Generac Power Systems Fan H 100 User Manual

POWER SYSTEMS, INC.

H-100 Control Panel

Technical Manual

This manual should remain with the unit.

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Table of Contents

H-100 Control Panel Technical Manual

The Event Log...............................................................23

Maintenance Settings ....................................................24

Air/Fuel Ratio Control (Option) .....................................24

I²T Current Monitoring (Option) ...................................24

Internal Exercise Function ............................................25

QuietTest^®Setup Using GenLink ..................................25

Normal Exercise Setup Using GenLink.........................26

QuietTest^®Setup Using Front Panel..............................27

Set Date and Time ........................................................33

Date and Time Setup Using GenLink.........................33

Date and Time Setup Using Front Panel ....................33

Adjust Display Contrast ................................................34

Enable Generac Commercial Transfer Switch (HTS) ....35

HTS Setup Using GenLink.........................................35

HTS Setup Using Front Panel ....................................35

Communications...........................................................37

Remote Annunciator Connection (Option).....................37

New Generation GenLink (NGG)...................................37

GenLink Relay Control ..............................................37

Set Engine Hours.......................................................37

Absolute Maximum Ratings .......................................37

Environmental Ratings ..............................................37

Table of Contents

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

General Information ......................................................... 2

Introduction....................................................................2

Features ..........................................................................2

Panel Setup.....................................................................2

Changing the Controller Configuration ........................2

Customization..............................................................2

The Measurement “Engine”.............................................3

Analog Channels ..........................................................3

Analog Maths...............................................................3

Analog Alarms .............................................................4

Other Analog Options ..................................................5

Analog Sensor Ratings.................................................5

Output Functions ............................................................5

Spare Analog Channels................................................5

Engine Management........................................................6

Generator Parameters..................................................6

Engine Settings............................................................6

Starting and Stopping - Sequence Diagrams...................7

Voltage Regulator (Option) ..............................................8

Governor (Speed Regulator) Option................................8

Trending .........................................................................9

Remote Trending .........................................................9

Local Trending...........................................................10

GenLink Local Trending Setup..................................10

Trigger/Collection Type ..............................................13

The ILC.........................................................................10

The Front Panel Display................................................11

Left Display................................................................11

Right Display .............................................................11

Left Display Pages......................................................11

Right Display Pages....................................................13

Alarms.......................................................................13

Engine...........................................................................14

Status............................................................................16

Service ..........................................................................17

Generator......................................................................18

Diagnostics....................................................................19

Exercise/HTS ................................................................21

The Control Panel .........................................................23

The Alarm Log ..............................................................23

Appendix............................................................................38

Appendix A — Analog Functions ...................................38

Appendix B — H-100 General I/O and Connector

Information ...........................................40

H-100 Analog Inputs..................................................40

H-100 Digital Outputs................................................41

H-100 Digital Inputs ..................................................41

H-100 Digital Output Functions.................................42

H-100 Connector Pin Descriptions ............................46

Appendix C — Miscellaneous H-100

Internal Alsrms/Warnings ......................47

Notes...................................................................................48

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER,

or visit the website at www.generac.com.

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General Information

H-100 Control Panel Technical Manual

INTRODUCTION

PANEL SETUP

The H-100 Control Panel is an electronic control box

that functions as an advanced standby generator

controller. Its technology is based on the flagship PM-

DCP system with all its flexibility included. A familiar

user interface in the form of GenLink®-DCP is used

to program, monitor and change the parameters in

the unit. The interface appears the same as it does

for the PM-DCP.

‹

CHANGING THE CONTROLLER

CONFIGURATION

The H-100 Control Panel controller is setup in the

factory to match the product it is shipped with and

generally no changes are required. For spares pur-

poses the controller can be re-configured in the field

using the GenLink software tool and a PC.

Specialized programs are built into the H-100 Control

Panel to allow customers to configure spare I/O to

their own needs. For example, built in Integrated

Logic Controller (ILC) logic can eliminate the need

for ancillary external controllers. Everything can be

user customized from measurements to alarms to

the screen displays.

If you need to change the function of the panel the

best way to get a basic setup for a product is to use

GenLink to download a “product file”. This will setup

all the basic parameters and just leave customization

and calibration to be done. Product files are available

on the web site for downloading cross referenced to

product serial numbers/generic product types. The

manufacturer does not recommend changing the

settings individually for a product as this is labori-

ous and prone to human error. Some of the settings

require detailed knowledge of things like governor

settings which are not easily discernable.

Why do we do this? Having one set of control firm-

ware buys us the economy of scale which can be

passed on to the customer. It also has great technical

advantages. The H-100 Control Panel and all PM-DCP

products are built around a common “core” of firm-

ware. This provides EVERY product with the same

technical tools. For example, both the H-100 Control

Panel and PM-DCP products can call out for assis-

tance via a modem, every product can provide trend-

ing data for its measured parameters, any measured

value can be setup to create alarms or warnings, each

product has a built in ILC, etc. H-100 Control Panel

is very flexible.

Some configurations are changeable from the H-100

Control Panel touch pad and displays. These configu-

rations will be described later and include:

• Setting Display Contrast

• Setting System Time and Date

• Setting up/Enabling Internal Exercise

• Enabling Interface with Generac Commercial

Transfer Switch (HTS)

FEATURES

• Local/remote connection to a PC for GenLink®-

DCP communication.

‹

CUSTOMIZATION

• Interface with up to four Generac Commercial

The controller is designed to be very flexible and

allow great levels of customization via the GenLink

tool. Once you have customized your controller, you

should save the settings away to floppy or hard disk

for backup. This can be done during the customiza-

tion process, or at any time subsequent to customiza-

tion by uploading the settings from the controller to

GenLink and then saving them to disk. The digital

outputs can be set to turn on from any one of a list

of functions, or they can be used as part of the built-

in ILC. The digital inputs can be moved, inverted,

renamed, given delay times, made alarms, used

in the ILC, logged/not logged, etc. Refer to the sec-

tion “MEASUREMENT ENGINE” for details. Analog

inputs are dealt with in the same section.

Transfer Switches (HTS).

• Interface with up to two Remote Annunciator

Panels.

• Customizable display.

• New Generation GenLink.

• Built-in Frequency and Voltage controller.

• External modem option with dialout capability

upon alarm.

• Communication via standard CAN bus and Modbus

protocols.

• Programmable I/O channel properties.

• Programmable alarm/warnings.

• Alarm and event logging with time stamping.

• Parameter logging and trending both to file and

graphical.

There are some parameters which are specific to the

product, such as an engine controller or transfer

switch. These are all customizable via GenLink. Refer

to the relevant section for details.

• Built-in diagnostics.

• Internal ILC for combinatorial logic functions

including analog inputs.

• Spare customer programmable Analog input capac-

ity.

• Spare customer programmable Digital I/O capac-

ity.

• Firmware can be updated via Telephone line.

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H-100 Control Panel Technical Manual

‹

ANALOG MATHS

THE MEASUREMENT "ENGINE"

The measurement “engine” is the key feature of the

system. All the inputs to the controller are processed

by this module. Each physical input is measured and

the result processed by an individual set of rules that

are set via a PC and GenLink. Normally, a product

is delivered with the inputs and outputs pre-con-

figured and nothing needs to be done, however the

manufacturer has provided complete flexibility to

each measurement (except where product safety is

concerned). The inputs are divided into analog and

digital channels.

Each of the 23 channels is processed by a set of mea-

suring rules using constants that are set via GenLink.

Usually these constants can be changed by the cus-

tomer. In the following illustration, the measurement

is represented by M and the GenLink constants are

in italics. The measurement is processed in the fol-

lowing order and the result is then stored for cus-

tomer display or use.

M = M * Calibration Factor

This is used to calibrate out any reading inaccura-

cies where calibration factor is a number such that

1024 is equivalent to 1, so it’s really M * calibration

factor/ 1024. GenLink will hide this computation so

you can enter floating point numbers such as 1.1 or

0.987 etc.

