Generac Rampower 232 User Manual
POWER SYSTEMS, INC.
®
Operator’s Manual
“E” Option Control Panels
This manual should remain with the unit.
This manual contains standard drawings and schematics.
For specific drawings, please refer to the Owner’s Manual of the unit.
Generac®Power Systems, Inc.
Important Safety Instructions
E Option Control Panels
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas. Safety should be stressed to all
operators and potential operators of this equipment.
!
!
Study these SAFETY RULES carefully before
installing, operating or servicing this equipment.
Become familiar with this manual and all literature
pertaining to your generator set and related equipment. This equipment can operate safely, efficiently
and reliably only if it is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precautions.
Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals
affixed to your equipment are, therefore, not
all-inclusive. If you use a procedure, work method or
operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you
and others. You also must make sure the procedure,
work method or operating technique that you choose
does not render the equipment unsafe.
GENERAL HAZARDS
• For safety reasons, Generac recommends that this
equipment be installed and serviced by a Generac
Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations.
The operator also must comply with all such codes,
standards and regulations.
• When working on this equipment, remain alert at all
times. Never work on the equipment when you are
physically or mentally fatigued.
• Inspect the equipment regularly, and promptly repair
or replace all worn, damaged or defective parts using
only factory-approved parts.
• Before performing any maintenance on the generator
or any related equipment, disable the generator to
prevent accidental start-up. Remove the control
panel fuse and then disconnect the battery cables by
removing the one indicated by a NEGATIVE, NEG or
(–) first. To re-enable the generator, reconnect the
battery cables connecting the one indicated by a
NEGATIVE, NEG or (–) last, then re-install the control panel fuse.
ELECTRICAL HAZARDS
• Generators produce dangerous electrical voltages
and can cause fatal electrical shock. Avoid contact
with bare wires, terminals, connections, etc., while
the generator and related equipment are running.
Ensure all appropriate covers, guards and barriers
are in place before operating the equipment. If you
must work around an operating unit, stand on an
insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing
this equipment, place insulative mats over a dry
wooden platform. Work on the equipment only while
standing on such insulative mats.
• Wire gauge sizes of electrical wiring, cables and cord
sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected.
• Before installing or servicing this equipment, make
sure that all power voltage supplies are positively
TURNED OFF at their source. Failure to do so will
result in hazardous and possibly fatal electrical
shock.
• When installed with an automatic transfer switch, the
generator may crank and start anytime without
warning. To prevent injuries caused by sudden startup, disable the generator’s automatic start circuit
before working on or around the unit. Then, place a
“Do Not Operate” tag on the generator control panel
and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH
THE VICTIM. Use a nonconducting implement,
such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply
first aid and get immediate medical help.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
FIRE HAZARDS
• For fire safety, the generator and related equipment
must be installed and maintained properly.
Installation always must comply with applicable
codes, standards, laws and regulations. Adhere
strictly to local, state and national electrical and
building codes. Comply with regulations the
Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the
equipment is installed in accordance with the manufacturer’s instructions and recommendations.
Following proper installation, do nothing that
might alter a safe installation and render the unit
in noncompliance with the aforementioned codes,
standards, laws and regulations.
!!
Table of Contents
E Option Control Panels
Generac®Power Systems, Inc. 1
Safety Rules ..............Inside Front Cover
Section 1 — General Information..........2
Overview ................................................................2
Engine Control ......................................................2
E Option Control Module ......................................2
Alarms....................................................................4
Alarm Processing....................................................5
Programmable Parameters ....................................6
E Panel Modem Setup Procedure ..........................9
E Panel RS 232 Cables ..........................................9
Additional Panel Components ..............................10
Checking/Replacing the E Panel Control Module
Internal Fuse ....................................................11
User Programmable Inputs ..................................11
Wiring Examples ..................................................12
Programming Examples ......................................13
Section 2 — Operation........................14
Output Function Table ............................................14
E Panel Master Control Box Configuration Settings15
E Panel Display Map ............................................18
Section 3 — Troubleshooting and
Diagnosis ........................20
Oil Pressure Sensing ..............................................20
Low Coolant Level ..................................................22
Coolant Temperature Sensing ................................25
Oil Temperature Sensing ........................................27
AC Voltage Display ..................................................29
RPM Sensor and Engine Speed Alarms ..................29
Engine Does Not Crank ..........................................31
Overcrank................................................................34
Appendix — Phoenix and
Deutsch Connectors ........35
Section 4 — Glossary..........................38
E Control Panel Definitions ....................................38
Section 5 — Electrical Data ................39
E Panel Drawing Application Matrix ......................39
Section 6 — Exploded Views and
Parts Lists ......................60
Section 7 — Notes ..............................76
AUTHORIZED SERVICE DEALER LOCATION
To locate the GENERAC AUTHORIZED SERVICE
DEALER nearest you, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
OVERVIEW
The “E” option control panel is a programmable
engine control and monitoring system. It allows the
user to customize the generator starting and running
sequence, monitor engine parameters and configure
the alarms. This can be done either through its own
control module, featuring liquid-crystal display
(LCD) and keypad, or using a PC and RS232 serial
communications. The module includes user programmable inputs and outputs that allow it to be tailored to a vast range of applications. All of the setup
information is stored in nonvolatile (permanent)
memory.
ENGINE CONTROL
The module has a three-position selector switch that
selects between “Auto” mode, “Off” and “Manual” start
mode. When the switch is in the OFF position, the
generator will not start, and it will stop if it is running.
When the switch is turned to MANUAL, the generator
will start immediately and will continue to run until
the switch is turned to the OFF position or a shutdown alarm is activated. With the switch in the AUTO
position, the generator will wait for either the remote
start contacts to close or for a start command to be
sent from the serial link. The generator will run until
the remote start contacts open, a stop command is
sent down the serial link, a shutdown alarm is activated or the switch is turned to the OFF position. The
remote start contacts always will have priority over
the serial link commands so that the serial link cannot stop the generator if the remote start contacts are
closed. When GenLink®software, which may be
obtained from a Generac Authorized Service Dealer, is
connected to the E panel via modem, the panel will
monitor the connection to ensure that the line has not
dropped. If the E panel detects that the line has been
dropped, it will disconnect the modem so that it is
ready for another incoming call. If the generator had
been started via the modem connection, then it will be
stopped immediately unless the remote start contacts
are closed or the generator is in manual. However, if
the GenLink®software disconnected cleanly (as a
result of a user command) with the generator running,
then the generator will continue to run for a another
three hours unless it receives a stop command.
When a start command is received, the engine preheat
will be engaged, if it is selected. The user can program
the preheat to engage for a programmable time before
engaging the starter motor, to engage while the engine is
attempting to start, or to do both. In order to protect
the engine from trying to start while it is already running (if the rpm sensor is damaged), an alarm is generated if there is oil pressure when the start command is
sent. An alarm also is generated if there is a voltage
output from the generator but the rpm sensor detects
zero engine speed.
The user can program the length of time that the starter
motor is engaged during a start attempt. After the first
attempt, the generator will pause for a programmable
length of time before the next attempt. The number of
attempts also is programmable, after which the failed
to start alarm is activated.
The user can program a warm-up time that is active
after the generator has started. This could be used in
conjunction with a programmable relay output to
inhibit the transfer switch from applying load until
the generator is ready. The warm-up time can be set
to zero if this function is not required. This timer is
separate from the alarm hold off timer, which allows
the generator to run for a time before certain alarms
(such as low oil pressure) are active.
If the generator is in the AUTO mode and a stop command is received, a programmable cool-down timer
can be used to keep the generator running with no
load for a fixed time. This also can work in conjunction with a relay output to inhibit the transfer switch.
If the timer is set to zero, this function is disabled. If
the selector switch is turned to OFF, then the generator will stop immediately without waiting for the cooldown time.
Certain alarm functions are designated as shutdown
alarms. These alarms will stop the generator and
inhibit it from starting until the alarm condition has
cleared and the alarm has been reset.
E OPTION CONTROL MODULE
OVERVIEW
The LCD on the front of the module (Figure 1.1) features a 24-character by two-line display screen that will
show one of seven pages. There is a keypad with six
keys that are used for operating the display and selecting the various pages. A key-activated switch allows the
user to select whether the generator is in the “Auto”
mode, “Off” mode or “Manual” run mode. Four LEDs
indicate the following conditions:
• “Power” – Battery power is OK.
• “Not Auto” – The generator is not in the automatic
mode.
• “Com Alarm” – A common alarm condition has
occurred.
• “Gen Run” – The generator is running.
NOTE:
The “Power” LED will go out immediately if the
battery voltage dips below the alarm limit, but the
alarm will not be triggered unless the voltage is
low for more than five minutes.
