"
Figure 160

Chapter 10
Power Monitor
Figure 161
The Power Monitor (PM). The LED in the top left is the status light. The description of the status light and
what each mode represents is on a label on the side of the PM.
Figure 162
This is the status and indicator label found on the side of the PM.

Chapter 10
N1B
N1C
PM
2 1 8 7
N1C
N1A
3 4 5 6
N2A
N3
Figure 163
This shows the connections to the Power Monitor Relay. N1A & N2A are the sensing wires to the control
panel. If the PM senses low voltage on any phase, it will open pin 1 from pin 8. Its normal position is with the
switch closed between pins 1 & 2. As long as it has good voltage the relay stays energized and closes the
contact between pins 1 & 8.

bers.
Section 2 - Transfer Switches

MOUNT SOCKET & RELAY
RTSN #1 RTSN #2 RTSN #3
(SEE NOTE 2) SAME CONNECTIONS FOR
IN CONTROL PANEL. RTSN#3 THRU
(SEE NOTE 3) RTSN# XX AS NEEDED
23A
N1
N1 240 VAC
IN CONTROL PANEL. N2
N2 240 VAC
23
TB1 TRANSFER
Multiple Transfer Switches
6 5 4 3 194 or 15B
A B +12 VDC
1 0
2 WARNING
NOTE WIRE ORIENTATION
3
4 C3211G-T
11/S1 8 PIN SOCKET 23A
11 5 7 8 1 2 194A
44/S3 6 23A
7 194A
8 (SEE NOTE 2) XX = ADDITIONAL ATS
CB1 9
11 10
NB 0
E1 E3 44 11
22 12 15A 15A
ICT 33 (SEE NOTE 2)
UTILITY FROM T/SW 1 N1
UTILITY FROM T/SW 2 N2 NOTES:
TRANSFER RELAY COIL 3 23 1. NO RELAY NEEDED FOR 2 TRANSFER SWITCHES.
TRANSFER RELAY COIL 4 194 MORE THAN 2 REQUIRE A RELAY MOUNTED IN
NOT TO BE USED 5 183 N1 N1 THE GENERATOR CONTROL PANEL.
FOR THIS APPLICATION 6 178 N2 N2
7 23 23 2. WIRE 15A FROM TERMINAL 12 OF TB1 WILL
8 194 194 CHANGE TO 194A AFTER TERMINATION IN RTSN (1)
194A WILL THEN CONTINUE TO THE LAST
CUSTOMER
TRANSFER SWITCH.
CONNECTIONS
Figure 164 – R-Panel Multiple Transfer Switches

3. RELAY - GENERAC PART NO. 0C3211E
(12Vdc COIL, CONTACTS RATED 10A@ 240Vac)
ENGINE - GENERATOR RELAY SOCKET - GENERAC PART NO. 0C3211G
(8-PIN OCTAL, 300V)
Chapter 10
install more than 2 switches. Additional hardware will be required, see the notes on the drawings for part num-
with the generator and transfer switch. Refer to Figure 164 for R-panel and Figure 165 for Nexus panels to
The R-Series and Nexus controllers are limited to two transfer switches using the standard hardware provided
175
Section 2 - Transfer Switches
MOUNT SOCKET, RELAY &
5 AMP FUSE & HOLDER
IN CONTROL PANEL.
(SEE NOTE 3)
IN CONTROL PANEL. RTSN #1 RTSN #2 RTSN #3
(SEE NOTE 2) SAME CONNECTIONS FOR
RTSN#3 THRU
RTSN# XX AS NEEDED
23A
TO ALTERNATOR
12 VOLTS
194
183
178
0
23
CUSTOMER CONNECTION
DC COMMON
194
Figure 165 – Nexus Multiple Transfer Switches

+12 VDC
6 5 4 3 23
TRANSFER
CB1 N1 N2
UTILITY
SENSE
T1
LOAD
WARNING 240VAC
NOTE WIRE ORIENTATION CUSTOMER CONNECTION
N1 N2 T1 194A
E1 E3
C3211G-T
8 PIN SOCKET
N1
7 8 1 2 23A
L1
N2
194A
23A
(SEE NOTE 2) XX = ADDITIONAL ATS
23 23
194 194
0 0
15A 15A
(SEE NOTE 2)
N1 N1 N1
N2 N2 N2
T1 T1 T1
CONNECTIONS
NOTES:
ENGINE - GENERATOR 1. NO RELAY NEEDED FOR 2 TRANSFER SWITCHES.
MORE THAN 2 REQUIRE A RELAY MOUNTED IN
THE GENERATOR CONTROL PANEL.
2. WIRE 15A FROM FUSE HOLDER WILL
CHANGE TO 194A AFTER TERMINATION

IN RTSX (1) 194A WILL THEN CONTINUE
TO THE LAST TRANSFER SWITCH.
3. RELAY - GENERAC PART NO. 0C3211E
(12Vdc COIL, CONTACTS RATED 10A@ 240Vac)
RELAY SOCKET - GENERAC PART NO. 0C3211G
(8-PIN OCTAL, 300V)
FUSE ATO TYPE 5 AMP (TAN) - GENERAC PART NO. 0E7403A
FUSE HOLDER W/8" WIRE LOOP - GENERAC PART NO. 0E7402
Chapter 10
176
Chapter 10
Digital Load Management

Introduction
The 100, 200, and 400 amp single-phase RTS transfer switches have the added option of managing loads in
the event the generator becomes overloaded. The system consists of a Load Management controller (LMC),
up to 4 optional (purchased separately) Digital Load Management modules (DLM), and up to 2 air condition-
ers.
The LCM uses the frequency of the Generator to detect when an overload is occurring. The frequency is a
direct correlation to the speed of the engine. Therefore, when the engine reaches a point it can no longer
maintain rated speed, the frequency will drop, and the LCM will disconnect controlled loads.
Load Management Controller

The LMC (Figure 166) is designed around the basic principal that when frequency drops the engine in most
cases is overloaded. The LMC responds to this overload condition by removing all controlled loads from
the Generator. Refer to Table 5 for the priority designation of the particular loads. Once disconnected and
frequency has stabilized a five minute timer will begin. Once the timer has expired, the LMC will attempt to re-
initialize the loads which are connected to priority level 1. Between each priority a 30 second pause will occur
to allow loads to stabilize before the next priority is connected.
Once all four priorities have been re-initialized, the sequence is complete and the LMC will continue to monitor
for the next over load condition.
Air Conditioner DLM Modules

Priority 1 AC 1 DLM 1
Priority 2 AC 2 DLM 2
Priority 3 DLM 3
Priority 4 DLM 4
Table 5 – Priority Designations

Chapter 10
0 GROUND
194 +12V
23 TRANSFER T1
NEUTRAL
AIR 1
CONTACTOR
1
AIR 2
CONTACTOR
2
PRIORITY 1
PRIORITY 2 CONTACTOR
3
PRIORITY 3
PRIORITY 4 CONTACTOR
4
Figure 166
Sequence Of Operation
The 4 green status LEDs will indicate when a load priority level is enabled.
●● All loads are enabled when the transfer signal (Wire 23) is not grounded.
●● If the transfer signal is pulled low (Active)
●● All loads are enabled until an overload is detected
●● When an overload is detected all loads are removed
●● After 5 minutes priority 1 loads are enabled.
●● After another 30 seconds priority 2 loads are enabled
If an overload is detected within 30 seconds of a level being enabled, all loads are disabled again and the
sequence repeats. However, the level that caused the overload and all levels higher will not be enabled again
for 30 minutes.

Chapter 10
Digital Load Module

Introduction
The Digital Load Module (DLM) is used to control or turn on and off a load under the control of the Load Shed
Controller (LSC) in the transfer switch.
The DLM consists of a 2-pole normally open relay mounted in an enclosure. The 2-pole contactor is rated to
control:
●● Current Rating
–– 55 amps resistive
–– 40 amps inductive
●● Voltage – 600 VAC
●● Motor Rating – 3 HP @ 240 VAC
●● Lock Rotor Amperage – 240 Amps @ 240 VAC
●● Coil Voltage – 120 VAC (.06A holding current)
Figure 167 – Digital Load Management Module
A UL type 3R enclosure primarily provides a degree of protection against falling rain and sleet and is
undamaged by the formation of ice on the enclosure. It is suitable for mounting indoors or outdoors.
The DLM module is UL listed as industrial control equipment, to U.S. and Canadian safety standards.
2-Pole Contactor
Conductor sizes must be adequate to handle the maximum current to which they will be subjected to, based
on the 75°C column of tables, charts, etc. used to size conductors. The installation must comply fully with all
applicable codes, standards and regulations.

Chapter 10
Load Connections
Ground Stud Terminals T1 & T2
} }
Line Connections
Contactor Control
Terminals L1 & L2 Connections
Figure 168 – Line Load Control Connections

Chapter 10

1. What is the purpose of Wire 194?
2. What is the Return to Utility delay timer on the RTS switch?
3. What is the purpose of the Power Monitor?
4. What are the trip and select coils used for on the “WN” style switch?
5. If Wire 23 is shorted to ground, what will the generator and transfer switch do upon the return of utility?

Chapter 10
References
Generac Power Systems, RTS “HS” Style Transfer Switch Technical Manual, PN 0G0399
0G4338
Generac Power Systems, Commercial Study Guide Supplement, PN 0E2223

Chapter 10

184
11 HTS Series Transfer Switches
Keywords
●● “W” Type
●● Communications
●● System Ready
●● Remote Start
Contents
Chapter 11 - HTS Series Transfer Switches......... 185
HTS Transfer Switch............................................... 186
Remote Start....................................................... 192
Sequence of Operation......................................... 194
Troubleshooting Tips............................................... 200
References.............................................................. 201
185
Chapter 11
HTS Series Transfer Switches
HTS Transfer Switch

The Generac “HTS” “W” style automatic transfer switch is used in commercial and industrial applications. It
is available in the same ranges and ratings as the GTS switch. HTS “W” and “Wn” style switches are open
transition switches, able to perform either an in-phase transfer (between two live sources) or a Time Delay
Neutral transfer. It is designed to operate with a Power Manager G or H series of generator controller. It uses
a 2-wire, RS-485 communication link to the generator controller. Operation of the switch is instigated by the
H or G control panel, however, all aspects of the time delay neutral timing and in-phase transfer are handled
locally by the HTS control board. The indicators and switches on the front of the switch panel provide status
indication; System Ready; Switch Position; Standby Operating and Utility Available. The switches provide for
Test, Fast Test, Return to Normal, and Reset.
Utility voltage is monitored by the HTS and fed back to the engine control panel for comparison against set
points used to determine if the Utility voltage is “good”. All timers and set points are programmable in the
Power Manager controller through the use of GenLink DCP. GenLink DCP is covered in a separate section of
this study guide.
Some of the operational decisions are made by the HTS control itself, so the appropriate parameters are
passed on to the HTS via the communications link. If the communication link were to break, the HTS will
still function. It will monitor the Utility and Generator voltages and make the transfer determination itself,
rather than being commanded by the generator control panel. It will either use the last parameters sent, or
(if communications were never established), it will take its settings from onboard DIP switches and a set of
resident parameters.
The HTS acts as a Modbus slave on the RS-485 communication network. For the “H” series of control panels,
Communication Port 1 is used for the RS-485 connection. The base Modbus address for the switch is set for
240 but can be modified using dip switches. Up to 4 HTS switches can be addressed in the communication
network. The baudrate of the switch can also be modified, if the version of software in the switch controller is
1.08 or higher. The available baud rates are 4800 (base), 9600, 38400, and 57600. The baudrate is selected
through the dip switches. The HTS switch will only work as a Modbus slave, No Parity and 2 Stop Bits.
The Power Manager controller (H or G) comes factory set as:

●● Modbus Master Port
●● 4800 Baud
●● No Parity, 2 Stop Bits
These settings can be changed through GenLink DCP.

Chapter 11
The basic components found in the HTS switch include:

●● Transfer switch contactor mechanism, the same “W” or “Wn” contactor mechanism used in the RTS
switches.
●● HTS control board
●● Transformer board (power supply for the control and TR and TD relays
●● Relay board (Transfer, Time Delay, Signal Before Transfer)
●● Switches and transformers
The transfer switch mechanism, “W” or “Wn” type, is the same mechanism used in the RTS switch. It
operates exactly the same way.
The HTS control board carries out the commands issued from the generator controller, but does perform
the time delay neutral and inphase transfer functions of the switch on its own. Its on-board dip switches
are read once only at power up. If the communications with the H panel are working, it will override the dip
switch settings. This way there are no conflicts and the transfer switch will use the latest settings even if
communications fail. The dip switches set the following default parameters:
●● Voltage Codes
●● Single or Three-phase
●● TDN or In-Phase transfer
●● Switch type – CTTS or OTTS
●● Modbus address – default is switch 1, address 240. Up to 4 switches can be used with an H panel
●● 60 or 50 Hz application
●● Baudrate for communications
These dips come preset from the factory for the switch they are installed in. If the board needs to be replaced,
set the dips per the directions given in the Owner’s Manual. You can use the label mounted on the cover or on
the inside of the door, but we recommend you use the Owner’s Manual settings.
The cover of the HTS control holds three AAA rechargeable NiMh batteries. The spade connector on the cover
of the switch must be connected for the batteries to charge. The batteries connect to the control PCB through
an adapter. The adapter slides onto two pins that stick out of the PCB. The latch of the connector should face
the back of the switch for proper polarity. These batteries only provide power for communications with the H
control panel when utility voltage and generator voltage is not available. They are charged by a charge circuit
on the PCB, with a RED LED light which indicates when the batteries are actively charging.

Chapter 11
J1 Connector
Battery
Connector
DIP Diagram
J2 Connector
Figure 169
The HTS control board mounted inside the switch enclosure. The Battery connector must be connected when
the switch is powered up from utility. The batteries take approximately 12 hours to fully charge.

Chapter 11
Battery Charge Battery Adapter &

DIP Switches LED Connector
Figure 170
The HTS control PCB with the cover removed. There is a ribbon cable in the top left portion of the board
which fits in a slot in the cover. It is important to get the cable in the slot to prevent damage to the cable. The
ribbon cable connects the switch to the indicators and switches on the front of the switch door.
The batteries connect to the board through the adapter and connector. The connection is polarity sensitive;
make sure the latch faces the back of the switch. The battery charge LED will be ‘ON’ when the batteries are
charging.

Chapter 11
Figure 171
The Transformer board provides DC power to the control PCB and to the relay board. The board has two
transformers, one for utility and one for generator, and a rectifier circuit for each to provide nominal 12VDC
over Wire 194 to the control PCB and the relay board. There are two different transformer boards: 0F4410A
and 0F4410B. The 0F4410A is used when the phase voltage of the switch is 240 or 480. The 0F4410B is
used on the 208 volt switches. The 208 transformers are banded with Black and Red Tape, and the 240 volt
transformers are banded with Blue and Red tape. When troubleshooting this board, check the DC output
voltage when each of the supply sources are providing power, independent of the other. The DC output voltage
should be approximately 12 - 14VDC. The transfer and time delay relays need at least 10VDC to actuate.

Chapter 11
There is a simple check to determine if there is a problem with either the Transformer Board or the Control
PCB. You must make the check with Utility voltage only and again with Generator voltage only present. You
will be checking the DC output voltage from the transformer board to the control PCB.
+ + -
DC Output Terminals
Figure 172
1. With the batteries in the PCB cover connected, and Utility or Generator voltage available, measure the
output voltage (DC) at the DC out terminals on the transformer board. The far right terminal is the
negative and the next two to the left are DC voltage +. With the batteries connected and either Utility
or Generator AC voltage present the DC output voltage should be approximately 12 to 15 VDC.
2. Disconnect the batteries from the control PCB and check the transformer DC output voltage again.
It should rise to 14 to 17 VDC. If it is less than 14VDC it could indicate a problem with the PCB.
Perform the next check.
3. With the batteries disconnected, disconnect the J1 connector at the TOP of the control PCB. Measure
the DC output voltage again from the transformer board. It should be approximately 17VDC.

Chapter 11
Figure 173 – Relay Board without Two Wire Start option
Figure 174 – Relay Board with Two Wire Start option
The Relay board holds the Transfer Relay (TR), Time Delay relay (TD) and the Signal-Before-Transfer relay
(SBT). These relays get their power from the transformer board and require at least 10VDC to operate.
Remote Start
The HTS switches are standard with a remote start option that provides a back up when loss of communica-
tions is present. This standard was implemented in May of 2011. For switches that were manufactured prior,
a retro kit is available for purchase.
100 - 400 Amp Switches 0H64300SRV
600-2600 Amp Switches 0H64320SRV

Chapter 11
Figure 175
This image shows the switches and indicators mounted on the door of the switch.
●● System Ready LED. This LED serves two functions: It indicates solid green when the system is ready
– this means that the generator control is in the “AUTO” position and the HTS maintenance disconnect
switch is in the “AUTO” position. If the system communications are “bad” for any reason the LED will
flash. That means if communication with the switch is not enabled, or the wires are not connected
properly, or the communication baud rate, parity and stop bits do not match the control.
●● Utility Available LED. This LED indicates that utility voltage is present but does not indicate that it is
within the tolerances set by the H panel. It does indicate that utility voltage is within 70-130% of nomi-
nal.
●● Standby Operating LED. This LED will light when the generator is running. Running means that the
generator frequency is between 20 and 80 Hz. This LED will flash, along the Utility Available LED to
indicate a “fail to synch” condition.
●● Switch Position LEDs. The switch position is monitored by two auxiliary contacts mounted on the
side of the switch mechanism. These LEDs display the position of the Main contacts. If there is a
transfer switch error (fail to close or open) these LEDs will both flash.
●● Test button. The Test switch will only operate if the communications link is active (good), and the gen-
erator is not running. Pressing the switch will cause the generator controller to start the generator and
command a transfer to standby using all the pre-programmed timers and settings. The unit will trans-
fer back to utility when the switch is pressed again and the “Return to Utility” timer expires.
●● Fast Test button. The Fast Test button will only operate if the communications link is active. Pressing
this button will cause the H panel to command a transfer to standby using all the standard settings,
but with the timers reduced to 1 second. Two timers will not be affected – Signal Before Transfer and
Time Delay neutral. The unit will initiate a transfer back to utility after 5 seconds of the transfer mecha-
nism in the Standby position.
●● Return to Normal button. This switch will abort the Return to Utility timer and cause the system to
return to the Utility position, if the Utility source is good. It will not operate if the communications link
is bad.
The sequence of operation for the HTS switch is as follows. This sequence can be found in the HTS “W” Type
Transfer Switch Owner’s Manual.

Chapter 11
When acceptable Utility source voltage is available, the Maintenance Disconnect switch is in AUTO, the
communication link to the generator is good, and the Generator controller is in AUTO, observe the following:
●● Utility Available LED, on front of door, is ON.
●● Utility Switch Position LED, on front of door, is ON.
●● System Ready LED, on front of door, is ON.
Sequence of Operation
SEQUENCE 1 - UTILITY VOLTAGE DROPOUT
●● Utility Voltage goes outside of the value set in the generator control panel (range is 5-25 Vrms of nomi-
nal voltage, factory default setting is +/- 25 Vrms). If the communication link is not good the ATS con-
troller will take control and the range is 70 to 130% of the nominal voltage selected with a 5 second
utility loss timer and a 30 second utility return timer.
●● Voltage dropout triggers sequence 2.
SEQUENCE 2 - LINE INTERRUPT DELAY

●● Line interrupt Delay can be set between 0 and 60 seconds. Factory default setting is 2 seconds.
●● If voltage dropout lasts longer than the Line Interrupt Delay setting, the generator start sequence will
start.
●● Once the Generator voltage reaches Load Accept Voltage and Load Accept Frequency this will trigger
Sequence 3.
SEQUENCE 3 - ENGINE MINIMUM RUN AND ENGINE WARM UP TIMERS

●● Engine Minimum Run timer starts. The Engine Minimum Run timer can be set from 5 to 30 minutes.
Factory default setting is 5 minutes.
●● Engine Warm up timer starts. The Engine Warm up timer can be set from 0 to 1,200 seconds. Factory
default setting varies depending on the engine used.
●● Standby Operating LED, on front of door, is ON.
●● The expiration of the Engine Warm up timer triggers sequence 4.
SEQUENCE 4 - SIGNAL BEFORE TRANSFER

●● Signal Before Transfer timer does not operate in a Utility Fail sequence.
●● Sequence 5 starts immediately.

Chapter 11
SEQUENCE 5 - ATS TRANSFER TO GENERATOR POSITION

●● ATS transfer mechanism operates to connect the Customer Load to the Generator supply. Customer
Load will be supplied from the Generator until sequence 6 is initiated.
●● Generator Switch Position LED, on front of door, is ON.
SEQUENCE 6 - UTILITY VOLTAGE PICKUP

●● The ATS controller continues to monitor the Utility source voltage. When the Utility voltage is above the
voltage dropout setting plus the Hysteresis value, sequence 7 will be initiated.
SEQUENCE 7 - RETURN TO UTILITY TIMER

●● Return to Utility timer starts. The Utility source voltage must stay above the pickup level. If the Utility
voltage falls below the pickup value, the Return to Utility timer is reset. The Return to Utility timer can
be set from 1 to 30 minutes. Factory default setting is 1 minute.
●● The expiration of the Return to Utility timer triggers sequence 8.
SEQUENCE 8 - SIGNAL BEFORE TRANSFER

●● Signal Before Transfer timer starts. The Signal Before Transfer relay is energized for the duration of the
timer. The Signal Before Transfer timer can be set from 0 to 30 seconds. Factory default setting is 2
seconds.
●● The expiration of the Signal Before Transfer timer triggers sequence 9.
SEQUENCE 9 - ATS TRANSFER TO UTILITY POSITION

●● ATS transfer mechanism operates to connect the Customer Load to the Utility supply. Customer Load
will be supplied from the Utility.
●● The connection of the Customer Load to the Utility source triggers sequence 10.
●● Utility Switch Position LED, on front of door, is ON.
SEQUENCE 10 - ENGINE COOLDOWN TIMER

●● Engine Cooldown timer starts The Engine Cooldown timer can be set from 0 to 1,200 seconds.
Factory default setting varies depending on the engine used.
●● The engine generator will shutdown when the Engine Cooldown timer and the Engine Minimum Run
timer expires.
NOTE: At the conclusion of sequence 10 the system is armed and ready for the next Utility failure or
exercise sequence.

Chapter 11
All of the switch parameters are programmable through the use of GenLink DCP.
Figure 176
This is the Transfer Switch Configuration menu, accessible using Genlink DCP.
Summary of Parameters for the HTS switch Configuration Menu
Parameter Range Default value

Utility voltage deviation 24-120Vrms +/- 25Vrms
Utility voltage Hysteresis 4-48Vrms 12Vrms
Line Interrupt Delay 0 – 60 seconds 2 seconds
Load Accept Voltage 85 – 95% of nominal 90% of nominal
Load Accept Frequency 85 – 95% of nominal 90% of nominal
Engine Warm up timer 0 – 1200 seconds Engine dependant
Minimum Run timer 5 – 30 minutes 5 minutes
Signal Before Transfer timer 0 – 30 seconds 2 seconds
Time Delay Neutral timer 0 – 10 seconds 2 seconds
Return to Utility timer 1 – 30 minutes 1 minute
Engine Cooldown timer 1 – 30 minutes Engine Dependent
Table 6

Chapter 11
Figure 177
The Menu item shown above; Remote start will operate the following switches; will cause each switch with
this choice enabled to transfer when any 2-wire start closes. This would be a way to transfer switches served
by one generator but two separate utility sources to transfer if any of them lost utility.
To access the HTS configuration menu you must be connected to the H-panel with Genlink DCP and the panel
must be communicating with the switch (switch enabled). See the sections of the study guide that cover
connecting with Genlink DCP. The switch can be connected using the Transfer Switch Configuration menu in
Genlink DCP. Once the switch is connected the settings can be adjusted to meet the customer requirements.
It is important to calibrate the switch so that it sees accurate Utility and Generator voltages. This is easily
done by having both Utility and Generator power available (generator running); check the voltage at the
switch for both Utility (N1-N2) and Generator (E1-E2) and make the switch display in the Transfer Switch
Configuration menu match the actual voltage at the switch. Use the + and – buttons to do this. If you do not
calibrate the switch it will not perform an In-phase transfer.
Figure 178

Chapter 11
Use the Transfer Status display screen in Genlink DCP to check the status of the HTS switch. If
communication with the switch is enabled you will be able to see the Software Version of the switch in the
upper left corner of the display.
Figure 179
The display is divided into four parts. The upper left corner is the Utility status. The upper right corner is
the Generator status. The middle section is a graphic showing the status of the switch contacts – whether
connected to utility or generator. The bottom section is the switch and transfer status. You can select which
switch to look at with the Switch Number box in the lower left corner. Up to four HTS switches can be
connected to an H-Panel.

Chapter 11
Figure 180
If the switch faults the Transfer Status screen will display the fault. In the above screen it indicates Transfer
Switch Error (fault). The H-panel will also display the same Alarm in its display and in the Alarms menu of
Genlink DCP. The switch would also display this fault by flashing the two switch connected LEDs at the same
time. This indicates that the switch could not complete the transfer for some reason.

Chapter 11
Troubleshooting Tips
●● Make sure the switch and the generator are both in the “AUTO” position and the generator MLCB is
closed. Make sure the communication wires (RS-485) are properly connected and the shield ground-
ed on ONLY ONE END. Make sure the generator is running and there is full phase voltage at E1, E2,
and E3 at the transfer switch. The System Ready Green LED on the HTS control panel should be on
steady.
●● If the System Ready LED is flashing it means there is no communications with the H-Panel. Use the
H-Panel Diagnostic Display (page 6) to check the status of the RS-485 communication port (Port 1).
It should read “Mbus Mstr/RS-485 4800/8/2/None”. If it is a Master and the “8/2/None”, you can set
the HTS DIP switch to match the Baudrate. If it is not a Master “8/2/None” you will need GenLink DCP
to change the H-panel to the correct setting.
●● If the System Ready LED is flashing, and you have more than one HTS switch on the communication
wire, make sure that each switch has its own Modbus address set with the DIP switch. Don’t forget to
re-power the control when you make a DIP switch change.
●● If the switch fails to transfer to Standby, and the two Switch Position LEDs are flashing, it indicates
a switch fault. Check for phase to phase voltage (approximately 240VAC) at the B1 & B2 terminals.
If there is phase to phase voltage at B1 & B2, and the switch has not transferred to emergency, the
problem is with the switch mechanism; the limit switches, bridge rectifier circuit board, closing coil,
internal wiring, etc. If there is not phase to phase voltage at B1 & B2, then the problem is with the TR
relay, the HTS controller, or the wiring in between. One thing that will prevent a transfer is not enough
DC voltage on Wire 194. Verify that the transformer board is putting greater than 10VDC on both 194
Wires.
●● If the switch fails to transfer between two live sources (Utility & Emergency) and the Standby and
Utility available LEDs are flashing, it indicates that the inphase transfer failed (a fail to synch condition).
If it is a startup, verify that the phases between the Utility and Generator match. If they match, the fre-
quency of Utility and Generator may match exactly and no phase shift is occurring. In this case use
the De-synch offset function in the Generator controller (Governor Configuration) and set it for +0.1
Hz. You will need GenLink DCP to do this. It is also a good idea to select “TDN if fail to transfer” in the
Transfer Switch Configuration menu (using GenLink DCP). The configuration menus will be covered in
the H panel section of this study guide.