‹

ANALOG CHANNELS

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 depends on the

product. Table 1 shows the channel allocation.

THEN

Some of the 14 fixed channels are “DERIVED” read-

ings in that they are calculated from the other read-

ings. For example, power is calculated from both volt-

age and current. These are not real hardware chan-

nels, but they result in an analog reading that can be

treated as a “fixed channel” just like any other.

M = M processed by function x:

Table 1

CPU

Channel

Derived

No.

Channel Title

Update Rate

3.84 ms

Value

Yes

User Configurable #1 (Usually Oil Temp)

User Configurable #2 (Usually Coolant Temp)

User Configurable #3 (Usually Oil Pressure)

User Configurable #4 (Usually Coolant Level)

User Configurable #5 (Usually Fuel level)

User Configurable #6 - Spare -

User Configurable #7 (Usually throttle position)

Special Oxygen sensor

3.84 ms

Special Battery charge sensor

Battery Voltage/ PSU voltages

Generator Phase A RMS Current

Generator Phase B RMS Current

Generator Phase C RMS Current

Generator average current

3.84 ms

Phase A ZERO CROSSING

Phase B ZERO CROSSING

Phase C ZERO CROSSING

Every Phase ZERO CROSSING

Phase A ZERO CROSSING

Phase B ZERO CROSSING

Phase C ZERO CROSSING

Every Phase ZERO CROSSING

4 - 8 ms variable (geared)

Every O2 ZERO CROSSING

Generator Phase A RMS Voltage

Generator Phase B RMS Voltage

Generator Phase C RMS Voltage

Generator average voltage

Total Generator Power KW

Total Generator Power Factor

Generator Frequency

RPM #1

Oxygen sensor zero crossings

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H-100 Control Panel Technical Manual

Where x can be:

Setpoints

1. THERMISTOR

2. CURRENT

3. LINEAR

4. PRESSURE

5. UNALTERED

6. POLY_3RD

There can be up to 4 setpoints to support 2 alarms

and 2 warnings, of which there can be a maximum of

2 GT or LT types. The setpoints are in the same units

that the measurement is displayed in.

Delay Time

There are 2 delay fields that can be set with differ-

ent times in each. Any or none of these times can be

applied to any of the alarms or warnings via GenLink

radio buttons.

7. POLY_2ND

8. POLY_1ST

9. POLY_1ST_N1

10. POLY_1ST_N2

11. CAL_SCALE

12. CFM_SENSOR

13. GEN_FP_POLY

The function x may use any of the coefficients 1,2,3

and in some cases will use calibration factor as a 4th

coefficient (in this case use scaling factor for calibra-

tion). The coefficients are used to allow adjustment

of the basic functions to cater for future or alternate

sensors. They perform different tasks in different

functions, see APPENDIX A for further details. Note

that if calibration factor is used as a coefficient, it will

be shown (and entered) by GenLink as (actual coef-

ficient/1024).

For example, a measurement may have to be greater

than the setpoint for 1 second to cause an alarm, or

less than another setpoint for 2 seconds to cause a

warning. The resolution of this time interval is 0.1

seconds.

Hysteresis

Applied hysteresis in display or final units (for exam-

ple battery voltage is displayed in units of 1/100ths

of a volt). When an alarm/warning has gone active,

the hysteresis is subtracted from the GT setpoint or

added to the LT setpoint to calculate the modified

setpoint needed to make the alarm go inactive.

For example, if the coefficient is -378, it will be dis-

played as -0.36914.

Shutdown

When set, this alarm condition (alarms only, not

warnings) has been selected to shutdown the engine.

THEN

M =M * Scaling Factor:

Dialout

Where scaling factor is a number such that 1024 is

equivalent to 1, so it’s really M * scaling factor/1024.

GenLink will hide this computation so you can enter

floating point numbers such as 2.1 or 0.987 etc.

When this field is set, the dialout feature is selected.

If an alarm or warning occurs for this channel the

processor will automatically call for assistance via

telephone (if the external modem option is fitted).

Dialout can be selected either for warnings, alarms,

neither, or both. There is a predefined and prioritized

list of 10 phone numbers that will be tried. The con-

troller expects GenLink to answer the call and log the

fault. It is possible for the customer to program any

Modbus device with a modem to respond to the call.

‹

ANALOG ALARMS

Each of the 23 channels is processed by a set of

alarm rules using constants that are set via GenLink.

Usually these constants can be changed by the

customer. Note that all alarms will be entered into

the alarm log and will operate the audible alarm.

Warnings will operate the audible alarm also, and will

be put in the alarm log. The following list shows the

alarm properties.

Active When

You can select other criteria to determine when

alarms and warnings become active. This is further

divided in that you can define these criteria indepen-

dently for LT and GT alarm types.

Types

This section is used to turn alarms and warnings on

or off and define if the input must be greater than a

value (GT) or less than a value (LT). There can be up

to 2 alarms and 2 warnings, of which there can be a

maximum of 2 GT or LT types.

ALWAYS ENABLED = This alarm or warning is

always enabled under every circumstance.

HOLD OFF = Alarms/Warnings with this qualifica-

tion only become active after a programmable hold

off time has been met. The hold off timer starts after

the engine has started. Stopping the engine cancels

the hold off timer.

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H-100 Control Panel Technical Manual

IMMEDIATE = Alarms/Warnings with this qualifica-

tion only become active immediately after the engine

has started.

OUTPUT FUNCTIONS

Output functions are flags that are set/reset by the

internal program to indicate a certain status, for

example “Engine Running”. The Measurement Engine

allows these flags to be treated as “channels” that can

be made into alarms/warnings, display messages,

operate real outputs and also be fed as inputs to the

ILC. For example, use the “Ready To Start” output

function to operate a relay by mapping it to a physical

output via GenLink, or you could feed it into the ILC

to do combinatorial logic.

Sensor Failure Check

When this field is set, the input sensor is checked

for short circuit or open circuit failure. Normally

each of the inputs are conditioned externally to be 4-

20mA current loops. Any currents outside this range

indicate a sensor failure. This will cause an alarm to

occur. The alarm can be selected to shut down the

engine if so desired via the next field. The alarm will

be entered in the alarm log.

See TABLE OF OUTPUT FUNCTIONS in appendix

Shutdown on Sensor Failure

‹

SPARE ANALOG CHANNELS

When this field is set, the engine will shut down if

there is a sensor failure. If the field is unchecked, the

failure will just cause an alarm message to appear

and the audible alarm to sound. The alarm will be

entered in the alarm log.

Depending upon the particular configuration of your

product, the following input channels may be avail-

able for custom measurements:

Channel #

Normal function

Coolant level

‹

OTHER ANALOG OPTIONS

Fuel Level

Event Log

Spare

When set, the channel measurement is compared to

the setpoint with either the GT or LT options. Once

the condition is met (eg measurement GT setpoint)

the event is logged along with a date/time stamp into

the volatile memory based event log. Six other param-

eters that can be chosen by the customer will also be

logged. Volatile means that when power is removed

from the unit, the memory will be lost.

Throttle position

Oxygen sensor 0-1Vdc

Battery charge current 0-5Vdc

Analog Outputs

There are no analog outputs available for customiza-

tion.

‹

ANALOG SENSOR RATINGS

Typically the sensors used by the manufacturer have

the following ratings:

Temperature

Pressure

35 - 300 deg. F

0 - 150 psi

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H-100 Control Panel Technical Manual

• Preheat Enable — The following four options are

selectable (only for Diesel):

- Preheat disabled.

ENGINE MANAGEMENT

The engine management module is very similar to

that used in the manufacturer's other products. It

controls engine cranking, engine starting, engine

running and engine stopping. These functions are

performed to a set of “rules” that can be customized

via parameters from GenLink. In turn, the module

needs to know certain things about the engine which

it expects to be programmed in from GenLink.