Section 1 — General Information
E Option Control Panels
2 Generac®Power Systems, Inc.
Generac®Power Systems, Inc. 3
Figure 1.1 – Control Module Layout
KEYPAD
The keypad consists of six keys labeled as follows:
↑ (up), ↓ (down), ← (left), → (right)
,
Enter, and Reset.
The left and right arrow keys are used to select the different pages on the display. The up and down arrow
keys are used to scroll between options within a page.
They also are used for selecting characters when the
user is entering messages or parameters for the
alarms. The left and right arrow keys move the cursor
when the user is entering data. The enter key takes the
user into a page on the display to change data (when
applicable) and also accepts data that has been entered.
It also is used to accept an alarm. The reset key ignores
data that has been entered and returns the original
value. It also is used to return from the parameter entry
mode once the user has finished changing the data, and
to reset any latched alarms that have cleared.
DISPLAY
The display is organized into a series of pages, each
page displays information about the status of the generator. For example, the “Alarm Status Message Page”
displays the highest priority current alarm or status
condition. The user will be able to scroll between the
pages using the left and right arrow keys. Certain
actions also cause the display to change pages, e.g.,
when an alarm becomes active, the display automatically will go to the alarm status page and display the
alarm message.
The back light for the display is normally off. If the
user presses any key, the back light will come on
automatically and remain on for five minutes after
the last key was pressed. It also will come on if any
status message is current, which means the display
will switch to the alarm status page. The back light
will flash when an alarm or shutdown message is
active, and the audible alarm will sound.
When the display is showing certain pages, the user
is able to scroll between relevant items within the
page using the up and down arrow keys. For example,
if the display is showing the “Alarm Log Page,” the
user can use the up and down arrow keys to scroll
between the entries on the alarm log. A description of
each page is given below.
Software Version Page
This page displays the software revision. Pressing the
enter key in this page will perform a display and LED
test.
Generator Command Page
This page displays the command sent to the generator. The possible commands are as follows:
• Generator switched off
• Generator in manual mode
• Generator in auto mode – stop command
• Generator in auto mode – remote run command
• Generator in auto mode – serial link run
command
Generator Status Page
This page displays the current status of the generator.
Options will be as follows:
• Stopped – ready to run
• Stopped – start inhibit active
• Pre-heating (with timer counting down)
• Attempting to start (with timer counting down and
number of attempts)
• Pausing before start attempt (with timer counting
down and number of attempts)
• Started – running up to speed
• Warming up
• Ready to accept load
• All alarms enabled
• Cooling down
• Stopping
• Stopped due to alarm
If the user has not pressed a key for some time, any
change in status will cause this page to be displayed
provided that there are no active alarms or status
messages from other inputs. If an alarm condition
occurs, the alarm status page will be displayed automatically.
Alarm Status Message Page
This page displays alarm messages and programmable status messages. Messages are displayed
according to priority, with the shutdown alarms
having highest priority, and status messages having
lowest priority.
Section 1 — General Information
E Option Control Panels
4 Generac®Power Systems, Inc.
If an alarm becomes active, the display will switch to
this page and display the highest priority alarm message. The back light and alarm LED will flash, and the
audible alarm will be activated. The user must press
the enter key to accept the alarm, at which time the
back light will be on continuously. If the alarm is nonlatching, the alarm message will clear as soon as the
condition is cleared. If the alarm is a latching alarm,
then the user must press the reset key to clear the message. Once a message has cleared, the display will show
the next priority alarm message.
After an alarm has been accepted, the user is able to
scroll through other active alarm and message
screens using the up and down arrow keys.
Alarm Log Page
This page displays the last 50 alarm messages. When
the user selects this page, it displays the latest alarm
message. Pressing the up or down arrow keys will
allow the user to scroll up and down the list of messages.
Instrumentation Page
This page displays one of the analog signal values.
Pressing the up or down arrow keys will scroll to
other analog display screens.
Parameter Entry Page
This page allows the user to modify the various set
points and programmable options. See the
“Programmable Parameters” section of this manual
for more specific option information. The user must
press the Enter key when this page is displayed and
will then be prompted for a password. The password
is a six-digit number and the default value is 000000.
However, the user will be able to change the password. Digits will be selected using up and down
arrow keys, and the cursor will be moved by the left
and right arrow keys. When the user presses the
Enter key, the password will be checked. If the password is correct, the display will show one of the data
entry screens.
There are four parameter entry menus: “Engine
Parameter,” “System Alarm,” “Digital I/O” and “Analog
Input.” The user will be able to scroll through the various parameters in each menu using the up and down
arrow keys. The left and right arrow keys are used to
switch between the four menus. When a parameter that
requires changing is displayed, the user presses the
Enter key to enable data entry. A cursor will appear at
the first character that can be altered. The user can
then change the character using the up and down arrow
keys. The user can move to the next character or previous character using the left and right arrow keys.
Pressing the Enter key will accept the new setting.
Pressing the Reset key will ignore the new setting.
If an alarm condition occurs when the user is entering data, the data will be ignored, and the display will
show the alarm screen. If a status condition occurs
when data is being entered, the display will not
change.
Once the user has finished entering data by pressing
the Enter key, pressing the Reset key will allow the
user to select other pages using the left and right
arrow keys.
ALARMS
All analog channels have alarms associated with
them. There is also a coolant level alarm, an emergency stop alarm and eight user definable inputs that
can be used to generate alarms. Alarms can be status
messages, non-latching alarms, latching alarms or
shutdown alarms. When a new alarm condition
occurs, the alarm LED and the display back light will
flash. Also, the alarm relay contacts will close (operating the audible alarm), and the display will show
the alarm message. The user will be able to accept the
alarm (turn off the audible alarm) from the keypad,
and if the alarm condition has cleared, he or she also
will be able to clear the alarm. Non-latching alarms
will clear themselves if the alarm condition is no
longer present. Latching alarms require the user to
clear the alarm from the keypad even if the alarm
condition is no longer present. Shutdown alarms are
similar to latched alarms, but they also cause the
generator to stop and will not allow it to start again
until the key-switch has been turned to the OFF position to reset the alarm. Status messages are similar
to non-latching alarms except that they do not activate the alarm relay or the alarm LED and are not
recorded on the alarm log.
Alarms can be always active, immediately active when
the generator is commanded to run, or active after
the hold off timer has expired. This timer delays the
operation of certain alarms until a programmable
time after the engine has started. Some alarms allow
the user to define the type of alarm and when it is
active.
The following chart is a summary of the alarms and
the programmable options:
Section 1 — General Information
E Option Control Panels
Generac®Power Systems, Inc. 5
ALARM PROCESSING
INPUT ALARM FUNCTIONS
The E option panel will monitor the status of the analog and digital inputs, and generate alarm messages
as required. Digital alarms and user-defined analog
alarms are fully programmable. The user is able to
select the type of alarm, the state of the input that will
trigger the alarm, and the alarm message when it is
active. The configurations are defined as follows:
Alarm Active
The user is able to select when the alarm is active.
The options will be as follows:
• Disabled: If this option is selected, the alarm is
disabled and has no effect.
• Always: With this option selected, the alarm is
active regardless of the state of the generator.
• Immediate: In this mode, the alarm is not active
when the generator is stationary. It becomes active
as soon as the generator starts to crank and
remains active until the generator stops.
• Hold Off: This option waits until a preset time
after the generator is running before becoming
active. The hold off time can be set by the user.
Note that the hold off time is common to
all alarms.
Section 1 — General Information
E Option Control Panels
Alarm Message Alarm Active Options Alarm Type Options
Pre-Low Oil Pressure Warning Hold Off Non-Latch
Low Oil Pressure Shutdown Alarm Hold Off Shutdown
Pre-High Coolant Temp. Warning Hold Off Non-Latch
High Coolant Temp. Shutdown Alarm Hold Off Shutdown
Low Coolant Temp.Warning Always Non-Latch
Pre-High Oil Temp. Warning Immediate, Hold Off, Disabled Non-Latch
High Oil Temp. Shutdown Alarm Immediate, Hold Off, Disabled Shutdown
Low Battery Voltage Warning* Always Non-Latch
Overspeed Alarm Immediate Shutdown
Underspeed Hold Off Status, Non-Latch, Latch, or Shutdown
Overcrank Alarm Immediate Shutdown
Over Voltage Hold Off Status, Non-Latch, Latch, or Shutdown
Under Voltage Hold Off Status, Non-Latch, Latch, or Shutdown
Over Frequency Hold Off Status, Non-Latch, Latch, or Shutdown
Under Frequency Hold Off Status, Non-Latch, Latch, or Shutdown
High Fuel Warning Always, Disabled Non-Latch
Low Fuel Warning Always, Disabled Non-Latch
Low Fuel Shutdown Alarm Always, Disabled Shutdown
User Analog Alarms** All Options Available All Options Available
Low Coolant Level Alarm Hold Off Shutdown
Emergency Stop Always Shutdown
RPM Sensor Failure Alarm Always Shutdown
Start Inhibit – Oil Pressure Immediate Shutdown
Oil Pressure Sensor Failure Always Shutdown
Oil Temp.Sensor Failure Always, Disabled Shutdown
Coolant Temp.Sensor Failure Always Shutdown
User Digital Input Alarms*** All Options Available All Options Available
High Battery Voltage Warning Always Non-Latch
* Battery voltage must be below alarm limit for 5 minutes to trigger alarm.