Chapter 11

1. What type of wire do we use for communications on the HTS?
2. What type of batteries must be installed in the HTS communications board?
3. What is the purpose of the transformer board in the HTS transfer switch?
4. How do you set up the parameters of an HTS transfer switch?
References
Generac Power Systems, RTS “HS” Style Transfer Switch Technical Manual, PN 0G0399
0G4338

202
12 R-Series Control Panels
Keywords
●● Crank Relay
●● Run Relay
●● Overcrank
●● Overspeed
●● Sensing Transformer
●● Battery Charger
Contents
Chapter 12 - R-Series Control Panels.................. 203 Inputs and Outputs.............................................. 221
Introduction............................................................. 204 Inputs............................................................. 221
Components............................................................ 204 Analog Inputs.................................................. 224
Component ID..................................................... 207 Outputs........................................................... 226
Configuration Settings.......................................... 209 Battery Chargers.................................................. 227
R-100 Fault Condition Table............................ 209 2 Amp Battery Charger.................................... 227
R-200 Fault Condition Table............................ 210 10 Amp Battery Charger.................................. 228
R-200A Fault Condition Table.......................... 211  Check Your Knowledge....................................... 229
R-200B Fault Condition Table.......................... 212 References.............................................................. 230
R-200C Fault Condition Table.......................... 213
R-100 Digital Controller .................................. 214
R-200 Digital Controller .................................. 215
R-200A Digital Controller ............................... 216
R-200B Digital Controller................................ 217
R-200C Digital Controller................................ 218
203
Chapter 12
Generac R-Series Digital Control Panels
Introduction
The R series Digital Control Panels were used in Generac gaseous liquid cooled product for several years.
They replaced what had previously been referred to as the “Pre-Pack” controls used on the liquid cooled
commercial product. There are 5 versions of the R-control panel in the field: R-100, R-200, R-200A, R-200B
& R-200C. All perform the same basic functions of monitoring utility voltage, engine startup, transfer to
standby, re-transfer back to utility, engine shutdown, weekly exercise, and generator protection (overcrank,
overspeed, low coolant level, hi coolant temperature, low oil pressure, low battery voltage, and low fuel
pressure). The differences in the panels will be seen as we look at each individual control.
All of the R-panels use the same LED indicators, alarms and warnings.
• System Ready Green LED
• Low Fuel Pressure Yellow LED
• Low Battery Red LED
• Low Oil Pressure Red LED
• Hi Coolant Tem/Low Coolant Level Red LED
• Over Speed/RPM Sensor Loss Red LED
• Over Crank Red LED
OVERCRANK
OVERSPEED
LOW COOLANT LEVEL
HI COOLANT TEMPERATURE
LOW OIL PRESSURE
LOW BATTERY
LOW FUEL PRESSURE
SYSTEM READY
Figure 181
Components
The R-panel controller monitors the front panel switch position and reads the DIP switch position settings
when the control board is initially powered up.
Switch OFF
With the switch in the OFF position, the controller exercise timer will be keeping time and the controller will
also be monitoring the battery voltage and low fuel pressure sensor.
Switch in MANUAL
With the switch in the manual position the controller will start and run the generator.
Switch in AUTO
In the AUTO position the controller will go into a “standby” mode and monitor the utility voltage and the
exercise timer, and determine if the generator needs to be started and the load transferred.
204 Section 3 - Digital Control Panels

Chapter 12
AUTO-OFF-MANUAL
Switch Exerciser
Fault Indicator Switch
LED’s
Figure 182 – Front of R-Panel controller.
Figure 183 – Printed Circuit Board
Looking inside the door of the controller showing the control PCB, the J1
connector (on the left), and the J2 connector (on the right).
Section 3 - Digital Control Panels 205

Chapter 12
Figure 184 – Inside the R-panel enclosure of a QT020 with the 1.6L engine.
Figure 185 – Inside the R-Panel enclosure of a QT045 with the 4.2L engine.

Chapter 12
Component ID
A
G
B
C E
D
F
Figure 186
Identify the components labeled above:

A.

B.

C.

D.

E.

F.

G.


Chapter 12
While starting and running the generator the controller will monitor the engine condition and shut the engine
down on:
• Over Crank
• Over Speed
• High Coolant Temperature
• Low Coolant Level
• Low Oil Pressure
• Engine Speed Signal Loss/RPM Sensor Loss
• Dead Battery
• Ignition Module Fault (R-200B)
Unit Shutdown Alarms are latched shutdown alarms. If one of the shutdown conditions occur, the unit will
shutdown, the appropriate LED will illuminate, and the unit will not start again without manual intervention.
The cause of the shutdown will need to be investigated and corrected, and the switch will need to be moved to
the OFF position to clear the shutdown alarm.
The following are the timer settings for the R-panel in the Automatic mode of operation. All of these timer
values can be found in the respective R-panel Technical Manual.
Switch in AUTO
• Utility Voltage Dropout - below 60% percent of nominal
• Utility interrupt timer - 15 seconds
• Engine Warm up timer - 10 seconds
• Utility Voltage Pickup - above 80 percent of nominal
• Return to Utility Delay - 15 seconds
• Engine Cool down timer - 1 minute(s)
The following are the Crank Cycle settings for the R-Panel.
• Initial crank cycle - 15 seconds
• Crank Rest - 7 seconds
• 5 additional crank cycles of - 7 seconds
• Crank rest between cycles - 7 seconds

Chapter 12
Configuration Settings
The following fault tables are taken from each of the R-panel Technical Manuals (R-100, R-200, R-200A,
R-200B, and R-200C). These show the various faults and alarms that will display on the control panel LEDs.
R-100 Fault Condition Table

Switch Position
Condition System Low Low Low High Over Over Manual Auto Off
Ready Fuel Bat Oil Temp Speed Crank
Generator Switch is OFF @ X OFF OFF OFF OFF O

in the OFF Mode
System Ready for ON @ X OFF OFF OFF OFF O

Automatic Start

in the MANUAL Mode
Weekly Exerciser X @ Flashing Flashing Flashing Flashing Flashing O O O

is not Set (Note A) (---------------------------------------1 sec rate -------------------------------------)
Battery Voltage <12.2V X @ ON O O O

for > 1 minute (Non-Latching)
Battery Voltage <6V OFF @ ON O O

For > 0.05 seconds
Unit Shutdown due OFF @ X ON O O

To Low Oil Pressure
Unit Shutdown due

To High Temperature OFF @ X ON O O
or Low Coolan.t Level

To Engine Overspeed
Unit Failed to Start OFF @ X ON O O

During it's Crank Cycle
Utility Voltage is Flashing @ X O O

< 60% of Nominal 1 sec rate
Engine Speed Signal OFF @ X Flashing O O

Fault/RPM Signal Loss
Control Board is Flashing @ X O O O

In GTS Mode 5 sec ON, 1 sec OFF
DIP Switch #6 is OFF @ ON ON ON ON ON O O O

not set correctly
@ = Low Fuel Pressure is a Yellow LED and will be ON when fuel pressure is less than 5 inches Water Column
X = indicates that the LED can be ON or OFF depending on the Operating Mode (i.e. Manual, OFF or Auto)
Note A: a RED LED fault indication has priority over the flashing LED's used to indicate exercise time not set
Table 7

Chapter 12
R-200 Fault Condition Table

Switch Position

in the OFF Mode

Automatic Start

in the MANUAL Mode



For > 0.05 seconds

To Low Oil Pressure

To High Cooant Temp

To Engine Overspeed


Unit Shutdown due OFF @ X Flashing O O

To Low Coolant Level


Table 8

Chapter 12
R-200A Fault Condition Table

Switch Position

in the OFF Mode

Automatic Start

in the MANUAL Mode



For > 0.05 seconds

To Low Oil Pressure

To High Cooant Temp

To Engine Overspeed





DIP Switch #5 is OFF @ ON ON ON ON ON O O O

not set correctly
Table 9

Chapter 12
R-200B Fault Condition Table

Switch Position

in the OFF Mode

Automatic Start

in the MANUAL Mode



To Low Oil Pressure

To High Coolant Temp

To Engine Overspeed




Unit Shutdown due to OFF @ X Flashing O O

Ignition Module Fault

DIP Switch #6 & #7 OFF @ ON ON ON ON ON O O O

not set correctly
Table 10

Chapter 12
R-200C Fault Condition Table
Switch Position

in the OFF Mode

Automatic Start

in the MANUAL Mode



To Low Oil Pressure

To High Coolant Temp

To Engine Overspeed



Engine Speed Signal Fault OFF @ X Flashing O O

Flywheel/RPM Signal Loss (slow)
Engine Speed Signal Fault OFF @ X Flashing O O

Cam/RPM Signal Loss (fast)

Table 11

Chapter 12
The differences in the various R-panel controls have to do with frequency, governor drivers, engine RPM,
and the ignition timing and the use of an external Ignition Control Module for the different engines used. It
is CRITICAL that the DIP settings for each unit and its application are correct before powering the panel up.
The DIP switch settings are read only at startup, and, once read, the panel will follow that configuration. If
you make changes to the DIP switches, the simplest way to reset the panel is to press the Exercise switch
for approximately 5 seconds – or, you can pull the F2 fuse in the bottom left corner of the control panel.
Remember to reference the correct Technical Manual for the panel you are working on for the proper settings
of the DIPS.
R-100 Digital Controller
The R-100 controller incorporates the Generator control circuitry, the ignition coil driver circuitry (timing), the
stepper motor governor driver circuitry, and the interface circuitry to an external digital governor driver (for the
Bosch throttle body actuator). It uses a waste spark ignition system for 4 or 6 cylinder engines. The following
table shows the various configurations for the generators with the R-100 controller.
Engine DPE 23-pin

Rated Rated Field Boost Control
Size L, C/B Frequency RPM connector
kW Voltage Resistor PCB P/N
(cyls) (Amps) color
1.5 (4) 20 208 5.5 25 50/60 3600 0F4245F Blue
1.5 (4) 20 240 4 25 50/60 3600 0F4245F Blue
2.5 (4) 25 208 7 15 50/60 1800 0F4245E Black
2.5 (4) 25 240 5.5 15 50/60 1800 0F4245E Black
3.0 (6) 30 Any 7 15 50/60 1800 0F4245E Black
3.0 (6) 50 Any 7 15 50/60 3600 0F4245F Blue
3.9 (6) 40 Any 7 15 50/60 1800 0F4245E Black
3.9 (6) 70 Any 7 15 50/60 3600 0F4245F Blue
Table 12
The control board DIP switch settings and their explanations are listed in the R-100 Technical Manual (PN
0F6402).
Switch OFF Switch ON
Position 1 50 Hz 60 Hz
Position 2 ATS Mode GTS Mode
Position 3 Low Speed Exercise Normal Speed Exercise
Position 4 LP Vapor Fuel (LP) Natural Gas Fuel (NG)
Position 5 1.5L or 3.9L Engine 2.5L or 3.0L Engine
Position 6 6 Cylinder Engine 4 Cylinder Engine
Position 7 CCW Stepper Rotation CW Stepper Rotation
Position 8 Reserved Reserved
Table 13

Chapter 12
R-200 Digital Controller

The R-200 controller incorporates the Generator control circuitry, the ignition coil driver circuitry (timing), and
the interface circuitry to an external digital governor driver (for the Bosch throttle body actuator). It uses a
waste spark ignition system for 4 or 6 cylinder engines. The following table shows the various configurations
for the generators with the R-200 controller.
DPE Field 23-pin

Engine Size L, Rated Control
Rated kW C/B Boost Frequency RPM connector
(cyls) Voltage PCB P/N
(Amps) Resistor color
2.4 (Hy) (4) 35 or 45 Any 7 15 60 3600 0F8710B White
3.0 (Dura) (6) 60 Any 7 15 60 3600 0F8710B White
Table 14
The control board DIP switch settings and their explanations are listed in the R-200 Technical Manual (PN
0F9784).

Position 1 50 Hz 60 Hz
(“HS” transfer switch) (“W” transfer switch)
Position 5 1.5L or 3.9L Engine 2.5L or 3.0L Engine
Position 6 6 Cylinder Engine 4 Cylinder Engine
Position 7 CCW Stepper Rotation CW Stepper Rotation
Table 15

Chapter 12
R-200A Digital Controller

The R-200A controller incorporates the Generator control circuitry, the ignition coil driver circuitry (timing),
and the interface circuitry to an external digital governor driver (for the Bosch throttle body actuator). It uses
a waste spark ignition system for 4 or 6 cylinder engines, or an external Ignition Control Module on select 2.4
and 4.2 liter engines. The ignition control module provides independent spark ignition coil drive for each cyl-
inder of the engine. The following table shows the various configurations for the generators with the R-200A
controller.
Engine DPE Field 23-pin

Rated Rated Control
Size L, C/B Boost Frequency RPM connector
kW Voltage PCB P/N
(cyls) (Amps) Resistor color
1.6 18 Any 3 15 60 1800 0G3958C Gray
1.6 20 Any 4 15 60 3600 0G3958D White
1.6 25 Any 4 15 60 3600 0G3958D White
1.6 30 1-ph 240 4.5 15 60 3600 0G3958D White
1.6 30 3-ph Any 5.5 15 60 3600 0G3958D White
2.4 (Mit) 25 Any 7 15 60 1800 0G3958C Gray
2.4 (Mit) 35 Any 5 15 60 3600 0G3958D White
4.2 35 1-ph 240 5.5 15 60 1800 0G3958C Gray
4.2 35 3-ph Any 7 15 60 1800 0G3958C Gray
Table 16
The control board DIP switch settings and their explanations are listed in the R-200A Technical Manual (PN
0G1369)

Position 5 2.4L 1.6L
Position 6 45kW (2.4L, 3600 rpm 35kW (2.4L, 3600 rpm and
and 4.2L, 1800 rpm) 4.2L, 1800 rpm)
Position 7 1.6L, 2.4L 4.2L
Table 17

Chapter 12
R-200B Digital Controller

The R-200B controller incorporates the Generator control circuitry and the interface circuitry to an external
digital governor driver (for the Bosch throttle body actuator). It uses an external Ignition Control Module on
the 2.4 and 4.2 liter engines. The ignition control module provides independent spark ignition coil drive for
each cylinder of the engine. The following table shows the various configurations for the generators with the
R-200B controller.
Engine DPE 23-pin

Rated Rated Field Boost Control
Size L, C/B Frequency RPM connector
kW Voltage Resistor PCB P/N
(cyls) (Amps) color
2.4 (Mit) 45 Any 5 15 50/60 3600 0G8455B White
2.4 (Mit) 22 1-ph 3 15 50/60 1800 0G8455A Gray
2.4 (Mit) 22 3-ph 6 15 50/60 1800 0G8455A Gray
2.4 (Mit) 27 1-ph 3 15 50/60 1800 0G8455A Gray
2.4 (Mit) 27 3-ph 6 15 50/60 1800 0G8455A Gray
2.4 (Mit) 36 Any 7 15 50/60 1800 0G8455A Gray
2.4 (Mit) 60 Any 7 15 50/60 3600 0G8455B White
4.2 45 (48) 1-ph 5.5 15 50/60 1800 0G8455A Gray
4.2 45 (48) 3-ph any 7 15 50/60 1800 0G8455A Gray
Table 18
The control board DIP switch settings and their explanations are listed in the R-200B Technical Manual (PN
0G9375).

Position 1 60 Hz 50 Hz (where applicable)
Position 4 LP Vapor Fuel Natural Gas Fuel
Position 6 22/27kW (1800 rpm) 36kW Turbo (1800 rpm)
45kW (3600 rpm) 60kW Turbo (3600 rpm)
Position 7 2.4L (1800 rpm) 4.2L (1800 rpm)
Table 19

Chapter 12
R-200C Digital Controller

The R-200C controller incorporates the Generator control circuitry and the interface circuitry to an external
digital governor driver (for the Bosch throttle body actuator). It uses an internal 4 channel Ignition Control
circuit on the current 2.4 liter engines. The following table shows the various configurations for the generators
with the R-200C controller.
Engine DPE Field 23-pin

Rated Rated Control
Size L, C/B Boost Frequency RPM connector
kW Voltage PCB P/N
(cyls) (Amps) Resistor color
2.4 (Mit) 45 Any 5 15 50/60 3600 0H1176B White
2.4 (Mit) 22 1-ph 3 15 50/60 1800 0H1176A Gray
2.4 (Mit) 22 3-ph 6 15 50/60 1800 0H1176A Gray
2.4 (Mit) 27 1-ph 3 15 50/60 1800 0H1176A Gray
2.4 (Mit) 27 3-ph 6 15 50/60 1800 0H1176A Gray
2.4 (Mit) 36 Any 7 15 50/60 1800 0H1176A Gray
2.4 (Mit) 60 Any 7 15 50/60 3600 0H1176B White
Table 20
The control board DIP switch settings and their explanations are listed in the R-200C Technical Manual (PN
0H1374).
Position 1 60 Hz 50 Hz (where applicable)
Position 4 LP Vapor Fuel Natural Gas Fuel
Position 6 22/27kW (1800 rpm) 36kW Turbo (1800 rpm)
45kW (3600 rpm) 60kW Turbo (3600 rpm)
Table 21

Chapter 12
Figure 187 – Typical R-200A Control PCB
Figure 188 – Typical R-200B Control PCB

Chapter 12
Figure 189 – Typical R-200C Control PCB

Chapter 12
Inputs and Outputs

The R-control panel has several input and output functions that it uses to interface with the engine, generator
and transfer switch. Some of these are control inputs, digital inputs, analog inputs, and digital outputs.
Inputs
The Auto-Off-Manual switch is a control input. It provides power to the PCB and the Transfer Relay. It is a
double pole, double throw, center off switch. The switch’s purpose is to set the main PCB board to the desired
mode of operation as selected by the operator.
Figure 190
●● Wire 15: Fused Battery voltage (12VDC)
●● Wire 15A: Fused Battery voltage from the switch when the switch is in either the AUTO or MAN
position. It provides power to the PCB and the crank and run relays.
●● Wire 194: Fused Battery voltage from the switch when the switch is in either the AUTO or MAN
position. It provides power to the Transfer Relay.
●● Wire 239: Fused Battery voltage from the switch when the switch is in the MAN position. Tells the
board to crank and run the generator.
SW1 194
15A
1 4
2 5
15
239
3 6
Figure 191 – AUTO-OFF-MANUAL Switch

Chapter 12
Digital Inputs are contact closure signals – “on” or “off”. The control panel puts out a low voltage, current
limited signal on a wire to a contact. When the contact is open the voltage on the wire is “high”. When the
contact is closed, to control ground, the voltage on the wire is “low”. The control panel sees the change in
voltage potential and responds in whatever way its program tells it to do. Examples of Digital Inputs are;
●● Low Oil Pressure switch
●● High Coolant Temperature Switch
●● 2-wire Start
●● Low Fuel Pressure Switch
The schematic diagram in “Figure 192” shows the Low Oil pressure Switch (LOS), High Coolant Temp Switch
(HCT), and the Low Fuel Pressure switch (LFP).
LOS
86 0
2
WTS 1
68 0
A
WLS B
573 0
LFP
601 0
Figure 192
LOS
Wire 86 is 12VDC from the PCB. These are normally closed contacts that are held open by engine oil pressure
when the unit is cranking or running. Should oil pressure drop below 8 psi, the contacts will close and the
engine will shut down.
HCT
Wire 85 is 5VDC from the PCB. These are normally open contacts. When engine coolant temperature
exceeds 284 F degrees (or use the degrees symbol). the contacts will close and the engine will shut down.
LFP
Wire 601 is 5VDC from the PCB. This is a normally open contact. When fuel pressure is above 5 In-H2O, the
contacts will close. When the fuel pressure drops below 5 In-H2O the contacts will open.

Chapter 12
LOW FUEL PRESSURE SWITCH
HIGHT TEMPERATURE SWITCH
LOW OIL PRESSURE SWITCH

Figure 193 – Typical Engine Protective Devices

Chapter 12
Analog Inputs
Analog Inputs are measurable values that the control panel sees coming from sensors, pickups, or other
inputs. The sensor or input provides a measurable value from some low value to a high value and anything
in between. The control panel sees the value change and if the input reaches a predetermined setpoint, the
control responds. Some examples of Analog Inputs are:
●● Low Coolant Level sensor
●● Utility Voltage sensing
●● Engine RPM
●● Camshaft RPM or position
●● Battery Voltage
The schematic diagrams in “Figure 194” show the Water Level Sensor (WLS), the Utility Voltage Sensing
Transformer (TR1), a Magnetic Pickup (MP1), and a Cam Sensor (CS).
WLS
Wire 573 is 5VDC from the PCB. The sensor is a probe which is normally immersed in coolant. The applied
voltage passes a current through the coolant and the voltage on Wire 573 drops to approximately 1.2VDC. If
the coolant falls below the sensor probe the current will go to zero and the applied voltage will go up to 5VDC.
TR1
This is a simple step down transformer. Utility phase voltage is applied to the primary side and a voltage of
approximately 16VAC comes out on the secondary side. The output voltage on the secondary will be directly
proportional to the input voltage on the primary.
MP1
This is a typical mag-pickup used for both flywheel speed sensing and cam speed/position sensing. The AC
voltage on Wire 79 must be the correct value for the particular engine application, when the unit is running.
These values can be found in the PIB for mag-pickup adjustment.
CS
This is a Hall Effect sensor used to see the position of the camshaft. It triggers each time the #1 cylinder is at
top-dead-center (TDC) and is used for ignition timing on the 1.6L engine.
225 79
224 0
N.C.
194 +
CS TR1
402 OUT
0 - MP1
N1 WLS
A B
N2 573 0
Figure 194

Chapter 12
Figure 195 – Typical Water Level Sensor

3
RED [79]
BLACK [0]
SHIELD
1
Figure 196 – Typical Magnetic Pickup - @1000 ohms resistance

Chapter 12
Outputs
Digital Outputs are the means the control uses to make things in the system happen. The outputs normally
drive relays which change the state of contacts, which, when they open or close, activate solenoids, start
a motor or anything else that needs to happen. The control operates the relay by applying or removing the
control ground for the relay. Examples of Digital Outputs are:
●● Crank Relay
●● Run (Fuel) Relay
●● Transfer Relay
●● Alarm Relay
The schematic diagram below (Figure 197) shows some of the Digital Outputs from the PCB.
Wire 13 is un-fused battery voltage

Wire 15 is fused battery voltage.
Wire 15A is fused battery voltage from the Auto-Off-Man switch – powered only when the switch is in the
AUTO or MAN position.
RL1 – Crank Relay

Wire 56A is the control wire for RL1. The PCB takes 56A to ground to energize the relay. This will close Wire
15 to Wire 56, which will energize the Start Contactor solenoid, which will close Wire 13 to Wire 16 and cause
the starter solenoid to engage and drive the starter motor to crank the engine.
RL2 – Fuel (Run) Relay

Wire 14A is the control wire for RL2. The PCB takes Wire 14A to ground to energize the relay. This will close
Wire 15 to Wire 14 and energize the Fuel Solenoid, which will open and allow fuel to flow to the regulator.
Wire 14 also powers some other components in the system: Field Flash (Boost); Ignition Control Module (ICM
– If used).
0
ALT
14A F2
14
49
15
RL2
15A
56
FS2 0 SC 56
0
56A
13 16
56 14 SC
0 FS
15 13
RL1
13
15A
(+)
(-)
BAT SM
0
Figure 197
Chapter 12
Battery Chargers
There are three possible battery chargers that you will see on the QT & QTA product. All three require 120VAC
input voltage from a service connected breaker. The breaker should be on the emergency load fed side of the
service system.
2 Amp Battery Charger
AC 2 amp
Glass Fuse Green and
Yellow LED’s
DC 5 amp mini
spade Fuse
Figure 198
This is a 2 Amp, 13.4 volt “float” type charger. A “float” type charger will charge the battery at its maximum
output current rating until the battery voltage reaches a “float” voltage, and then the charge current will
decrease to maintain the battery at that “float” voltage value.
Figure 199
This is a 2.5 Amp, 13.5 volt “float” type charger. A “float” type charger will charge the battery at its maximum
output current rating until the battery voltage reaches a “float” voltage, and then the charge current will
decrease to maintain the battery at that “float” voltage value. No fuses, no indicators.
Chapter 12
10 Amp Battery Charger
GREEN AND
DC 5 AMP YELLOW LED’S
SPADE FUSE
AC 2 AMP
GLASS FUSE
Figure 200
This is the 10 amp battery charger used on the QTA Industrial product and some H-Panel products. It is an
“equalizer” type charger. An “equalizer” charger will charge the battery at its maximum output current rating
until the battery voltage reaches an “equalize” voltage, then the charge current will decrease to maintain the
battery at a lower “float” voltage.
Each of these chargers requires that the battery be connected to the charger before it will turn on. The
battery voltage must also be above 11 volts before the charger will begin charging the battery. More technical
information and part numbers for the fuses can be found in the R-200 Technical Manuals.
The Wiring Diagram in “Figure 201”shows the customer utility connections that need to be made to the
R-control customer connection box. The L1, N, and GND come from a service breaker in the customers
service panel.
120 VAC
UTILITY
SUPPLY
GND
L1
TB-BC
N
1
2
3
L1
BCH
N
+- L N
3 4 1 2
13
0
Figure 201

Chapter 12

1. How do you set the exercise timer on the R-panel?
2. Which wire on an R-panel controlled generator tells the printed circuit board that it is in AUTO?
3. What is the purpose of the dip switches on an R-panel PCB?
4. What is the WLS?

Chapter 12
References
Use the following references to gain a better understanding of and find further information of the R-series
Digital Control Panels.
Generac Power Systems, R-100 Digital Controller Technical Manual, PN 0F6402
Generac Power Systems, R-200 Digital Controller Technical Manual, PN 0F9784
Generac Power Systems, R-200A Digital Controller Technical Manual, PN 0G1369
Generac Power Systems, R-200B Digital Controller Technical Manual, PN 0G9375
Generac Power Systems, R-200C Digital Controller Technical Manual, PN 0H1374
Generac Power Systems, Service Reference CD Set, PN 0C3409
Generac Power Systems, Diagnostic Repair Manual for 37/40kW with 3.9L Engine and R-100 Control Panel,
PN 0G4548
Generac Power Systems, Diagnostic Repair Manual for R-200B 2.4L Engines, PN 0H0983
Generac Power Systems, Diagnostic Repair Manual for the Pre-Pack w/1.5L Engine, PN 0F7698

Chapter 12

232
13 Nexus Control Panels
Keywords
●● Activation
●● CAN bus
●● Security Codes
Contents
Chapter 13 - Nexus Control Panels...................... 233 CAN Bus Alarm............................................... 237
Introduction............................................................. 234 Check Engine.................................................. 237
Activation Process............................................... 234 Maintenance Warning..................................... 238
Alarms, Warnings and Run Events. ........................ 235 Components............................................................ 238
Run Log ............................................................. 235 Internal Battery Charger ...................................... 238
Switched To Off.............................................. 235 Fuses.................................................................. 239
Running Manually .......................................... 235 25 Amp Fuse (F1)........................................... 239
Stopped In Auto Mode ................................... 235 10 Amp Fuse (F2) (If equipped)....................... 239
Running Utility Loss........................................ 235 7.5 Amp Fuse (F3) (Not Shown)...................... 239
Running In Exerciser ..................................... 235 Nexus AVR.......................................................... 240
Running From Radio....................................... 235 Security Access...................................................... 241
Alarms and Warnings.......................................... 235 Security Codes.................................................... 241
Low Oil Pressure Shutdown Alarm: ................ 235 Level I Password:............................................ 241
High Coolant Temperature Shutdown Alarm: ... 236 Level II Password:........................................... 241
Over-speed Shutdown Alarm - Latching........... 236 Extended EDIT Menu Options:......................... 241
RPM Sensor Fail Shutdown Alarm – Latching.. 236 Level I:............................................................ 241
Low Fuel Pressure Warning............................. 236 Level II:........................................................... 241
Missing CAM Pulse Shutdown Alarm – Latching....236 Programming....................................................... 241
Missing Crank Pulse Shutdown Alarm – Latching...236 Menu Layout........................................................... 242
Governor Sensor Fault Shutdown Alarm – Latching..236  Check Your Knowledge....................................... 243
Wiring Error Alarm.......................................... 237
Under-Voltage Shutdown Alarm....................... 237
Over-Voltage Shutdown Alarm......................... 237
Internal Failure Shutdown Alarm...................... 237
233
Chapter 13
Generac Nexus Digital Control Panel
Introduction
The new NEXUS control panel incorporates the following functions within the control panel itself: AVR –
Automatic Voltage Regulator, Battery Charger, Governor and Governor Driver circuitry, Ignition driver circuitry
for up to 4-cylinders (no waste spark) CAN Bus connectivity for Ignition Control Modules for 6 or more cylin-
der engines.
A two line LCD display which provides, Status, Alarm, Alarm History, control function and programming ability.
Figure 202 – Nexus Controller
Activation Process
When battery power is applied to the Generator during the installation process, the controller will light up. The
Generator will need to be activated before it will function automatically. If the activation process cannot be
completed the generator can be started manually. If the generator has been started manually and you need to
activate it the battery will need to be disconnected and Wire T1 will need to be disconnected to depower the
panel for it to “reset” the panel to get back to the activation screen.
Activating the Generator is a simple one time process that is guided by the controller screen prompts. Once
the product is activated, the controller screen will not prompt you again, even if you disconnect the Generator
battery and Wire T1.
The five digit activation code can be obtained by two methods. The first is via the internet at activategen.com.
The second is by dialing 1-888-9ACTIVATE (922-8482). In both cases, a pass code is issued to enter in the
controller. Check the owner’s manual for detailed instructions of the process.

Chapter 13
Alarms, Warnings and Run Events.