- Preheat during cranking.

- Preheat before and during cranking.

- Preheat before and during cranking and until

load ready.

The Preheat output pin shares its function with the

Air/Fuel Solenoid output. You must choose one of

the two functions as follows:

‹

GENERATOR PARAMETERS

- To select Air/Fuel - set the “Diesel” parameter on

the governor settings page to “No”. Set Preheat to

“Disabled”

- To select Preheat - set the “Diesel Y/N” param-

eter on the governor settings page to “Yes”. Set

Preheat to one of the enable selections.

• Engine Cooldown Time — The generator will run

for at least this time after remote start becomes

inactive.

• Engine Flywheel Teeth — Number of flywheel teeth

or pulses per revolution for RPM input. RPM 1 is

used for the engine controllers.

• CT Ratio/Generator — Current Transformer ratio

for the generator. This value is the result from

reducing the CT ratio. E.G. If the CT ratio is

100 amps to 5 amps, the resulting value is 20.

Normally, the CT ratio will be x amps to 1 amp on

H-100 Control Panels.

• Pause Between Cranks Time — The time between

• Generator Phase Configuration — Select either

single-phase or three-phase configuration depend-

ing on how the unit is supplied.

each successive crank operation.

• Number of Start Attempts — The maximum num-

ber of times the engine will attempt to start (crank)

before faulting out with overcrank.

• Load Accept Frequency — The generator must

reach this frequency before issuing the “Accept

load” signal.

• 60 Hertz RPM — The engine RPM needed to supply

60 Hertz power.

• Quiet-Test RPM — The engine RPM used when

running Quiet-Test .

• Load Accept Voltage — The generator must reach

this voltage before issuing the “Accept load” sig-

nal.

Number

PARAMETER

UNITS

Engine Flywheel Teeth

CT Ratio - Generator

Generator Phase Configuration 1 or 3

60 Hertz RPM

Quiet-Test® RPM

Teeth

Number PARAMETER

UNITS

Preheat Time

(S)econds

RPM

Start Detection RPM

Crank Time

RPM

‹

ENGINE SETTINGS

Alarm Hold-off Time

Engine Warmup Time

Target Frequency

Target Voltage

All of the following times are in seconds:

• Preheat Time — The time preheat is applied for

before cranking if enabled.

• Start Detection RPM — The Engine must reach this

RPM before disengaging the starter.

• Crank Time — The maximum time in seconds that

each crank will last

• Alarm Hold-off Time — The time after starting at

which the hold-off alarms become enabled.

• Engine Warmup Time — The engine will run for

at least this time before issuing the “Accept load”

signal.

Vrms

Preheat Enable

Engine Cooldown Time

Pause Between Cranks Time S

Number of Start Attempts

Load Accept Frequency

Load Accept Voltage

Vrms

• Target Frequency — The target generator frequency

(Hz).

• Target Voltage — The target generator voltage

(RMS).

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H-100 Control Panel Technical Manual

STARTING AND STOPPING - SEQUENCE DIAGRAMS

Exercise without transfer

starting and stopping sequence

keyswitch in auto position.

Loss of utility with HTS

starting and stopping

sequence keyswitch in

auto position.

Remote start

contacts

CLOSED?

Time to

exercise?

HTS indicates

loss of Utility?

2-wire Remote Starting and

Stopping Sequence

Keyswitch in Auto Position

Start the Engine

NOTE: Shutdown Alarms will

cause the engine to turn off

or not start.

NOTE: Shutdown Alarms will

cause the engine to turn off

or not start.

NOTE: Shutdown Alarms will

cause the engine to turn off

or not start.

Exercise

time

expired?

load accept

limits?

load accept

limits?

NOTE: A Remote Start signal

will terminate exercise and

proceed to normal running mode.

Stop the Engine

Warmup timer

expired?

Warmup timer

expired?

Issue load

accept signal

Command HTS

to transfer to

Generator Power

Remote start

contacts

OPEN?

HTS indicates

return of

Utility?

Cooldown

timer expired?

Cooldown

timer expired?

Stop the Engine

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H-100 Control Panel Technical Manual

• QuietTest® KP,KI,KD — Frequency regulation sta-

bility constants used for QuietTest® mode opera-

tion.

• Actuator Type — Indicates the type of governor

actuator. The following types are available:

- POWERFLOW — Barber Coleman Powerflow,

voltage driven without position feedback

VOLTAGE REGULATOR (OPTION)

All panels include automatic voltage regulation as

standard. There are various settings that can be

made to the voltage regulator via GenLink. The set-

tings are normally factory preset and are shown here

for completeness.

• Voltage KP/KI/KD — Voltage regulation stability

constants.

- BOSCH GAS — Bosch Butterfly, current driven

with position feedback

• PMG — YES indicates a Permanent Magnet Excited

- LINEAR CURRENT — Linear, Current Driven

without position feedback

- DETROIT DIESEL — Detroit diesel PWM Driven

- BOSCH HORIZONTAL DIESEL — Bosch Diesel

Arm with Horizontal Connecting Rod and current

driven with position feedback

- BOSCH VERTICAL DIESEL — Bosch Diesel Arm

with Vertical Connecting Rod and current driven

with position feedback

alternator.

• VF Corner 1 / 2. — These are used for v/f control

to reduce the output voltage when a large load is

applied that slows down the generator. If the fre-

quency drops below these setpoints, the voltage

is reduced proportionally as the frequency drops

according to the Volts per Hertz ratio.

• Panel Type — Indicates the panel type that the H-

100 Control Panel has been programmed to be. It

will normally be H-100.

• Actuator Offset — Number corresponding to lowest

actuator position (Close Throttle).

• Volts per Hertz — Number of volts to reduce the

generator voltage for each hertz below VF Corner

1 frequency.

• Actuator Fullscale — Number corresponding to

highest actuator position (Open Throttle).

• Actuator Normal 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 Target Frequency - 3 Hz is

reached. Therefore, if “soft start” is enabled, the

actuator start position MUST be high enough to

reach, Target Frequency - 3 Hz.

• Actuator QuietTest® 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 QuietTest® Target Frequency - 3

Hz is reached. Therefore, if “soft start” is enabled,

the actuator start position MUST be high enough

to reach, QuietTest® Target Frequency - 3 Hz.

• Soft Start Time — The time to stay at each soft

start step before moving on to the next step. ( Only

applies if soft start is enabled ).

• Soft Start Frequency — An entry of 0 Hz disables

soft start. Any other value enables soft start which

ramps up the generator frequency at a rate deter-

mined by “Soft Start Time” to minimize smoke.

This value selects the first frequency to target after

start up. Once this frequency is attained, the gen-

erator will hold this frequency for the “Soft Start

Time” and then move to the next step. Each step

is 3 Hz higher with the final step being “Target

Frequency” - 3 Hz. Each step is held for the “Soft

Start Time”. During soft start, the throttle will not

be allowed to exceed the “Actuator Start Position”.

• Diesel — Indicates if this is a diesel powered gen-

erator. This modifies such features as frequency

control, and others.

• AVR Dump Improve — Makes the regulator mod-

ule increase the gain temporarily on a load dump

to improve the transient voltage response.

• Unit Rated Power — This is the generator’s rated

power in kW.

Voltage Regulator (Option) Chart

NO.

PARAMETER

Voltage KP

UNITS

Voltage KI

Voltage KD

PMG

Y/N

Hertz

VF Corner 1

VF Corner 2

Panel Type

Volts per Hertz

AVR Dump Improve

Unit Rated Power

V/Hertz

Y/N

GOVERNOR (SPEED REGULATOR)

OPTION

All panels include automatic frequency (speed) regu-

lation as standard. There are various settings that

can be adjusted for the governor via GenLink, these

include the target frequency. The settings are normal-

ly factory preset and are shown here for complete-

ness, they do not apply to all governor types.