** Each user analog input channel has a high and low alarm.
*** Each user digital input can be programmed to trigger an alarm on high or low level.
6 Generac®Power Systems, Inc.
ALARM TYPE
Status
This type of alarm will display a message on the
screen. The message will not be logged. This is the
lowest priority of alarm types.
Warning – Non-Latched
This type of warning will activate the audible alarm,
and flash the alarm LED and display back light. The
associated message will be displayed on the screen.
When the user accepts the warning (by pressing the
Enter key), the back light will stop flashing, and the
alarm LED will be on continuously. The message will be
displayed on the alarm screen, but the user will be able
to scroll through other screens. The LED and message
will clear when the warning condition clears. This type
of warning is logged.
Alarm – Latched
This type of alarm will act similarly to the non-latched
warning, except that the alarm does not clear when the
alarm condition clears. When the alarm condition
occurs, the audible alarm sounds, the LED and back
light flash as before, and the user must accept the
alarm to stop them. The alarm will continue to be displayed on the screen even after the alarm condition has
cleared. The user must either press the Reset key or
turn the key-switch to the OFF position to clear the
alarm after the alarm condition has cleared. This type
of alarm is logged.
Shutdown
This type of alarm will act similar to the latched
alarm, but it also will stop the engine when the alarm
condition occurs. It can be reset only by turning the
key-switch to the OFF position. All shutdown alarms
are latching, and this type of alarm is logged.
Alarm Status
This is the value at which the alarm is active. For analog alarms, it is a number corresponding to the alarm
limit. Digital alarms are either “normally open” or
“normally closed,” and an alarm is generated when
the input is not in the normal state.
Alarm Message
Each alarm will have a message associated with it. The
analog alarm messages will be preset, and the digital
alarm messages and user-defined analog messages will
be entered via the keypad or the serial link.
OTHER ALARMS
Overcrank
This alarm is unlike other alarms as it is not associated with an analog or digital signal. The user is able
to define the number of crank attempts, the length of
each crank attempt and the rest time between
cranks. After the last attempt has been made, an
overcrank alarm will be generated. The user must
turn the key-switch to the OFF position to clear the
alarm.
Coolant Level
This alarm is generated by the coolant level detector.
This device senses whether coolant is present or not.
It has no user-definable level setting and is a shutdown alarm that is active after the hold off time.
There are no user-definable parameters for this
alarm.
PROGRAMMABLE PARAMETERS
The E option panel allows the user to configure various options to control the generator starting and
stopping cycles, and the way that the alarms operate.
Parameters are entered either from the control module or via the serial link. A description of the programmable parameters follows:
PREHEAT ENABLED
This parameter determines how the preheat function
works. The preheat can be fully disabled, enabled
before starting only (for the duration of the preheat
time), or before and during starting (for the duration
of the preheat time and also while the starter is
engaged). Note that if the user wishes to engage the
preheat during starting but not to have a preheat
before starting, it is possible to set the preheat time
to zero.
PREHEAT TIME
When a start command is received, some engines
require preheating before the generator attempts to
start. When the preheat function is enabled, this
parameter allows the user to determine the time that
the preheat contact closes before activating the
starter solenoid.
START TIME
Once a start command has been received and
the preheat time has expired (if enabled), the starter
solenoid will be engaged. This parameter allows the
user to determine how long the starter solenoid is
engaged before the start attempt is regarded as having failed. If the generator does not start within this
time, the generator will wait for a preset time before
attempting to start again. The user also can program
the number of start attempts the generator tries.
Section 1 — General Information
E Option Control Panels
Generac®Power Systems, Inc. 7
PAUSE TIME
If the generator does not start within the programmed start time, it will pause before trying to
start again. This parameter determines the length of
that pause.
START ATTEMPTS
This parameter determines the number of times that
the generator tries to start. If the generator has not
started after this number of attempts, an alarm is
generated.
STARTER DISENGAGE SPEED
While the starter is engaged, the engine speed is monitored. Once it reaches this value, the starter motor is
disengaged, and the engine is regarded as having
started.
HOLD OFF TIME
Once the engine has started, some alarm functions
(such as low oil pressure and under speed) are not
activated immediately since the engine must be given
time to reach a stable condition. This parameter
determines the time that elapses before the hold off
alarms are activated.
COOL-DOWN TIME
It is sometimes desirable to run the generator for a
given time with no load before stopping to allow the
engine to cool down. This parameter determines the
length of time that the generator continues to run
after a stop command is sent in AUTO mode. Note
that if the key-switch is turned to the OFF position
when the generator is running, it will stop immediately regardless of this setting. This value also should
be set to zero if this function is controlled by the
transfer switch.
LOAD ACCEPT VOLTAGE AND FREQUENCY
Once the generator has started, the voltage and frequency will ramp up until they reach the values at
which the generator can accept load. These parameters allow the user to set the values. The values
should be set slightly lower than the nominal values
to allow for a margin of error in the regulator and
governor settings. Once the values have been
reached, the warm-up timer is started.
WARM-UP TIME
Some applications require that the generator is
allowed to run for a given time before a load is
applied. This parameter allows the user to set that
time. Note that if this function is controlled elsewhere
(e.g., within a transfer switch), this time should be set
to zero. The generator is ready to accept load when
this timer expires. This parameter can be assigned to
an output relay.
VOLTAGE SCALING FACTOR
The voltage scaling factor is used to scale the sensing
voltage applied to CON4-4 and CON4-6.
On generators manufactured prior to the second
quarter of 2000: Sensing voltage was measured from
line-to-line, so the scaling factor was primarily set to
1.0. On generators manufactured starting the second
quarter of 2000: Sensing voltage is measured from
the frequency meter, in this case the scaling factor is
used so the “E” panel displays line-to-line voltage.
This scaling factor can also be used to “calibrate” the
“E” panel display.
FLYWHEEL TEETH
This parameter holds the number of flywheel teeth.
This value is used to determine the engine speed
from the magnetic pickup signal.
USER-DEFINED OUTPUT FUNCTIONS
There are three user-defined outputs, and the preheat
output also can be used as a user-defined output if the
preheat function is disabled. Each output can be programmed to signal that an alarm is active, to indicate
one specific alarm or input condition, to indicate the
status of the key-switch, or to indicate the current status of the generator. These relay contacts can be used
to switch up to 30 volts AC or DC at 1 amp.
Programming example for user output #2 to be active
on any generator alarm shutdown:
1. Press the left or right arrow key until the display
reads “Parameter entry” and press ENTER.
2. Enter your password and press ENTER.
3. Use the left and right arrow keys to find the
“Digital I/O Menu”.
4. Use the up and down arrow keys to locate “Output
2 Function”. The bottom line of the display will
read the current setting. Press ENTER.
5. Use the up and down arrows to scroll through the
list until “Generator Alarm Shutdown” is displayed in the bottom line. Press ENTER.
6. User output #2 is now programmed to become
active (relay energized) on any generator shutdown
alarm.
7. Press RESET. This exits the programming mode
and returns you back to the parameter entry
screen.
NOTE:
See the “Output Function Table” on Page 14 and
the “E” Panel Display Map on pages 18-19 for
more detail.
Section 1 — General Information
E Option Control Panels
8 Generac®Power Systems, Inc.
ANALOG INPUT SCALING FACTORS
The two user-defined analog inputs can be scaled so
that the display uses meaningful values rather than the
voltage level at the input. The user enters the value to
be displayed when the input voltage is zero and when it
is at the maximum value. (An analog input to the E
panel is a voltage sourced input with a zero- to 10-volt
range.) All alarm settings are based on this scaling, and
the instrumentation display shows the input value
based on this scaling too.
ANALOG INPUT MESSAGES
This is a message up to 24 characters long that is displayed on the instrumentation display when the corresponding value is being shown.
ANALOG INPUT ALARM MESSAGES
There is a user-definable message for each alarm
condition on each analog input. This message is
shown on the alarm display when the alarm condition is active and is stored in the alarm log.
ANALOG INPUT ALARM SETTINGS
Each analog input has two alarms associated with it.
One is activated when the input value is higher than
the high set-point, and the other is active when the
input is lower than the low set-point. The user also
can define when the alarm is active (or disable it) and
the severity of the alarm (from simply displaying a
status message to shutting down the generator – see
“Alarm Processing” on Page 5).