The Nexus panel will annunciate and display the Warnings and Alarms; the panel will also hold up to 50 warn-
ings/alarms in its Alarm Log with date/time stamping.
Warnings are Non-Latching, which means they will automatically clear when the condition clears.
Alarms are Latching, which means the condition must be cleared (repaired) before the alarm message on the
screen will clear. To clear an alarm condition the generators auto off manual switch must be placed to the off
position and the alarm needs to be cleared or repaired.
Some Alarms are Shutdown Alarms, which means when they are triggered the unit will automatically shut
down.
Run Log
The Nexus panel has a built in run log that will log events such as:
Switched To Off
The Nexus panel will save the date and time when the panel was switched to the off position. This is a good
tool to use onto when trouble shooting a customer complaint of the generator not automatically starting.
There might not have even been an issue. They might have just had it in the off position.
Running Manually
Logged when the generator was running in the manual mode
Stopped In Auto Mode
Logged when generator has completed its cool down mode after a power failure
Running Utility Loss
Logged when generator is running due to a utility loss, customer can see from the panel why the generator is
running.
Running In Exerciser
Logged when the generator is performing the weekly exercise
Running From Radio
Logged when the generator is running from the wireless remote
Alarms and Warnings

Low Oil Pressure Shutdown Alarm:
Automatically shuts the unit down when engine oil
pressure falls below 10 psi. Subject to a 10 second hold off timer on start up to allow the engine time to build
up oil pressure. When oil pressure is below 10psi contacts are closed. Wire numbers 86, 0; 5VDC on Wire 86
when engine is running

Chapter 13
High Coolant Temperature Shutdown Alarm:

The shutdown triggers when coolant temperature exceeds 257ºF. Has a 0.25 second delay before shutdown,
subject to a 10 second hold off time on start up. Wire numbers 68, 0; 5VDC on Wire 68 when engine is run-
ning, the sensor is continuously monitored. If there is a fault for 5 continuous seconds the unit will shut-down
and the alarm will display.
Over-Crank Shutdown Alarm:
Occurs if the engine has not started within the specified crank cycles. First crank cycle is 16 seconds crank
followed by a 7 second rest. The next 5 cycles will be 7 seconds of crank followed by 7 seconds of rest. If the
unit fails to start by the end of the 6th crank/rest cycle the alarm will display and the unit will not attempt to
crank until the alarm is reset.
Over-speed Shutdown Alarm - Latching
Speed is measured by the mag pickup and the alarm is calculated by the control panel. Over-speed is defined
as +20% of nominal engine speed for 3 seconds. 1800 rpm = 2160 rpm shutdown 3600 rpm = 4320 rpm
shutdown Immediate shutdown will occur if engine speed is +25% of nominal rpm. 1800 rpm = 2250 rpm
immediate shutdown 3600 rpm = 4500 rpm immediate shutdown
RPM Sensor Fail Shutdown Alarm – Latching
During Cranking: No valid RPM signal within 4 seconds of cranking will cause the unit to shut-down and lock
out on RPM Sensor Loss. During running: RPM signal lost for 1 full second, the control will shut the unit
down, wait 15 seconds, then re-crank the engine if in Auto; it will NOT re-crank in Manual. If the RPM signal
is detected the engine will start and run normally, if the RPM signal is lost, it will shutdown. The control will
attempt two re-cranks (if in Auto). After two re-crank attempts it will shut-down and latch out on RPM Sensor
Loss Alarm.
Low Fuel Pressure Warning
This is a digital input to the control panel. 5VDC on Wire 601. The switch is held open by fuel pressure, when
fuel pressure drops below 5 In W.C. the switch closes. If there is a loss of fuel pressure or it drops below 5
inches of water column, a warning will be displayed on the panel. The machine will still try to start if put in
manual or in auto with a loss of utility, and will either over crank or start if there is enough fuel. If it does man-
age to start it may not be able to pull load or some % of load.
Missing CAM Pulse Shutdown Alarm – Latching
Only used on 4 cylinder engines (non ICM with CAN bus). The alarm will go active after 5 continuous seconds
of missing CAM pulses (non-ICM units). On ICM Units the panel will display an “Ignition Fault” Alarm that will
specify either CAM or Speed Sense or simply “Ignition Fault”. If it displays the “Ignition Fault” alone, the prob-
lem is most likely with a coil pack or spark plug.
Missing Crank Pulse Shutdown Alarm – Latching
The alarm will activate after 12 consecutive revolutions where the crank pulse is missing.
Units using an ICM and CAN bus will display an Ignition Fault alarm, with appropriate designation, for either a
Crank Sensor or CAM Sensor fault.
Governor Sensor Fault Shutdown Alarm – Latching
Throttle position is monitored by an analog feedback signal on Wires 765, 766, & 767. If throttle position is
seen as outside of normal (what the governor calls for) the unit will shutdown. If the throttle is commanded to
move and no movement is seen the unit will shutdown.
Chapter 13
Wiring Error Alarm

When power is first applied to the controller it performs a check of the wiring to the transfer relay output chan-
nel. If high (AC) voltage is seen on the wire it will display a Wiring Error Alarm and the unit will not run. Mis-
wiring is not covered under warranty. Many controls have been ruined by AC voltage on the DC voltage chan-
nels. The panel does a self check for AC voltage on Wires 23 & 194.
Under-Voltage Shutdown Alarm
If the generator voltage drops below 60% of nominal for more than 5 seconds the unit will shut-down and the
Alarm will be displayed.
●● 208 x 60% = 125V
●● 240 x 60% = 144V
●● 480 x 60% = 288V
Over-Voltage Shutdown Alarm
If the generator voltage rises above 110% of nominal voltage for more than 3 seconds the unit will shut-down
and the alarm will be displayed.
●● 208 x 110% = 229V
●● 240 x 110% = 264V
●● 480 x 110% = 528V
If the generator voltage rises above 130% of nominal for more than 0.2 seconds the unit will shut-down and
the alarm will be displayed.
●● 208 x 130% = 270V
●● 240 x 130% = 312V
●● 480 x 130% = 624V
Internal Failure Shutdown Alarm
Any internal failure that can be detected (corrupted firmware data) will cause this shutdown alarm. This alarm
cannot be cleared. If you encounter this alarm contact the Generac service department.
CAN Bus Alarm
The NEXUS provides information to and receives information from the ICM through a CAN bus connection.
(Controlled Area Network communications) If CAN bus communication fails, a CAN bus Alarm will be gener-
ated. The alarm may be generated if:
1. The physical link is broken.
2. The Ignition Module fails or resets.
3. The Nexus Controller fails or resets.
4. Having the Battery Chargers 120 VAC connected without a battery installed.
5. A blown 10 amp Ignition Module fuse (approximately 12 inches away from the starter).
6. A blown 25 amp system fuse (located approximately 12 inches away from the DC alternator).
NOTE: The “CAN bus Alarm” will not clear on its own. To clear the alarm, press the “enter” key to
acknowledge the alarm. The alarm will clear and if the fault is still present, the alarm will reoccur.
Check Engine
The liquid cooled Nexus units that are equipped with the Generac emission system have a fault annuncia-
tion called “Check Engine.” In the event that the emissions system is not operating within set parameters the
Chapter 13
“Check Engine” message will appear on the display. This message is annunciation only and will not shut the
unit down. The “Check Engine” annunciation has 2 distinct modes of operation, one for Natural gas and the
other for Vaporous Propane.
For natural gas Nexus emissions units – If the panel does not see a signal from the O2 sensor for one minute
after the 4 minute warm up period the check engine warning light will turn on. The warning will not shut the
unit down.
For vaporous Nexus emissions units - If the panel does not see a signal from the O2 sensor for one minute
after the four minute warm up period the check engine warning light will turn on. The warning light will not shut
the unit down. The check engine light also will turn on if the panel does not see the output of the O2 sensor
modulating. The warning will not shut the unit down.
Note: Check Engine is a self resetting warning. It will clear automatically if the condition that caused it
clears.
Maintenance Warning
When a maintenance period expires, a warning message will be displayed. Pressing the Enter key will clear
and reset the maintenance counter for the maintenance condition displayed.
Components
Internal Battery Charger
The battery charger provides power for all of the functions of the control panel except the actual CRANKING of
the engine and some power to the ICM (on ICM equipped engines). The charger is normally powered by util-
ity voltage through a fused circuit in the RTS type transfer switch. If the panel fuse is pulled the panel will stay
powered, however the unit will not crank or run. If the charger output voltage drops below the battery voltage
the battery will provide power (through a “diode” OR bridge internal to the control).
The battery only enters its charge cycle when its open circuit voltage drops below 12.6V.
It charges for 18 hours and then float current is checked.
●● If float current is greater than 600mA or the open circuit voltage is less than 12.5 volts an “Inspect
Battery Warning” will be displayed.
●● If the unit cranks during the 18 hour charge cycle, the charge cycle will reset, check voltage, and if
needed charge for another 18 hours.

Chapter 13
Fuses
25 Amp Fuse (F1)
The 25 amp fuse provides fused 12VDC to the battery charge alternator, fuel primer solenoid, and control
panel.
10 Amp Fuse (F2) (If equipped)
For external ignition module systems the 10 amp fuse protects Wire 15B and provides 12VDC to the ignition
control module.
7.5 Amp Fuse (F3) (Not Shown)
The 7.5 Amp fuse is located on the front of the Nexus Controller and protects the panel along with the digital
outputs circuits of the controller.
15
15
15
2
F1
25A
3 16 16
15B 15B ICMJ1-16
16
12
15B
13
5 F2 SM
10A
12
4 6
13 13
SC 10 13
1 1
GND
+
1 -
BAT
Figure 203 – External Ignition Module Fuses

Chapter 13
Nexus AVR
The AVR is integrated into the control panel, there is only one adjustment that can be made to the AVR. The
output voltage can be adjusted using the Voltage Calibration screen in the edit menu. The AVR has the same
operational characteristics of a traditional voltage regulator. The type outlined in Chapter 4.
For testing purposes it has a characteristic that allows troubleshooting to be simplified. If the voltage regulator
does not measure an AC voltage on the DPE winding, the display voltage in the “DEBUG” menu will not reg-
ister the voltage output of the breaker. The diagnostic manual uses this to our advantage and sets up a logic
chart that if you have these certain things the problem is in this circuit, and if this happens then it is in the
circuit. It sets four different scenarios of where the problem could be.
1. Field Flash Circuit
2. DPE Circuit
3. Regulator Circuit
4. Sensing Circuit

Chapter 13
Security Access
Within the EDIT menu on the controller certain parameters are available only with a security access code.
Security access codes are broken into two levels. Level I, used primarily during installation. The Level II is for
authorized service dealers only and allows a technician to program and setup a panel.
Security Codes
Use the panel keypad and press the buttons in the following order starting from the main menu:
Level I Password:
s, s, ESC, t, s, ESC, s
Level II Password:
ESC, s, s, t, t, ESC, ESC
Extended EDIT Menu Options:
Items in bold are additional options available with each security access.
Note: The Level II security code will grant access to all of Level I items
Level I:
Exercise Time, Current Time, Language, Calibrate Voltage, Switch Type, Pickup Volts, Startup Delay, Fuel
Type, Reset Maintenance.
Level II:
Exercise Time, Current Time, Language, V Code, Parameter Group, Calibrate Volts, Switch Type, Pickup
Volts, Startup Delay, Fuel Type, Reset Maintenance.
Programming
Each model of engine and voltage requires a unique set of parameters to ensure proper operation of the unit.
These parameters are programmed using the V Code and Parameter Group settings within the EDIT menu after
a Level II security code has been entered. These settings are available using the latest version of SIB10-11-
NALL downloaded from GENservice.

242
Chapter 13
Password is entered
on this page. MAIN MENU
ESC
HISTORY STATUS EDIT DEBUG

ESC ESC ESC ESC
CONTRAST
ALARM LOG RUN LOG STATE DISPLAY COMMAND VERSIONS
QT TEST
INPUTS OUTPUTS DISPLAYS
(IF APPLICABLE)
SOFTWARE LANGUAGE
ESC
HARDWARE
Press the “ESCAPE” key IF APPLICABLE

ESC to jump back up through
LANGUAGE
the menu levels. ENGINE TIME/DATE EDIT WITH
HOURS
PASSWORD
Use the “+/-” key
+/- to navigate through VOLTAGE
the menu.
ENGINE EXERCISE CODE
RPM TIME/SPEED START-UP
Use the “ENTER” key DELAY
ENTER to select items or
enter data. PARAMETER
GENERATOR RESET GROUP
FREQUENCY MAINTENANCE FUEL TYPE
The possible Status messages of the display
are as follows: CALIBRATE
Menu Layout
BATTERY The possible commands VOLTS

• Switched Off/Time & Date VOLTAGE RESET
on Line 2 of the display
Figure 204 – Nexus Menu Layout

• Ready to Run/Time & Date MAINT
are as follows:
• Utility Loss Delay/Pausing for X Seconds
• Switched Off PARAMETER
• Cranking/Attempt # X GROUP
• Running Manually EXERCISE
• Running in Exercise/Time & Date
• Stopped in Auto Mode TIME
• Running/Cooling Down
• Running - Utility Lost
• Running - Warning/Warning Message SWITCH
• Running in Exercise TYPE
• Running - Alarm/Alarm Message
• Running from Radio CURRENT
• Stopped - Alarm/Alarm Message
TIME
• Stopped - Warning/Warning Message
• Cranking/Pausing for X Seconds PICK-UP
VOLTS
• Running/Time & Date
• Running/Warming Up
• Cranking - Warning/Warning Message NOTE: OLDER VERSIONS MAY HAVE SLIGHTLY DIFFERENT PARAMETERS.
• Cranking - Alarm/Alarm Message
Section 3 - Digital Control Panels

Chapter 13

1. What is CAN bus as it relates to the Nexus Controller?
2. What is the purpose of the 10 amp fuse when equipped on a Nexus controlled unit?
3. Where is the battery charger located on a Nexus unit?

244
14 Introduction to the
PM-DCP H-100
Keywords
●● Digital Control Platform ●● Current Transformers
●● Modem ●● Governor Driver
●● Communications ●● Bosch Actuator
●● Modbus
●● Trending
●● Integrated Logic Control
●● Interface Transformer
●● Voltage Regulator Driver
Contents
Chapter 14 - Introduction to the PM-DCP H-100.. 245
Introduction............................................................. 246
Components............................................................ 247
Component ID..................................................... 252
Automatic Voltage Regulator................................ 253
Governor Control Circuit...................................... 259
Control Relays (RB1)........................................... 261
Fuses.................................................................. 262
245
Chapter 14
Introduction to PM-DCP H-100
Introduction
The H-100 Control Panel is based on the Power Manager Digital Control Platform (PM-DCP), and uses the
same core firmware for the PM-DCP line of controllers. The following are the PM-DCP controllers and their
applications:
• H-100 – used on Commercial and Industrial standalone generator sets up to 600 kW

• PM-GC – used on Industrial standalone generators 300 kW and larger
• PM-PC – This is the Modular Power System (MPS) Parallel Controller used on all MPS capable generator
sets
• PM-SC – this is the Modular Power System (MPS) System Controller used on all MPS systems
The PM-GC, PM-PC, and PM-SC are all based on the G-Control Panel, which is the “big brother” to the
H-panel. Everything you learn about the H panel came directly from the G panel in standalone applications.
Both have a common processor core and related firmware (operating system). Both use the same GenLink
DCP software program for the operator to interface with and configure the control panel.
Some features of the H-100 panel are:

• Local or Remote connection to a PC via Genlink DCP for remote monitoring and configuration
• Dual display user interface
• Interface with up to 4 HTS commercial transfer switches
• Interface with multiple 21 Light Remote Annunciator Panels (RAP) or Remote Relay Panels (RRP)
• Built in Frequency (Governor) and Voltage Regulator control
• External modem option with dial-out capability on Alarm
• Communication via CAN bus and Modbus protocols
• Programmable I/O channel properties (Alarms, Warnings, Shutdowns)
• Alarm and Event Logging with Date/Time stamping
• Built in Trending
• Built in Diagnostics
• Internal ILC (Integrated Logic Control)
• Spare customer programmable Analog input capacity
• Spare customer programmable Digital I/O capability
The different chapters of this section of the study guide will detail all of the aspects of the H-100 control which
you will need to be familiar with in order to perform startup, service maintenance and troubleshooting of the
H-Panel controlled generator set.
246 Section 4 - Power Manager - DCP H-100 Control Panel

Chapter 14
Components
The typical components found in an H-Panel controlled generator set include, besides the engine and
alternator; the H-Panel, Voltage Interface Transformer, a Voltage Regulator Driver, Current Transformers (CT),
Governor Driver, Ignition Control Module (ICM), Control Relay Boards (RB), engine sensing components,
battery charger, optional Modem, various other input and output components as required by the application.
Figure 205
H-100 Control Panel – dual displays, user Key-pad interface, Emergency Stop button, Common Alarm Horn,
Auto-Off-Man key switch, 9-pin serial connection
The user Key-pad interface allows the user to page through and select the various menus provided in the
dual display screens. The Emergency Stop button provides a positive disconnect for the Run and Crank
circuits. The Alarm Horn provides an audible output whenever there is a Warning or Alarm. The Auto-Off-Man
switch provides the user with the means to select the operating mode of the generator set. The 9-pin serial
connection provides the means to connect a PC to the control using Genlink DCP.
Section 4 -Power Manager - DCP H-100 Control Panel 247

Chapter 14
Figure 206
The backside of the H-100 Control Panel showing the two 35 pin Amp-seal connectors, the connections to the
E-Stop, alarm horn, key-switch and 9-pin serial connector.
The 35 pin Amp-seal connectors are where all of the connections are made to the H panel. The black cover
on the one on the right is the strain relief cover. It prevents pulling wires out of the connector as the harness is
moved. If you have to trouble shoot and trace wires from the connector to their location on the generator set,
use the wiring diagram. Do not try to follow wires through the harness – you will cause more problems than
you fix. If you have to probe the individual wires use either a wire piercing probe or a needle back probe to go
in to the back of the individual wire connections. Do not insert the standard meter test probe into the back of
the wire connection or into the female connector in the plug – you will damage the connectors and cause more
problems than you are trying to fix.
LOCKING TABS
PIN NUMBERS
Figure 207 35 Pin Amp-seal connector

Chapter 14
The pin numbers are listed at either end of the connector body. The locking tabs need to be gently lifted, both
the inner Black and the outer Red, to release the pin lock.
Figure 208 The pin-lock released
The pin lock only moves out about 1/4 inch. Do not remove the pin lock from the connector body – it will be
extremely difficult to get it back over all the pins.

Chapter 14
To remove a wire from the connector, release the pin-lock, find the wire you need to remove, push the wire
in and twist it. This will release the lock. Gently pull the wire out. When the wire comes out you can inspect
the tin female pin. The pin has three leaves that grip the male pin. If these leaves are spread out too far the
connector will not make good contact. You can push each leaf back into the pin body to make it work again.
Locate the pin-hole which the wire belongs in and carefully insert it into the body – push firmly to seat the pin
fully and then push the pin lock in until it fully seats.
Figure 209
Female Pin on wire showing leaves. If you need to replace a wire and pin there
is a replacement 10’ long wire available with a pin crimped on it – PN0F1414.
Figure 210
If you need to check low voltage signals on wires or to connectors, or to check for wire continuity use either
needle type back probes or wire piercing probes as shown above. The needle probes are available through
many sources such as Fluke, Snap-On, and Digi-Key. Generac also provides a good set of wire piercing
probes, Generac PN 0G7172.
The procedures outlined above, and the procedure for working with Deutsch connectors, is outlined in Service
Product Information Bulletin PIB05-14-S.
Chapter 14
Figure 211 – 0J09460SRV Test Probe Kits
The test probes shown in the figure above are designed to allow a standard meter test lead to be inserted
into an AMP style socket. The diameter of the pin is the exact diameter of needed to prevent damage to the
socket..

Chapter 14
Component ID
E
A
B
C
F
D
Figure 212
Identify the labeled components in the picture:
A.

B.

C.

D.

E.

F.


Chapter 14
Automatic Voltage Regulator

The H-Panel has the Automatic Voltage Regulator built into the control panel. It senses all phase voltages
through a voltage Interface Transformer board (IFT). The IFT reduces the phase voltage to approximately
48VAC phase to phase (0-28.8VAC Ph to N). The IFT is located in the customer connection section of the
enclosure on commercial units and on the front of the AC connection box on Industrial units.
Figure 213 – This is a single-phase Interface Transformer from a QT unit.
Figure 214 – These are three-phase Interface Transformers from QT units.
Figure 215 – Interface Transformer
The connections are made inside the AC connection enclosure.

Chapter 14
The H-panel AVR circuitry always needs to ‘see’ the same input sensing voltage (48VAC phase to phase),
so there are separate Interface Transformer boards for each voltage code. This is important mainly on the
Industrial units, which can be reconfigured depending on the voltage code of the stator. If you reconfigure the
unit, but don’t change the IFT to the correct part number the unit will not regulate voltage properly.
DIP SWITCHES
Switch 1
ON for PME
OFF for DPE
Switch 2
Not Used
Figure 216 – Voltage Regulator Driver and DIP Switch
The voltage regulator driver will amplify the signal from the H-panel voltage regulation circuit and increase
or decrease excitation voltage to the field. It gets its power from the same DPE winding as the independent
AVRs, which were discussed in Section 1, Chapter 4. Since the H-panel is used in both Commercial and
Industrial applications it will work with alternators which use DPE or Permanent Magnet Excitation (PME) as
the power supply to the VR Driver. The difference between DPE and PME is in the frequency of the AC power:
DPE provides AC power at 60Hz, and PME provides AC power at 240 Hz. The dip switch on the VR Driver is
used to set up the Driver circuitry to work with the frequency of the power being provided – DIP 1 will be ‘ON’
for PME power (240 Hz), and ‘OFF’ for DPE power (60Hz). DIP 2 is not used at this time. It is important to
make sure DIP switch 1 is set properly before starting the unit.

Chapter 14
NOTE 3 14
R1
4 29
ALT 49 DB
0,25Ω, OR 50Ω
CB1
DPE 2 162
AVR
1 1 1 FIELD -
VOLTAGE 2 194
REGULATOR 3 6 DPE
4 4
5 4 4 FIELD +
6 403
7 404
8 J2
9
10 406
11 405
12
13 162
14
Figure 217 – Schematic Diagram of the Voltage Regulator Driver and Field Flash Circuit.
Because this is an H-Panel the item labeled AVR is actually the voltage regulator driver.
ALT 49 49
DB
TB3-7X 14 14
-
R1 29
SEE NOTE
1 1 1 TB2-4X
2 194 194 J2-31
3 6 6 TB2-1X
4 4
5 4 4 TB2-3X
6 403 403 J2-8
7 404 404 J2-20
AVR 8
9
10 406 406 J2-30
11 405 405 J2-19
12 CB
13 162 2 TB2-2X
14 SEE NOTE
Figure 218 – Wiring Diagram of the Voltage Regulator Driver and Field Flash Circuit

Chapter 14
The H-panel monitors load current through Current Transformers (CTs) mounted in the AC connection box.
These CTs provide a current output signal proportional to the current flowing in the load leads. These current
signals, along with the voltage, are used to calculate apparent power, real power, reactive power (PF-Power
Factor), and kW hours that the machine operates.
Figure 219
CTs mounted in a typical QT product. Note that these will be enclosed by the alternator connection box cover
and then the enclosure.
Some important points to remember about CTs are:

• They are polarity sensitive
• There is a definite direction the load leads pass through the center
• Because they produce current it is very dangerous to try to work with the CT leads when there is
current flowing through the load leads. Always make sure the power source (generator or utility) is
shut down when working with CT’s.

Chapter 14
ALTERNATOR ALTERNATOR
MAIN TERMINALS MAIN TERMINALS
STATOR STATOR
T1 L1 K
CT1 L T1 L1 K
CT1 L
L1 L1
k l k l
T2 L2 K
CT2 L
L2
k l
T3 L3 K
CT2 L T3 L3 K
CT3 L
L3 L3
PME + - k l PME + - k l
FIELD FIELD
00 00
00 00
398B
399B
398B
399B
398C
399C
398A
399A
398A
399A
AVR 1
AVR 1
S1
S1
CB 2
CB 2
S2
S2
S3
AVR 6
00
AVR 6
R1/AVR 4
R1/AVR 4
J2
J2
IFT IFT
N1 N1
N2 N2
00 N3
224 224 224 224
225 225 225 225

J2 J2
226 226
227 227 227 227
CONNECTIONS FOR 1Ø UNIT CONNECTIONS FOR 3Ø UNIT
ALTERNATOR CONNECTION BOX
Figure 220
Schematic Diagram showing the PME (DPE) connections, Field connections, single-phase and three-
phase connections, CT connections and Interface Transformer connections

Chapter 14
398A J2-12
399A J2-11
398B J2-35
399B J2-34
398C J2-10
399C J2-9
398C
399C
398B
399B
398A
399A
k k k
l l l
L L L
K K K
CT1 CT2 CT3
(L SIDE OF CT TO STATOR)
Figure 221 – Wiring Diagram CT Connections
TO GENERATOR
IFT
AØ BØ CØ
N1 S1 S1
N2 S2 S2
N3 S3 S3
224 224 J2-6 L1 L2 L3 N
225 225 J2-29
226 226 J2-17
227 227 J2-7
MLCB
E1 E2 E3 N
AØ BØ CØ
CUSTOMER
CONNECTIONS
Figure 222 – Wiring Diagram MLCB & IFT Connections
TB2
Y X
PERMANENT 6 1 6 AVR-3
MAGNET
EXCITER 2 2 2 CB
+
4 3 4 AVR-5
EXCITER
FIELD
- 1 4 1 AVR-1
5 0 CO-6
0 TB1-4X
6
Figure 223 – Wiring Diagram PME (DPE) and Exciter Field Connections

Chapter 14
Governor Control Circuit

The H-Panel has its own Governor built into the control. It can monitor either Frequency or Engine
RPM as the speed reference source. The governor provides a PWM signal to the Governor Driver
which then amplifies the signal to change the position of the Bosch Throttle Body Actuator.
Figure 224 – H-Panel Governor Driver
14 NOTE 3
1
771 771 769 J1

767
GA1
765 0 0
770 770
766R 766R 766R
766 J1
766V 766V 766V
12
6
GA BOSCH DRIVER
GD
Figure 225
Schematic Diagram of the Bosch Driver (GD), Actuator (GA1) and throttle position Signal Conditioner (GA)

Chapter 14
TB3-2Y 0 0 10
9
770
8
771
4
RB1-7 14 14
1
GD
TB3-2Y 0 0
12
J1-33 769 769
1
12
4 5
GND 0 LOCATED IN
J1-17 766R
3 6 CONTROL PANEL
2 1
J1-18 766V
ESC3
771
766
767
765
770
1 6
GA1
Figure 226 Bosch Governing System
Wiring Diagram showing the Bosch Driver (GD), Actuator (GA1) and Governor position Signal Conditioner
(ESC3)
Wire 14 is the Run wire which powers up the Governor Driver. The H-Panel puts out a Pulse Width Modulated
(PWM) signal on Wire 769 to the driver. The driver in turn changes the voltage applied to the actuator to move
the throttle plate. A quick way to troubleshoot this system is to put a 9 volt DC battery to Wires 770 (+) and
771 (-) going to the actuator. The actuator should stroke all the way open. When you remove the voltage the
actuator will close (spring tension). You can also check the feed back circuit, Wires 765, 766, and 767. PIB
05-2-S gives the procedure for testing the Bosch Actuator.
Wires 766R and 766V connect to the Throttle Position Analog Input channel on the H-Panel. ESC3 is the
Signal Conditioner for the throttle position feedback. We will look at the signal conditioners for the Analog
Input Channels in the next section of the study guide.

Chapter 14
Control Relays (RB1)

The control Relay board in the H-Panel is the way the control makes the fuel turn on, the engine crank, the ICM
power up, and is part of the E-Stop circuit. These outputs are called Digital Output Channels.
RB1
1 A-2
AH1 229 445 J1
2
K1
3
NOTE 1 0
A-1
15B NOTE 6
4
ES1 15E
5
K2
6 A-3
NOTE 5 15A R15B J1/ES1
7 A-5
NOTE 3 14 256 J1
8
K3
9
NOTE 5 15A
A-4
15 NOTE 4
10
ICM/SC 56
11
K4
12 A-6
NOTE 5 15A 56A J1
Figure 227 – Typical Relay Board for an H-Panel
The relay contacts are shown in their ‘normal’ de-energized position. When a relay energizes it changes the
state of the contact. The relays are powered by Wires 15A and 15, which we’ll look at in a later section. To
energize a relay the control panel takes its control wire to ground. When the relay energizes, the contacts
change positions so that the ‘NC’ contact is open and the ‘NO’ contact is closed.
When reading the H-panel schematic and wiring diagrams use the notes beside the various wire numbers to
find out what they are or do. Also use the labels and the legend to find out where the wire comes from or goes
to. If the label says J1, J2, GD, AVR, ICM, or something else, check the connections table to find the wire
number, the pin it connects on, what it goes to, and its function.