• Standby KP,KI,KD — Frequency regulation stability

constants used for normal mode operation.

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H-100 Control Panel Technical Manual

• Dump Enable — Indicates if extra load dump gov-

ernor compensation is desired to reduce increase

in frequency caused by drop in load. The following

three selections are available:

- No Dump — No additional compensation.

- Dump — Reset governor algorithm when load

dump detected.

Governor (Speed Regulator) Option Chart

NO. PARAMETER

UNITS

Standby KP

Standby KI

Standby KD

QuietTest® KP

- Dump & Hold — Same as Dump, but also hold

throttle closed until frequency back in range.

• Engine Linearization — Selects engine torque

to actuator position translation curve for Bosch

Actuators.

QuietTest® KI

QuietTest® KD

Actuator Type

Actuator Offset

Actuator Fullscale

Actuator Normal Start Position

Actuator QuietTest® Start Position

Soft Start Time

0 = No conversion - torque = position

1 = Butterfly Actuator with minimum position

same as unpowered actuator

2 = Diesel arm with Horizontal rod

3 = Diesel arm with Vertical rod

Seconds

Soft Start Frequency

Diesel

Y/N

4 = Same as 1, but minimum position at actuator

mechanical stop

Dump Enable

5 = Same as 4, but with limited position resolu-

tion of 1

6 = Same as 4, but with added energy to accom-

modate throttles that normally operate in the

nearly closed position at no load

• Integral limit/Antiwindup — Choose whether to use

an integral limit or an anti-windup strategy.

YES = integral limit

Engine Linearization

Integral limit/Antiwindup

Limit / windup parameter

Pwm Counts per ampx10

Desynch Offset

Y/N

TRENDING

NO = anti-windup

Just like in the PM-DCP, there are two types of trend-

ing available - Remote and Local.

• Limit/windup parameter — If “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 algo-

rithm becomes active.

‹

REMOTE TRENDING

GenLink performs remote trending by polling the

controller for the selected data at the desired rate.

Up to 8 analog channels can be monitored at a 0.3

second rate. If a faster rate is desired, reducing the

number of analog channels monitored will allow for a

0.1 second rate. The polling rate can be varied from

0.1 seconds to several hours. GenLink can save the

data to a file and/or display it as a near real-time

graph. The file is MS Excel compatible ( CSV format

). Examples of things you can trend are the generator

frequency response (in 0.1 second steps) to a block

load or Generated power over a day.

• Pwm Counts per ampx10 — Number of 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.

• Desynch Offset — Offset of –0.9 to +0.9 Hertz to be

applied to the target frequency to improve passive

synchronizing by Automatic Transfer Switches. If

an in-phase or synchronized transfer is required,

use this setting to adjust the generator frequency

to 0.1 Hz above nominal Utility frequency.

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‹

LOCAL TRENDING

No Trigger

The event trigger is ignored and samples are continu-

Local trending is done inside the controller where up

to 1000 samples can be stored in memory. GenLink

provides an interface to select the analog channels to

be trended, the rate to be sampled at, and optional

triggers to be used to specify when to sample. Up to 6

analog channels can be sampled. However, the 1000

samples are divided by the number of channels. For

example, there will be 1000 samples of 1 channel or

only 166 samples of each of 6 channels. The analog

samples can be sampled at one of three basic polling

rates: Low Speed, Mid Speed, and High Speed. For

the Low Speed and Mid Speed modes, there are also

several settings that can be used to determine when

to sample. GenLink can save the data to a file and/or

display it as a snap-shot graph. The file is MS Excel

compatible ( CSV format ).

ally being placed into the buffer.

Pre-Trigger

Samples are continually being placed into the buffer

until the event trigger becomes true. Then no more

samples are placed into the buffer.

Post-Trigger

No samples are placed into the buffer until the event

trigger becomes true. Then samples are placed in the

buffer until it is full.

Pre- and Post-Trigger

Samples are continually being placed in the buffer

until the event trigger becomes true. This point is

considered ½ of the buffer. Samples continue to be

placed into the buffer until it is full.

‹

GENLINK LOCAL TRENDING SETUP

When setting up the local trending, verify that the

“Armed” box is unchecked and press “Apply”. To

change the settings with the trending armed may

result in corrupted data. Select a rate at which to

take samples.

Pressing the “View” button will show a graph of

the samples in the buffer at the time the button is

pressed. The graph has a “Save” button that allows

the user to save the data out to a file in a MS Excel

compatible ( CSV ) format.

• Low Speed rate samples the processed analog

channel values at a rate that is able to be set in

increments of 0.1 seconds.

• Mid Speed rate is about 2 milliseconds which

captures the new analog channel value as soon

as it is processed by the measurement and alarm

modules.

• High Speed rate is 0.4 milliseconds and is reserved

for the raw AC wave forms of generator voltage and

current.

There are 6 pull-down boxes that allow the selection of

up to 6 analog channels. All channel pull-down boxes

after the first pull-down box with NULL CHANNEL

selected are ignored. If High Speed is selected, the

pull-down boxes are not used. Instead, there are 6

check boxes that can be used to select which voltage

and current lines are to be trended.

THE ILC

The built-in ILC uses simple combinatorial logic to

generate digital outputs and limited generator con-

trol. The ILC uses ladder logic for programming,

and a separate offline programming tool is avail-

able to generate the ILC programs. These are then

downloaded via GenLink and are started or stopped

by means of a checkbox on the GenLink ILC page.

Once downloaded and started, they will remain active

unless they are stopped via GenLink, even if power

is cycled.

The I/O scan time of the ILC is about 100 ms worst

case. This means that all inputs and outputs are

scanned within 100 ms. Also, the ILC processes

one rung every 5 ms, so 5 rungs will take 25 ms.

However, this is in parallel with the I/O scan and not

added to it.

The “Capture When” pull-down box allows the trend-

ing to be limited to the engine running or engine being

stopped. If the “Stop at End of Buffer” box is selected,

then the trending will start when the “Capture When”

condition is true and stop when the 1000 samples

have been taken.

The offline tool uses graphic symbols to design the

“rungs” of the ladder logic. The rungs are simple and

can only have 2 combinatorial elements in them, but

by the use of “soft contacts” the output of one rung

can be fed into the input of another to provide more

combinations. As well as the logical combinations,

there are also analog comparisons, counters and tim-

ers available for use in the rungs. As an example this

allows the following type of logic to be built:

Any digital or analog channel can be used as an event

trigger. The event trigger needs to be set up in that

channel's setup screen. Checking the “Capture Only

When Trigger is True” box will cause the samples to

only be taken while the event trigger is true. Checking

the “Capture on Shutdown Alarm” will cause the sam-

ples to start upon the setting of a shutdown alarm.

The event trigger can be used to start sampling, stop

sampling, or center the sampling by selecting the

appropriate radio button:

IF (in automatic) AND (engine running) AND (air

temperature >25 deg) FOR (20 seconds) THEN

OPERATE (output 7).

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Generator control is limited to the following output

options (referred to as “Hooks”).

field. Moving off an edit field while in edit mode auto-

matically enters the value displayed. Also, while in

edit mode, pressing the Home button will return the

parameter to the last value entered.

1. Use Keyswitch

2. Force Off – cleared with “Use Keyswitch” hook

3. Force Manual – cleared with “Use Keyswitch”

hook

‹

LEFT DISPLAY PAGES

4. Force Auto – cleared with “Use Keyswitch” hook

5. Force Dialout

6. Halt ILC

7. Force Alarm/Warning #1

8. Force Alarm/Warning #2

9. Force Remote Start

The left display has five “fixed” parameter pages:

System Voltages, System Power, Transfer Switch

Mimic Diagram, Generator Frequency Graph, and

System Alarm Log. A sixth page is selectable, but has

no function at this time. The left display page is deter-

mined by selecting the right display menu item, “Left

Display”. To change the left display, do the following:

For detail in programming the ILC, refer to the ILC

manual.