DIGITAL INPUT ALARM SETTINGS
Each digital input also can generate an alarm. The
user can program the alarm message, the input state
that generates the alarm, when the alarm is active,
and the alarm type. A digital input to the E panel is
NOT a voltage sourced input, but a dry contact closure to ground. Voltage never should be sourced to a
digital input. The signal options to a digital input are
as follows:
• Open: This signal is an open circuit.
• Closed: This signal is a contact closure to ground.
OIL PRESSURE ALARMS
The oil pressure input has two associated alarm
functions. The pre-low oil pressure warning is a nonlatched, hold off alarm with a user-definable setpoint. The low oil pressure shutdown is a shutdown,
hold off alarm with a user-definable set-point. The
shutdown alarm set-point should be the lowest of the
two settings so that the user will have some warning
of a low oil condition before the generator is shut
down.
OIL TEMPERATURE ALARMS
The oil temperature has a non-latched warning and a
shutdown alarm associated with it. The set-points are
programmable, and the alarms can be immediate,
hold off or disabled.
COOLANT TEMPERATURE ALARMS
The coolant temperature input has three associated
alarms. The pre-high coolant temperature alarm is a
non-latched, hold-off alarm. The high coolant temperature alarm is a shutdown, hold-off alarm. The
low coolant temperature warning is a non-latched,
always active alarm. Set-points for each alarm are
programmable.
BATTERY VOLTAGE ALARMS
The low battery voltage warning set-point is programmable. The warning will be activated if the battery voltage is below this value for more than five
minutes. This is a non-latched, always active alarm.
Note that the “Power” LED on the front panel is extinguished immediately if the battery voltage is less than
this value. The high battery voltage alarm set-point is
also programmable. The warning is active immediately when the battery voltage is higher than this
value.
ENGINE SPEED ALARMS
The user can program the overspeed and the underspeed alarm. The overspeed alarm is an immediate
shutdown alarm. Underspeed is a hold off alarm that
can either be non-latched, latched or shutdown.
GENERATOR VOLTAGE ALARMS
An alarm can be generated for high voltage and low
voltage. The set-points are user-definable, and the
alarms can be either non-latching, latching or shutdown.
GENERATOR FREQUENCY ALARMS
An alarm can be generated for high frequency and
low frequency. The set-points are user-definable, and
the alarms can be either non-latching, latching or
shutdown.
FUEL LEVEL ALARMS
Alarms can be generated by an optional fuel level sensor. The high fuel level warning is non-latching. There
is also a low fuel level warning that is non-latching
and a low fuel shutdown alarm. Each of these alarms
has a set-point and can be always active or disabled.
Section 1 — General Information
E Option Control Panels
Generac®Power Systems, Inc. 9
E PANEL MODEM SETUP PROCEDURE
NOTE:
Generac only supports the US Robotics 56k V90
Sportster modem for connection of the “E” Panel
to the phone line. Other modems may work in this
application, but have not been tested by Generac.
1. Set modem Dip switches as shown in Figure 1.2.
Power cycle the modem (turn modem off, then on).
2. Connect the cable between the “E” panel and the
modem (see Figure 1.4).
3. Set the “E” panel for “modem connection and
setup”. Power cycle the “E” panel (remove and
relace front panel fuse).
4. In GenLink, select the proper setup string for the
modem at the PC end (not the “E” panel).
Figure 1.2 — US Robotics 56k V90 Sportster
Dip Switch Settings
E PANEL RS232 CABLES
The “E” panel can communicate via its RS232 port to
a remote PC. The connection is made either directly
to the serial port on a PC, or via a modem and telephone line.
The “E” panel has a 9-pin male “D” type connector,
and is configured as DTE (Data Terminal
Equipment). The serial ports on most PCs also have
a DTE configuration, and are usually 9-pin “D” type
male connectors. Most modems have a DCE configuration (Data Communication Equipment) and a 25pin female connector.
Connecting an “E” panel directly to a PC requires a
“Null Modem” connection. This can be achieved with
either a null modem cable, or a standard serial cable
with a null modem adapter. Figure 1.3 shows the
required pin connections between the two cables for
a 9-pin serial connector on the PC.
Figure 1.3 — “E” Panel to PC Cable
Configuration
NOTE:
Use shielded cable, 100 feet maximum in length.
Connect the shield drain wire to Pin 1 on the E
panel end only.
Connecting the “E” panel to a modem requires a standard modem cable. The cable supplied with the
modem should work. If a longer cable is required, the
connectors should be wired as shown in Figure 4.
Figure 1.4 — “E” Panel to Modem Cable
Configuration
NOTE:
The modem is not intended to be mounted inside
the control panel. It should be mounted inside the
enclosure (no vibration) or inside a nearby building or shelter if the generator does not have an
enclosure.
NOTE:
Use shielded cable, 100 feet maximum in length.
Connect the shield drain wire to Pin 1 on the E
panel end only.
SERIAL COMMUNICATIONS
Serial Communication Via Modem
(Also refer to the appropriate Genlink Manual)
The control panel has the ability to communicate to a
PC via an RS232 serial port. The PC software will be
able to interrogate the module. The user also will be
able to program the parameters on the PC and download them to the module if using the Pro version. The
user will be able to start and stop the generator if it is
in AUTO mode.
The module does not have a built-in modem.
However, software will include the ability to interface
with an external modem. The user can initialize the
modem from the panel. Generac offers a remote
annunciator (models #’s 004391-0, 004392-0 and
004391-1, 004392-1) which allows the E panel to
communicate with both a modem and a remote
annunciator. See the Remote Annunciator Panel manual (part number 0A7450) for a complete description
of these panels.
Section 1 — General Information
E Option Control Panels
10 Generac®Power Systems, Inc.
Section 1 — General Information
E Option Control Panels
Remote Annunciator Panel
(Refer to manuals 0A7450 and 0A9825)
The serial connections can be configured to allow the
control panel to connect to a remote
annunciator/remote relay panel, which is configured
as RS485, to meet NFPA 110. Only one communication port is available for either a modem or remote
annunciator.
NOTE:
The following diagram and instructions apply only
to those units manufactured before January 2000.
Units manufactured after January 2000 incorporate a selector switch on the back of the control
module. This switch will allow selection of either
RS232 or RS485 without opening the module.
Altering the Serial Communications Setup
The E option control panel is capable of being used
with either a modem or a remote annunciator/
remote relay panel, depending on the configuration of
the serial connections. The unit comes set up for connection to a modem (RS232). In order to use the control panel with a remote annunciator/remote relay
panel (RS485), adhere to Figure 1.5 and the instructions that follow.
1. Remove harness retaining screws, then unplug all
five wire harnesses from the back of the E panel
control module.
2. Remove the four phillips head screws retaining the
rear cover of the control module.
3. Open the back of the control module.
4. Locate the DB-9 wire harness that runs from the
DB-9 connector on the back panel to the black
header on the lower circuit board inside the control module.
5. Carefully remove the black connector from
the header by pressing the locking tab and
lifting up.
6. Insert the black connector into the RS485
header (J11). Make sure that the connector is fully
inserted and that the locking tab snaps into place.
7. Replace the back panel and the four screws.
Figure 1.5 – E Panel Serial Communications
Setup Modification
USER PASSWORD
The user can set the password. This is a six-digit
number and is initially set to 000000.
ADDITIONAL PANEL COMPONENTS
In addition to the control module, the E option panel
contains the following components (see Figure 1.6):
AC VOLTMETER
This meter indicates the generator AC output voltage.
To determine the nominal rated AC voltage of the
unit, refer to the unit’s data plate.
NOTE:
Some generators are re-connectable to a variety of
voltages. Some units may be equipped with a
rotary “Voltage Selector Switch.” Be sure to read
the “Generator AC Lead Connections” section in
the Owner’s Manual.
AC AMMETER
This meter indicates the current draw of connected
electrical loads, in amps. Also see “Line-phase
Selector Switch.” For continuous operation, never
exceed the rated maximum continuous current
capacity of the generator.
FREQUENCY METER
This meter indicates the generator’s AC output frequency in “Hertz” (cycles per second).
LINE-PHASE SELECTOR SWITCH
This four-position switch permits selection of either
line-to-line or line-to-neutral readings on the panel voltmeter and ammeter. Switch positions are as follows:
Figure 1.6 – E Option Panel Components
Switch Single-phase Units Three-phase units
1 Line E1 to Neutral Line E1 to E2
2 Line E3 to Neutral Line E2 to E3
3 Line E1 to E3 Line E3 to E1
OFF No Reading No Reading
Generac®Power Systems, Inc. 11
VOLTAGE ADJUST POTENTIOMETER
This potentiometer permits the operator to “fine
adjust” the generator’s AC output voltage on units
rated below 400 kW. Adjustment range is plus or
minus five percent. Turn the knob clockwise to
increase voltage, counterclockwise to decrease voltage.