Chapter 14
Fuses
The fuse block in the bottom left corner of the control panel is where Wire 13, un-fused battery voltage, comes
in and goes out as fused battery voltage on Wires 15, 15A, 15B and 15C. The different suffix designation for
each wire is explained in the notes section of the Schematic Diagram for the particular unit you are working on.
13 F1 15A 15A
F1 15A
15A NOTE 5
13 F2 10A 15B
F2 10A
15B NOTE 6
13 F3 10A 15C
NOTE 2 13
F3 10A
15C NOTE 7
F4 -
Figure 228
Fuse F2 is the fuse that protects the H-Panel control. So if you have a panel that appears dead, check F2.
Also, we will learn that when working with GenLink DCP there are times when we must re-power the panel to
make certain configuration changes effective, in that case you would pull F2.
When you use the schematic diagram to assist you in learning how the system operates, use the notes
section. On the typical H-panel schematic diagram the notes say the following about Wire 15:
●● Wire #15 is fused +12VDC when the E-stop is not activated.

●● Wire #15A is fused +12VDC for general Use
●● Wire #15B is fused +12VDC for the engine control module
●● Wire #15C is fused +12VDC for the ignition
The fuses are standard ATO spade type fuses.

●● 5 Amp fuse, PN 0D7178H
●● 10 Amp fuse, PN 0D7178J
●● 15 Amp fuse, PN 0D7178K

Chapter 14

1. What products are the H-100 used on?
2. What style of connectors are used on the H-100?
3. What is the purpose of the CT?
4. What is the purpose to the AVR driver?
5. What is the purpose of the Interface Transformers?

264
15 H-Panel Inputs and Outputs
Keywords
●● Digital Inputs ●● Signal Conditioner
●● Digital Outputs ●● Voltage Sensing
●● Analog Inputs ●● Current Sensing
●● Modbus ●● Open Collector
●● RS-232 ●● Stop Bits
●● RS-485 ●● Parity
●● CAN bus ●● Baud Rate
●● Modem
Contents
Chapter 15 - H-Panel Inputs and Outputs............. 265 Communication Ports.............................................. 286
Inputs and Outputs.................................................. 266 RS-232 (Port 0) (Genlink/Modem)....................... 286
Analog Signal Conditioners .................................... 267 RS-485 (Port 1).................................................. 287
4-20mA Analog Inputs from Engine Sensors........ 267 H-Panel RS-485 Wiring to 4 HTS switches and
Troubleshooting Analog Engine Sensors............... 272 21-Light RAP/RRP.......................................... 287
H-100 (PM-DCP) Automatic Voltage Regulation... 273 Baud Rate, Data Bits, Parity.................................... 289
Current and Voltage Sensing Processing......... 273 Baud rate............................................................. 289
Digital Inputs........................................................... 277 Start bit............................................................... 289
Input Active Level for Digital Input Channels......... 279 Data bits.............................................................. 289
Digital Channel Input Active Level LOW (Inverted).280 Parity bit.............................................................. 289
Digital Outputs........................................................ 283 Stop bits.............................................................. 290
Other Digital Output Channels............................... 284  Check Your Knowledge....................................... 290
Spare Digital Outputs (Industrial Units Only)......... 285
265
Chapter 15
H-Panel Inputs and Outputs
Inputs and Outputs

The H-100 Control Panel operates by monitoring various inputs and making things happen by providing
various outputs. The diagram below shows the different inputs and outputs used by the H-100 Control Panel.
Battery Supply 12/24 VDC RS-232 GenLink
4-20mA Analog Inputs (7) RS-485 Switches/Acc
0-1V Analog Input (1)

CanBus
0-10V Analog Input

Charger Current Monitor Power Manager Modem
0-1A rms Current Sensing H-100 Controller

Inputs
Magnetic Pickup Input (1)
Digital Inputs (11)

PWM (2)
Voltage Sense (3) Open Collector Outputs (12)
Figure 229
We will look at these by breaking them down into 5 basic categories.

●● Analog Inputs
●● Digital Outputs
●● PWM and Other Outputs
Analog Inputs can be broken down into the following groups:

●● 4-20 mA Analog Inputs from engine sensors
●● 0-1A RMS Current Sensing Inputs
●● 0-28.8 VRMS Voltage Sensing Inputs
●● 0-10VDC Battery Charge Current Monitor
●● 0-1VDC O2 Sensor (for emissions and Air/Fuel Ratio Control)
●● 0-1VAC Magnetic Pickup input

Chapter 15
Analog Signal Conditioners

4-20mA Analog Inputs from Engine Sensors
The typical engine sensor works by applying a current limited voltage to a resistive element. The resistive
element can be a pressure sensor, a temperature sensor, level sensor, etc. When the attribute that the sensor
is monitoring changes the resistance value of the sensor will change and, by applying Ohm’s Law, the voltage
to the sensor will change. The control can see this change of voltage and respond in whatever manner it is
programmed to do.
E = I x R In a sensor circuit the current (I) is held constant and a known voltage is applied (usually 5VDC).
As the parameter being measured changes, the resistance value of the sensor element changes.
As the resistance increases the voltage applied (measured) will increase.
As the resistance decreases the voltage applied (measured) will decrease.
The control measures the applied voltage across the sensor
(resistive element) and ground. This voltage drop is calibrated
against the pressure, temperature, or fluid level; whatever parameter
is being measured.
However, since these sensor signals are voltage, and the wires between the engine and the control have to
pass across the alternator, the signals can be affected by the large, changing magnetic field in the alternator.
In the PM-DCP controls we prevent this signal interference by changing the voltage value to a current value at
the sensor, through the use of signal conditioners.

Chapter 15
Current Loop
to/from
Control Panel
Figure 230
The signal conditioner provides a looped current output from the controller to the sensor and back to
the controller. As the resistance of the sensor changes the current going to the controller will change
proportionally. The normal current the controller expects to see is between 4 and 20mA (milli-amps). If the
sensor or circuit faults, either open or grounded, the controller will see less than 4mA or greater than 20mA
and indicate a sensor fail warning for that channel (if it is selected in the Analog Channel Configuration Menu).
The linearising/bias resistor is sized to the type of sensor being used. These cannot be changed as this is a
‘potted’ conditioner. If you find it faulted, just replace it with the spare in the warranty kit.

Chapter 15
J1
68R
68V
ESC1
68R
68V
0
4 5
3 6
2 1
WTS
68A
68
6
2 1
68A 68
1
WTS1 WTS1
Figure 231 – The Water Temperature Sender and its Signal Conditioner
The Water Temperature Sender is a thermistor element which changes its resistance value as temperature
changes.
J1
69R
69V
NC
1 3
69R
69V
N.C.
3 2 1
OPS1
OPS1
Figure 232
The Oil Pressure Sensor has its signal conditioner built in. Earlier styles of oil pressure sensor had a signal
conditioner in the harness.

Chapter 15
ESC2
573R
573V
0
4 5
J1
3 6
573R
573V
2 1
WLS
573A
573
6
A B
573A 573
B
WLS1
WLS1
Figure 233 – Water Level Sensor and Signal Conditioner
The Water Level Sensor uses the coolant as the resistive element. It passes a current from the tip of the
sensor to the base, as long as the sensor is immersed in coolant. When the sensor is not immersed in coolant
no current will flow.
Figure 234
This is the replacement coolant level sensor and signal conditioner for units experiencing problems with the
sensor tip becoming fouled with contaminant deposits. The part numbers and procedure for installing this
sensor are given in Product Information Bulletin PIB09-8-GALL. There are 2 different part numbered yellow
banded signal conditioners, they are NOT interchangeable!
Chapter 15
Figure 235
Typical H-Panel Analog Input Channel Allocations shown in the Diagnostics Menu of GenLink DCP
The GenLink DCP Diagnostics screen for an H-Panel shows both the Processed and Raw Values in one
display.
Raw values which display “N/A” represent a value for which there is no actual input; the “Processed” value for
these channels is derived from other analog input values.

Chapter 15
Troubleshooting Analog Engine Sensors

The key to troubleshooting the engine sensors will be using the Diagnostics provided by the PM-DCP panel.
The first step in troubleshooting these sensors is to divide and conquer. This means to determine quickly
whether the problem is with the sensor, the signal conditioner, the wiring or the control.
The easiest check to make is to remove the Signal Conditioner from its socket and check the voltage at Pin 1
(the “V” wire). The voltage on the “V” wire should be 12VDC.
Next, put a 1kOhm (1000 Ohm), ¼ or ½ Watt resistor in the signal conditioner socket between pins 1 & 2.
This will close the current loop to the controller – between the 12VDC on the “V” wire and the “R” signal return
wire. It will provide a fixed, known current to the control panel which should then be displayed in the Analog
Diagnostics display of the panel for that channel. You can also use the Analog Diagnostics screen in GenLink
DCP to view the Raw value. The nominal ‘Raw’ value you should see when you do this test is approximately
“411”. This is a unit-less number which should display in the ‘Raw’ section of the Diagnostics for the channel
you are checking.
If you do not see a raw value at all, either the circuit between the Signal Conditioner socket and the control is
open, or the configuration for that channel is incorrect, or there is a problem with the Control Panel.
If you do get the correct ‘411’ reading for that channel, then the problem is with the Signal Conditioner, the
wiring between the socket and the sensor, or the sensor itself. You can check the continuity quickly between
the socket and the sensor, replace the signal conditioner with one from the warranty kit, and compare the
resistance of the sensor to a new one, to determine if it is bad.
Listed below are the Signal Conditioner part numbers and color codes used with the sensors on a PM-DCP
control panel.
●● Water Level Conditioner (0E4911A – Yellow used with brass body sensor)
●● Water Level Conditioner (0H1635 – Yellow used with sensor PN 0H1827)
●● Water Temp Conditioner (0E4911C – Blue)
●● Oil Temp Conditioner (0E4911C – Blue)
●● Intake Temp Conditioner (0E4911B – Red)
●● Fuel Level Conditioner (0E4911D – Green w/Gems) or (0E4911 – Black w/Rochester) the proper
sensor depends on the type of level sensor used;
The Gems sensor is the linear float sensor; the Rochester has the swing float.
●● Any 3-wire sender (0E49110SRV – Black) Oil pressure, throttle position feedback, and other future
3-wire senders. No Bias Resistor

Chapter 15
H-100 (PM-DCP) Automatic Voltage Regulation

We have already looked at the sources for the Current and Voltage Sensing inputs, as well as the Magnetic
Pickup input. The battery charge current monitor is only used on Industrial units with the 10-Amp battery
charger. The O2 sensor input is only used with emissions certified engines.
Current and Voltage Sensing Processing

Precision
rectifier
To Micro-controller
ADC input
Buffer Amplifier
Input from current

transformer (CT)
x21
secondary Zero Crossing
0 - 1A rms Detector
Burden
resistor
(33m Ohm) To Micro-controller
Figure 236
This is the circuit diagram for the Current Sensing inputs to the H-100 Panel. Don’t worry about the circuit –
look at the two things that are done with the inputs. The top right is the precision rectifier to allow the signal
to be digitized. The bottom right is the Zero Crossing detector. The zero crossing detector gives us one of the
inputs that is needed to calculate PF, KVAR, KVA, kW hours, etc.
MAIN TERMINALS
T1 L1 K
CT1 L
398A J2-12
k l 399A J2-11
T2 L2 K
CT2 L
398B
399B
J2-35
J2-34
398C J2-10
k l 399C J2-9
T3 L3 CT3
398C
399C
398B
399B
398A
399A
K L
k l k k k
l l l
00 L L L
398B
399B
398C
399C
398A
399A
S1
S2
K K K
CT1 CT2 CT3
J2
IFT (L SIDE OF CT TO STATOR)
Figure 237 – Typical CT Schematic Diagram (left) and Wiring Diagram (right); H-Panel Unit

Chapter 15
Precision
rectifier
To Micro-controller
ADC input
Buffer Amplifier
_.. 2
Zero Crossing
Detector
Input from Interface
Transformer
0-48VAC Nominal To Micro-controller
Figure 238
This is the circuit diagram for the Voltage Sensing inputs to the H-100 Panel. Again, don’t worry about the
circuit – look at the two things that are done with the inputs. The top right is the precision rectifier to allow the
signal to be digitized. The bottom right is the Zero Crossing detector. What is the Zero Crossing detector for?
TO GENERATOR
IFT
AØ BØ CØ
N1 S1 S1
N2 S2 S2
N3 S3 S3
224 224 J2-6 L1 L2 L3 N
225 225 J2-29
226 226 J2-17
227 227 J2-7
MLCB
E1 E2 E3 N
AØ BØ CØ
CUSTOMER
CONNECTIONS
Figure 239 – Typical H-Panel IFT Schematic (left) and Wiring Diagram (right)

Chapter 15
TO LOAD
MLB
MLB = MAIN LINE CIRCUIT BREAKER N

N = NEUTRAL SENSING
SENSING IFT/VDB
SENSING
STATOR STATOR 14/219 DIODE 29 RESISTOR

POWER POWER
FIELD BOOST WINDING WINDING
CIRCUIT EXCITER 4
FIELD VOLTAGE
MAGNETIC REGULATOR
FIELD 0
(INSIDE H OR G PANEL)
BELT DRIVEN EXCITER

ENGINE -
ALTERNATOR ROTOR DC AC ARMATURE
DIRECT DRIVE
ENGINE MOUNT
REGULATOR
DRIVER
MAGNETIC
FIELD DIODE BRIDGE
TO BATTERY
STATOR 2 DPE BREAKER
EXCITATION
WINDING
6
Figure 240 – Typical Brushless H-Panel Operating Diagram

Chapter 15
Figure 241
Note that the sensing voltage comes from the IFT (Interface Transformer) to the H-Panel at 48VAC line-to-line.
The voltage regulator circuit looks at the average of the voltage inputs and compares that value to the target
value. If the average value does not match the target value the regulator provides an output (Gate-Trigger)
signal to the Voltage Regulator Driver to increase or decrease excitation to the field to bring the voltage to the
correct target value.
Scaling is used to change the sensed voltage to match the correct voltage code of the generator set. Since the
sensing voltage will always be 48VAC (H) the scaling will reduce the digitized value to either 240 or 208, or
increase it to 600. With scaling set at 1.0000 the 48VAC value is passed through as 480.
Calibration is used to adjust for differences in sensing values due to differences in the actual sensing
transformers. If the voltage value for each phase is not calibrated the target voltage may not be reached and
the display and any calculations that use voltage will not display correct values.

Chapter 15
Digital Inputs
As was looked at in the R-Panel section of this study guide, digital inputs enable the controller to see the state
of a set of ‘dry contacts’. There are 11 digital inputs that the H-Panel uses in its normal operation, one of them
being an internal signal. The control puts out a 5VDC current limited signal on a wire to the contact. When the
contact is open, the signal will be ‘High’ (5VDC). When the contact is closed the signal will be ‘low’ (0VDC).
Some of the Digital Inputs used are:
●● Auto Switch
●● Manual Switch
●● Emergency Stop
●● Remote Start (183 & 0)
●● Battery Charge Fail (only with 10-Amp Charger on Industrial Units)
●● Line Power
●● Gen Power
The full list of possible Digital Inputs used in the H-100 is in Appendix B of the H-100 Technical Manual.
NOTE 5 15A 15A

NOTE 1 0
SW1 MAN
175 0
00X
J2 AUTO
174
ALARM X00
AH1 +
RB1 229
E-STOP
ES1
J1 R15B
RB1 15E
NOTE 4 15
J2 R15
Figure 242
Schematic Diagram showing the Auto-Off-Man Switch (SW1), the E-Stop (ES1), and the Alarm Horn (AH1)
which is driven by a Digital Output.

Chapter 15
+5V
4K7
To Micro-controller
47K
Switch Schmitt inverter
0.1uF
Optional input devices
Open-collector
Relay contact
transistor
Figure 243 – Digital Input Circuitry
This is a circuit schematic showing how the Digital Input Circuit works. It is important to remember that
although it is called a Digital Input that does not mean you put a voltage signal (on or off) into it. It is simply
a circuit that indicates to the controller the state of the dry contact. For instance, Line Power and Gen Power
inputs are simply dry contact closure switches mounted on the transfer switch body.

Chapter 15
Input Active Level for Digital Input Channels
Figure 244
If you think of the dry contact as a light switch, when the light switch contact is closed the light (Raw value) is
‘ON’. When the light switch contact is open, the light (Raw value) is ‘OFF’. With the Input Active Level setting
‘High’, the processed value will read the same as the Raw value.
With the contact closed the Raw value could also be considered to be “to ground”; this is what causes the
5VDC signal to go low, to 0VDC.

Chapter 15
Digital Channel Input Active Level LOW (Inverted)
Figure 245
When the Input Active Level setting is ‘low’ the Processed value will read the opposite of the Raw value. The
Raw value always reflects the state of the contact; if the contact is closed the Raw value is ‘ON’; if the contact
is open the Raw value is ‘OFF’.
The input active level can only be changed through the Digital Input Channels Configuration Menu using
GenLink DCP, and requires a level one dongle.

Chapter 15
3 3
J2-5 174
4 4
J2-28 175
CO SWC
3 B 1
4 B1 2
SW1
NOTE 1 0
SW1 MAN
175 0
00X
J2 AUTO
174
ALARM X00
Figure 246
Typical H-Panel Schematic (top) and Wiring Diagram (bottom) for the Auto-Off-Man switch (SW1). These are
typical digital inputs.
If you were to check the voltage on Wires 174 & 175 at this time the meter would read 5.0VDC.
Note that the Wiring Diagram also shows the connector and Pin numbers that the control wires connect to.

Chapter 15
Figure 247
Typical H-Panel Digital Input Channel Allocations shown in the Diagnostics Menu of GenLink DCP.
The GenLink DCP Diagnostics screen for an H-Panel shows both the Processed and Raw Values in one
display.
Note that in this particular display the “Raw” value when the input contact is closed indicates “GND” (ground)
instead of “ON”. Both mean the same thing for the “Raw” value: the contact is closed.
HUIO Inputs are extra digital input channels available when you use a HUIO module. Each HUIO module
provides 4 additional Digital Input channels and 4 additional Digital Output Channels. They operate as slave
modules on the RS-485 communications network.

Chapter 15
Digital Outputs
The Digital Outputs enable the control panel to makes things happen; crank, run (fuel, ignition), fault relay,
and alarm horn are a few. The control panel causes a relay or an LED to turn on or off by controlling its
G Controller
ground wire. The controlPCB
panel does this through what is called an open collector, which is another word for a
transistor, which is simply an electronic switch.
+30V DC (max)
Digital Output Circuit

(Open-collector transistor)
Relay coil
200mA max
from Micro-controller
One output
circuit
Figure 248
This is a circuit schematic showing how a digital output works. The transistor is switched (on or off) and
that takes the relay control wire to ground, which energizes the relay. This could control an LED instead of a
relay. The relay contacts can carry a greater current than the transistor can. If more current is needed in the
controlled circuit, the relay can control a solenoid, which has larger contacts and can carry a higher current.
For example the Crank circuit in the R-panel, Nexus panel and H-panel.

Chapter 15
Figure 249
Typical H-Panel Digital Output Channel Allocations shown in the Diagnostics Menu of GenLink DCP. HUIO
modules provide extra digital input and output channels. Each HUIO module provides 4 additional Digital Input
channels and 4 additional Digital Output Channels. Each HUIO Module operates as a slave on the RS-485
communications network; only available for H-Panels. Digital Output Channels will be either OFF or ON.
Other Digital Output Channels

There are some Digital Output Channels which are driven internally and as functions of other features of the
PM-DCP control panel. These cannot be changed through GenLink DCP; they are hardware/firmware driven.
Some of these are:
●● Throttle PWM
●● Air/Fuel Ratio PWM
●● AVR Gate trigger
●● Watchdog Toggle
PWM stands for Pulse Width Modulated, which if viewed on a scope would look like a square wave. This is
used as an output to the Governor Driver for throttle position, and to the Air/Fuel Ratio controller for emissions
control.
The AVR uses a Gate Trigger which tells the SCR circuitry in the Voltage Regulator Driver when to turn on
and off to control the excitation output. The gate controls the timing of the SCR. Remember AC voltage is
a sine wave, and to rectify to DC we would normally use a diode. An SCR can be triggered to ‘fire’ (turn on
or conduct) at any point in the sine wave. So the gate trigger tells the SCR when to turn on and produce DC
voltage. Controlling the point in the sine wave when the SCR conducts and allows voltage/current to flow will
determine the voltage/current applied to the load – in this case the field windings.

Chapter 15
The Watchdog Toggle is an indicator that the Watchdog circuit is operating. The Watchdog circuit is an
internal function of the processor which would alarm if the processor failed to complete all of its tasks in a
certain time period. This indicator will periodically flash which indicates it is functioning. It also causes the
Alarm LED to flash periodically (approximately every 30 seconds). It also has a hard overspeed function
called variously; the Overspeed Watchdog, HW Overspeed, or Overspeed Shutdown. This Overspeed
Watchdog is set for 78 to 80Hz. If this overspeed is tripped it can only be reset by cycling power to the control
panel (the F2 fuse).
Spare Digital Outputs (Industrial Units Only)

There are 4 (four) digital output channels connected to auxiliary relays for the use of the customer (often
called customer configurable relays). The channel allocation for these relays is different on H and G panels.
The easiest way to remember them or identify them is to use the Schematic or Wiring Diagram for the unit you
are working with.
GROUND STUD
RB3
TB1-14X
TB1-14X
J2-23
J2-22
J2-33
J2-21
1 A-2
NO OC5 J2
AUX 1
2
NC K1
3 A-1
COM 15A NOTE 5
GRN
OC6
OC5
OC7
OC8
15A
15A
4
NO K2
RB3A
CUSTOMER SPARE OUTPUTS
5 A-3
AUX 2
NC OC6 J2
1
6
2
3
5
4
6
COM
4
RB3
3
7 A-5
NO OC7 J2
K3
K2
PCB K1
K4
5
8
6
AUX 3
1
NC K3
RELAY
9 A-4
COM 15 NOTE 4
11
12
10
10
9
6
8
2
4
NO K4
11 A-6
AUX 4
NC OC8 J2
COM
COM
COM
COM
NC
NC
NC
NC
NO
NO
NO
NO
12
AUX 4 AUX 3 AUX 2 AUX 1 COM GRN
GRN
SURGE ARRESTOR
SPARE OUTPUTS
Figure 250 – Configurable Relay Boards
Typical Schematic (right) and Wiring Diagram (left) showing the 4 Spare Output relays (customer
configurable relays) used on Industrial H-Panels.
The 4 Customer Configurable relays and the HUIO output relays can all be mapped by using either the Digital
Output Functions Configuration Menu (Output Mapping) or the ILC. The ILC is covered in Industrial Training.

Chapter 15
Communication Ports
The H-100 has three means of communication.
●● Communication Port 0 is RS-232 and Modem communications. Port 0 (RS-232) is the way the
GenLink DCP program in a PC will interface with the controller.
●● Communication Port 1 is for RS-485 communications with HTS switches and Remote Annunciator
and Relay Panels (RAP & RRP)
●● CAN bus communication can only be enabled. It is used to get information from an engine controller
like those used on the John Deere, Fiat and Volvo Tier II and Tier III diesel Engines. These will only be
used in Industrial application generator sets.
On any communication network there can be many different devices communicating. However, there can be
ONLY ONE MASTER! Everything else on the communications wire is a slave. Some of the configuration of
communications ports can be changed depending on the devices being used.
Port 0 is RS-232 communications for GenLink DCP and Modem

Port 1 is RS-485 communications with HTS switches and Remote Annunciator and Relay Panels (RAP & RRP)
CAN bus communication can only be enabled. It is used to get information from engine controllers on Tier III
diesel Engines.
RS-232 (Port 0) (Genlink/Modem)

The RS-232 port (PORT 0) provides the communications link between your PC, running GenLink DCP, and
the controller. GenLink DCP is always the Master. The control panel will always be the Slave. The settings
for GenLink DCP come preset to: Modbus Master, 9600 baud, No Parity, 1 stop bit. 8 bits is always the
transmission rate. The settings for the PM-DCP controllers, whether H-Panel, PM-GC, PM-PC, or PM-SC,
will always be: Modbus Slave, 9600 Baud, No Parity, 1 Stop Bit. It is recommended that you do not change
these settings.
When an H-Panel is equipped with a Modem to enable the panel to dial out on alarms, and for remote access
with GenLink DCP over a phone line, the Modem connection will use the RS-232 Port. It will change the
Baudrate to the Modem setting (typically 57600). This will present a problem trying to connect to the serial
port. Generac provides a special serial connection cable for just this purpose – PN 0F7707. It has a special
jumper in the control panel connector which will disable the Modem and enable the RS-232 communications
port. It is highly recommended you use this cable.

Chapter 15
RS-485 (Port 1)
The RS-485 port (Port 1) is used to communicate with HTS switches, RAP and RRP panels. The default
setting of Port 1 of the H-Panel, from the factory, is: Modbus Master, 4800 Baud, No Parity, 2 Stop Bits.
The 21-Light RAP can operate at any of four different baudrates. The HTS switches with software version
1.08 and higher can also work at any of those same four baudrates. So the H-panel Port 1 baudrate can be
changed to a higher baudrate if you desire. The other settings must stay the same – No Parity and 2 Stop
bits. Remember, all the devices on the communications network must have the exact same settings – Period!
H-Panel RS-485 Wiring to 4 HTS switches and 21-Light RAP/RRP

The baud rate can be 4800, 9600, 38400 or 57600
H-Panel
(Master) 21-LT
Port 1 RS-485 RAP/RRP
No Parity 2 Stop Bits
HTS HTS HTS HTS

#1 #2 #3 #4
(Slave 240) (Slave 241) (Slave 242) (Slave 243)
Figure 251

Chapter 15
Figure 252 – Typical H-Panel Communication Port Settings Configuration Menu
Any change to this screen requires the H-panel to be power cycled before the change will take effect.

Chapter 15
Baud Rate, Data Bits, Parity

Serial communication using RS-232 and RS-485 requires that you specify four parameters: the baud rate of
the transmission, the number of data bits encoding a character, the sense of the optional parity bit, and the
number of stop bits. Each transmitted character is packaged in a character frame that consists of a single
start bit followed by the data bits, the optional parity bit, and the stop bit or bits. A typical character frame
encoding the letter “m” is shown here.
Figure 253
Baud rate
Baud rate is a measure of how fast data is moving between instruments that use serial communication.
RS-232 uses only two voltage states, called MARK and SPACE. In such a two-state coding scheme the baud
rate is identical to the maximum number of bits of information, including “control” bits, that are transmitted per
second. MARK is a negative voltage and SPACE is positive; the figure above shows how the idealized signal
looks on an oscilloscope.
Start bit
A start bit signals the beginning of each character frame. It is a transition from negative (MARK) to positive
(SPACE) voltage; its duration in seconds is the reciprocal of the baud rate. If we’re transmitting at 9600 baud,
then the duration of the start bit and each subsequent bit will be about 0.104 ms (0.000104 seconds). The
entire character frame of eleven bits would be transmitted in about 1.146 ms (0.001146 seconds)
Data bits
Data bits are transmitted “upside down and backwards.” That is, inverted logic is used and the order of
transmission is from least significant bit (LSB) to most significant bit (MSB). To interpret the data bits in a
character frame, you must read from right to left, and read 1 for negative voltage and 0 for positive voltage. For
the figure above, this yields 1101101 (binary) or 6D (hex). An ASCII conversion table would show that this is
the letter “m”.
Parity bit
An optional parity bit follows the data bits in the character frame. The parity bit, if present, also follows inverted
logic: read 1 for negative voltage and 0 for positive voltage.
This bit is included as a simple means of error checking. The idea is this: you specify ahead of time whether
the parity of the transmission is to be even or odd. Suppose the parity is chosen to be odd. The transmitter will
then set the parity bit in such a way as to make an odd number of 1’s among the data bits and the parity bit.
The transmission in the figure above uses odd parity. There are five 1’s among the data bits, already an odd
number, so the parity bit is set to 0.

Chapter 15
Stop bits
The last part of a character frame consists of 1, 1.5, or 2 stop bits. These bits are always represented by a
negative voltage. If no further characters are transmitted, the line stays in the negative (MARK) condition. The
transmission of the next character frame, if any, is heralded by a start bit of positive (SPACE) voltage.
The preceding explanation was courtesy of the following website.

http://francis.courtois.free.fr/jc1/serial/Basics/BitFormat.html
Note: The key with communications is this – regardless of what devices and how many (to a point), the
baudrate, bits, stop bits and parity on all of the devices must be exactly the same or there will be no
communications. Period!