Press the “MENU” button.

THE FRONT PANEL DISPLAY

The front panel display consists of two LCD displays

that are 4 rows of 20 characters each and a key pad

with seven buttons and two LEDs.

Press the  button to move to the “Left Display”

field.

‹

LEFT DISPLAY

Press the “ENTER” button to display the “Left

Display” menu page.

The left display is used to display a “fixed” set of

parameter pages and has no cursor or entry fields.

The key pad has no direct control of its contents. Its

contents are determined by a menu selection on the

right display.

‹

RIGHT DISPLAY

The right display has several pages and responds

directly to the key pad. There are two “quick” buttons

on the key pad that are used to go directly to either

the Home page or the Menu page. The Enter button

is used to enter and exit edit mode, operate an out-

put override, or select another page. When not in edit

mode, the arrow buttons are used to navigate around

the page to either an edit field or a control field.

When in edit mode, the up/down buttons slew up or

down through the available values and the right/left

buttons are used to change to a different digit or edit

The “>…..<” indicates which page is currently dis-

played on the left display. Use the arrow buttons to

move the cursor to the desired page name and press

the “ENTER” button. The left display will change

to the new page and the “>…..<” will move to the

selected page name.

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LINE 1: “Transfer Switch Name” indicates which

switch inputs are being displayed such as “From

HTS #1”. To select a switch to display, select the

switch number on the HTS page (refer to the Right

Display Pages - Exercise/HTS page). If there are

no HTS switches connected, then the Line Power

and Generator Power inputs are displayed and the

“Transfer Switch Name” is “From Line/Gen Inputs”

> Volts <

LINE 2: Title line showing the left side is the Utility

switch and the right side is the Generator switch.

LINE 3: Character graphics showing the switch

This is a typical three phase System Voltages page.

LINE 1: Phase titles for the voltage and current.

LINE 2: Line-to-line voltages in Volts RMS.

LINE 3: Line currents in Amps RMS.

states – open or closed.

LINE 4: Character graphics indicating the load com-

ing off the bottom of the diagram.

> Alrm Log <

LINE 4: Generator frequency in Hz and total system

power in kilowatts.

This is the System Alarm Log page. It displays the last

20 alarms or warnings that occurred with a time and

date stamp. Two records are displayed at a time.

This is a typical single phase System Voltages page.

LINE 1: Phase titles for the voltage and current

– voltage title/current title.

LINE 1/3: The record’s alarm or warning number

(lowest number being the most recent) followed by the

date and time that the alarm or warning occurred.

LINE 2: Line-to-line voltage for AB and Line-to-

Neutral voltage for A and B in Volts RMS.

LINE 2/4: The alarm or warning description mes-

sage. The depicted display shows a basic format in

place of the first record and an empty record for the

second. The records scroll up at about a 4 second

rate.

LINE 3: Neutral current and Line currents in Amps

RMS.

LINE 4: Generator frequency in Hz and total system

power in kilowatts.

The message format symbols are explained below:

First 2 characters:

> Switch <

?? – Empty slot

Wr – Warning

Al – Non-shutdown alarm

SD – Shutdown alarm

Last 2 Characters:

Sn – Sensor failure

Hi – Tripped by being greater than threshold

Lo – Tripped by being less than threshold

– (blank) Internal alarm or warning

This is the Transfer Switch Mimic Diagram page.

It shows the position of the Utility Switch and the

Generator Switch. This depicted display shows the

Utility switch closed and the Generator switch open.

There can be up to 4 HTS switches connected to the

generator.

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Press the “MENU” button:

> Power <

Use the arrow keys to move the cursor to the desired

menu item and then press the “ENTER” button. Most

menu items have multiple pages under them. When

that is the case, there is a “More  (x-y)” field at

the lower right hand corner of the page where “x” is

the page number and “y” is the total number of pages

available under this menu item. To move forward or

backward through the pages, the cursor is placed

on the  or  character using the arrow buttons

and the “ENTER” button is pressed. When a page is

first displayed, the cursor normally starts on the 

character to promote ease of scanning through the

pages.

This is a typical System Power page.

LINE 1: Total system real power in kW.

LINE 2: Total system reactive power in kVAR.

LINE 3: Total system apparent power in kVA.

LINE 4: Total system power factor.

> Graph Hz <

‹

ALARMS

There are three System Alarm and Warning pages.

Each page is capable of displaying three alarms or

warnings. If there are more than nine total alarms

and warnings to list, then only the most recent nine

will be visible. All alarms and warnings remain in the

list until they are cleared. Warnings clear when they

are no longer active. Normal Alarms clear when they

are no longer active and have been acknowledged.

Shutdown alarms clear only after the key switch has

been placed in the OFF position and they are no lon-

ger active. There are a few shutdown alarms that will

only clear after a power cycle of the controller and

they are no longer active. Besides using the menu to

get to the alarm pages, the right display immediately

changes to the first alarm page when an alarm or

warning first becomes active. If a shutdown alarm is

active and an alarm or warning is not acknowledged,

the displays will flash with the Alarm LED.

This is the Generator Frequency Graph page. This

graph provides a coarse representation of the genera-

tor frequency. The graph scrolls from right to left at 2

characters per second (last 10 seconds of data on the

display). The bottom of the graph is 50 Hz and the

top is 70 Hz. There are 32 levels between bottom and

top. Therefore, each level is approximately 0.6 Hz.

> Other <

Do the following to view the alarm/warnings pages:

Press the “MENU” button.

This is the Other page. At this time, it has no function

and serves as a place holder.

‹

RIGHT DISPLAY PAGES

The right display is menu based with eight main menu

items: System Alarm and Warning pages, Engine

Parameter pages, System Status pages, Maintenance

Status Pages, Left Display Menu page, Generator

Parameter pages, System Diagnostic pages, and

Internal Exercise and HTS pages. To select a page for

the right display, do the following:

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Press the “ENTER” button.

The alarm has cleared since the gas pressure is now

adequate.

This is a typical System Alarm and Warning page.

The n/a indicates there is not an alarm or warning

to display on that line. As depicted, this display indi-

cates a Fuel Pressure alarm for low pressure. This

would be a common alarm for a system that has the

gas line turned off. The “Al” indicates it is an alarm.

The “*” indicates the alarm has not been acknowl-

edged. The “DI2/FUEL PRESS” message indicates it

is a fuel pressure alarm (DI2 was included in the text

by the user to indicate it is Digital Input #2). The “Lo”

indicates the alarm was tripped because the input

value fell below a set threshold.

Move the cursor to the  on the bottom line by press-

ing the  button twice or the  button once.

The message format symbols are explained below:

First 2 characters:

Press the “ENTER” button to see the next page.

Wr – Warning

Al – Non-shutdown alarm

SD – Shutdown alarm

Third Character:

– Has not been acknowledged

Last 2 Characters:

Sn – Sensor failure

Press the “ENTER” button to see the next page.

Hi – Tripped by being greater than threshold

Lo – Tripped by being less than threshold

(blank) – Internal alarm or warning

Press the “ENTER” button while the cursor is on

"ACK" to acknowledge the alarm.

ENGINE

There are four Engine Parameter pages. In most H-

100 Control Panels, there are spare analog channels

available or unused analog channels. They can be

displayed on these pages. If they are not configured,

they will not be displayed.

The “*” is now gone since the alarm has been

acknowledged.

Do the following to view the engine parameter pages:

Press the “MENU” button.

Turn the gas line on.

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This is a typical second engine parameter page. The

first two values on this page are not able to be config-

ured as other values.

LINE 1: Engine RPM

LINE 2: Battery Voltage in Volts DC.

If any of these signals are not configured, they will

display “n/a” for their value.

LINE 3: Normally Battery Charger Current (Analog

Channel #9). If it is not configured, the line will be

blank.

Press the  button.