ALARM HORN
This horn sounds an audible warning when an alarm
condition exists. See the “Alarms” section for further
information.
DC PANEL FUSE
This 15-amp fuse protects the panel components.
This fuse is not to be confused with the control module internal fuse discussed in “Checking/Replacing
the E Panel Control Module Internal Fuse.”
EMERGENCY STOP SWITCH
When pressed, this switch will automatically shut
down the entire generator set. The operator must pull
the switch out to its original position to reset it and
allow for generator operation.
CHECKING/REPLACING THE E PANEL
CONTROL MODULE INTERNAL FUSE
Typically, the main indication of fuse failure is the
absence of any illuminated front panel LEDs (even
with the key in the OFF position, the “Power” LED
will be illuminated) and no text visible on the module
display. It should be noted however, that these conditions can exist if either:
a. The generator start battery is dead (less than five
volts) or disconnected.
b. The main panel fuse (15 amp) is blown.
c. The battery supply wires (#13 and #0) to the
panel control module are open circuit (disconnected).
d. The “Power” connector (CON4) is disconnected
from the rear of the control module.
e. The generator start battery connections have been
reversed. Reversal of the battery connections
WILL blow the internal fuse and is the most likely reason for its failure.
Before removing or disconnecting the E panel control
module, check that none of the above conditions (ae) exist.
If you are satisfied that the problem lies with the
control module:
1. Disconnect the generator start battery.
2. Unplug all four wire harnesses from the back of
the control module.
3. Loosen, then detach, the two retaining clips securing the control module and remove the module.
4. Using a multimeter (e.g., Fluke 87) set to the diode
range, measure between pins 1 (BAT+) and 2 (BAT) of connector CON4 on the module.
• With the positive meter lead connected to pin
2 and the negative lead to pin 1, the meter
should read between 0.4 and 0.6 volts, which
indicates that the internal fuse is OK.
• Reversing the meter leads would give a slowly
increasing voltage reading on the meter, which
also indicates a good fuse.
• An open circuit fuse will give an open circuit
meter reading (.OL on Fluke 87).
If the meter reads open circuit:
5. Remove the four phillips head screws retaining the
rear cover of the control module.
3. Open the back of the control module.
4. Locate the internal printed-circuit board mounted
fuse, which is behind and to the left of CON4.
5. Remove the white plastic cover from the fuse holder and remove the fuse.
6. If the fuse has blown, replace the fuse (part
#0A5705), reassemble the control module, and
reinstall the control module and its connections.
7. Reconnect the generator start battery and check if
the control module now functions.
If the fuse blows again, or was not blown when the
module was opened, or the module still does not
function, the E panel control module must be
replaced.
USER PROGRAMMABLE INPUTS
The E panel has eight (8) user programmable inputs.
These inputs can be used for annunciation, prealarm, or shutdown alarms. Four of the inputs,
Battery Charge Fail, Gen Power, Line Power, and
Programmable Input 4 are set up to annunciate on
the control panel display and at the optional 20 Light
Remote Annunciator (Programmable Input 4 will
light the unlabeled “spare” LED). These four inputs
can be used for other connections if a remote annunciator is not used. The other four inputs, if utilized,
will annunciate at the control panel only.
The user programmable input connection points are
located inside the E option control panel on a 12position strip labeled TB3 (refer to Figures 1.7 and
1.8 on page 12.). The first four terminals are labeled
“prog input gnd”. These are the common ground connection points for the user supplied switch devices to
be used for the programmable annunciation.
NOTE:
These ground terminals are for user programmable input use only. The are not to be used for
grounding any other circuits.
Section 1 — General Information
E Option Control Panels
12 Generac®Power Systems, Inc.
Figure 1.7 — TB3 Units Up to 400 kW
Figure 1.8 — TB3 Units Over 400 kW
The remaining eight terminals on TB3 are for the “positive” side of each user programmable input switch circuit. These eight terminals have a five VDC potential
available in an open-circuit condition (whether the
control panel key switch is in the off, manual, or auto
position). The inputs can be programmed to annunciate upon either an open circuit condition (five VDC
potential at the terminal) or a grounded condition
(zero VDC potential at the terminal). This voltage state
is determined by the user supplied switch either opening or closing to cause an annunciation.
Program set-up for the user programmable inputs is
carried out in the Digital I/O Menu of the E module
(please refer to the Display Map on pages 18-19). Each
of the eight inputs has four parameters in which specific options must be selected to make the annunciation function properly. These four parameters are
labeled Input Channel Message, Input Channel Setting,
Input Channel Alarm Enable, and Input Channel
Alarm Type. Following is a brief description of each:
• Input Channel Message — for selecting letters and
numbers to spell out what the display will read
upon activation of that specific input.
• Input Channel Setting — for selecting whether
annunciation should activate upon that specific
circuit opening or closing to ground.
• Input Channel Alarm Enable — for enabling or dis-
abling annunciation function of that specific input.
Also, if enabled, for selecting when annunciation
will be active. The choices are: Disabled, Always,
Immediate and Hold-off. See E Control Panel
Definitions on page 38.
• Input Channel Alarm Type — for selecting the type
of alarm annunciation and the effect it has on the
generators control system. The four choices are:
Status, Non-latched, Latched and Shutdown. See
E Control Panel Definitions on page 14.
WIRING EXAMPLES
USER PROGRAMMABLE INPUT NUMBER 1
On units rated below 400 kW, input number 1 is programmed for “Battery Charge Fail” annunciation at
the control panel display, and the LED on the 20 Light
Remote Annunciator (if used). A user supplied AC
relay is wired in to be powered up by AC voltage that
supplies the unit Battery Charger (see Figure 1.9).
Figure 1.9 — Battery Charge Fail Wiring
◆
Section 1 — General Information
E Option Control Panels
Generac®Power Systems, Inc. 13
Upon loss of this AC supply voltage, the relay will deenergize. The normally closed contacts on the relay
are to be connected to TB3 in the control panel. One
wire connects to any of the four “Prog Input Gnd”
terminals, the other wire connects to terminal number 5 (B/C Fail). With the relay de-energized, terminal
5 will be grounded, signaling the E module to activate
on Programmable Input 1.
USER PROGRAMMABLE INPUTS NUMBERS
2 AND 3
On units rated below 400 kW, input numbers 2 and 3
are programmed for “Gen Power” and “Line Power”
respectively, indicating the transfer switch position
(Standby or Utility). Annunciation will occur at the
control panel display and at the Remote Annunciator
(if used). These signals will come from a set of spare
auxiliary contacts located on the main contactor
assembly in the transfer switch. The auxiliary contact
switch is a set of dry contacts with three terminals:
Common, Normally Open, and Normally Closed.
Wires must be connected to these three terminals and
routed to the generator control panel. These three
wires must not be run in the same conduit as the generator’s main output conductors. The wire connected
to the Common terminal on the auxiliary contacts
will connect to any of the Prog Input Gnd terminals
on TB3. The wire connected to the Normally Open
terminal on the auxiliary contacts will connect to terminal 6 (Gen Power) on TB3. The wire connected to
the Normally Closed terminal on the auxiliary contacts will connect to terminal 7 (Line Power) on TB3.
ALL USER PROGRAMMABLE INPUTS
On units rated below 400 kW, input numbers 4
through 8, and units rated over 400 kW, input numbers 1 through 8 can be used for virtually any kind of
annunciation the user wishes to set up, within the
parameters previously described, via an opened or
closed switch device. Proper wiring consists of two
wires from the user supplied switch: one wire connects to one of the “Prg Inpt Gnd” terminals (1
through 4 on TB3), the other wire connects to a
Programmable Input terminal on TB3.
PROGRAMMING EXAMPLES
USER PROGRAMMABLE INPUT NUMBER 1
To be used for Battery Charge Fail annunciation.
After properly wiring the circuit as described in
Wiring Examples, program as follows:
1. Power up the E panel by connecting unit battery
(ies) and inserting control panel fuse. The module
will run through a self-test mode. Once it has completed its self-test, it will display the generator status (Stopped, ready to run).
2. Use the LEFT or RIGHT arrow keys to scroll over
to the PARAMETER ENTRY column.
3. Once at the PARAMETER ENTRY column, press
ENTER. Enter the password (if different from the
factory set password 000000) and press ENTER.
From the ENGINE PARAMETER MENU, press the
RIGHT arrow to get to the DIGITAL I/O MENU.
4. Using the UP or DOWN arrows (the column is a
continuous loop), scroll to INPUT CHANNEL 1
MESSAGE and press ENTER. Up to 24 letters,
numbers and other characters can be entered to
spell out what will be displayed upon this input
becoming active. In this case, enter Battery Charge
Fail. After entering the message, press ENTER.