1. How many analog inputs are there in an H-Panel?
2. Which device communicates on the RS-232 port of the H-panel?
3. Which devices communicate on the RS-485 port of the H-Panel?
4. How many digital inputs are available on the H-Panel, not including the HUIO?

Chapter 15

292
16 H-Panel Display Screens
Keywords
●● Diagnostics
Contents
Chapter 16 - H-Panel Display Screens................. 293
Introduction............................................................. 294
Navigation............................................................... 294
Home.................................................................. 294
Menu................................................................... 294
Alarms................................................................ 295
Left Display......................................................... 295
Engine................................................................. 297
Generator............................................................ 298
Status.................................................................. 299
Diagnostic........................................................... 299
Maintenance........................................................ 302
Exercise/HTS....................................................... 303
293
Chapter 16
H-Panel Display Screens
Introduction
The H-Panel display consists of two 4-line LCD displays, the Auto/Off/Man key switch, the 4 display curser
navigation keys (right, left, up & down arrows), the Home display key and the Enter key.
The following are the display menus and their explanation and use in working with the H-Panel display. Not all
of the displays are shown here. There is an exercise in the training kit which takes you through each display
and shows you what can be changed, and how certain displays are utilized. This exercise will give you a
basic working knowledge of how to navigate through them.
To navigate through the right display simply use the up, down, left, and right arrow keys to move the flashing
curser around the screen. When the curser is flashing on a selection, pressing the ENTER key will open
that selection. If you are in a menu with selections that can be manipulated (turned on or off, increased or
decreased, time settings, etc), pressing the ENTER key when the flashing cursor is on that selection will cause
it to stop flashing; you can then use the arrow keys to change that setting.
Some screens have more than one page. To select the next page or previous page move the flashing cursor to
the bottom right of the display onto the right or left arrow and press the ENTER button. The screen will move
to the next (right) or previous (left) page.
Navigation
Home
The Right display is the main navigation display. Pressing the HOME button (in the middle of the arrow
keypad) will display the following screen in the Right Display.
Figure 254
The HOME screen displays the basic engine parameters. Oil Temperature, shown as “n/a ºF”, is an option.
Menu
Pressing the MENU button will bring you to the Menu display shown below.
Figure 255
The rest of this section will go through each of the selections in the main menu and the use of the left display.
Chapter 16
Alarms
Figure 256
This is the ALARMS screen in the Right Display. It will display the first 9 Active alarms or warnings. If more
than 3 alarms are active you will need to page through to read them all. WR = Warning, Al = Alarm, SD
= Shutdown Alarm. The suffix will display whether the input that triggered the alarm was Hi or Low or will
display SN, which stands for Sensor Fault. If sensor fault is displayed it means that the sensor has left the
4-20mA operating range. If there is no suffix it means it was an internal alarm. The cursor will be flashing
on the ACK (Acknowledge) character. Pressing the Enter button will Acknowledge the alarm and the * (not
shown) beside the alarm will disappear.
Left Display
Figure 257
This is the Left Display Page menu in the Right Display. It will display in the left screen whichever selection
has the carat symbols (> <) around it. The following are the left display screens:
Figure 258
This is the VOLTS screen; it is considered the ‘Home’ screen for the left display and displays the Volts, Amps,
Hz and kW.

Chapter 16
Figure 259
This is the POWER screen in the Left Display; notice that all three segments of the power triangle are displayed
here plus the power factor.
Figure 260
This is the SWITCH screen in the Left Display. It shows the current status of the transfer switch contactor if
it is communicating with an HTS switch, or GTS Switch status if the auxiliary contacts on a GTS switch are
connected to the Line and Generator digital input channels.
Figure 261
This is the kW hours screen in the Left Display. It displays the Last run kW hours and the Total run kW hours
on the machine.
Figure 262
This is the Alarm Log screen in the Left Display. It will scroll through all 20 logged alarms and shows the
Date/Time stamp as well as the Alarm or Warning that triggered it. The scroll rate is about 3 seconds per log
item.

Chapter 16
Figure 263
This is the GRAPH Hz screen in the Left Display. At 60Hz the line will be in the center of the screen and will
scroll from right to left – new values coming in on the right side. A deviation from 60Hz is represented by the
line below the main line and represents approximately a 0.2 Hz change.
Engine
Figure 264
This is the first page (1 of 4) of the ENGINE screen in the Right Display. If a value is n/a it means it is an
option not being used.
Figure 265
This is page 2 of the ENGINE screen in the Right Display. The Bat Charge is only available on Industrial units
with the 10 Amp battery charger.
Figure 266

Chapter 16
This is page 3 of the ENGINE screen in the Right Display. The time run is the Engine Hours on the unit. This is
not re-settable except by the factory.
Figure 267
This is page 4 of the ENGINE screen in the Right Display. This is the raw value coming from the Bosch throttle
body actuator feedback mechanism.
Generator
Figure 268
This is page 1 (1 of 3) of the GENERATOR screen in the Right Display. It shows the same information as the
Volts selection in the Left Display menu.
Figure 269
This is page 2 of the GENERATOR screen in the Right display. It does not show everything that the Generator
selection in the Left Display menu displays.
Figure 270

Chapter 16
This is page 3 of the GENERATOR screen in the Right Display. The i2T limits will display as a percentage of
the allowable if there is an overload condition.
Figure 271
Status
This is Page 1 (1 of 2) of the STATUS screen in the Right Display. Right now it indicates that the unit is
Running, and that the run command was sent from the HTS Transfer Switch; the unit is warmed up, but the
Alarms are still Off. The hold off timer controls the alarm. This is one of the screens in which changes can
be made through the display. Position the flashing cursor on the Time and hit ENTER and you can use the
Up-Down arrow keys to change the time; the same can be done for the date by changing the month, day and
year. The complete list of status messages can be found in the H-100 Control Panel Technical Manual.
Figure 272
This is page 2 of the Status screen in the Right Display. This screen will display the Firmware version that is
loaded in the panel. If there is an ILC loaded in the panel its program name will be displayed and its status will
be shown (Stopped or Running).
Diagnostic
Figure 273
This is Page 1 of the Diagnostic screen in the Right Display. This screen will show the status of the first 10
Digital Input Channels. Digital inputs are either On (1) or Off (0). It is useful for checking whether the panel is
‘seeing’ a specific digital input.
Chapter 16
Figure 274
This is page 2 of the Diagnostic screen in the Right Display which shows the Digital Output Channels status.
Digital Outputs are either On (1) or Off (0). At this screen you can turn a digital output on for approximately
2 seconds – this is called inverting the output. Move the flashing cursor under the channel you want to
invert and press ENTER. The channel will go active (turn on) for approximately 2 seconds. The digital output
channels can be found in the H-100 Control Panel Technical manual.
Figure 275
Figure 276
These are pages 3&4 of the Diagnostics screen in the Right Display which shows the Analog Input Channels.
These do not follow the same channel numbering as that shown when using Genlink DCP. The values
displayed here are also the “Raw” analog input values, so they may not equate to what you are expecting for a
particular channel.

Chapter 16
If you put a 1000 Ohm resistor between pins 1 & 2 of a signal conditioner socket, what value would you
expect to see displayed on the diagnostic screen for that analog channel? Approximately 411 should be
shown.
Figure 277
This is page 5 of the Diagnostics screen showing the configuration of Port 0 on the H-panel. This is an
RS-232 port; it says Modem because a modem is installed and an interface (0F7707) cable is not connected
to the panel.
What is the default setting for Port 0 for RS-232 communications?

Baudrate = 9600
Bits = 8
Stop Bits = 1
Parity = None
Figure 278
This is page 6 of the Diagnostics screen showing the configuration of Port 1, the RS-485 communication port.
The RS-485 communication port is used for establishing communications between the H-panel control and it
peripherals (HTS transfer switches, RAP, RRP, HUIO modules, etc.).

Chapter 16
Maintenance
Figure 279
Figure 280
Figure 281
These are pages 1-3 (of 4) of the MAINTENANCE screen in the Right Display. If there are any maintenance
warnings configured, the percentage of life remaining on the item will be displayed here. These can only be
changed by using Genlink DCP.
Figure 282
This is page 4 of the MAINTENANCE screen in the Right Display. If you need to change the display screen
contrast move the flashing cursor up to the 0 of the contrast number and press ENTER. Then use the up/down
arrow keys to change the screen contrast. When you reach a readable contrast press the ENTER key again.

Chapter 16
Exercise/HTS
Figure 283
This is page 1 (of 4) of the EXERCISE/HTS screens in the Right Display. This is another screen in which
changes can be made. Move the flashing cursor to the Y/N of the Exercise Enabled and press ENTER; use
the up/down arrow keys to change from Yes (Y) to No (N). You can also set the day of the week and the time
of day the unit is to exercise, using the same method. The Time Remaining will show how much time is left
on the exercise when the unit is in exercise. The default exercise setting in the H-Panel is 20 minutes. Newer
firmware versions allow the exercise time to be set from 15 to 254 minutes.
Figure 284
This is page 2 of the EXERCISE/HTS screen in the Right Display. In this screen you can select Quiet-Test, Start
Exercise Now, and Transfer (Xfer) on Exercise. The Exercise Now is a good way to demonstrate what the unit
will sound like during Quiet Test. The Transfer on Exercise function only works with HTS switches, and only
those with software versions higher than 1.08.
Figure 285
This is page 3 of the EXERCISE/HTS screen in the Right Display. This shows the status of the switch selected,
the Utility Hz and Utility Vrms at the switch, the Battery voltage (the backup batteries in the cover of the HTS
control – they are only for maintaining communications), and the version of software in the HTS control. To
select a different switch move the flashing cursor to the HTS # 1 and press enter; use the up/down arrow
keys to move from switch to switch and press ENTER when you get to the switch you want to monitor.

Chapter 16
Figure 286
This is page 4 of the EXERCISE/HTS screen in the Right Display. This is where you can enable
communications with each of the connected HTS switches. Move the flashing cursor to the HTS # 1 and
press ENTER; use the up/down arrow keys to move from switch to switch and press ENTER when you get to
the switch you want to enable; and press ENTER. Move the flashing cursor to the Disabled/Enabled position
and press ENTER; use the up/down arrow keys to enable or disable the switch selected.

1. What is on page 4 of the engine screen?
2. What screen on the H-panel is used to identify the baudrate the RS-485 is operating at?
3. What needs to be done on the H-panel to enable a HTS transfer switch?

Chapter 16

306
17 GenLink DCP Configuration and
Diagnostic Menus
Keywords
●● Input Channels
●● Output Channels
●● Output Functions
●● Engine Settings
●● Regulator Settings
●● Governor Settings
●● Air/Fuel Settings
●● Transfer Switch Settings
Contents
Chapter 17 - GenLink DCP Configuration and Air/Fuel Settings................................................... 332
Diagnostic Menus..................................... 307 Thermal Protection Settings................................. 333
Configuration and Diagnostic Menus...................... 308 Transfer Switch Configuration.............................. 334
Introduction......................................................... 308 Exercise Configuration......................................... 335
Diagnostics......................................................... 309 HUIO Setup.......................................................... 335
Analog Input........................................................ 310 Governor Settings................................................ 336
Digital Input......................................................... 314 Governor PID Control.............................................. 339
Digital Output....................................................... 319 Introduction......................................................... 339
Digital Output Function......................................... 322 PID Governing Principles...................................... 340
Communications Settings.................................... 325  Check Your Knowledge....................................... 342
Engine Settings.................................................... 328 References.............................................................. 342
Generator Settings............................................... 330
Nameplate Data................................................... 331
Panel Brand.................................................... 331
307
Chapter 17
GenLink DCP Configuration and Diagnostic Menus
Configuration and Diagnostic Menus

Introduction
The configuration menus are used to configure the various inputs, outputs, and controls which the H control
panel uses. This is where operational parameters, alarms, warnings and shutdowns are programmed. These
are the main menus used to affect the operation of the generator.
●● Analog Input Channels

●● Digital Input Channels
●● Digital Output Channels
●● Digital Output Functions
●● Communication port settings
●● Engine settings
●● Regulator settings
●● Governor settings
●● Generator settings
●● Nameplate Data
●● Air/Fuel settings
●● Thermal Protection settings
●● Transfer Switch settings
●● Exercise settings
●● HUIO settings
Figure 287
Chapter 17
Diagnostics
These display the current status or values of the various inputs and outputs. Each selection shows all of the
inputs or outputs for that choice – so it is a handy way to identify which channel a particular input or output is.
●● Analog Input Channels – displays both the ‘Raw’ and ‘Processed’ values of the analog inputs
●● Digital Input Channels – displays both the ‘Processed’ and ‘Raw’ values of the digital inputs (OFF or
ON)
●● Digital Output Channels – displays the status of the outputs – OFF or ON
●● Digital Output Functions – displays the status of the processor ‘Flags’ or functions – either OFF or ON
●● Com Ports – displays the activity of the com ports
●● Engine 0J1939 CAN bus Status – displays the engine parameters and alarms/warnings provided by
the ECM over the CAN bus communications port
Figure 288
We will look at each configuration menu in turn and its associated diagnostic menu.

Chapter 17
Analog Input
Figure 289
This is the Analog Input Diagnostic display. The analog values come into the panel as ‘Raw’ signals. The
control processes these raw values through a measurement “Engine”. The whole process is described in the
H-100 Control Panel Technical Manual and is also covered in the Help menu.
There are 23 analog channels, of which 14 have fixed functions. The remaining 9 channels are split between
product specific inputs (such as oil temperature), and customer spares. The exact split and distribution of the
channels can be found in the H-100 Technical Manual. Some of the 14 fixed channels are “derived” readings
in that they are calculated from the other readings (Total Power for example).
The measurement engine takes the ‘Raw’ value and processes it then displays it as a ‘Processed’ value. The
processed value reads in real units; degrees Fahrenheit, psi, etc. The measurement engine is programmed
from the factory for the analog inputs used on the generator application and generally does not need
adjustment or changing.

Chapter 17
Figure 290
This is an Analog Input Channel configuration display. It consists of five different display categories and the
control buttons along the bottom. Any changes to these configuration values require a level one configuration
dongle (with the exception of Event Logging). The menus are broken down into ‘boxes’ and are explained
below.
In the top left is the Channel Text box, showing the Channel ID, Display Text and type of units that the
processed value displays. For customer configurable inputs, the display text and units text can be changed to
display the type of input that is being read. The channel ID should never be changed.
The Scaling box is where the values that the measurement engine uses to process the raw inputs are entered.
There is a good explanation of each of these selections in the Help menu and in the H-100 Technical manual.
You will normally never have to change any of these settings, with the exception of Calibration for the Voltage
and Current Channels. Voltage and Current Calibration will be covered in a separate section.
The Event Logging box is where you enter the trigger Event Setpoint and the Event Comparison type. When
you enable a Log Event trigger, each time the processed value reaches the comparison type selected, an entry
will be made in the Event Log. The Event Setpoint value is always entered in the units displayed in the Channel
Text box. For example, if you want to trigger an Event Log when the coolant temp is greater than 230 degrees,
you would enter 230 for the setpoint and select GT for the comparison type.

Chapter 17
The Alarm/Warning Configuration box is where you get the greatest flexibility with the analog input channels.
This is where you set the alarm and warning points and determine what happens when an alarm occurs.
There are three different types of alarms:

●● Warning – This is a non-latching alarm. The display backlight will flash, the Alarm light will flash,
and the Alarm horn will sound. If the condition clears, the alarm message will clear and the display
and alarm light will stop flashing and the horn will silence. When the Enter or Acknowledge button is
pushed, the backlight will stop flashing, the alarm light will be on and the alarm horn will silence. The
warning message will continue to display in the alarm screen until the condition clears. When the con-
dition clears the warning will reset and disappear from the screen. Warnings are logged in the Alarm
Log.
●● Non-Shutdown Alarm – This is a latching alarm. When an Alarm condition occurs, the display and
alarm light will flash and the horn will sound. They will not clear until the acknowledge button is
pushed, even if the condition clears. When the condition is cleared and the acknowledge button is
pushed, the alarm message and light will clear.
●● Shutdown Alarm – this is a latching alarm. When the condition occurs, the unit will shutdown, the
display and alarm light will flash and the horn will sound. If the condition clears, the lights and horn
will continue to sound until they are acknowledged. When they are acknowledged the alarm will con-
tinue to display until the key-switch is turned to the ‘Off’ position and the condition has cleared.
There are four choices for when the alarms will be active.
●● Disable – the alarm will not be active
●● Always Enabled – the alarm is always active – whether the unit is running or not
●● Immediate – the alarm goes active as soon as the unit cranks and runs
●● Hold Off – the alarm goes active after the engine hold off timer expires – this allows certain inputs to
reach an acceptable value before the alarm goes active. For example, oil pressure has to build up dur-
ing cranking. The Hold Off timer is located in the Engine configuration menu.
You can have a total of 2 alarms and 2 warnings per channel, with 2 Greater Than and two Less Than values.
The Setpoint values are entered as real values (psi, RPM, volts, etc.) There are two delays available (A & B).
The delays start when the trigger becomes true, reset when the trigger becomes false, and trigger the alarm/
warning when they expire. There is also a No Delay choice. The delays are set in the bottom right, under
Common Settings, in the form of 0.1 second increments.
There are four Shutdown check boxes; however shutdowns only work on Alarms.
The Dial out check box will cause a Modem Equipped unit to call out and dump a .csv file to the first PC
running GenLink DCP it can connect to.

Chapter 17
Common Settings
●● Sensor Failure Check – when checked, this looks for a valid input from the sensors; less than 4mA or
greater than 20mA will generate a sensor warning on that channel. The display will read, “WR, chan-
nel text, SN”.
●● Shutdown on Sensor Failure – when checked, this will generate a shutdown when a sensor input is
not valid. The display will read, “SD, channel text, SN”.
●● Hysteresis – this is the reset value for the channel. This value is added or subtracted from the set-
point (added for less than, subtracted for greater than), and establishes the reset value. This is used to
prevent nuisance alarms from inputs which are fluctuating around the setpoint.
●● Delay A & B – the delay time, in 0.1 second increments, for the alarm setpoints
There are several buttons along the bottom of the display, some of which are common to all of the
configuration menus.
●● The Previous and Next buttons - allow you to move from channel to channel.
●● The Go-To button will take you to the channel entered in the box to its right.
●● The Print button will print the current screen.
●● The Refresh button will refresh all of the channels and will take the screen back to the channel 1 dis-
play.
●● The Apply button will make any changes made to the current display take effect. If changes are made
and the apply button is not pressed, the changes will not take effect.
●● The Close button closes the current display menu.
●● The Help button will open the Help menu for the currently displayed page. The Help menu is a valu-
able resource for learning more about any of the options available with Genlink DCP.

Chapter 17
Digital Input
Figure 291
This is the Digital Input Channels diagnostic screen. Digital input channels (also called Discrete Inputs) are
dry contact inputs and provide on-off inputs to the control. The control provides a current limited 5VDC signal
on a wire, which when connected to the control ground (through the dry contact), goes to 0VDC. The control
sees a Raw Value that is either GND (Ground – ON) or OFF (Open Circuit). The Processed value can either
reflect the same Raw value, or be inverted to give the opposite value. This is done by changing the input
active level for that channel from High to Low. A High Input Active level means the Processed value and the
Raw value will be the same. A Low input active level means the Processed value will be the opposite of the
Raw value.

Chapter 17
Figure 292
If you think of the dry contact as a light switch, when the light switch contact is closed the light (Raw value) is
‘on’. When the light switch contact is open, the light (Raw value) is ‘off’. With the Input Active Level setting
‘High’, the processed value will read the same as the Raw value.

Chapter 17
Figure 293
When the Input Active Level setting is ‘low’ the Processed value will read the opposite of the Raw value. The
Raw value always reflects the state of the contact; if the contact is closed the Raw value is ‘On’; if the contact
is open the Raw value is ‘Off’.
The input active level can only be changed using GenLink DCP and requires a level one dongle.

Chapter 17
Figure 294
This is a Digital Input Channel configuration display. It consists of five different display categories and
the control buttons along the bottom. Any changes to these configuration values require a Level One
Configuration dongle (with the exception of Event Logging). The menus are broken down into ‘boxes’ and are
explained below.
In the top left is the Channel Text box, showing the Channel ID and Display Text which the digital input channel
displays. For customer configurable inputs, the display text can be changed to display the type or name of the
input that is being read. The channel ID should never be changed.
The Event Logging box allows you to trigger an event log when the digital input changes state. The Event Set
Point can be either High or Low. High would trigger an event when the processed value changes from Off to
On; Low would trigger an event when the processed value changes from On to Off.
The Input Active Level box allows you to invert the processed value as explained previously. Input Active
Level High means the processed and raw values would read the same. Input Active Level Low means the
processed value would read the opposite of the raw value. The mapping check boxes are for use with H User
Input Output (HUIO) modules on Industrial units.

Chapter 17
The Alarm/Warning Setpoint box allows you to set an alarm or warning for the digital input and has several
options.
• Delay to Set – this sets a time delay, in 0.1 second increments, before the alarm/warning will trigger
when the input changes state
• Delay to Clear - this sets a time delay, in 0.1 second increments, before the alarm/warning will clear
when the input changes state
• A/W Active Level – triggers the alarm or warning when the processed value changes from Off to On
(High), or On to Off (Low).
• Select Alarm/Warning – sets no alarm or warning (None); Alarm (latching); or Warning (non-latching)
• Choose When Alarm/Warning Becomes Active – Always Enabled; Immediate; or Hold-Off. These
were described previously.
The Actions on Alarm/Warning box allows you to choose what happens when the alarm or warning is
triggered. Shutdown means that it will shut the unit down. This is a Latching shutdown and can only be
cleared by acknowledging the alarm, clearing the condition and turning the key switch to the off position. The
unit will only shutdown if the Alarm box is checked. Dial-out will cause a Modem equipped panel to dial out
and dump a .csv file to the first PC it calls which is running GenLink DCP.
The control buttons at the bottom of the screen have the same functions as previously discussed.

Chapter 17
Digital Output
Figure 295
This is the Digital Output Channels diagnostic display. Digital output channels (also called Discrete Outputs)
are the way the control activates relays, lights, horns, and other on/off devices. Some of these channels are
dedicated depending on the type of prime mover. For instance, Spare Output channels #4 and #9 are used
on industrial units which use the 13.3L HINO gas engine. Two channels are PWM signals and another is the
AVR gate trigger. The HUIO outputs are used on units with the optional HUIO modules.
On Industrial units there are four customer configurable relays mounted in the customer connection panel.
These four relays are channels 5, 6, 7 & 8, which are designated AUX 1 Output, AUX 2 Output, AUX 3 Output,
and AUX 4 Output. These relays can be mapped from the Digital Output Function configuration menu.

Chapter 17
+30V DC (max)
(Open-collector transistor)
Relay coil
200mA max
from Micro-controller
One output
circuit
Figure 296 – Digital Output Circuit
This diagram shows how the panel controls the digital output channels through an open collector (transistor).
The output can be a relay or an LED. The power for the relay (or LED) can be up to 30VDC max, and the
maximum current allowed is 200mA. The control energizes the base of the transistors (two to a channel)
which switches the control wire of the relay to ground which energizes the relay or LED. If more current is
required to activate the device, use the small relay to drive a larger solenoid to avoid the possibility of putting
too much current through the control board; an example of this would be the crank circuit.

Chapter 17
Figure 297
This is the Digital Output Channel configuration page. The only thing you can do is change the Display Text to
reflect what the channel does. It takes a level one dongle to change the text.

Chapter 17
Digital Output Function
Figure 298
This is the Digital Output Functions diagnostic display. Digital Output Functions are ‘flags’ which provide a
means of seeing what the controller is doing. For instance, the Common Alarm flag is ‘ON’ which means an
Alarm is active. When a flag is ON, that condition is active.
Digital Output functions are used to drive the signals to Remote Annunciator Panels (RAP) and Remote Relay
Panels (RRP). They also provide the status messages in the display and are the channels used to map the
customer configurable relays on Industrial units and HUIO outputs.. They can be used to trigger warnings,
alarms and dial out functions.

Chapter 17
Figure 299
This is a Digital Output Function configuration display. It consists of five different display categories and the
control buttons along the bottom. Any changes to these configuration values require a level one configuration
dongle (with the exception of Event Logging and Output Mapping). The menus are broken down into ‘boxes’
and are explained below.
In the top left is the Channel Text box, showing the Channel ID and Display Text which the digital output
function channel displays. For customer configurable DOF channels, the display text can be changed to
display the type or name of the function that is being used. The channel ID should never be changed.
The Event Logging box allows you to trigger an event log when the digital output function changes state. The
Event Set Point can be either High or Low. High would trigger an event when the ‘flag’ value changes from Off
to On; Low would trigger an event when the ‘flag’ value changes from On to Off.
The Output Mapping box allows you to map the function to a Digital Output Channel. The Output channel
Mapping is used on Industrial units equipped with the customer configurable relays or HUIO modules. When
mapping an output channel the Active level choice determines the state of the relay vs. the state of the
function; Active Level High means that the output channel will be turned ON when the output function is ON;
Active Level Low means that the output channel will be turned ON when the output function is OFF. Do not
try to map more than one DOF to a single output channel; the result will be a shutdown alarm for a Multiple
Defined Discrete Output.

Chapter 17
The Alarm/Warning Setpoint box allows you to set an alarm or warning for the digital output function and has
several options.
●● Delay to Set – this sets a time delay, in 0.1 second increments, before the alarm/warning will trigger
when the function ‘flag’ changes state
●● Delay to Clear - this sets a time delay, in 0.1 second increments, before the alarm/warning will clear
when the function ‘flag’ changes state
●● A/W Active Level – triggers the alarm or warning when the ‘flag’ value changes from Off to On (High),
or On to Off (Low).
●● Select Alarm/Warning – sets no alarm or warning (None); Alarm (latching); or Warning (non-latching)
●● Choose When Alarm/Warning Becomes Active – Always Enabled; Immediate; or Hold-Off. These
were described previously.
The Actions on Alarm/Warning box allows you to choose what happens when the alarm or warning is
triggered. Shutdown means that it will shut the unit down. This is a Latching shutdown and can only be
cleared by acknowledging the alarm, clearing the condition and turning the key switch to the off position. The
unit will only shutdown if the Alarm box is checked. Dial-out will cause a Modem equipped panel to dial out
and dump a .csv file to the first PC it calls which is running GenLink DCP.
The control buttons at the bottom of the screen have the same functions as previously discussed.

Chapter 17
Communications Settings
Figure 300
This is the COM Ports Diagnostics page. There are two communication ports on an H-Panel: Port 0 is for
RS-232 and Modem communication; Port 1 is for RS-485 communication with HTS switches and RAP and
RRP panels. The diagnostic page will display the Function of the port, the Baudrate (and bits, stop bits and
parity) of the port and the port Status. The status will change about every 3 seconds and display the Rx (data
received) and Tx (data transmitted) values; the total Tx values, and the CRC and Format errors. The port to be
observed is selected in the Port box.
Figure 301
This is the total Tx values Status display: it will show the total Tx values the panel transmitted (Mine) and the
total received (Rx – Other).

Chapter 17
Figure 302
This shot shows the CRC and Format errors on the communications bus. CRC is the acronym for Cyclic
Redundancy Check. A procedure used in checking for errors in data transmission, CRC error checking uses
a complex polynomial to generate a number based on the data transmitted. The sending device performs the
calculation before transmission and sends its result to the receiving device. The receiving device repeats the
same calculation after transmission. If both devices obtain the same result, it is assumed that the transmission
was error-free. The procedure is known as a redundancy check because each transmission includes not only
data but extra (redundant) error-checking values. The Fmt is for Format errors which occur in the character
strings sent in the communications.

Chapter 17
Figure 303
This is the Communication Port Settings configuration screen. There are two ports which can be configured
and one port which can only be enabled or disabled.
●● Port 0 is the RS-232 port used for communication with GenLink DCP and with a Modem. This port
is always a Modbus Slave port; Genlink DCP is the Master. The default setting from the factory is
Modbus Slave, 9600 baud, No Parity 1 Stop Bit. These setting should not be changed. These settings
match the setting for Genlink DCP, which is the Modbus Master, 9600 baud, No Parity 1 Stop Bit.
●● Port 1 is the RS-485 port used for communications with HTS switches, RAP and RRP panels. The
factory default is 4800 Baud, No Parity 2 Stop Bits. When using HTS switches with control board
software version 1.08 and higher, the Baudrate can be increased to 4800, 9600, 38400 or 57600;
the appropriate dip switch on the HTS control board will have to be set to match the Baudrate of the H
panel. 21-Light RAP and RRPs have an auto-detect Baudrate feature which enables them to adapt and
communicate at any of the above four listed Baudrates. The 20-Light RAP and its RRP boards only
communicate at 4800 Baud, No Parity 2 Stop Bits. Regardless whether it is the 20-Light RAP, 21-Light
RAP or HTS switch, it must always be No Parity 2 Stop Bits.
●● The CAN Bus Interface can be enabled or disabled by checking the box. This is used on Industrial
units using ECM (Engine Control Module) or ECU (Engine Control Unit) diesel engines.