LINE 4: “More” field to allow page selection.

Press the “ENTER” button.

This is a typical third engine parameter page.

LINE 1: Total number of hours the engine has run.

LINE 2: Coolant Level Sensor (Analog Channel #4)

reading in steps 0 - 1023.

LINE 3: Often the Fuel Level Sensor (Analog Channel

#5) reading in %. As depicted, Analog Channel #5 is

not configured – leaving the line blank.

This is a typical first engine parameter page. The

three values on this page are not able to be configured

as other values.

LINE 4: “More” field to allow page selection.

LINE 1: Oil Temperature (Analog Channel #1) in

degrees Fahrenheit.

Press the “ENTER” button.

LINE 2: Oil Pressure (Analog Channel #3) in pounds

per square inch.

LINE 3: Coolant Temperature (Analog Channel #2)

in degrees Fahrenheit.

LINE 4: “More” field to allow page selection.

If any of these signals are not configured, they will dis-

play “n/a” for their value such as the Oil Temperature

shown above.

This is a typical fourth engine parameter page.

Press the “ENTER” button.

LINE 1: Auxiliary Analog Channel input (Analog

Channel #6).

LINE 2: Throttle Position Sensor (Analog Channel

#7) reading in steps 0 - 1023.

LINE 3: Emissions Sensor (Analog Channel #8)

reading. As depicted, Analog Channels #6 and #8 are

not configured – leaving the lines blank.

LINE 4: “More” field to allow page selection.

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The engine is starting or running because the GenLink

commanded it to start and the key switch is in the

AUTO position.

STATUS

There are two System Status pages. These pages

show the system status, system time, and system

versions.

“Running exercise”

Do the following to view the system status pages:

Press the “MENU” button.

The engine is starting or running because internal

exercise was activated and the key switch is in the

AUTO position.

“Stopped, Key SW Auto”

The engine is stopped and the key switch is in the

AUTO position.

“Running, QuietTest”

The engine is starting or running because QuietTest®

was activated and the key switch is in the AUTO posi-

tion.

Press the  button twice.

“Running, HTS Xfer SW”

The engine is starting or running because the HTS(s)

indicated a need for the generator power and the key

switch is in the AUTO position.

LINE 2: Generator Status. It can have the following

values:

“Resetting”

The generator control system is resetting.

“Stopped”

Press the “ENTER” button.

Generator is stopped and not preheating.

“Stopped, Preheating “

Generator is stopped and preheating.

“Cranking”

Generator is starting and not preheating.

“Cranking, Preheating”

Generator is starting and preheating.

“Pause between starts”

This is a typical first System Status page.

LINE 1: Engine Running Status. It can have the fol-

lowing values:

Generator is pausing between consecutive start

attempts.

“Stopped, Key SW Off”

“Started,not to speed”

The engine is stopped and the key switch is in the

OFF position.

Generator is started, but has not attained normal

running speed yet.

“Running from Manual”

“Warming, Alarms Off “

The engine is starting or running and the key switch

is in the MANUAL position.

Generator is started and is up to speed, but is waiting

for warmup timer to expire.

“Running from 2-wire”

“Warmed Up,Alarms Off”

The engine is starting or running because the 2-wire

start signal was activated and the key switch is in the

AUTO position.

Generator is started and warmed up, but the hold-off

alarms are not yet enabled.

“Warming, Alarms On”

“Running from serial”

Generator is started and the hold-off alarms are

enabled, but is waiting for warmup timer to expire.

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“Warmed Up, Alarms On”

SERVICE

There are four Maintenance Status pages. The first

three pages show the status of the scheduled mainte-

nance items. The fourth page allows changing of the

display contrast.

Generator is started, warmed up, and the hold-off

alarms are enabled.

“Running,cooling down”

Generator is still running, but waiting for cool down

timer to expire.

Do the following to view the service pages:

Press the “MENU” button.

“Stopping”

Generator is running down after being turned off

normally.

“Stopping due to Alrm”

Generator is running down after being turned off due

to a shutdown alarm.

“Stopped due to Alarm”

Generator is stopped due to a shutdown alarm.

Press the  button three times or the  button

once.

LINE 3: System Time and Date. It is able to be

changed on this page by using the arrow buttons to

go from field to field or to modify a field in edit mode

and the “ENTER” button to enter and exit edit mode.

There are five editable fields: Hours, Minutes, Month,

Day, and Year. The day of the week will change as the

displayed date is changed. See the “SET DATE AND

TIME” section of this manual for details.

LINE 4: “More” field to allow page selection.

Press the “ENTER” button.

This is a typical second System Status page.

This is a typical first Maintenance Status page. Each

line displays a maintenance item that has been set

up via GenLink. The value displayed is the approxi-

mate % of life remaining before maintenance should

be performed. Refer to the Maintenance setup using

GenLink.

LINE 1: Firmware and Hardware release versions.

LINE 2: Configuration File identifier – serial num-

ber, model number, or text.

LINE 3: ILC program name. This text string is blank

or blocks (as shown above) when there is no ILC

program loaded.

Press the “ENTER” button.

LINE 4: ILC program running status followed by the

“More” field to allow page selection.

This is a typical second Maintenance Status page.

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Each line displays a maintenance item that has

been set up via GenLink. The value displayed is the

approximate % of life remaining before maintenance

should be performed. Refer to the Maintenance setup

using GenLink.

Press the “ENTER” button.

Press the  button and then the  button.

This is a typical third Maintenance Status page. Each

line displays a maintenance item that has been set

up via GenLink. The value displayed is the approxi-

mate % of life remaining before maintenance should

be performed. Refer to the Maintenance setup using

GenLink.

Press the “ENTER” button.

This is a typical first Generator Parameter page for a

three phase system.

LINE 1: Phase titles for the voltage and current.

LINE 2: Line-to-Line voltages in Volts RMS.

LINE 3: Line currents in Amps RMS.

This is a typical fourth Maintenance Status page. The

first line is the display contrast. The display contrast

is able to be changed on this page. However, changing

this setting can result in the display becoming non-

readable. Use caution. Use the arrow buttons to go to

the contrast field. Press the “ENTER” button to enter

edit mode. Use the arrow buttons to change the con-

trast value (range is 00 to 37). Pressing the “HOME”

button while in edit mode will return the value to the

last entered value. Press the “ENTER” button to exit

edit mode.

LINE 4: Generator frequency in Hz followed by the

“More” field to allow page selection.

The voltages can be converted to values representing

the line-to-neutral voltages by changing the title line

(first line) using edit mode. Use the arrow buttons

to move to one of the title fields – A-B, B-C, or C-A.

Press the “ENTER” button to enter edit mode. Use

the up or down arrow button to change the display to

A-N, B-N, and C-N. Press the “ENTER” button to exit

edit mode. The same process is followed to return to

line-to-line displays. This also affects the left display

voltage page.

GENERATOR

There are three Generator Parameter pages – voltage

parameters, power parameters, and i2t parameters.

Do the following to view the generator parameter

pages:

Press the “MENU” button.

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This is a typical first Generator Parameter page for a

single phase system.

LINE 1: Phase titles for the voltage and current

– voltage title/current title.

LINE 2: Line-to-Line voltage for AB and Line-to-

Neutral voltage for A and B in Volts RMS.

LINE 3: Neutral current and Line currents in Amps

RMS.

This is a typical third Generator Parameters page. It

LINE 4: Generator frequency in Hz followed by the

graphically displays the percent of i t thermal limit

“More” field to allow page selection.

currently attained. If the limit is exceeded, an alarm

will be set and the generator will shutdown to protect

the alternator. This display will then show % Temp

>Over Limit<”. GenLink can provide more informa-

tion regarding actual limits exceeded. This page is

Press the “ENTER” button.

disabled if the i t function is disabled.

DIAGNOSTICS

There are six System Diagnostic pages. They are digi-

tal inputs page, digital outputs page, two analog input

pages, RS-232 communications status page, and RS-

485 communications status page.