5. Press the UP arrow to display INPUT CHANNEL 1
SETTING. Press ENTER, the display will read
Input Function, OPEN=ALARM. The Battery
Charge Fail annunciation should occur upon the
user supplied relay de-energizing and its normally-closed contact closing, therefore, select
CLOSED=ALARM by pressing the UP or DOWN
arrow. Press ENTER, the display will read Input
Channel 1 Setting, CLOSED=ALARM.
6. Press the UP arrow, the display will read Input 1
Alarm Enable, DISABLED, press ENTER. The
choices are DISABLED, ALWAYS, IMMEDIATE,
and HOLD OFF. This alarm should always be
active, therefore, scroll up or down and select
ALWAYS, and press ENTER.
7. Press the UP arrow, the display will read Input
Channel 1 Alarm Type, STATUS MESSAGE, press
ENTER. The choices are STATUS MESSAGE,
NON LATCHING ALARM, LATCHING ALARM and
SHUTDOWN ALARM. This annunciation for
Battery Charge Fail should be a STATUS message,
therefore, scroll up or down and select STATUS
MESSAGE by pressing ENTER.
Programming for User Input Channel 1, Battery
Charge Fail is now complete. The E module has been
programmed for a STATUS alarm message that is
ALWAYS active. Upon loss of AC supply voltage to the
generators battery charger, the user supplied relay
will de-energize, its normally closed contacts will
close, grounding TB3 terminal 5 to Prg Input Gnd.
The E module will display BATTERY CHARGE FAIL.
Because it was programmed as a STATUS alarm and
not a LATCHING or SHUTDOWN alarm, the status
message will clear when AC power is restored to the
battery charger.
NOTE:
The Battery Charger Fail LED on the 20 Light
Remote Annunciator (if connected) will also turn
on when Input Channel 1 is activated.
◆
◆
◆
Section 1 — General Information
E Option Control Panels
14 Generac®Power Systems, Inc.
Section 2 — Operation
E Option Control Panels
Output Function Name Description
Function ID
00 Output Disabled Output not in use
01 Common Alarm Active for all latched, non-latched and shutdown alarms
02 Low Oil Pressure Warning Active after hold off time
03 Oil Pressure Shutdown Active after hold off time, low oil pressure
04 High Coolant Temp. Warning Active after hold off time
05 Coolant Temp. Shutdown Active after hold off time, high coolant temperature
06 Low Coolant Temp. Alarm
07 High Oil Temp. Warning
08 Oil Temp. Shutdown High oil temperature
09 Low Battery Voltage Must be below set value for five minutes
10 High Battery Voltage
11 Overspeed Shutdown
12 Underspeed Alarm Active after hold off time
13 Over Voltage Alarm Active after hold off time
14 Under Voltage Alarm Active after hold off time
15 Over Frequency Alarm Active after hold off time
16 Under Frequency Alarm Active after hold off time
17 High Fuel Alarm Above the warning set-point
18 Low Fuel Alarm Below the warning set-point
19 Low Fuel & Shutdown Below the shutdown set-point
20 Failed to Start Alarm Overcrank
21 Coolant Level Alarm Low coolant level
22 RPM Sensor Failed Alarm Magnetic pickup failure
23 Start Inhibit Alarm Oil pressure was present at start request
24 Emergency Stop Alarm Emergency stop active
25 Oil Press. Sense Fault Sensor is either open or short circuit
26 Oil Temp. Sense Fault Sensor is either open or short circuit
27 Coolant Temp. Sense Fault Sensor is either open or short circuit
28 Analog Channel 1 High Input at user analog channel 1 is above programmed high set-point
29 Analog Channel 1 Low Input at user analog channel 1 is below programmed low set-point
30 Analog Channel 2 High Input at user analog channel 2 is above programmed high set-point
31 Analog Channel 2 Low Input at user analog channel 2 is below programmed low set-point
32 Digital Channel 1 Active User programmable digital input 1 is active
33 Digital Channel 2 Active User programmable digital input 2 is active
34 Digital Channel 3 Active User programmable digital input 3 is active
35 Digital Channel 4 Active User programmable digital input 4 is active
36 Digital Channel 5 Active User programmable digital input 5 is active
37 Digital Channel 6 Active User programmable digital input 6 is active
38 Digital Channel 7 Active User programmable digital input 7 is active
39 Digital Channel 8 Active User programmable digital input 8 is active
40 Generator in Auto Key switch in auto position
41 Generator in Manual Key switch in manual position
42 Generator Off Key switch in off position
43 Stopped Generator stopped
44 Shutdown Due to Alarm Generator shutdown
45 Stopped Ready to Run Generator ready to start
46 Running Generator running
47 Ready to Accept Load Generator has reached load accept voltage and frequency set-points, and
the warm-up timer has expired
48 All Alarms Active Generator running
OUTPUT FUNCTION TABLE
Generac®Power Systems, Inc. 15
Section 2 — Operation
E Option Control Panels
E PANEL MASTER CONTROL BOX CONFIGURATION SETTINGS
ENGINE PARAMETER MENU
Parameter Value Units
RS232 Port
or RS485 Port
Restore All Values to
Default Settings
Voltage Scaling Factor
Flywheel Teeth Number
Panel I.D.
User Password
Preheat Option
Load Accept Frequency Hz
Load Accept Voltage V
Starter Disengage Speed RPM
Number of Start Attempts Number
Generator Cool Down Time min.
Generator Warm Up Time sec.
Alarm Hold Off Time sec.
Start Attempt Pause Time sec.
Start Timer sec.
Preheat Timer sec.
Available Options: P1 = No Preheat, Before Start, Before and During Star t
C1 = Direct Connection, Modem Connection, Modem Connection & Setup
Connection Mode (C1)
Direct Connection Only
Master Password
Required (Factory Only)
.05 to 300
30 to 200
000000 to 999999
000000 to 999999
(P1)
0to90
0 to 2000
0 to 4000
0to10
0 to 600
0 to 600
0to15
5 to 600
3to15
0to30
SYSTEM ALARM MENU
Parameter Value Units Active Type
Low Fuel Shutdown Alarm % Shutdown Alarm
Fuel Level Low Warning % Non-latching Alarm
Fuel Level High Warning % Non-latching Alarm
Under Freq. Hz Hold Off
Over Freq. Hz Hold Off
Under V oltage V Hold Off
Over Voltage V Hold Off
Engine Underspeed Alarm RPM Hold Off
Engine Overspeed Alarm RPM Immediate Shutdown Alarm
Battery Volts High Warning V Always Non-latching Alarm
Battery Volts Low Warning V Always Non-latching Alarm
Oil Temp. Shutdown Alarm Deg. F Shutdown Alarm
Oil Temp.Warning Deg. F Non-latching Alarm
Coolant Temp. Shutdown Alarm Deg. F Hold Off Shutdown Alarm
Coolant Temp. High Warning Deg. F Hold Off Non-latching Alarm
Coolant Temp.Low W arning Deg. F Always Non-latching Alarm
Oil Press. Shutdown Alarm PSI Hold Off Shutdown Alarm
Oil Press.Warning PSI Hold Off Non-latching Alarm
Available Options: A1 = Disable, Hold off, Immediate
A2 = Disable, Always
T1 = Shutdown Alarm, Latching Alarm, Non-latching Alarm, Status Message
0 to 100
0 to 100
0 to 100
0 to 100
0 to 100
0 to 2000
0 to 2000
0 to 4500
1000 to 4500
4to30
4to30
-5 to 275
-5 to 275
-5 to 275
-5 to 275
0 to 245
0 to 100
0 to 100
(A2)
(A2)
(A2)
(T1)
(T1)
(T1)
(T1)
(T1)
(A1)
(A1)
16 Generac®Power Systems, Inc.
Section 2 — Operation
E Option Control Panels
DIGITAL I/O MENU
Channel Message Setting Alarm Enable Alarm Type
Output 1 (F1)
Output 2 (F1)
Output 3 (F1)
Preheat Output Function (F1)
User Input 1 *1 Battery Charge Fail (S1) (A1) (T1)
User Input 2 *1 Generator Power (S1) (A1) (T1)
User Input 3 *1 Line Power (S1) (A1) (T1)
User Input 4 *2 Backup Low Oil Pressure (S1) (A1) (T1)
User Input 5 *2 Backup High Engine Temp. (S1) (A1) (T1)
User Input 6 *2 Oil Filter Blocked (S1) (A1) (T1)
User Input 7 *2 MLCB (S1) (A1) (T1)
User Input 8 *2 Ruptured Tank (S1) (A1) (T1)
Messages can be a maximum of 24 characters including spaces.
Available Options: A1 = Disabled, Hold Off, Immediate, Always
F1 = See output function table for available options.
S1 = Closed (Low Signal/Contact Closure to Ground), Open (High signal/Open Circuit)
T1 = Shutdown Alarm, Latching Alarm, Non-latching alarm, Status Message
*1 Assigned if used with 20 light Remote Annunciator or Remote Relay Panel Otherwise available for any
customer options.