Chapter 17
Engine Settings
Figure 304
This is the Engine Settings configuration page. There are thirteen parameters which can be configured in this
screen, along with the Print, Apply, Close and Help buttons along the bottom of the screen.
●● Preheat time (s); Sets the preheat timer for diesel engines. Adjustable in 1 second intervals. This
timer works with the Preheat Enable selection at the bottom of the screen
●● Preheat Enable: Enables the preheat digital output channel for diesel engines. There are 4 choices;
Disabled; Before Cranking; During Cranking; Before & During cranking. These are settings for
Industrial units with diesel engines.
●● Start Detection RPM (rpm): This is the RPM value the engine must reach before the control will dis-
engage the starter; it is the RPM value when the engine is considered to be running.
●● Crank Time (s): This is the time in seconds that the control will crank the engine when trying to start
it. This should be left at 15 seconds to prevent starter motor overheat.
●● Pause Between Crank Time (s): This is the number of seconds the control will wait between crank
attempts; it gives the starter motor a chance to cool down.
●● Number of Start Attempts: This is the number of times the control will attempt to start the engine. If
it does not start after the last attempt an “SD Overcrank” alarm will be displayed. The alarm must be
acknowledged and the key switch turned off before the unit will attempt to crank again. Generally, if
the unit does not start by the second crank attempt you should be checking the fuel supply, the ignition
system, and any faults which may prevent the unit from starting.
●● Alarm Hold Off Time (s): This timer will prevent any alarms selected as hold off alarms from activat-
ing until after the timer expires. It is normally set to 15 seconds.
●● Engine Warmup Time (s): This timer sets how long the engine must run before it is considered
Ready for Load. The Ready for Load is a digital output function flag which interacts with an HTS
switch. The HTS switch will not transfer until this timer has expired and the voltage and frequency are
within the programmed limits. This will not affect the same setting in a GTS switch.
●● Load Accept Frequency (Hz): This is the minimum generator frequency that must be produced before

Chapter 17
the Ready for Load function flag will go active. This will affect the operation of an HTS switch, but not
a GTS switch.
●● Load Accept Voltage (Vrms): This is the minimum generator voltage that must be produced before
the Ready for Load function flag will go active. This will affect the operation of an HTS switch, but not
a GTS switch.
●● Target Hz (Hz): This is the frequency setting for the H-panel Governor circuit. Don’t try to ‘tweak’ the
frequency here to help with an inphase transfer – use the De-synch Offset in the Governor Settings
configuration.
●● Target Voltage (Vrms): This is the target voltage setting for the H-Panel Voltage Regulator circuit.
Make sure you have calibrated the voltage channels and checked the rest of the voltage regulation cir-
cuit before you attempt to “fix” voltage regulation problems with this setting.
●● Engine Cooldown Time (s): This sets the time in seconds that the engine will run after the HTS switch
has transferred, or after the 2-wire start circuit has been opened. It is always a good idea to allow an
engine some cool down time. With Generac GTS and HTS transfer switches this is a function of the
switch configuration – but switches made by other manufacturers may not have a cool down time
function. If that is the case, then use this cool down timer. It will extend the engine and alternator life.
All of these settings require level one security access to change. They come preset from the factory to meet
the general requirements of each unit. If you need to change these settings but are not sure what the results
should be, consult your Service Manager, your IDC Master Technician, or the Generac Service Department
before you make changes.
NOTE: The Regulator Settings and Governor Settings configuration menus are covered in two separate
sections in this study guide.

Chapter 17
Generator Settings
Figure 305
This is the Generator Settings configuration screen. Any changes here require a level two security dongle.
●● Engine RPM, pulses per revolution: sets the pulse count from the magnetic pickup to the H control
for engine flywheel speed sensing. This setting is determined by the engine make/model and the fly-
wheel tooth count on the engine.
●● Generator CT Ratio: Sets the ratio of the Current Transformers (CT) used to measure the load current.
If this setting is incorrect the Amps value in the display will most likely be way off – more than just a
few amps. Do not correct this problem by trying to calibrate the current channels. Check the actual
CT ratio and make sure it matches this setting.
●● Generator Phase Configuration: The choices here are either Single Phase or Three-phase.
●● 60 Hz RPM: This tells the Governor circuit the correct RPM to maintain to provide 60 Hz. This is the
other option for Governor sensing. The normal sensing for the governor is from the Alternator (fre-
quency). There are several RPM choices available in this selection. Two are direct drive: 1800 RPM
(4-pole rotor) and 3600 RPM (2-pole rotor). The rest are units that drive a 4-pole rotor through a gear-
box.
●● Quiet-Test RPM: There are only two choices here: 1400 and 1800. Any unit that uses a gearbox or
runs at 3600 RPM will quiet test at 1800 RPM. Only 1800 RPM units will quiet test at 1400 RPM.

Chapter 17
Nameplate Data
Figure 306
This is the Nameplate Data configuration screen. It requires a level two security dongle to change the serial
number. The Customer Data is a handy spot to keep notes about configuration changes, customer specific
requirements or messages for the next tech.
Panel Brand
There are currently two brands of panels: Generac and Olympian.
Generac panels are configurable by Generac certified service technicians using Generac Level One Service
Dongles and GenLink DCP version 3.0 or higher.
Olympian panels are configurable by CAT certified service technicians using Olympian Level One Service
Dongles and GenLink DCP version 3.0 or higher.
There are currently only two places the Panel Brand is listed – in the Nameplate Data and in the Reports Menu.
Also CAT Olympian Product is Olympian labeled.
If you connect to a panel brand with the wrong dongle you will only have Level 0 (customer) access.

Chapter 17
Air/Fuel Settings
Figure 307
This is the Air/Fuel Ratio Control Settings configuration screen. These settings are configured at the factory
to comply with emissions certification. If you need help or assistance with these settings or the emissions
compliance of the unit you must contact the Generac Service Department. Never change these settings unless
told to by the Generac Service Department.

Chapter 17
Thermal Protection Settings
Figure 308
This is the Thermal Protection Settings configuration screen. Thermal protection settings protect the
alternator and rotor windings from overheat due to overload or short circuit conditions. The algorithm it uses
is based on the I2T formula for current flow and temperature rise in a conductor. If the percentage limits for
any given alternator configuration are reached the unit will shut down and display the “SD i2t Gen Tmp Hi”
alarm. The only setting which can be changed is the Alternator Size (390 or 520), and it requires a level two
dongle. This function can also be turned ON or OFF with a level one dongle. This setting should remain on.
The “Limiting at 300% of Rated Current” is a feature in stand-alone units that limits the single-phase fault
current to a ten-second delay rather than an immediate shutdown. This feature gives other equipment (motor
controllers, ground fault controllers, etc,) an opportunity to clear the fault before the generator shuts down on
Over-current.

Chapter 17
Transfer Switch Configuration
Figure 309
This is the Transfer Switch Configuration Menu. This Menu is only used when the control panel is
communicating with Generac HTS type transfer switches. It does not have any functionality with Generac GTS
switches or other manufacturer’s transfer switches.
All of the Menu options are discussed in the HTS Transfer Switch chapter of this study guide.

Chapter 17
Exercise Configuration
Figure 310
This is the Exercise Configuration screen. This screen is intended to work with the HTS style transfer
switch. The GTS switch has its own exercise timer board. This function could also be used with a different
manufacturers transfer switch which does not have an exercise function. In that case the unit could only
exercise – it would not perform a transfer on exercise. The time is based on a 24 hour clock. If quiet test
is selected the unit will not do a transfer on exercise. However, if while the unit is performing a quiet test, it
receives a start command from an HTS switch or a 2-wire start command from a GTS switch (due to utility
failure), it will ramp up to normal operating frequency and voltage and the switch will perform the transfer.
HUIO Setup
Figure 311
This is the HUIO Setup configuration screen. This is used to enable communication with HUIO modules. Up
to four HUIO modules can be used with the H panel, providing 16 digital input channels and 16 digital output
channels. There are 4 digital input channels and 4 digital output channels per HUIO. With HUIO modules the
H-Panel is the MASTER on the RS-485 communication network and each of the HUIO modules is a slave
device. Use the HUIO Manual for information on how to set the slave address for each HUIO module used.

Chapter 17
Governor Settings
This section will cover the Governor Settings Configuration Menu. The Governor is integrated into the
H-Panel and controls the Bosch throttle body actuator through the governor driver. The current required to
move the actuator is more than we want to try to push through the circuitry in the H-Panel, so the H-Panel
governor provides a PWM signal to the governor driver which then provides the current output needed to move
the actuator to position the throttle.
Figure 312
This is the Governor Settings configuration screen. All of these settings are discussed in both the H-100
Control Panel Technical Manual and in the Help menu of Genlink DCP. Listed below are the various settings
and their explanations. A full discussion of the PID control principles is at the end of this section.
Control Constants - KP (Proportional), KI (Integral), and KD (Derivative)

●● Standby - These are the PID constants applied to the governor control loop in normal standby mode.
●● Synchronizing – Not used in H-Panels.
●● Quiet-Test - These are the PID constants applied to the governor control loop in Quiet-Test mode.
●● Power – Not used in H-Panels.

Chapter 17
Actuator Type: Indicates the type of governor actuator. The following types are available:
●● Powerflow – Barber Coleman Powerflow; voltage driven without position feedback
●● Bosch Gas – Bosch throttle body (butterfly); current driven with position feedback
●● Linear Current – Linear, current driven with position feedback
●● Detroit Diesel – Detroit Diesel PWM driven
●● Bosch Horizontal Diesel – Bosch Diesel with horizontal connecting rod; current driven with position
feedback
●● Bosch Vertical Diesel – Bosch Diesel with vertical connecting rod; current driven with position feed-
back
●● John Deere J1939 CAN bus
●● Volvo J1939 CAN bus
●● FPT NEF J1939 CAN bus
●● FPT Cursor J1939 CAN bus
Actuator Offset: Number corresponding to the lowest actuator position (closed throttle)
Actuator Full scale: Number corresponding to the highest actuator position (throttle fully open)
Actuator Normal Start Position: The position the actuator will be ‘parked’ at from start until the “Start
Detection RPM” is reached. If “Soft Start” is enabled, this is also the maximum position of the throttle until the
Target Frequency minus 3Hz is reached. Therefore, if “Soft Start” is enabled, the actuator start position MUST
BE HIGH ENOUGH to reach 57Hz (on a 60Hz unit).
Actuator Quiet-Test Start Position: The position the actuator will be parked at from start up until the “Start
Detection RPM” is reached. If “Soft Start” is enabled, this is also the maximum position of the throttle until the
“Quiet-Test Target Frequency” minus 3 Hz, is reached. Therefore, if “Soft Start” is enabled, the actuator start
position MUST BE HIGH ENOUGH to reach the “Quiet Test Target Frequency” minus 3 Hz.
Soft Start Timer: The time (in 0.01 second increments) to stay at each soft start step before moving on to
the next step. This only applies if soft start is enabled.
Soft Start Frequency: An entry of 0Hz disables the soft start. Any other value enables soft start which ramps
up the generator frequency at a rate determined by the “Soft Start Timer” to minimize smoke during startup.
This value selects the first frequency to target after start up. Once this frequency is attained, the generator will
hold this frequency for the “Soft Start Timer” duration then ramp up by 3Hz to the next step. This process is
repeated in 3Hz increments until the frequency exceeds 57Hz, at which time the PID control will kick in and
take the speed to the Target Frequency and regulate it there. During soft start the throttle will not be allowed to
exceed the “Normal Start Position”.

Chapter 17
Diesel: Indicates if this is a diesel powered generator. This modifies frequency control as well as other
features.
Dump Enable: Indicates if extra load dump governor compensation is desired to reduce the increase in
frequency caused by a large drop in load. The following three selections are available:
●● No Dump – No additional compensation
●● Dump – Resets the governor algorithm when a load dump is detected
●● Dump & Hold – The same as Dump, but also holds the throttle closed until the frequency drops back
into range.
Engine Linearization: Selects the engine torque to actuator position translation curve for the Bosch actuators.
There are currently 6 choices.
●● 0 = no conversion; Torque = position
●● 1 = Bosch throttle body actuator (butterfly) with minimum position the same as an un-powered actua-
tor.
●● 2 = Horizontal Diesel Actuator
●● 3 = Vertical Diesel Actuator
●● 4 = The same as 1, but with the minimum position at the actuator stop
●● 5 = The same as 4, but with a limited position resolution of 1
●● 6 = The same as 4, but with added energy to accommodate throttles that normally operate in the
nearly closed position at no load
Integral Limit / Anti-Windup: The choice is to use either an integral limit (YES) or an anti-windup strategy
(NO)
Limit / Windup Parameter: If the “Integral Limit” is selected, this is the maximum value the integral is
allowed. If “Anti-windup” is selected, this is the integral value above which the anti-windup algorithm becomes
active.
PWM counts per amps x10: The number of Pulse Width Modulated (PWM) counts required to drive one-tenth
of an amp into a linear current driven actuator. This only applies to the “Linear Current” actuator type.
De-synch. Offset (Hz): Applies an offset of from -0.9Hz to +0.9Hz (in 0.1Hz increments) to the target
frequency to improve the passive synchronizing with an automatic transfer switch using the In-Phase Transfer
function. If an In-Phase or synchronized transfer is required, use this setting to adjust the generator frequency
to 0.1Hz above the nominal Utility frequency (normally 60Hz).
Sensor Source: Selects the sensor source the governor uses to compare against the target frequency/speed.
The default setting from the factory is Alternator; this provides the cleanest source signal for the governor
function. The alternate source is Flywheel, which is the magnetic pickup input. If this setting is changed to
Flywheel, the control PID constants will most likely need to be adjusted to the new source.

Chapter 17
Governor PID Control

Introduction
The DCP governor uses a PID (Proportional – Integral – Derivative) control loop to maintain the engine speed
alternator frequency at the desired target speed/frequency. The same control loop is used in the voltage
regulator to maintain the output voltage at the desired target voltage. There are several terms associated with
PID control loop processes that are helpful to understand:
●● SP or Setpoint: this is the Setpoint or Target Value the control is trying to maintain. In the DCP con-
trol governor this can be the target frequency or the target RPM. For the voltage regulation circuit this
is the target voltage.
●● PV or Process Variable: this value is the actual value the control is seeing from the unit. This can
be frequency or RPM for the engine; it would be output voltage for the voltage regulator. Frequency is
sensed directly off the voltage sensing leads; RPM is sensed off the magnetic pickup; output voltage
is sensed directly off the MLCB sensing leads. If the SP is frequency, then the control is looking at the
actual frequency of the machine. When there is an error between the SP and the PV then the control
takes action to correct the error. This is the function of the governor: to maintain the Process Variable
equal to the Set Point.
●● CV or Control Variable: this is the output which the governor controls to make the PV match the
SP. For frequency or RPM control the Control Variable is the fuel. The amount of fuel delivered to the
cylinders is controlled by changing the position of the fuel control through the actuator. For voltage
control the control variable is the field excitation. To change the output voltage the excitation is either
increased or decreased.
●● Proportional: the output to the control variable will be proportional to the error. Increasing the
Proportional term will increase the control response to an error. Decreasing the proportional term will
decrease the control response to an error. For example; for frequency (speed) control, if the error is
small the control will change the fuel to the engine a small amount. If the error is large the control will
change the fuel to the engine by a larger amount. If you increase the Proportional term too high, the
unit will become unstable and hunt. If it is too low the unit will be slow to respond on a load change.
A unit operating with only a proportional control (no integral or derivative) will never recover to its
desired target speed when load is applied or removed.
●● Integral: is used to bring the process variable all the way back to the setpoint. It does this by creating
an artificial setpoint as long as there is an error between the actual set point and the process variable.
This automatic reset operation is done by integrating the error and adding that value to the output of
the controller’s proportional term. This is a mathematical process (calculus – integration – finding
the area under a curve). The integral term can build up over time: the longer there is an error the big-
ger the integral value gets and the more it adds to the proportional output. This is why we have the
Integral Limit and Anti Windup functions in the governor configuration. These are predetermined at the
factory through extensive testing and should not be changed. If the integral term is too high the unit
will hunt (overshoot and undershoot around the setpoint); if the integral is too low the unit will slowly
return to the setpoint.

Chapter 17
●● Derivative: Derivative looks at the rate of change in the Process Variable – how fast it is moving away
from or toward the target. The derivative term is only active when the error is changing. Because
the setpoints on a generator are constant (frequency and voltage), the error only changes when the
Process Variable is moving away from or toward the Setpoint. This happens anytime there is a load
change. Derivative is what provides the ‘kick’ to the control to change the fuel setting (or excitation) to
drive the Process Variable back to the setpoint. If the derivative term is too high the unit will overshoot
and undershoot the target (hunting). If the derivative term is too low the unit will be slow to return to
the target.
PID Governing Principles

To try to understand how these three terms work together we use the following illustration. It is important to
remember that in our process (power generation) the Setpoint (whether frequency or voltage) is held constant.
We will only consider one aspect of the unit in this example – frequency or speed.
Imagine a car maintaining a constant 60MPH on the highway. The driver can see the speedometer and uses
that input (the PV) to maintain the SP (60 MPH in his brain to abide by the law) by adjusting his foot on the
pedal (the fuel setting through the throttle linkage) to maintain the desired 60 MPH. If the speed drops off he
will increase fuel to bring it up and if the speed increases he will decrease fuel to bring it down.
When the car comes to a hill the speed will decrease because it is not producing enough power at the current
fuel setting to maintain its speed going up the hill. The driver sees the speed drop off and responds by
pushing the throttle open. How much he opens the throttle is dependant on his proportional setting. If the hill
is steep and the speed drops rapidly, the proportional will give a large throttle change and the derivative will
add to it, depending on how quickly the speed is changing. If the driver pushes the throttle to the floor (and
the engine has enough power – imagine a highly modified Chrysler Hemi, Camaro or Ford Mustang), the speed
will accelerate rapidly toward the desired 60 MPH. This is when the Derivative kicks in again and says, “Hey,
we’re approaching the target speed pretty fast, better back off on the throttle to prevent overshoot.” So the
driver backs off on the throttle a bit and the car gradually approaches the 60MPH speed. Integral meanwhile
has been watching everything and says keep the throttle a little higher than you need until we get right back on
target, then back off and stay right at 60MPH. Eventually we will again be at our target speed of 60MPH with
the engine running at a higher fuel/power setting than before to maintain the desired speed up the hill.
As the car goes over the top of the hill the speed will increase (the engine is producing more power than
needed). If the speed increases a large amount, proportional will see that we are way over the speed we want
and decrease the throttle by a large amount; derivative will look at how fast we are accelerating and add its
input to the proportional. Then when the speed starts to decelerate, derivative will look at how quickly we are
approaching the target speed and say, “Better give it a little more throttle so we don’t undershoot our target
speed. As we approach the target speed integral will say, “okay decrease a little more until we get back on our
target speed.” Eventually the speed will be back on target, and the fuel/power setting will be reduced to the
new required amount to maintain 60MPH on the level road.
In this illustration there is a lot more happening in the driver’s brain. The driver can anticipate the changes
needed as the car approaches the hill and apply throttle as the car starts up the slope – so there is very little
or no change in speed. As the car approaches the top of the hill the driver can anticipate and reduce throttle
as the car crests the hill so there is little or no change in speed. This is because the driver’s brain can see the
hill and anticipate the change in load (hill) and speed. The PID controller can only act on what it can see –

Chapter 17
which is the target speed, the actual speed, and the rate of change of the speed; it cannot see or anticipate the
change in load, so it does the best with what it has.
The PID settings on the controller are set to provide good control response. They are set through extensive
testing at the factory. Once established for one engine/kW application, the settings are used for all of that
engine/kW size. It is sometimes necessary to adjust the PID settings on a controller to adjust for differences
in BTU content of the fuel (NG or LP), or to adjust for geographical or environmental conditions (high altitude,
high humidity, extreme high or low temperatures), or to adjust for different load demands
The key to working with the governor PIDs is to first see how the unit operates and handles load change when
it is up to normal operating temperature. If the unit is stable at no load and handles load changes without any
problems or instability, then you don’t need to make adjustments. If the unit is unstable at no load or is very
slow to respond to load changes, then you might need to make changes. Before you make any changes to
the governor PID settings, save the configuration file for the unit to its folder on your PC, and write down the
original PID settings. That way if you mess it up you can always return to where it started and start over.
If you are going to attempt to improve the performance of the unit by changing the governor PID settings do
the following:
●● Make sure that the fuel supply to the unit is good at no load and full load. Often the problem with a
units response to load change is fuel related – not enough supply volume for the demand.
●● Make sure the unit is properly sized to the load. This applies in particular to large 3-phase motors and
UPS systems.
●● Write down the PID settings before you make changes
●● Change the PID values in small increments proportional to the starting setting. This means that if the
KP value is 15 don’t try your first change by jumping it up by ten – try incrementing by values of 1 or 2
at a time. If the KP value is 70 then you could try incrementing by a value change of 5 at a time.
●● You must be able to apply load to the unit when you make changes to see what the effect of the
change is on the performance of the unit. Always apply the same amount of load as different loads
will cause the unit to respond differently.
●● Use Remote Trending at 0.3 second intervals and watch the frequency and voltage channels – these
are the two which will show how the unit responds to the load change.
●● Remember that the PIDs are all interactive. Changing the setting of one will affect its influence on the
others and how it is influenced by the others. The simplest to work with are the P and D. You can
make minor changes to these without having to work with the integral. If you find yourself ending up
with large changes to the PID settings, there may be something else wrong with the system.
●● Operate the unit against a load bank. If it performs properly against the load bank but not the customer
load, then start looking at what type and what size load the generator is running against.
If you feel that you need to adjust the Voltage Regulator PIDs, please contact the Generac Service Department
and talk with a Generac Service Technician before you make any changes. Often times the reason a generator
will not operate properly against a load, for instance against a large 3-phase motor or a large UPS load, is that
the generator was not sized correctly to start with. It is not a generator fault; it is the fault of whoever sized the
generator for the load and type of load. For more information on properly sizing a generator to a load see the
references at the end of this chapter.

Chapter 17

1. What is the de-sync offset used for on a H-Panel?
2. When would delay A and B be used on Analog Input channels?
3. What can you use digital output functions for?
References
Generac Power Systems, Generator Sizing Guide, PN 0172610SBY
The Power Design Pro program located in the Industrial section of www.Generac.com
J. Wright, “Chapter 8: Alternators (Synchronous Generators),” sections 8.6 through the appendix, in On-Site
Power Generation, A Reference Book, 4th Edition, Electrical Generating Systems Association (EGSA), 2006, pp.
111-135.

Chapter 17

344
18 H-Panel Voltage Regulation and
Current & Voltage Calibration
Keywords
●● Calibration
●● AC Sensing
●● Voltage
●● Current
Contents
Chapter 18 - H-Panel Voltage Regulation and Current
& Voltage Calibration............................... 345
Introduction............................................................. 346
H-Panel Voltage Regulation and Calibration........... 346
Scaling................................................................ 350
Regulator Settings............................................... 351
H-Panel Voltage Calibration Procedure................... 353
Example 1........................................................... 356
H-Panel Current Calibration.................................... 357
Example 2........................................................... 358
References.............................................................. 359
345
Chapter 18
H-Panel Voltage Regulation & Current and Voltage Calibration
Introduction
The automatic voltage regulator is an integral part of the H-panel. The voltage regulation circuit senses all
phase voltages through an Interface Transformer board (IFT). The IFT provides a nominal 48VAC phase to
phase sensing signal (28.8Vac phase to neutral). The AVR circuit converts the analog voltage to a digital
signal, puts it through a scaling factor (to provide for 208, 240, 480, and 600 VAC sensing), and then through
a calibration factor to calibrate out differences in the sensing voltages. The sensed voltages are averaged and
the average sent to the voltage regulator as the actual voltage. When the regulator sees a difference between
the Set-Point (Target Voltage) and the actual voltage, it changes the AVR Gate Trigger to the voltage regulator
driver to increase or decrease the excitation to the field to bring the actual voltage to the target voltage.
H-Panel Voltage Regulation and Calibration

Operation
Figure 313
Chapter 18
Un-calibrated
Figure 314

Chapter 18
H-Panel Voltage Regulation and Calibration

Calibrated
Figure 315

Chapter 18
120/208 and 120/240 Three-phase.
Figure 316

Chapter 18
Scaling
The scaling factor is used to adjust the panel to regulate and display the correct voltage for 120/208, 120/240,
377/480, and 600 volt systems. The IFT always provides a nominal 48VAC (phase to phase) sensing signal,
which means the panel has to be scaled to display and regulate the proper voltage. The following are the
scaling factors for the various voltage options.
Voltage Code A – 120/240 Single-phase Scaling A-N & B-N = 0.2500

Scaling A-B = 0.5000
Voltage Code G – 120/208 Three-phase Scaling A-B, B-C, C-A = 0.5000
Voltage Code J – 120/240 Three-phase Scaling A-B, B-C, C-A = 0.5000
Voltage Code K – 277/480 Three-phase Scaling A-B, B-C, C-A = 1.0000
Voltage Code L – 346/600 Three-phase Scaling A-B, B-C, C-A = 1.1572

Chapter 18
Regulator Settings
Figure 317
This is the Voltage Regulator Settings configuration menu; all but two of the selections require a level two
security dongle.
Voltage KP, KI and KD: These are the voltage regulator control loop gain constants. They come preset from
the factory to provide optimal voltage regulation control. These values are all interactive, as was discussed
in the Governor PID section. Care should be taken when trying to use these settings to make a unit more or
less responsive. If you are making changes to these settings, it is highly recommended that you write down
the original values before you start, so you always have a reference point to return to. Always consult the
Generac Service Department if you have questions or are intending to make significant changes to these
parameters.
PMG: Yes or No: Tells the voltage regulator circuit the frequency of the power supply it is using to change the
excitation voltage to the field. The ‘YES’ selection indicates the power supply to the driver is Generac PMG
which operates at 240Hz. The ‘NO’ selection indicates the power supply is either Generac DPE or a WEG
PMG (500kW and larger), both of which operate at 60Hz. Don’t forget to check the DIP switch setting on the
Voltage Regulator Driver also; it needs to be set for either DPE or PMG.
VF Corner (Hz): These are used for V/F control to reduce the output voltage when a large load is applied
which slows down the prime mover. If the frequency drops below these setpoints, the voltage is reduced
proportionally as the frequency drops, according to the Volts per Hertz Ratio.
SEL/CkSync Board: Not used on H-Panels.
Volts per Hertz (V/Hz): Sets the number of volts to reduce the generator voltage for each Hertz below the V/F
corner frequency.

Chapter 18
AVR Dump Improve: Makes the regulator module increase the gain temporarily on a load dump to improve
the transient voltage response.
Power Factor: Not used on H-Panels
Unit Rated Power (kW): This is the generators rated power in kW. If you ever re-configure a G or K code
stator to the J code stator, this is where you would de-rate the power output of the machine.
kW Demand (kW): Not used on H-Panels.
Reverse Power Limit (kW): Not used on H-Panels.
Panel Type: Indicates the panel type that the control is programmed to be. H-Panels will always be H-100
Multi-Voltage Option: Only selected if the unit is a multi-voltage capable unit.
User Load Capacity Management: Not used with H-Panels.
Backup Paralleling Options: Not used with H-Panels.

Chapter 18
H-Panel Voltage Calibration Procedure
Figure 318
This is the Analog Input Channel Voltage Phase A-B (channel 15) configuration channel. The Calibration box
in the top right corner of the screen is where the calibration values will be entered. Voltage Calibration is
required on Industrial units and is highly recommended on commercial (QT) units. If the voltage calibration
is not performed properly, or at all, there is a chance that the display will not reflect the actual generator output
voltage and that the output voltage will not be the exact voltage that is set in the panel as the target voltage.
This will affect not only the voltage output but the kW display value and the kW hours calculation.
To perform the voltage calibration you will need the proper safety equipment (per NFPA-70E), calibrated
voltmeter, access to the MLCB terminals, and be in a position where you can see the H-panel Display, the
voltmeter, and your PC screen. The object of voltage calibration is to make the display voltage and the
actual voltage match on all three channels; A-B, B-C, C-A (A-N, B-N and A-B on a single phase unit). You
will calibrate each channel, one at a time, comparing the display voltage to the meter (actual) voltage, and
adjusting the calibration factor to match the display to the actual within 1 volt.