This is a typical second Generator Parameter page for

a three phase system.

Do the following to view the diagnostics pages:

Press the “MENU” button.

LINE 1: Total system real power in kW.

LINE 2: Total system power factor.

LINE 3: Percentage of the system rated power being

used.

LINE 4: The “More” field to allow page selection.

Press the  button twice and the  button.

This is a typical second Generator Parameter page for

a single phase system.

LINE 1: Phase titles for the power and power factor

– Total, A-Neutral, B-Neutral.

LINE 2: Real power in kW – Total system, A-Neutral,

B-Neutral.

Press the “ENTER” button.

LINE 3: Power Factor – Total system, A-Neutral, B-

Neutral.

LINE 4: The “More” field to allow page selection.

Press the “ENTER” button.

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This is a typical first System Diagnostics page. It dis-

plays ten of the discrete inputs into the H-100 Control

Panel. Inputs to the controller are internally pulled

to 5 v, so to activate an input you must short it to

ground.The following names are normally assigned

to these inputs:

#12 Activate Emissions Module or Preheat

Press the “ENTER” button.

#1 Key switch in AUTO position

#2 Key switch in MANUAL position

#3 Emergency Stop Active

#4 Remote 2-wire start Active

#5 Battery Charger Failure

#6 Rupture Basin or Low Fuel Pressure

#7 Transfer Switch in Line Power Position

#8 Transfer Switch in Emergency Power Position

#9 Modem is connecting or connected

#10 Modem is present

Press the “ENTER” button.

The above two pages are typical System Diagnostics

Analog Input pages. The analog channel values that

are displayed are the “raw” unprocessed data and

are 10 bit numbers ranging from 0 - 1023 represent-

ing a voltage or current on the analog input channel.

The following names are normally assigned to these

inputs:

This is a typical second System Diagnostics page.

It displays ten of the discrete outputs out of the H-

100 Control Panel. Outputs from the controller are

generally open collector. This means that they sink

current through a load and you will NOT see any volt-

age change on them when they are activated, unless

they are connected to a load. These outputs can be

temporarily inverted from this page. Extreme caution

should be exercised while inverting outputs since it

can result in operation of starters, fuel solenoids, etc.

To invert an output, use the arrow buttons to position

the cursor on the output value to be inverted. Press

the “ENTER” button. The output will be inverted for

approximately 2 seconds and then return to normal

control. Only one output can be inverted at a time and

leaving the page cancels all output inversions.

PAGE 3-6 LINE 2:

#1 A current (CT1)

#2 B current (CT2)

#3 C current (only three phase) (CT3)

PAGE 3-6 LINE 3:

#4 A-B voltage (A-N if single phase) (Vsense1)

#5 B-C voltage (B-N if single phase) (Vsense2)

#6 C-A voltage (only three phase) (Vsense3)

PAGE 3-6 LINE 4:

#7 Oil Temperature (AN1)

PAGE 4-6 LINE 1:

#8 Coolant Temperature (AN2)

#9 Oil Pressure (AN3)

The following names are normally assigned to these

outputs:

#10

Coolant Level (AN4)

PAGE 4-6 LINE 2:

#1 Key switch in AUTO position

#1 Activate Starter Relay

#2 Activate Fuel Relay

#3 Activate Alarm/Warning Relay (Buzzer)

#4 Activate Gas Relay on 13.3L Engines

#5 Auxiliary Discrete Output #1

#6 Auxiliary Discrete Output #2

#7 Auxiliary Discrete Output #3

#8 Auxiliary Discrete Output #4

#9 Activate Ignition Module on 13.3L Engines

#11

#12

#13

Fuel level (AN5)

Auxiliary Analog Input (AN6)

Throttle Position Sensor (AN7)

PAGE 4-6 LINE 3:

#14

#15

#16

Emissions Oxygen Sensor (AN8)

Battery Charger Current (AN9)

Battery Voltage

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H-100 Control Panel Technical Manual

Press the “ENTER” button.

Press the  button.

Press the “ENTER” button.

The above two pages are typical of communications

diagnostics, one page for each port. The LCD display

will show four lines of information about the port:

This is a typical first Internal Exercise and HTS

page.

LINE 1: Indicates if internal exercise is enabled. This

field is editable.

LINE 1: Will show the type of port protocol that has

been selected. It will also show the Modbus address

(if appropriate) and whether the port is RS-232 or

RS-485.

LINE 2: Day of week and time of day to start the

exercise weekly. These fields are editable.

LINE 3: How much time remains before exercise is

completed. It starts with 20 minutes.

LINE 2: Will show the settings for the port such as

baud rate, bits per character, stop bits, and parity.

LINE 4: The “More” field to allow page selection.

LINE 3: Shows a live update of counts of messages

transmitted, received, and errors.

Press the “ENTER” button.

LINE 4: Shows a mimic of LED’s for TX, RX, and

ERR. For example, the TX LED lit (T*) means the H-

100 Control Panel is transmitting. Not lit (T-) means

it is not transmitting.

EXERCISE/HTS

There are four pages under this menu item – two for

internal exercise and two for HTS. This is where the

internal exercise can be setup and enabled (see the

Exercise Setup Using Front Panel section) and the

HTSs can be enabled and monitored.

This is a typical second Internal Exercise and HTS

page.

LINE 1: Indicates if QuietTest® is enabled. This field

is editable.

Do the following to view the internal exercise and

HTS pages:

LINE 2: Can be used to start a 20 minute exercise

period right now. This field is editable.

Press the “MENU” button.

LINE 3: Indicates if the HTS switches should be

exercised during normal exercise mode. This field is

editable.

LINE 4: The “More” field to allow page selection.

Press the “ENTER” button.

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HTS is in Time Delayed Neutral position.

“Synching”

HTS is waiting for Generator and Utility to become

synchronized before changing switch position.

“SB4 Xfer”

HTS has activated the “Signal Before Transfer” relay.

“Cls Gen SW”

This is a typical third Internal Exercise and HTS

page.

HTS is closing the Generator side of the switch.

“Cls Util SW”

LINE 1: The left side shows the HTS switch number

that the data on this page applies to. This field is

editable in that switch numbers 1 – 4 can be selected.

The Switch number selected on this page also selects

the switch to use for the Left Display Switch Mimic

diagram if that switch is enabled. In addition, it is the

selected switch number for the next page, and for the

remote annunciator lights for generator power and

line power. The right side of the first line is the mode

that the HTS is in. It can have the following values:

HTS is closing the Utility side of the switch.

“Opn Gen SW”

HTS is opening the Generator side of the switch.

“Opn Util SW”

HTS is opening the Utility side of the switch.

“No Utl/Coms”

HTS has detected loss of utility and communications

with the H-100 Control Panel.

“Disabled”

“No Comms”

This switch is not present in the system.

“Enabled”

HTS has detected utility present, but loss of commu-

nications with the H-100 Control Panel.

This switch is present in the system and operating

normally.

“Pwr Cycled”

“Fast Test”

HTS has been power cycled and is awaiting recon-

figuration commands from H-100 Control Panel.

The “FAST TEST” button on the HTS has been

pressed and fast test is being executed.

“SW Disabled”

“Norm Test”

HTS indicates that it is disabled.

The “TEST” button on the HTS has been pressed and

normal test is being executed.

The right side is the Utility frequency from the HTS

in Hz.

“No Comms”

LINE 3: The HTS backup battery voltage in Volts DC

followed by the Utility voltage from the HTS in Volts

RMS.

This switch is present in the system, but not com-

municating.

LINE 4: The HTS firmware version number followed

“Xfer Exer”

by the “More” field to allow page selection.

The system is running in exercise and is exercising

the HTS as well.

Press the “ENTER” button.

“Exercise”

The system is running in exercise, but is not exercis-

ing the HTS.