*2 Factory wired if unit is equipped with these options.Otherwise these inputs are available for any
customer requirements.
ANALOG INPUT MENU
Alarm Msg. (Alarm) (Alarm)
Value at Value at (Display) Message Setpoint Enable Type
0V 10V Title High Low High Low High Low High Low
Analog Channel 1 (A1) (A1) (T1) (T1)
Analog Channel 1 (A1) (A1) (T1) (T1)
Messages can be a maximum of 24 characters including spaces.
Available Options: A1 = Disabled, Hold Off, Immediate, Always
T1 = Shutdown Alarm, Latching Alarm, Non-latching alarm, Status Message
Generac®Power Systems, Inc. 17
Section 2 — Operation
E Option Control Panels
GenLink®Communications Flowchart
Dip Switch Setting
1Up
2Down
3Down
4Down
5Up
6Up
7Up
8Down
TABLE A
“E” Panel Pin Modem Pin
18
23
32
420
57
TABLE B
18 Generac®Power Systems, Inc.
Section 2 — Operation
E Option Control Panels
E PANEL DISPLAY MAP
Generac digital panel Generator switch off
Software version X.XX Generator switch off
will be on Attempting to start
X.X
or or or
or or or
or or or
or or or
or or or
Fuel Level High Enable Input Ch 7 Alarm Type Analog Ch 2 low Setpoint
Fuel Level Low Setpoint Input Channel 8 Message Analog Ch 2 High Enable
or or or
Under Freq Alarm Type Input Channel 7 Setting Analog 2 Low Alarm Msg
Fuel Level High Setpoint Input Ch 7 Alarm Enable Analog Ch 2 High Setpoint
or or or
or or or
XX.X Hz
Under Freq Setpoint Input Channel 7 Message Analog Ch 2 High Alarm Msg
Over Freq Alarm Type Input Ch 6 Alarm Type Analog Channel 2 Title
or or or
or or or
XX.X Hz X.X
Over Freq Setpoint Input Ch 6 Alarm enable Analog Ch 2 Value at 10V
Under Voltage Alarm Type Input Channel 6 Setting Analog Ch 2 value at 0V
or or or
or or or
XXX Volts
Under Voltage Setpoint Input Channel 6 Message Analog Ch 1 Low Type
or or or
or or or
XXX Volts
Over Voltage Setpoint Input Ch 5 Alarm Enable Analog Ch 1 Low Enable
Over Voltage Alarm Type Input Ch 5 Alarm Type Analog Ch 1 High Type
Parameter entry
Press Enter to Continue
Password Attempt number X
Or Enter Or Enter * Or Turn key to auto mode: Or
E-PANEL DISPLAY MAP
or
or
or
or or or or
X.X Enter
XXX Volts
Or
or
Thru Hours Run * Display test, stop command
Logged Alarm Number 50 XXXXX.X Hrs all pixels black, all 4 LEDs Turn key to manual mode:
ALARM STATUS ALARM LOG INSTRUMENTATION PARAMETER ENTRY SOFTWARE VERSION GENERATOR COMMAND
there are no messages Generator in auto mode
Analog Input 2 XXXXXX
X.X
Analog Input 1 Engine Parameter Menu Or System Alarm Menu Or Digital I/O Menu Or Analog Input menu
or
or
Direct Connection only
X RS485 Port
or
Fuel Level Low Fuel Shutdown Enable Input Ch 8 Alarm Type Analog Ch 2 Low Type
Battery Voltage RS 232 Port Low Fuel Shutdown Setpt Input Ch 8 Alarm enable Analog Ch 2 High Type
or
RS 232 Port
or
XXX p.s.I or
XX.X Volts Direct conection XX %
Oil Pressure Modem connection Fuel Level Low Enable Input Channel 8 Setting Analog Ch 2 Low Enable
or
or
RS 232 Port
to default settings
Restore all values
Modem connection & Setup
or
or
XXX deg F XX%
XXX deg. F X.X
Oil Temperature
Coolant Temperature
or
or
XXX
XXX.XX
Flywheel Teeth
Voltage Scaling Factor
or
or
XXXX Rpm XX% X.X
Engine Speed
Generator Frequency
Panel I.D.
XX.XHz
or
XXXXXX
or
XXXXXX
User Password
or
Preheat Option
or
or
XX.X Hz
XXX Volts
Load Accept Voltage
Load Accept Frequency
X
or
or
XXX RPM
Starter Disengage Speed
Number of Start Attempts
X Min
Generator Cool Down Time
STATUS
GENERATOR
Stopped ready to run No active messages * Logged Alarm Number 1 Generator Voltage
Or Or * this is true as long as Or
Generac®Power Systems, Inc. 19
Section 2 — Operation
E Option Control Panels
X.X
or or or
or or or
XXXX Rpm
Underspeed Alarm Type Input Channel 5 Message Analog Ch 1 low Setpoint
Overspeed Shutdown Setpt Input Channel 5 Setting Analog Ch 1 High Enable
or or or
or or or
XX.X V
XXXX Rpm X.X
Underspeed Alarm Setpt Input Ch 4 Alarm Type Analog Ch 1 High Setpoint
Battery Volts Low Setpt Input Channel 4 Setting Analog Ch 1 High Alarm Msg
Battery Volts High Setpt Input Ch 4 Alarm Enable Analog 1 Low Alarm Msg
or or or
XX.X V
Coolant Temp low Setpt Input Channel 4 Message Analog Channel 1 Title
Analog Ch 1 Value at 10V
Input Ch 3 Alarm Type
or or or
or or or
XXX Deg F
XXX Deg F X.X
Coolant Temp Shutdn Setpt.
Analog Ch 1 value at 0V
Input Ch 3 Alarm Enable
or or
or or
XXX Deg F X.X
Coolant Temp High Setpt
Oil Temp Shutdown Enable Input Channel 3 Setting
or or
or or
XX Deg F
Oil Temp Warn Enable Input Ch 2 Alarm Type
Oil Temp. Shutdown Setpt Input Channel 3 Message
or or
or or
XX Psi
XX Deg F
Oil Temp. Warn Setpt Input Ch 2 Alarm Enable
Oil Press Shutdown Setpt Input Channel 2 Setting
or
or
Input Ch 1 Alarm Type
XX Psi
Oil Press Warn Setpt Input Channel 2 Message
or
or
or
or
Input Channel 1 Setting
Input Ch 1 Alarm Enable
Preheat Output Function
Input Channel 1 Message
or
Output 3 FunctionorOutput 2 Function
Output 1 Function
or
or
X Sec
Gen. Warm Up Time
or
XX Sec
XX Sec
Alarm Hold Off Time
Start Attempt Pause Time
or
or
XX Sec
Start Timer
XX Sec
Preheat Timer
20 Generac®Power Systems, Inc.
OIL PRESSURE SENSING (Refer to Figure 3.1)
OVERVIEW
An analog Oil Pressure Sender (OPS) is used for
monitoring the engine oil pressure. This sender
allows the E panel to measure and display the Engine
oil pressure.
Refer to the owners manual for the OPS part number
and mounting location.
Wire number 69 is used to connect the OPS to the E
Panel. The Ground for the OPS is made through the
engine block.
The OPS is a resistive device, whose resistance
changes based on engine oil pressure. The resistance
of the sender results in a voltage being developed
across the sender. As the oil pressure increases, the
resistance will decrease, causing the voltage to
decrease. This changing voltage is read by the E Panel
and converted into the engine Oil Pressure.
The E Panel will monitor and display oil pressure
anytime the DC input to the E Panel is present.
TROUBLESHOOTING
Prior to any troubleshooting, the oil pressure parameters programmed into the E Panel should be
checked and verified. The oil pressure input has two
different set points associated with it. They are:
Pre-Low Oil Pressure Warning: This is the warning
set point. The generator's alarm will sound, but the
generator will continue to run.
Critical Low Oil Pressure Alarm: This is the alarm
set point. The generator will shut down and sound
the alarm.
It is important to verify that these parameters are set
correctly for the specific unit. Check the E Panel settings against the Generator setup sheet. If the generator setup sheet is not available, contact Generac's
service department for the recommended settings.
Figure 3.1 — Oil Pressure Sender Connections
TESTING THE CONTROL PANEL
It is relatively easy to do a thorough test of the E
Panel's Oil Pressure input.
Place the Auto/Off/Manual switch to the Off position
during this testing.
Open circuit testing
This test checks the high end of the oil pressure input
of the E Panel.
1. Remove the 69 wire from the control panel terminal strip. This simulates a sender open circuit
condition.
2. Look for the following response from the E Panel:
The back light will flash, the Com Alarm LED will
flash, and the display will read as follows:
OIL PRESS SENSE FAULT
PRESS ENTER TO ACCEPT
3. Press enter to accept the alarm.
Short circuit testing
This test checks the low end of the oil pressure input
of the E Panel.