Chapter 18
Figure 319
The ideal way to do this, and the fastest, is to be in a position where you can see the display, the meter and
Genlink DCP at the same time. There are several things you can do to make the process easier and faster.
Follow the steps below; these steps demonstrate calibrating a 480/three-phase unit.
●● Open the Analog Input Channels configuration menu to channel 15 (Phase A-B Voltage). Make sure
the calibration factor for each voltage channel is 1.0000.
●● Connect the meter to the generator side of the MLCB on the A-B terminals.
●● Start the generator with the Manual key switch, and let it warm up for a few minutes.
●● Read the A-B display voltage in the left screen of the H-panel and compare it to the A-B voltage on the
meter. If there is a difference of greater than 1 volt you must adjust the calibration factor.

Chapter 18
TIP #1: If the display voltage is higher than the meter (actual) voltage, the calibration factor will need to be
reduced (less than 1.0000). If the display voltage is lower than the meter (actual) voltage, the calibration
factor will need to be increased (greater than 1.0000).
TIP #2: On a 480 volt unit, changing the calibration factor by a value of 0.002 will change the output voltage
by approximately 1 volt. On a 208 or 240 volt unit, changing the calibration factor by a value of 0.004 will
change the output voltage by approximately 1 volt – this is due to the change in scaling. The calibration value
on a 600 volt unit will be somewhat less than the 0.002 value used on a 480 unit.
TIP #3: Use Tip #2 to quickly calculate how much the calibration factor needs
to change. For instance, if the display voltage for Phase A-B is 483, and the meter
(actual) voltage for Phase A-B is 474, the difference between the two is 9 volts.
9 x 0.002 equals 0.018. Since the display voltage is higher than the meter voltage it means that the calibration
value must be reduced (see Tip #1). 1.0000 minus 0.018 equals 0.982 – this is the value you should enter in
the calibration box for Voltage Phase A-B.
TIP #4: You can use a calculator to get find the initial calibration factor quickly. Simply take the Actual
Voltage for the channel you are calibrating and divide it by the Voltage in the H-Panel Display. Enter the value
(to the 4th decimal place) in the calibration factor block and hit Apply. After doing this separately for each
channel you can then go back through and “tweak” each channel using the tips outlined previously.

Chapter 18
Example 1
Below is an example of the typical calibration process on a 480 volt three-phase unit.

1. Phase A-B voltage – Meter = 474, Display = 483
Use your calculator and divide the meter voltage by the display voltage
474 / 483 = 0.9813
Enter 0.9813 in the calibration box for Phase A-B
New voltage Phase A-B Display = 478, Meter = 477
This change will affect the other two phase voltages, so move to Phase B-C voltage channel (16) and move
the meter leads to Phase B-C. Repeat the above steps.
2. Phase B-C voltage – Meter = 477, Display = 478

This is within 1 volt so no change is made.
Move the meter leads and go to the next channel, Phase C-A.
3. Phase C-A voltage – Meter = 477, Display = 484,

Use your calculator and divide the meter voltage by the display voltage
477 / 484 = 0.9855
New voltage phase C-A – Display = 480, Meter = 480
A quick check of the other phases display voltage compared to meter voltage shows
Phase A-B Display = 480-481, Meter = 480
Phase B-C Display = 481-482, Meter = 480.
Reduce the calibration factor on channel B-C by 0.002
Phase C-A Display = 480-481, Meter = 480
The calibration is complete. The display voltages may wander a bit around the setpoint voltage, this is normal.
They should, on the average, be within 1 or 2 volts of the target (actual) voltage. The actual voltage has
moved from 477 at the beginning to an actual voltage of 480 which is our desired target voltage. If you use
the tips given above it will save you time.

Chapter 18
H-Panel Current Calibration

The next item to be calibrated is the current sensing channels. Because current is a result of load and is
determined by the load on each phase, the current channel calibration will only affect the display. This is a
simple process and should take very little time. The things you will need to perform current calibration are:
proper safety equipment (per NFPA-70E); a calibrated Amp Clamp; a steady load – preferably in the mid load
range of the unit; a pen and paper and a calculator; Genlink open to the Analog current channel.
Figure 320
This is the Analog Input Channels Phase-A current configuration channel (channel 11). The Calibration box
in the upper right corner of the screen is where the calibration value will be entered to make the display value
match the meter (actual) value. We use a different process to calibrate the current channels than we used to
calibrate the voltage channels. Draw a simple three by three table and label it – as shown below.

Phase A Phase B Phase C
Actual Current (meter)
Display Current
Calibration Value
Table 22
Calculation is: Actual value divided by the Display value = the calibration value.
Chapter 18
Calibration Value calculation is Actual (to the nearest tenth) divided by the Display
gives a result of some value X.XXXXX, look at the 5th decimal figure - if it is greater than 5, round the 4th
decimal figure up one; if it is less than or equal to 5, leave the 4th decimal figure as is.
Example 2
Below is a step by step example of the procedure used to calibrate the current channels
●● Open the Analog Input Channels configuration menu to channel 11 (Current Phase A). Make sure the
calibration factor for each current channel is 1.0000.
●● Start the generator and apply a steady load. If you have a load bank apply 50% load. You can use the
customer load only if it is steady. If the current on the meter is constantly changing you cannot use it
– it will be like trying to hit a moving target. Let the unit warmup and stabilize.
●● Look at the current display values and write them in the appropriate row and column of the calibration
table (shown on the previous page and below).
●● Connect the clamp meter to the load side of the MLCB on each Phase cable and record its value, to the
nearest tenth, on the appropriate row and column of the calibration table (shown below).
●● Using the recorded values and a calculator, divide the actual value by the displayed value (actual/dis-
play) and write down the calibration value to the 4th decimal figure. If the 5th decimal figure is greater
than 5, round the 4th figure up one. If the 5th decimal figure is less than or equal to 5, leave the 4th
figure as is.
●● Enter the calibration values in their respective channel calibration box in the Analog Input Channels
configuration screen and click the Apply button.
●● Compare the new display values to the actual values. If you did everything correctly the display
should read within 0.5 amp of the actual value.

Phase A Phase B Phase C
Actual Current (meter) 54.6 54.8 55
Display Current 57 57 58
Calibration Value 0.9579 0.9614 0.9483
Table 23
Calculations
Phase A is 54.6 divided by 57 = 0.95789, round to 0.9579
Phase B is 54.8 divided by 57 = 0.96140, round to 0.9614
Phase C is 55 divided by 58 = 0.94827, round to 0.9483
When the calibration values are entered for each channel and the apply button is pressed all of the display
values will read 55 Amps which is within a half-amp of the actual.
Now that the voltage and current calibrations are complete the actual voltage is right on the target voltage
(480) and the display voltage reflects this on each phase. The Current display values equal the actual current
values. Now the kW and kW hour calculations will be accurate.

Chapter 18

1. What is scaling factor used for?
2. Where in Genlink DCP can you set the target voltage for an H-panel?
3. Why is it important to calibrate voltage and current when working with a H-Panel?
References
There are several chapters which provide a good understanding of voltage regulation and effects of load, etc,
in the EGSA Book.
Wright, J. “Chapter 8: Alternators (Synchronous Generators),” in On-Site Power Generation, A Reference Book,
Basler, M., et al., “Chapter 17: Automatic Voltage Regulators,” in On-Site Power Generation, A Reference Book,

360
19 Alarm & Event Logs
Reports and Maintenance
Keywords
●● Alarm
●● Event
●● Reports
●● Maintenance
Contents
Chapter 19 - Alarm & Event Logs, Reports and
Maintenance............................................ 361
Introduction............................................................. 362
Alarm Log............................................................... 362
Event Log................................................................ 364
Reports................................................................... 367
Maintenance........................................................... 372
Generator Maintenance Schedules......................... 374
361
Chapter 19
Alarm & Event Logs, Reports and Maintenance
Introduction
The Alarm and Event logs are two valuable troubleshooting tools. Both the Alarm and Event Logs will display
the Date/Time stamp of the trigger, and will also display up to 6 engine/generator parameter values taken at
the time of the trigger. These parameters are a snapshot of the values at the instant of the trigger. The Alarm
Log will hold the 20 most recent alarms or warnings that have been triggered by the control. The Event Log
will hold up to 20 events triggered by settings put in to the control through Genlink DCP. The Alarm Log can
be viewed through the display panel Menu or through Genlink DCP. The Event Log can only be viewed through
Genlink DCP.
Alarm Log
Using Genlink DCP the Alarm Log can be displayed and/or printed, and the parameters taken at the time of the
trigger can be selected.
Figure 321
Figure 322
Alarm Log parameter selection screen. The first two parameters require security level two access to change.
They are reserved by Generac. Loss of oil pressure and overheat (high coolant temp) are the two most
common causes of prime mover catastrophic failure. Generac wants to see these two parameter values in
each alarm log. The other 4 parameter selections only require a level one dongle to change and the channel
selection is up to the technician/customer. It is recommended that you set up the total power as a parameter
at a minimum.

Chapter 19
Alarm & Event Logs, Reports & Maintenance
Figure 323
This is a typical Alarm Log. The channel text which triggered the alarm, the type of alarm, the Hi/Lo trigger,
Time, Date and parameter values of the selected parameters will all be displayed. When the log is full (20
alarms) the next alarm/warning will come in as the top row and the last alarm in the list will drop off. The
alarm log can be printed out if you have a printer connected to your PC. If you change a parameter selection,
the previous alarms listed before the change will still show the previous parameter values.

Chapter 19
Event Log
Figure 324
The Event log parameter selection screen: Both parameter menu screens can be accessed once you enter
either one. All 6 parameter selection choices are available to the technician/customer. It is recommended that
you select some parameters for a baseline. If you are looking at a specific channel to trigger an event, it is a
good practice to make one of the parameters display that trigger channel. For instance, if you are triggering
an event from the Total Power channel when total power exceeds 80kW (on a 100kW unit), select total power
as one of the parameters to look at. This way you will see the event and be able to see the value that triggered
the event.
Event logs can be triggered from Analog Input channels, Digital Input channels and Digital Output Function
channels. Analog channels can be triggered at greater than, less than, equal to, not equal to, greater than/
equal to, and less than/equal to values. When you use an analog channel to trigger an event the setpoint will
be in that channel’s values. For instance; if you wanted to trigger total power at 110% of the units capacity,
and the unit was rated at 150kW, the trigger value would be 150 x 110% = 165kW.
Digital Input channels and Digital Output Function channels can be triggered when the channel is true or false.
True would be when the channel is ‘ON’; False would be when the channel is ‘OFF’. Digital Input channel
events look at the processed value to trigger the event.
It is a good idea to set up the Auto/Off/Man key switch to trigger event logs when it is in each position. This
will give you a date/time log of the position of the switch when a power outage occurred. The most common
cause of failure of a standby system to start, when the utility fails, is the system being turned “Off”. Use the
Digital Output Function diagnostic screen to identify these three channels. Trigger the event log for each when
that condition is True.

Chapter 19
Figure 325
Figure 326
Set the Auto/Off/Man key switch to trigger an event log, when it goes to each position, from the Digital Output
Functions configuration menu. The event should trigger when that condition is True (On).

Chapter 19
Figure 327
A typical Event log display screen; it will display the Channel Text, Date, Time, and the parameter values
selected. This log can be cleared by clicking the Clear button at the bottom of the screen. If there is a printer
connected to the PC that is running Genlink DCP, the Event log can be printed.

Chapter 19
Reports
Figure 328
Selecting the Reports Menu tab and Clicking the Reports button will open the Reports screen. Four reports
can be selected: Display Panel, Configuration, Alarm Log, and Event Log. All four can be selected or each
can be selected individually. Each Report can be printed, if there is a printer connected to the PC, or Saved to
an electronic file. It is highly recommended that each time you connect to a panel that you save the Alarm Log
as a report to the folder for that specific unit. This will give you a permanent alarm history on the unit. Before
a report will display, the selection must first be viewed. For instance, to open the Alarm Log or Event Log in
the Reports menu, first view the Alarm log or Event log and then open it in Reports. The same goes for the
configuration report; view all of the configuration menus before you open it in Reports and all the configuration
data will show up.

Chapter 19
Figure 329
This is the Configuration Report. If you do not view each configuration menu before you open the report the
values will all read 0. You must view the individual configuration menus before you open the Report to see the
actual values. This is a good report to save after you have calibrated and configured the unit on start-up. It
will give you a readable document of all the configuration values in the .xml file.

Chapter 19
Figure 330
This is the Alarm Log in the Reports menu. The log has already been viewed so the information in the log
shows up. It is highly recommended that you view the Alarm Log and save it as a report to the folder for that
unit, every time you service the unit. It will give you a written alarm history of the unit. This is very valuable in
troubleshooting.

Chapter 19
Figure 331
This is the Event Log Reports screen. The Event Log has been viewed before opening the Report, otherwise
there would be no data to display. The Event Log Report can also be saved to a file for history on the unit.

Chapter 19
Figure 332
If you select the “Save” option in the Reports screen, the Window file navigation screen will open. Select or
create a folder for the report you want to save. It will be saved as a .txt (text) file which can be opened later
with any text editor application.

Chapter 19
Maintenance
The Maintenance menu accessible through Genlink DCP is a way to trigger a maintenance warning based on
the Engine Hours, Operations or Date-Time.
Figure 333
The Maintenance form allows you to set up service intervals for various components of the Generator.
Maintenance parameters are only updated every 15 minutes, so any changes you send to the controller will
not show up for this time (for example the % life display will not update until 15 minutes after new settings
are loaded). When the service is due, the controller will issue a warning indicating which maintenance item
triggered the warning. To clear the warning, the service interval will have to be reset on this form for that
specific item. The service warning can be set to occur on either one or two conditions so that the condition
that expires first triggers the service notification. To disable a maintenance warning, set the “Cycle Type”
field to N/A. The audible alarm will NOT sound for each 15 minute re-occurrence of the warning after the first
maintenance warning is acknowledged. The front panel display will show the percentage of life left for each
possible maintenance item. All maintenance settings are kept in the Maintenance menu. Once changes are
made to the maintenance screen click “Apply” to save your changes. Maintenance settings are not included in
the configuration file transfer; they must be re-entered manually if the configuration file is re-loaded.

Chapter 19
These are the maintenance categories that are available to trigger a warning:
●● Oil Life
●● Oil Filter Life
●● Air Filter Life
●● Spark Plug Life
●● Battery Life
●● General Service Maintenance
●● Utility Transfer Switch
●● Generator Transfer Switch
●● Bi-Fuel Service
The following settings are available for each maintenance item:
Cycle Type: The Cycle type or service interval can be in:

●● Engine Hours (cumulative or a specific engine run hour)
●● Operations – number of operational cycles – for instance trigger a warning after 500 Transfer Switch
cycles. This only applies to H-Panels operating with HTS switches.
●● Date-Time – This is in the standard mm/dd/yyyy format.
Installed At: this entry is used to begin a service maintenance cycle

End of Life: this entry is used to determine when the maintenance is due; it will trigger the warning.
●● For Engine Hours – this should always be zero. The end of life is then simply the number of hours
from ‘NOW”.
●● For Date-Time you can double click in the field to bring up a calendar form or enter the date in the stan-
dard mm/dd/yyyy format.
●● For Operations the installed at value will be zero (0). The end of life will be when the operation count
reaches the end of life number.
Life Time Remaining % - this will display the remaining time in percentage before the next service is due.

Chapter 19
Generator Maintenance Schedules

This is a good time to talk about service maintenance cycles on standby generators. If you read through
the Owner’s Manual for the unit, or through the Generac Power Systems publication, A Guide to Basic
Maintenance Information (PN 0F5624), you will find the maintenance schedules recommended for standby
generators.
Generally the service maintenance required on a standby generator set can be broken down into 5 levels or
time periods. The following shows the typical levels and some of the maintenance to be performed at that
time:
• Level One – Monthly/every 10 hours of operation
Check fluid levels, belts, fuel system (leaks, proper pressure), battery (connections, electrolyte), , clear
enclosure of foreign objects,
• Level Two (break-in) – 6 months/first 20 - 50 hours of operation
change the engine oil, replace the oil/fuel, adjust the valves, check the drive belts and accessories, etc.
• Level Three – Every 6 months/50 hours of operation
Level One checks plus – test the automatic system start operation, run the unit at no load and check
for leaks, etc.
• Level Four – Annually/100 hours of operation
Level one and three checks plus - check all electrical connections for tightness, check the accessory
drive belts for condition and tightness, start and exercise the unit under full load for at least 2 hours,
perform engine oil analysis, etc
• Level Four – Bi-annually/250 hours of operation
Perform level one, three and four checks plus, change the oil, & all filters,
The particular maintenance service plan that your company offers the customer will probably be structured
similar to that above. The point is that the periodic maintenance performed on the generator set will ensure
that it lasts for twenty or thirty years with minimal problems. That means twenty to thirty years of service
contract which your company sells to the customer. That is where the money is in standby power generation.

1. What menu is used to pick what information is captured with either an alarm or an event occurs?

Chapter 19

376
20 Remote Trending
Keywords
●● Real Time
●● Save to a File
●● Channels
Contents
Chapter 20 - Remote Trending............................. 377
Introduction............................................................. 378
Trending.................................................................. 378
Export as CSV..................................................... 385
377
Chapter 20
Remote Trending
Introduction
Remote Trending is a feature of the H-panel which allows the technician to collect data for up to 16 engine/
generator parameters at variable time intervals. This data can be viewed in real time as a graph, or saved to
an electronic file in a .csv (comma separated value) format for later use with almost any spreadsheet program.
This feature allows a simpler method to obtain data to meet load bank requirements, and for analysis and
troubleshooting of generator operating characteristics.
Trending
The Remote Trending only works with Genlink DCP connected to the machine. The menu is accessed through
the Trending tab and then the Remote Trending choice. This will open the following screen.
Figure 334

Chapter 20
Remote Trending
Click the Save to buttom to open the

Windows file navigation screen
Figure 335
There are three choices for working with the trend file:
●● File – saves the data collected to a file on your PC.
●● Real Time – allows you to view the trending data on the graph in real time
●● Both – saves the date and allows you to view the graph at the same time
●● Save All AI – When trending and saving data to a file, selecting “Save All AI” will save all of the Analog
Channel data to the file – regardless of how many parameters are selected in the parameter menu.
The time interval selected can be in seconds, minutes or hours.
When you make changes to the time interval click the Refresh button to update the screen
The Start/Stop button in the bottom left corner will start and stop the trend.
Think of the trending function as a camera which takes a picture of each of the selected parameter values at
each time interval. If the trend interval is 15 minutes, then every 15 minutes each parameter value selected
is recorded in the file or on the display graph. If the trend interval is 0.3 seconds then each parameter value
is recorded every 300 milliseconds. The fastest interval available is the Fast trend which will only record two
parameter values every 100 milliseconds (0.1 seconds). The fastest trend interval for all the parameters is
300 milliseconds (0.3 seconds).

Chapter 20
Remote Trending
The Scaling sets the scale for each

parameter – the scale goes from the 0
point at the bottom to the full scale value
at the top. The graph of the parameter
will be displayed within this scale range.
Figure 336
This is the screen for both Real Time and File . Use the Save to button to select the folder and name the file
where you will save the trend data. It will be saved in a .csv file format – this can be opened with almost any
spreadsheet program. Set the time interval – it can be set in seconds, minutes or hours.
Scaling sets the range of the scale for each parameter. If the scale value is too low the parameter value may
be off the screen at the top. For instance, if the parameter scale is set to 200 but the actual parameter value is
250, the value will not show up on the graph display. Set the scale so that the parameter value falls within its
range. For instance, if the parameter is Voltage, and the unit is a 480 volt unit, set the scale to 500. The graph
for that parameter would then end up near the top of the display screen – showing 480 on a scale of 500.
Offset is used to move a display graph down and zoom in on the graph. Think of it as decreasing the scale
value but keeping the parameter value in the graphing area.

Chapter 20
Remote Trending
Figure 337
Parameters are selected by clicking on the drop down arrow to the right of each parameter box. Use the up/
down arrow buttons to scroll through the parameters available for trending.

Chapter 20
Remote Trending
Frequency
Voltage
RPM
Power kW
Current
Figure 338
This screen shows a trending display for five parameter channels: Total Power kW, Average Voltage, Average
Current, Engine RPM and Gen Frequency. The color box to the right of each parameter shows what color
the graph will display for that parameter. The box to the right of the color will display the actual value of that
parameter.
Notice that when the load increased the frequency, voltage and RPM all dropped temporarily, until the voltage
regulator and governor responded and brought all three back to the target settings. When load was removed
all three values increased temporarily, until the voltage regulator and governor responded and brought all three
back to the target settings.

Chapter 20
Remote Trending
Figure 339
This is the same graph with the Data Points turned on. With Data Point ‘On’ the display shows the point that
each parameter value is plotted. The distance between the points is the time interval. These graphs are all
shown with “Scale Illumination” on. The scale illumination is the background grid. The default grid is 20
lines across the horizontal axis and 15 lines on the vertical axis. If the default scale value for each parameter
is 1500, that means that each horizontal grid (up the Y-axis) represents a value of 100. If you change the
scale to 500, then each horizontal grid would represent a value of approximately 33 (500/15 = 33.3).

Chapter 20
Remote Trending
These shots show how the two interval adjustment boxes work.
Adjust the grid

spacing with the Interval
arrows
Figure 340
The right side interval adjustment has a default setting of 100%. There are 20 grid lines along the horizontal
axis with approximately 6 data points displayed in each grid box. By adjusting this value you will stretch grid
length to the right and reduce the number of data points per grid – this changes the time interval represented
by the grid.
Figure 341
This is the grid with the right interval adjusted to 50%. There are now 10 grid lines along the horizontal axis
with only three data points displayed in each grid box.
Adjust the data points per

grid spacing with the left
Interval arrows
Figure 342
The Left Interval box will adjust the number of data points per grid space. Its default setting is 0 – which
means that the maximum number of data points will be displayed per grid space (this is approximately 6 per
grid). By incrementing this value up the number of data points per grid will be reduced by the percentage
displayed. For instance, the left interval reads 50%, and there are three data points per grid displayed.

Chapter 20
Remote Trending
By changing these two intervals you can adjust how many data points are displayed per grid (left) and the time
value represented by each grid space (right).
When you are done with the trend, if you have saved it to a file, you can open it in almost any spreadsheet
program and print the data out in a report format, or a spreadsheet format, or a bar chart, or any other data
format your spreadsheet program supports. This data can then be printed out on your company paper (with
the appropriate header and other information) and given to the customer as a formal load bank report. The
report should show the start time and date, the time interval of the data points and the data taken. The
Trending function in Genlink DCP does all of these. Below is a sample of a saved trending file.
Export as CSV
Interval
Start Time
Timer
10000ms 9/3/2008; 9:56 AM
COOLANT OIL COOLANT BATTERY

Hours Minutes Seconds MS
TEMP PRESSURE LEVEL VOLTS
9 56 41 853 201 68 645 1434

9 56 51 857 200 67 646 1428
9 57 1 862 201 68 645 1431
9 57 11 866 201 72 650 1425
9 57 21 870 201 63 645 1434
9 57 31 875 201 70 648 1431
9 57 41 879 201 68 643 1437
9 57 51 884 202 63 643 1428
9 58 1 888 201 62 648 1422
9 58 11 892 201 60 642 1434
9 58 21 897 201 65 647 1431
9 58 31 901 201 67 642 1437
9 58 41 905 201 68 642 1434
9 58 51 910 202 69 645 1434
9 59 1 914 201 68 643 1434
9 59 11 919 201 66 643 1437
9 59 21 923 201 68 641 1431
Table 24
Periodic trending of a machine has great value in evaluating the performance of the machine over time. That is
one of the reasons we do periodic load banking on units.

Chapter 20
Remote Trending

1. What is the purpose of the “scaling” in the Genlink DCP remote trending screen?
2. What is the purpose of “offset” in the Genlink DCP remote trending screen?

Chapter 20
Remote Trending

388
21 21-Light RAP/RRP
HUIO
Keywords
●● Annunciator
●● Graphical User Interface
●● HUIO
●● Relay Panel
●● Digital Outputs
Contents
Chapter 21 - 21-Light RAP/RRP and HUIO........... 389
Introduction............................................................. 390
21-Light Remote Annunciator Panel (RAP)............. 390
The Panel “Configurator” (GUI)............................ 392
H Unit Input/Output (HUIO)..................................... 396
HUIO Digital Input Channels................................. 400
HUIO Digital Output Channels............................... 402
389
Chapter 21
21-Light RAP/RRP, HUIO
Introduction
Remote Annunciator Panels (RAP) and Remote Relay Panels (RRP) provide remote monitoring and
annunciation of generator parameters and generator system status. There are currently two different Remote
Annunciator panels (and their associated RRP) in use. The earlier version is a 20-Light Remote Annunciator
panel used with the D, E, and F control panels. This 20-Light RAP was adapted to work with the PM-DCP
controls (H & G-panels), and was called a PM-DCP 20-Light RAP. The most recent panel is the 21-Light
RAP and its associated relay panel. The 21-Light RAP was developed to work specifically with the PM-DCP
controls.
21-Light Remote Annunciator Panel (RAP)
Figure 343
The 21-Light RAP is available in three versions:

0G5719 – Remote Annunciator has both relays and LEDs/keypad (RAP/RRP)
0G5720 – RRP version – Remote Relay Panel (relays with no LEDs/keypad)
0G5721 – RAP version – Remote Annunciator Panel (LEDs/keypad without relays)
The Manual for the RAP/RRP is part number 0G6960 and is an excellent source of information about all the
operations, setup and specifications of this RAP/RRP. The next part of this chapter will explain a few specific
things about working with the 21-Light RAP/RRP annunciator panels.
Communication between the PM-DCP control and the annunciator panel is done through the RS-485
communication port. The communication link is a 2-wire – twisted pair with overall shield/screen (Belden
3105A or similar). The annunciator panel has an auto-detect feature which allows it to communicate at a baud
rate of 57.6K, 38.4K, 9600 or 4800 Baud (no parity, 2 stop bits). The RS-485 cable should not be run in the
same conduit or the same wire grouping as any high voltage or high current conductors. The Comms OK light
will flash if there is NO communication; it will stay lit solid when communications are good.
Each RAP has a single alarm relay output with SPDT contacts (one N.O. one N.C.). This relay is normally
energized when the annunciator is powered and no faults are present.
390 Section 4 -Power Manager - DCP H-100 Control Panel
Chapter 21
The RRP has 8 programmable relay outputs (RRP) which each have one Normally Open (N.O.) contact. They
are energized when the annunciator is powered and no faults are present. The maximum contact rating of any
of the relay contacts is 30VDC/1Amp.
There are two ways to program the relays: through the S1 & S2 dip switches, or through the Graphical User
Interface (GUI). The Owner’s Manual gives an excellent explanation of how the dip switches are used to
program the relays. The easier way is to use the GUI. Make sure you move dip 1 on S3 to the ON position to
use the GUI.
S-2 S-1
9-PIN 232
Serial Connector
S-3 S-4
Figure 344
The dip switches on S-1 & S-2 are used to program the relays. The dips on S-3 are used to enable the GUI
and the spare input for the 8th relay. The dips on S-4 are used to set the communications Baudrate. The
9-pin serial connector is used to connect the 0F7707 serial cable from the PC to the RAP/RRP to program it
using the Configurator (GUI).

Chapter 21
The Panel “Configurator” (GUI)
Figure 345
The Graphical User Interface (GUI), called the ‘Configurator’, is part of the Genlink DCP program bundle. The
annunciator configurator is an individual download, it will create an icon on your desktop when downloaded.
The Configurator uses the comm port assigned to either your usb to serial adapter or to the direct serial port
on your computer. Because GenLink DCP will attempt to use the same comm port, it is required that GenLink
DCP be closed before opening the Annunciator software, otherwise you will get a port conflict. Use the same
0F7707 serial cable to connect from your PC to the RAP/RRP that you are working with.

Chapter 21
Figure 346
When you initially open the annunciator program the screen will look like similar to Figure 346.
Figure 347
If you try to connect to the panel without moving dip 1 of switch 3 to the ON position you will get this warning.
It is just reminding you that the panel is using the dip switches to program the relays, and if you want to use
the GUI you will need to move dip 1 on switch 3 to the ON position.

Chapter 21
Figure 348
These are the selections available for programming each relay through the GUI. Here is a list of all the
parameters:
●● Battery Charge Failure ●● Low Oil Pressure ●● Pre-Low Oil Pressure
●● Low Battery Voltage ●● High Water Temp. ●● Pre-High Water Temp
●● High Battery Voltage ●● Low Water Level ●● Pre-Low Water Temp
●● Generator Power ●● Overcrank ●● Pre-Low Fuel
●● Line Power ●● Overspeed ●● Emergency Stop
●● System Ready ●● RPM Sensor Loss ●● Not In Auto
●● Comms Error ●● Generator Run ●● Spare

Chapter 21
Figure 349
Relay 8, only, will display the Spare Input Relay choice. This can be turned on either through the Relay 8 pull
down menu, or by selecting the “Spare Button – “Enabled”. The Spare Input Relay can also be selected by
moving dip 4 of switch 3 to the ON position. This spare input relay is then activated with the ‘blank’ input
switch on the keypad. It could be used to provide remote start by running the 2-wire start circuit to the 8th
relay contact in the panel. It could be used for anything else you may want to turn on or off through that relay
contact.
When you are done configuring the panel with the GUI, click on “Write to Device” button. If you configure the
relays through the GUI, make sure you leave dip-1 of switch 3 in the ON position when you disconnect; if you
turn dip-1, S3 OFF, the panel will revert to the dip settings for the relays and communications.
The 21-Light RAP Owner’s Manual is an excellent source of information when working with this panel; PN
0G6960. It can be found on the Service CD set you were given during training.

Chapter 21
H Unit Input/Output (HUIO)
4 4
INPUTS OUTPUTS
RS485
The HUIO module is designed to connect to an H-panel (only) and expand its input and output capability. Each
HUIO module has four (4) Digital Inputs and four (4) Digital Outputs. Up to four (4) modules can be attached
to the H-panel to give a total of 16 additional Digital Inputs and 16 additional Digital Outputs. The HUIO module
is part number 0G3226. The mating plugs that are needed to connect to it must be ordered separately; they
are part number 0G40110SRV. Ordering both of these part numbers will provide all of the components shown
below.
Figure 350
The state of the output relays can be seen on the 4 Red HUIO Led’s. The two Dip switches in the center are
used to set the Modbus Slave Address for each module.

Chapter 21
J3 J4
INPUT 1 1 3 RS485+
1
Jmp 1
GROUND FOR INPUT 1 2 2 RS485 SCREEN
3
INPUT 2 1 RS485-
Modbus Address J6
GROUND FOR INPUT 2
On 1 2
INPUT 3
GROUND FOR INPUT 3
INPUT 4 8 OUTPUT 4
Led 4
GROUND FOR INPUT 4 8 OUTPUT 4
J2 OUTPUT 3
Led 3
OUTPUT 3
OUTPUT 2
OUTPUT 2
Led 2
POWER + (12V) 1 OUTPUT 1
POWER - (GND) 2 1 OUTPUT 1
Led 1
J1 J5
NOTE:
1) Power is nominally 12V but can be 6-30 VDC.
2) The RS485 screen should be connected at both ends.
3) JMP 1 is the RS485 terminating resistor and should normally be fitted across Pins 2 and 3. (See manual for details.)
4) J4 is for the connection of a PC based diagnostic monitor.
5) J3 is reserved for the manufacturer’s programming purposes.
Figure 351
HUIO modules connect to an H-panel via the 3-wire RS-485 interface, along with other peripherals such as
HTS Transfer Switches, Remote Annunciators and Remote Relay panels. The RS-485 connection is made via
a three-way Klippon style connector (J6). Wiring between units should be made using a twisted pair shielded
cable such as Belden #9464. The shield should be connected AT BOTH ENDS as it acts as a common
ground between the optically isolated ports. The RS-485 network starts at the H-panel and can be daisy
chained to various peripherals such as remote annunciators, remote relay panels, HTS switches and HUIO’s.
See the chapter in the Study Guide about network communication for more information on connecting RS-485
networks.
Power for each HUIO Module comes in through the J1 connector. It can use power from the R15A circuit
(12VDC fused battery voltage) or the 220A circuit (24VDC Fused battery voltage) if there is room on the
customer connection terminal strip, or it can come from a separate external power supply. Requirements are
6-30VDC at 500 mA
The HUIO connects to the RS-485 bus as a Modbus slave and will operate automatically at one of the
following baud rates: 4800, 9600, 38400, 57600. The setting for Parity and Stop Bits in the HUIO module is
No Parity, 2 Stop Bits. The baud rate of the H-panel for the RS-485 port is set in Communication Port 1 using
GenLink DCP. The H-panel default setting is Modbus Master, 4800, No Parity, 2 Stop Bits. At power up, the
HUIO module will automatically search for the correct baud rate. If communications are not received within
three seconds, the HUIO will change its baud rate on a cyclical basis. The baud rate does not affect the speed
of response.
Chapter 21
Each HUIO has a base Modbus address of 230 plus a unique address which is set by the two dip switches on
the module (see Table 25). The H-panel must be programmed via GenLink DCP to tell it which HUIO modules
are connected (which addresses are in service); i.e. it is not plug and play.
ADDRESS SW1 SW2

230 0 0 Contains inputs 12-15 and
outputs 17-20
outputs 21-24
outputs 25-28
outputs 29-32
Table 25
In the event that communications to a HUIO fail, a warning will be posted in the Alarms Menu display of the
H-panel. This Warning will NOT shutdown the generator.
GenLink DCP must be used to program the functions of the individual channels such as alarms, alarm
properties, channel naming, etc. In GenLink DCP, insure the communication port for the RS-485 (Port 1
RS-485) is set to Modbus Master. Choose the baud rate that all the components on the RS-485 line will be set
to; parity and stop bits should always be: No Parity, 2 Stop Bits.
Note: You must cycle power to the H-panel for any Communication Port changes to take effect.
Figure 352

Chapter 21
The next step in programming is to tell the H-panel that a HUIO is to be connected (it’s not plug and play; if a
unit fails we need to know it’s supposed to be there so we can post a warning if it’s not). Set the dip switches
on the HUIO(s) to give each a unique Modbus address (see ““Table 25”). If only one unit is to be connected
we suggest leaving both switches in the “OFF” position to designate the unit as #1.
Next, in GenLink DCP, go to the Configuration HUIO Setup menu. Use the check boxes to select each of the
HUIO modules that are to be connected and apply the change. If the unit is not physically connected and
communicating, a warning will be displayed in the Active Alarms menu of the H-panel. If a HUIO is NOT
selected, then its inputs and outputs will be ignored by the program, even if it is physically connected.
Figure 353
Figure 354

Chapter 21
HUIO Digital Input Channels

The Digital Input Channels are numbered 12-27 in groups of four per HUIO module
Input #12 = HUIO #1 input 1 Input #20 = HUIO #3 input 1

The Digital Inputs show up in the GenLink DCP Diagnostic screen just like any other Digital Input. Each Digital
Input’s Raw Value displays as either OFF (Open contact), or GND (Ground – Closed contact). The Processed
Value displays as either OFF or ON.
Figure 355
Chapter 21
HUIO Digital Inputs can be configured through the Digital Input Channels Configuration menu in GenLink DCP.
They can be re-named, inverted (Input Active Level High or Low), delayed, used to generate an alarm/warning,
shutdown, dial-out, and used to trigger an event, just like any other Digital Input Channel. See the appropriate
chapter of the Study Guide for more information on working with Digital Input Channels in GenLink DCP.
A Direct Output Mapping function allows any HUIO (only) Digital Input to be mapped directly to its’ respective
HUIO Digital Output. This allows a HUIO Digital Input Channel to turn on (or off) its’ respective Digital Output
Channel. Alternatively, any alarm or warning generated by a HUIO Digital Input can be mapped to turn on or
off its respective HUIO Digital Output. The Output will only turn On/Off when that Input Channel is in an Alarm
condition.
Figure 356
Each HUIO Digital Input is made active (turned ON) via a dry contact closure to ground. Two pins per input are
provided for this purpose; one pin is grounded and the other is pulled up to 5VDC via an internal 4700 Ohm
resistor. A voltage free (dry) contact, such as a relay or open collector transistor, can be connected to and
used to ground the input. The required current carrying capacity for this contact is in the region of 1mA. See
Figure 2 in the HUIO Manual for connection details to J2.

Chapter 21
HUIO Digital Output Channels

The Digital Outputs are numbered 17-32 in groups of four per HUIO module.
Output #17 = HUIO #1 output 1 Output #25 = HUIO #3 output 1

The HUIO Digital Outputs show up in the GenLink DCP Diagnostic screen just like any other Digital Output.
Each Digital Output will display as being either ON or OFF. The Channel Name can be changed through the
Configuration Digital Output Channels display in GenLink DCP.
Figure 357

Chapter 21
HUIO Digital Output Channels can be Directly Mapped from their respective HUIO Digital Input Channel, as
explained in the HUIO Digital Input section previously; or they can be Mapped using the Output Mapping
function in Digital Output Functions. The procedure for using Digital Output Function Mapping is the same for
HUIO outputs as it is for the Customer Configurable Output Channels.
Use the Select Channel drop down menu to select the HUIO output channel to turn ON/OFF when the Digital
Output Function turns on.
For example; if the customer wants a remote indication (light or horn) when a Common Alarm occurs
(Common Alarm, DOF Channel 1), you could select HUIO_1_OUT_1 to turn ON (Active Level HIGH) when DOF
1 turns ON. Then use HUIO relay 1_1 to provide contact closure for a remote light or horn.
Figure 358
Each HUIO Digital Output is made up of a pair of normally open relay contacts which close when the output is
activated (turned ON). The relay contacts are Form A rated at 30VDC, up to 5.0A each. NO AC CONNECTIONS
SHOULD BE MADE TO THESE RELAYS. See the HUIO Manual, Figure 2 for connection details to J5. The state
of the output relays can be seen on the four Led’s beside each relay on the HUIO Module.
The information in this chapter is meant to supplement the information in the HUIO Owner’s Manual (PN
0G5354). Make sure you read and understand the owner’s manual for the HUIO module before working with it.

Chapter 21

A Answers
405
Appendix20A
Chapter
Remote Trending
Answers
Problems
Chapter 4
Problem 1
1. C
2. B
3. A
Problem 2
Wire 14: Provides the required field flash voltage to the bridge rectifier.
Wire 49: Provides field flash voltage to the engine mounted DC alternator.
BR1: Used to protect Wire 14 from high excitation voltage from either the voltage regulator or
engine alternator.
Wire 29: Is a wire between the bridge rectifier and the resistor.
R4: Limits current to the rotor during field flash to only provide the required voltage to the
regulator.
BA (Brush Assembly): Provides the mechanical connection between DC excitation voltage and the
rotor while it is rotating.
Wires 4 & 1: Provides DC field excitation voltage to the rotor.
Wires 6 & 2 (162): Provides AC excitation voltage to the voltage regulator
CB1: Main Circuit Breaker on the generator
CB2: The DPE circuit breaker. The circuit breakers protects the regulator and the stator from
drawing to much current from the winding.
AVR: Regulates the output of the generator at a specific voltage output level.
Wires 11 & 44: Power Leads out of a stator on single phase alternator.
Wires 22 & 33: Neutral Leads out of a stator on a single phase alternator.
Problem 3
Wire 14: Provides the required field flash voltage to the bridge rectifier.
Wire 49: Provides field flash voltage to the engine mounted DC alternator.
DB1: Used to protect Wire 14 from high excitation voltage from either the voltage regulator or
engine alternator.
DB2: Fly back diode; used to shunt any kick back spikes created when the rotor field collapses.
Wire 29: Is a wire between the bridge rectifier and the resistor.
R1: Limits current to the rotor during field flash to only provide the required voltage to the
regulator.
BA (Brush Assembly): Provides the mechanical connection between DC excitation voltage and
the rotor while it is rotating.
Wires 4 & 1: Provides DC field excitation voltage to the rotor.
406
Appendix A
Answers
Problem 4
4. D
5. B
6. A
7. C
Chapter 6
Problem 1
Using the Sizing Guide (0172610SBY) and Table 4 (LP Vapor), the first available pipe size that
allows a 130 ft run is the 1.5” pipe.
To calculate the required LP tank use Table 5 in the same manual. In the lower left hand of the
page the required LP Gal/Hr is listed for a 50 kW; which is 7.5 Gal/Hr Even though we are dealing
with a 48 kW we will use the next highest, which is the 50 kW. The next step to solve this problem
is to identify how many gallons are usable for different size tanks. Starting with a 500 gal tank the
table lists that 300 gals are available for this size tank. Next we take 300 and divide it by the 7.5
and determine how many hours the generator will be able to run at full load. This comes out to 40
hrs, since we are looking for 72 hrs of run time we need to try the next size up. For a 850 gallon
tank we can get 510 gals which divided by 7.5 is 68 hrs. The 850 gallon tank gets us close, but we
need 72 hrs at a minimum therefor we are left going with the next size up which is the 1000 gallon
tank and allow us 133 hrs of operation at full load.
Chapter 12
Component ID
A. DPE Breaker
B. Field Flash Diode
C. Field Flash Resistor
D. Automatic Voltage Regulator
E. Silicon Controlled Rectifier
F. Crank and Run Relays
G. Governor Driver
Chapter 14
Component ID
A. DPE Breaker, Field Flash Resistor, and Diode
B. Voltage Regulator Driver
C. RB1 Relay Board
D. Fuse Block
E. Governor Driver
F. Battery Charger
407
Appendix20A
Chapter
Remote Trending
Answers
Check Your Knowledge

Chapter 1
1. What is the formula for Ohms Law?
E=IxR
2. What does the term “RMS Voltage” represent?
Which part of the sine the meter actually measures. These types of meters measure the “Root
Mean Square” voltage of the sine wave.
3. What does the term “Frequency” represent?
How many cycles of the sine wave per second.
4. Current flow within a conductor creates a _____________ ____________.
magnetic field
5. What is the total resistance in the circuit?
Find Common 1 2 2
Denominator × =
40 2 80
2 1 3 3
Add Fractions
Together
+ = =
80 80 80 80
1 3
Cross Multiply =
RTotal 80
Solve for R Total 3( RTotal ) = 80
Isolate the Variable RTotal = 80 ÷ 3 = 26.6
RTotal 26.6
= Ω
Chapter 2
1. Name the three major components of a generator?
1. Prime Mover
2. Alternator
3. Control Panel
2. How do we calculate kW using the BHP of a prime mover?
kW = Horsepower (bhp) x 0.746
3. What are the wires numbers that make up the customer connections on a Nexus equipped generator?
N1, N2, T1, NEU, 23, 194, 178, 183
Chapter 3
1. What does the “X” in the QT product code represent?
Nexus, No Catalyst
2. Why are there double windings on the “D” code stator?
To allow a Delta wound stator to pull full rated amperage on the single phase windings
3. What voltage will a “G” code alternator produce line-to-line?
208 VAC Line-to-Line
408
Appendix A
Answers
Chapter 4
1. What does DPE stand for?
Displaced Phase Excitation
2. What are Wires 22 and 33 in a single phase generator?
Neutral
3. What is the purpose of R1 on a Generac generator?
To reduce the amount of voltage produced under field flash.
Chapter 5
1. Name two primary types of governing systems?
Droop and Isochronous
2. When is the magnetic pickup breakout harness used?
Installing or adjustment of the magnetic pickup. The harness allows the technician to run and
check and adjust voltage while the generator is running.
3. Why does Generac use a governor driver on the R-panel and H-panel?
Neither the R-Panel or H-Panel have circuitry capable of handling the high currents of a bosch
actuator. This is the responsibility of the driver.
4. What is the maximum battery voltage that can be applied to a Bosch actuator during testing?
9 VDC
5. What does it mean if a generator is designed to run isochronous?
The engine will maintain consistent 60 hertz and will only momentarily when load is applied and
will recover back to 60 hertz.
Chapter 6
1. What is the formula for calculating BTUs on a LP system?
LP ft3/hr x 2520 = BTUs/hour
2. When does the low fuel pressure switch trigger and alarm?
When fuel pressure drops below 5” WC
3. What is the maximum fuel pressure that a fuel solenoid can handle?
14” WC, above this and the solenoid can not overcome the downward force exerted by the fuel
4. What is the purpose of the air/fuel solenoid on emission systems?
Switches between negative pressure and atmospheric pressure to control how much fuel enters
the engine.
409
Appendix20A
Chapter
Remote Trending
Answers
Chapter 7
1. What is the amperage rating for a QT08046JNAN at .8 PF?
I = (kW x 1000) / (E x 1.73 x 0.8)
I = 80000 / (240 x 1.73 x 0.8)
I = 80000/ 332.16
I = 460 Amps
2. When running at .8 PF how many degrees are the current and voltage sine separated by?
37.016°
3. In a purely inductive circuit, what is the power consumed by the load?
0%
4. In a purely resistive circuit, what is the power consumed by the load?
100 %
Chapter 9
1. What does it mean for a switch to be a “closed transition” transfer switch?
The flow of electricity is not interrupted when going from one live source to another live source.
2. What does it mean for a switch to be an “open transition” transfer switch?
The flow of electricity is interrupted when going from one live source to another live source.
Chapter 10
1. What is the purpose of Wire 194?
To provide 12 VDC to energize the transfer relay
2. What is the Return to Utility delay timer on the RTS switch?
10 Seconds
3. What is the purpose of the Power Monitor?
To monitor all three phases of the system and start the generator when there is loss or drop in any
one phase.
4. What are the trip and select coils used for on the “WN” style switch?
The trip coil is used to disconnect it from either utility or generator. The select coil is energized to
allow the mechanism to transfer to a position that will allow the main coil to transfer to the genera-
tor position when it is energized.
5. If Wire 23 is shorted to ground, what will the generator and transfer switch do upon the return of utility?
The generator will shutdown after its cool down timer expires and the transfer switch will remain in
the generator position.
410
Appendix A
Answers
Chapter 11
1. What type of wire do we use for communications on the HTS?
A 2-wire, twisted, shielded pair.
2. What type of batteries must be installed in the HTS communications board?
Rechargeable AAA NiMH
3. What is the purpose of the transformer board in an HTS transfer switch?
To rectify either generator or utility voltage to DC to supply power to the communication and relay
boards.
4. How do you set the parameters of an HTS transfer switch?
The dip switches located on the communication board are used to program the default parameters.
The communication settings in the H-Panel parameters are set and can be changed using GenLink.
Chapter 12
1. How do you set the exercise timer on the R-panel?
Hold the set exercise switch for 10 seconds while the unit is in the AUTO position.
2. Which wire on an R-panel controlled generator tells the printed circuit board that it is in AUTO?
Wire 15A
3. What is the purpose of the dip switches on an R-panel PCB?
To program the printed circuit board to operate correctly with. To set frequency, transfer switch
type, fuel type, exercise speed and engine size and # of cylinders so proper ignition timing is set.
4. What is the WLS?
Water Level Sensor
Chapter 13
1. What is CAN bus as it relates to the Nexus Controller?
CAN bus is a communication link between the Nexus controller and the external ignition module.
2. What is the purpose of the 10 amp fuse when equipped on a Nexus controlled unit?
The 10 amp fuse limits the current supplied to the external ignition module.
3. Where is the battery charger located on a Nexus unit?
The battery charger is integrated into the Nexus controller.
Chapter 14
1. What products are the H-100 used on?
Prior production 70kW-150kW commercial product and industrial product.
2. What style of connectors are used on the H-100?
Amp style
3. What is the purpose of the CT?
To measure the amount of current flow in the stator.
4. What is the purpose of the AVR driver?
Since the H-Panel has no circuits capable of high current, the AVR driver provides a means for the
regulator circuit to control the stator and rotor.
5. What is the purpose of the Interface Transformers?
The interface transformers step down the voltage output of the stator to 48 VAC, which is then
used by the H-Panel for voltage sensing.
411
Appendix20A
Chapter
Remote Trending
Answers
Chapter 15
1. How many analog inputs are their in an H-Panel?
23
2. Which device communicates on the RS-232 port of the H-panel?
GenLink DCP
3. Which devices communicate on the RS-485 port of the H-Panel?
HTS, RAP, RRP, HUIO
4. How many digital inputs are available on the H-Panel, not including the HUIO?
11
Chapter 16
1. What is on page 4 of the engine screen?
Throttle Position
2. What screen on the H-panel is used to identify the baudrate the RS-485 is operating at?
Diagnostic Menu, page 6-6
3. What needs to be done on the H-panel to enable a HTS transfer switch?
Navigate to the “Exercise/HTS” screen and on page 4 of 4 and change from disabled to enabled for
each of the four switches installed.
Chapter 17
1. What is the de-sync offset used for on a H-Panel?
To increase or decrease the engine speed by a fraction of a cycle to decrease the time it takes for
an inphase transfer to occur.
2. When would delay A and B be used on Analog Input channels?
This allows for a longer delay on the greater than value and a different value for the less than.
3. What can you use digital output functions for?
To program configurable relays on an industrial unit and to operate a HUIO output channel
Chapter 18
1. What is scaling factor used for?
Scaling allows a value that is brought into the H-panel to be changed to something else. This is
why we can have 48 VAC brought into the panel and have it regulate at several different voltages.
2. Where in Genlink DCP can you set the target voltage for an H-panel?
Engine settings
3. Why is it important to calibrate voltage and current when working with a H-Panel?
A unit that has not had its voltage or current calibrated will not regulate as accurately as possible,
and the derived parameters (kW, kVAR, PF, etc.) may not be accurate.
Chapter 19
1. What menu is used to pick what information is captured when either an alarm or an event occurs?
Alarm/ Event Parameters
412
Appendix A
Answers
Chapter 20
1. What is the purpose of “scaling” in the Genlink DCP remote trending screen?
To set the range of the channel, for example if you expect the value to be about 400 then scaling
it to 500 would place it at the top of the screen and scaling it to 1000 would put it just below the
middle.
2. What is the purpose of “offset” in the Genlink DCP remote trending screen?
Offset changes where 0 is reflected for a given channel on the screen.
413
Index
A governor driver 41, 73, 80, 81, 83, 245, 247, 259, 260, 284
Governor Driver 41, 73, 80, 81, 83, 245, 247, 259, 260, 284
AC Excitation Circuit 57 Graphical User Interface 389, 391, 392
AC Sensing Circuit 57
AC voltage 1, 12 I
Air/Fuel Solenoid 87
apparent power 119, 129 ignition coil 87
ignition module 87, 104, 105, 208
B inductive 119, 120, 135, 136
interface transformer 245, 247, 253, 254, 257, 276, 346
battery charger 203, 227, 228 Isochronous 73, 74
baud rate 265, 289
bosch actuator 73, 80, 83, 84, 245, 260 K
Bosch Actuator 73, 80, 83, 84, 245, 260
brushed 21, 57 KISS 141, 143
brushless 21, 26, 28, 57, 66
L
C limit switches 153, 158, 162, 165, 200
calibration 276, 311, 345, 346, 348, 353, 357, 358 linear load 119
cam sensor 87, 224 liquid propane vapor 87, 88
canbus 265
M
capacitive 119, 120, 136
coil over plug 87 Magnetic Pickup 73, 76, 224, 225, 266, 273
coil pack 87 magnetism 1, 2
cold start solenoids 87 Mechanical 73, 77
communication 185, 245, 266, 293, 389 mixer body 87, 93
contactor 147, 162, 179, 226 modbus 245
crank sensor 87 Model Number 43
current transformers 245, 247, 256, 330 modem 245
D N
data tag 43 natural gas 24, 45, 87, 88, 89, 90, 91, 110, 214, 215, 216,
DC field excitation 57, 58 217, 218
digital inputs 1, 8, 221, 222, 265, 266, 277, 293, 389, 396, non linear load 119
400, 401
DPE Winding 57, 63 O
E ohm’s law 1, 2, 15, 121, 267
oxygen sensor 87, 112, 113
electromotive force 1
P
F
parallel circuits 1, 5
faraday’s law 1, 9 Parity 186, 265, 286, 287, 289, 301, 327, 397, 398
field flash circuit 57, 255 power factor 44, 119, 120, 121, 133, 137, 256, 352
Field Flash Diode 57, 64 power monitor 153, 160, 161, 173, 174
Field Flash Resistor 57, 64 prime mover 21, 24
Fly-Back Diode 57
flywheel 21, 26, 338 R
frequency 1, 17, 68, 74, 78, 84, 194, 196, 214, 215, 216, 217,
reactive power 119, 129, 130, 131, 133, 134, 135, 138, 256
218, 246, 259, 328, 337, 339, 382
real power 119, 129, 130, 133, 138, 256
fuel pressure 87, 88, 100, 101, 204, 222
relay panel 389, 390
fuel regulator 87, 88, 96, 111
remote start 185, 277
fuel solenoid 87
resistive 119, 120, 121, 126
G RMS voltage 1, 15
rotor 9, 21, 25, 26, 44, 179
gearbox 17, 21, 30, 44, 330
414
Index
S
second stage regulator 87
sensing transformer 203, 224
series circuits 1
signal conditioner 259, 260, 265, 269, 270, 272
sine wave 1, 133
Speed Droop 73, 74
stator 9, 21, 30, 44, 63, 66, 67
Stepper Motor 73, 78, 79
T
transfer relay 36, 153, 155, 161, 192, 221, 226
V
V/F Compensation 57
voltage code 43, 121, 132, 350
Voltage Regulator 41, 57, 58, 68, 69, 70, 71, 245, 246, 247,
253, 254, 255, 276, 284, 329, 341, 351
“V” type 153, 159, 172
W
“Wn” type 153, 165, 171
“W” type 150, 153, 160, 182, 193, 201
415
Part No. 0E2221 rev. J / Printed in USA 01/17/12 Generac Power Systems, Inc.
© 2012 Generac Power Systems, Inc. All rights reserved. S45 W29290 Hwy. 59 • Waukesha, WI 53187
Specifications are subject to change without notice
No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. 1-888-GENERAC (1-888-436-3722) • generac.com

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GENERAC SERVICE TRAINING

Chapter 2 - Generator Set Components.................................................................

Chapter 3 - Generator Configurations....................................................................

Chapter 4 - Voltage Regulation..............................................................................

Chapter 5 - Frequency and Governor Fundamentals...............................................

Chapter 6 - Gaseous Fuel Systems and Spark Ignition Systems.............................

Chapter 7 - Generator Load and Power.................................................................

Chapter 8 - Troubleshooting Fundamentals............................................................

Chapter 9 - Transfer Switch Fundamentals............................................................

Chapter 10 - RTS Series Transfer Switches...........................................................

Chapter 11 - HTS Series Transfer Switches...........................................................

Chapter 12 - R-Series Control Panels....................................................................

Chapter 13 - Nexus Control Panels.......................................................................

Chapter 14 - Introduction to the PM-DCP H-100...................................................

Chapter 15 - H-Panel Inputs and Outputs..............................................................

Chapter 16 - H-Panel Display Screens..................................................................

Chapter 17 - GenLink DCP Configuration and Diagnostic Menus............................

Chapter 18 - H-Panel Voltage Regulation and Current & Voltage Calibration...........

Chapter 19 - Alarm & Event Logs, Reports and Maintenance.................................

Chapter 20 - Remote Trending..............................................................................

Chapter 21 - 21-Light RAP/RRP and HUIO............................................................

Review of Electrical Fundamentals

We can illustrate this relationship three different ways.

If the resistance is higher what happens?

If the resistance is lower what happens?

Section 1 - Generator Basics 3

If the applied voltage increases what happens?

If the applied voltage decreases what happens?

4 Section 1 - Generator Basics

Series and Parallel Circuits

Figure 7 – Series Circuit

RTotal = R1 + R2 + R3 = 25 ohms + 9.2 ohms + 3 ohms = 37.2 ohms

I (current flow) = V/R V=12, R=37.2

I = 12/37.2 = 0.323 amps

Section 1 - Generator Basics 5

Figure 9 – Parallel Circuit

6 Section 1 - Generator Basics

Section 1 - Generator Basics 7

Ohm’s law also defines our power formulas. P (Watts) = E x I

The formula for single phase power is: P (kW) = E x I x PF

The formula for three-phase power is: P (kW) = E x I x 1.73 x PF

Digital Inputs Circuits

Figure 10 – Digital Input HIGH

Figure 11 – Digital Input LOW

SIGNAL HIGH = CONTACTS OPEN = 5VDC = OFF

1. Conductor – the conductor in a generator is the Stator Winding(s) (Armature)

Figure 12 – Typical Brushed Rotor

Section 1 - Generator Basics 9

Figure 13 – Magnetic Poles

10 Section 1 - Generator Basics

Figure 15 – Electromagnetic Induction

The amount of voltage induced into a conductor is dependent on three things.

Section 1 - Generator Basics 11

12 Section 1 - Generator Basics

Section 1 - Generator Basics 13

What voltage does the typical meter read on an AC circuit?

There are 3 ways to quantify the magnitude of a sine wave.

Section 1 - Generator Basics 15

16 Section 1 - Generator Basics

RPM × Number of Poles

A two pole rotor must turn at 3600 RPM to produce 60 Hz.

Section 1 - Generator Basics 17

4. Current flow within a conductor creates a _ .