1. Reconnect the 69 wire to the control panel terminal strip.
Connect a jumper wire between the 69 and 0
positions on the control panel terminal strip. This
simulates a sender short circuit condition
2. Look for the following response from the E Panel
2.1 For units with software version V1.11 and
earlier: The back light will flash, the Com
Alarm LED will flash, and the display will
read as follows:
OIL PRESS SENSE FAULT
PRESS ENTER TO ACCEPT
Press enter to accept the alarm.
2.2 For units with software version V1.12 and
later:
Use the arrow keys to go to the Oil pressure
display screen.
The screen should display oil pressure as
125 p.s.i.
Control panel testing complete
1. Remove the jumper between the 69 and 0 locations on the control panel terminal strip.
2. If any E Panel alarms are present, press enter to
accept.
Test Results
1. Tests 1and 2 Pass:
Move on to the next test "Testing the Oil Pressure
Sender".
Section 3 — Troubleshooting and Diagnosis
E Option Control Panels
Oil Pressure Sender Connections
Refer to the unit's Wiring Diagram for specific connector locations
E Panel
+5V
69 Location on the
Control Panel
terminal strip
E Panel
CON 2-5
Set Screw
Connector
69 69
69 Location in the
Deutsch Connector
("Sealed Connector"
Control Panels only)
69
Oil Pressure
Sender
(OPS)
This Ground (0)
connection is
made through the
Engine Block
Generac®Power Systems, Inc. 21
2. If either test 1 or 2 failed:
2.1 Repeat the open and short circuit testing
directly at the back of the E Panel as follows:
Open: The 69 wire should be removed from
CON2-5
Short: With the 69 wire still removed, insert
a jumper wire into CON2-5. Connect
the other end of the jumper to ground
(0).
After testing, remove the jumper wire from
CON2-5 and insert the 69 wire back into
CON2-5
2.2 Test results:
2.2.1 If these tests fail again directly at the
back of the E Panel, then the E Panel
has failed and should be replaced.
2.2.2 If these tests pass at the back of the E
Panel, but failed at the terminal strip,
then there is a wiring error between the
E Panel and the terminal strip. Check
this wiring carefully.
TESTING THE OIL PRESSURE SENDER
The resistance of the OPS can be checked in a power
down state as follows:
1. Remove the control panel fuse to power down the
E panel.
2. Unplug CON2 from the E Panel.
3. Measure the resistance of the oil pressure sender.
This measurement should be made between the
sender terminal and the sender body.
The sender resistance should measure between 225
and 260 Ohms at 0 PSI.
NOTE:
If the engine has just been stopped, allow sufficient time for the oil pressure to drop to zero
before making this measurement.
If the resistance measurement is not in this range, the
sender has failed. Replace the sender.
If the resistance measurement is in this range, move
on to the next test.
TESTING THE OIL PRESSURE SENDER
CONNECTIONS
Visual Inspection
Carefully check the wiring between the oil pressure
sender and the E Panel.
1. Check the 69 wire connection to the OPS.
1.1 Check for a proper crimp on the lug.
1.2 Check to see if the sender nut is tightened
securely. Be careful not to over tighten the
nut. If the nut is over tightened, the stud will
break free and cause incorrect sender readings. This nut should be tightened to 14 to 18
inch pounds.
1.3 Check for any environmental corrosion on
the lug or the sender terminal. Generac recommends the following actions if corrosion is
found:
1.3.1 Replace the lug.
1.3.2 Replace the sender if possible. If not
possible, thoroughly remove all of the
corrosion from the sender terminal.
1.3.3 Protect the lug and sender terminal
with an approved automotive dielectric
grease.
2. Check the 69 wire in the Deutsch connector (only
used on the "water tight connector" panels.)
2.1 Refer to appendix A for information on the
Deutsch connectors used.
2.2 Refer to the unit's wire diagram for the 69
location in the Deutsch plug.
3. Check the 69 wire on the control panel terminal
strip.
3.1 Check for a proper crimp on both lugs.
3.2 Check to see if both screws are tightened
securely. These screws should be tightened to
12 inch pounds.
4. Check the 69 wire going into CON2 on the back of
the E Panel.
4.1 Check to see if the wire is stripped properly
inside the green plug. The wire conductor
should be trapped inside the metal wire
clamp. The wire insulation should not be
trapped inside the metal wire clamp.
4.2 Check to see if the set screw is tightened
securely, but do not over tighten. This screw
should be set to 2 to 4 inch pounds.
5. Check for any wire damage along the entire run
between the E Panel and the sender.
5.1 Check for any areas along the wire with missing insulation. This could allow the 69 line to
momentarily come into contact with ground
causing a false shut down.
5.2 Check to see if the wire is pinched anywhere
along the run. A wire that is pinched between
the sheet metal can cause the 69 wire to
momentarily come into contact with ground
resulting in a shut down fault. A pinched wire
may also cause the wire to break inside the
insulation. This could cause the 69 line to
monetarily "open" while running. This will
also result in a shut down fault.
Section 3 — Troubleshooting and Diagnosis
E Option Control Panels
22 Generac®Power Systems, Inc.
Check the OPS mounting
The ground return (0) connection for the OPS is
made by the physical connection of the sender to the
engine block. This connection may be made directly,
or through a series of adapters or fittings.
Check for the following at each junction point:
1. Check for a tight mechanical connection.
2. Check for a good electrical connection.
Resistance measurement
The resistance of the OPS was measured in "Testing
the Oil Pressure Sender."
In that test, the resistance was measured directly
across the OPS. This test will now measure that same
resistance inside the control panel. This will provide
an additional test of the wiring and connections used
to connect the sender to the control panel.
1. Remove the control panel fuse to power down the
E Panel.
2. Unplug CON2 from the E Panel.
3. Measure the resistance between the 69 and 0 locations on the control panel terminal strip.
4. Compare this measurement to the measurement
taken directly across the OPS.
4.1 If this measurement is more than 2-3 Ohms
greater than the one taken directly across the
OPS, there is a problem with the sender connections. You can determine if the problem is
the 69 connection or the 0 connection as follows:
4.1.1 Measure the resistance between the
OPS stud and the 69 wire inside the
control panel. If this measurement is
greater than 2-3 Ohms, replace the
entire wire running between the control
panel and the OPS stud.
Repeat step D, measuring the resistance between the 69 and 0 locations on
the control panel terminal strip and
comparing it to the earlier reading.
4.1.2 Measure the resistance between the
body of the sender and the 0 location
on the control panel terminal strip. If
this measurement is greater than 2-3
Ohms, go back and carefully check the
following:
4.1.2.1 OPS mounting, including all
fittings and adapters.
4.1.2.2 Remove the OPS and check the
conditions of the threads.
Check for an excessive amount
of pipe sealant on the threads.
Ensure there is no pipe sealant
on the end of the sender covering the oil inlet hole. Repeat
step D, measuring the resistance between the 69 and 0
locations on the control panel
terminal strip and comparing
it to the earlier reading.
4.2 If this measurement is less than 2-3 Ohms
greater than the one taken directly across the
OPS, and a thorough visual inspection was
performed, the wiring is OK.
LOW COOLANT LEVEL (Refer to Figure 3.2)
OVERVIEW
A Low Coolant Level (LCL) sensor is placed in the
generator's coolant system. This sensor allows the E
Panel to detect a Low Coolant Level condition.
Wire number 85 is used to connect the LCL to the E
Panel. The Ground for the LCL is made through the
radiator frame or engine block (depending on where
the LCL is located). The LCL is a resistive device
whose resistance changes based on the temperature
of the LCL.
The resistance of the LCL results in a voltage being
developed across the LCL. This voltage changes as
the resistance changes. This changing voltage is read
by the E Panel.
The LCL is supplied with current from the E Panel.
This current will cause the LCL to generate heat. If
the LCL is in coolant, the coolant will keep the LCL
from heating up. If the LCL is in air, it will heat up
telling the E panel there is a low coolant condition.
In most systems, a back up High Water Temperature
(HWT) switch is wired in parallel with the LCL. This
switch is a normally open switch whose contacts will
close at a predetermined temperature setting. If this
HWT switch closes, it will result in the E Panel shutting down with a "Low Coolant Level" display.
Refer to owners manual for the LCL and HWT part
numbers and mounting locations.
The E Panel checks for low coolant level as follows:
Software version V1.03 and earlier: Will check for
a low coolant level anytime the DC input to the E
Panel is present.
Software version V1.04 and later: Will only check
for a low coolant level once the engine has started and
the hold off timer has expired.
There are no user-definable parameters for the Low
Coolant Level.
Section 3 — Troubleshooting and Diagnosis
E Option Control Panels
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