LINE 2: The left side is the status of the HTS. It can

have the following values:

“Idle”

HTS is waiting for conditions to change. No action is

being taken.

This is a typical fourth Internal Exercise and HTS

page. The left side of the first line shows the HTS

switch number that the data on this page applies to.

This field is editable in that switch numbers 1 – 4

can be selected. The Switch number selected on this

“Error”

HTS controller has detected an error.

“TDN”

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H-100 Control Panel Technical Manual

page also selects the switch to use for the Left Display

Switch Mimic diagram if that switch is enabled. In

addition, it is the selected switch number for the pre-

vious page, and for the remote annunciator lights for

generator power and line power. The right side of the

first line is the enable state of the HTS. It is editable

and can have the following values:

ALARM LED

COMMON ALARM

AUTO/OFF/MAN KEYSWITCH input

NOT IN AUTO LED output

EMERGENCY STOP SWITCH input

The alarm LED will flash every second if a new alarm

occurs. Once this alarm is acknowledged via the

touch pad or GenLink, the LED will remain lit until

the alarm condition goes away. The LED will flash at

least once every 30 seconds to indicate the controller

is working properly.

output

“Disabled”

This HTS switch is not included in the system.

“Enabled”

This HTS switch is included in the system.

The audible alarm will sound when a new alarm

occurs. It will be silenced when it is acknowledged.

NOTE:

Enabling a switch that is not present will result

in a switch communications warning after a few

seconds and will switch the display to the Alarms

page.

The keyswitch in AUTO position allows the system to

start automatically, in OFF position prevents the sys-

tem from operating, and in MANUAL position runs

the generator for test purposes only.

The “NOT IN AUTO” LED will flash every second if

the keyswitch is not in the AUTO position.

HOME

Press the “HOME” button while not editing a field.

The EMERGENCY STOP switch will stop the genera-

tor and post an alarm.

THE ALARM LOG

The alarm log is a permanent (non volatile) store of

the last 20 alarms that occurred. If power is removed

from the controller, the log will be retained. When the

alarm log is full and a new alarm occurs, the oldest

alarm will be removed to create space for the new

one.

This is a typical Home page. The contents of this

page along with the contents of the default left display

page (Volts) were selected such that all the normally

desired data would be available for viewing at once.

Each alarm is recorded along with a time/date stamp

and up to 6 optional measurements. Two of the six

measurements are fixed (via password protection) to

be coolant temperature and oil pressure.

LINE 1: Oil Pressure (Analog Channel #3) in pounds

per square inch followed by Oil Temperature (Analog

Channel #1) in degrees Fahrenheit.

The measurements you want to record are selected

from a pull down list in GenLink using the alarm/

event log menu, they can be analog inputs, digital

inputs or output functions. For example you can

record the generator voltages, frequency and the

state of the transfer switch when an alarm occurs.

The alarm log can be viewed via GenLink or the

left hand front panel display. Alarms are displayed

by GenLink in chronological order, the most recent

being at the top of the list.

LINE 2: Coolant Temperature (Analog Channel #2)

in degrees Fahrenheit.

LINE 3: Battery Voltage in Volts DC.

If any of these signals above are not configured,

they will display “n/a” for their value such as the Oil

Temperature shown above.

LINE 4: Often the Fuel Level Sensor (Analog Channel

#5) reading in percent. As depicted, Analog Channel

#5 is not configured – leaving the line blank.

All alarms/warnings and sensor failures are recorded

in the alarm log.

THE CONTROL PANEL

THE EVENT LOG

The H-100 Control Panel has some inputs and out-

puts which have been designated to be connected to a

standardized control panel. The format of the control

panel will vary from model to model and not all indi-

cators may be present, however the following signals

are always available:

The event log is similar to the alarm log except that

the data is stored in temporary memory (volatile) and

will be lost if power is removed. The event log has

space to hold up to 20 events. When the event log is

full and a new event occurs, the oldest event will be

removed to create space for the new one.

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The event log, as its name implies, is designed to

store events which are programmable from GenLink.

Each measurement channel or output function can

be set as an event along with a setpoint. For example,

if you set Digital Input #1 (the keyswitch in AUTO

position) as an event with a setpoint of logical one,

each time the keyswitch is set in the auto position, an

event will be logged. Similarly you can set an analog

event with an analog setpoint and a comparison type.

For example you can set an event if the oil pressure

is less than 10 psi or if power output is greater than

100 kW.

• To set a number of engine run hours, set the

“installed at” setting to zero then set “End of life”

to the number of engine hours required.

• NEVER set the “Installed at” hours to anything

other than zero.

A warning is generated when the maintenance cri-

teria are met. This warning can be cancelled by the

acknowledge button but will re-occur after 15 min-

utes. To permanently cancel the warning you must

reset the maintenance interval. This can only be done

via GenLink. The audible alarm will NOT sound for

each 15 minute re-occurrence of the warning after

the first maintenance warning is acknowledged.

Each event is recorded along with a time/date stamp

and up to 6 optional measurements. The measure-

ments you want to record are selected from a pull

down list in GenLink using the alarm/event log menu.

They can be analog inputs, digital inputs or output

functions. The event log can only be displayed via

GenLink, it cannot be viewed on the front panel.

Events are displayed by GenLink in chronological

order, the most recent being at the top of the list.

The front panel display will show the percentage of

life left for each possible maintenance item.

AIR/FUEL RATIO CONTROL (OPTION)

With the addition of an oxygen sensor and a solenoid

to control the air fuel mix, the H-100 Control Panel

can perform air/fuel ratio control to provide an opti-

mum (stochiometric) mix to reduce emissions. This

feature can be turned on or off via GenLink. The air

fuel solenoid output pin shares its function with the

preheat output. You must choose one of the two func-

tions as follows:

MAINTENANCE SETTINGS

The controller provides a mechanism to generate

multiple warnings based on maintenance intervals.

Normally it will be shipped with these warnings

turned off. GenLink is used to enable these warn-

ings by setting a maintenance interval for the alarm

of choice. The interval can be in engine run hours,

a specific engine run hour, number of operations, a

specific date or a combination of two of these meth-

ods. For example you can set the interval associated

with oil life to 6 months or 100 engine hours (which-

ever occurs first). The transfer switch is one example

of where a number of operations is relevant, spark

plug life is not.

• To select air/fuel - set the “Diesel y/n” setting on the

governor page to “No”. Set preheat to “No”

• To select preheat - set the “Diesel y/n” setting on the

governor page to “Y”. Set preheat to “Y”

I²T CURRENT MONITORING (OPTION)

Optionally the H-100 Control Panel can apply pre-

dictive firmware modeling to give I2T protection for

the rotor and stator assembly. Based on parameters

entered into the H-100 Control Panel via GenLink,

the firmware models the temperature rise and fall

of the alternator assembly and limits operation to

prevent it being damaged. The entered parameters

basically describe the thermal properties of each

alternator to the firmware. GenLink allows you to

choose the alternator model, and this automatically

downloads the appropriate parameters. The H-100

Control Panel will normally be delivered prepro-

grammed with the appropriate data . GenLink will

allow you turn this feature on or off as desired. There

is a GenLink display of the allowable temperature

limits for the selected alternator (2 limits, one for the

stator and one for the rotor) and also a display of the

predicted temperatures.

• To disable a maintenance warning, set the “mainte-

nance cycle” field to N/A.

• To set a specific date, set the “installed at” setting

to the current date then set “End of life” to the

specific date.

• To set a number of operations, set the “installed at”

setting to zero then set “End of life” to the number

of operations required.

• To set a specific operation number (say at opera-

tion 500), set the “installed at” setting to the cur-

rent number of operations, then set “End of life” to

the operation number.

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H-100 Control Panel Technical Manual

INTERNAL EXERCISE FUNCTION

Generators best maintain their readiness by being

exercised once per week. This prevents the machine

from stagnating and provides an opportunity to dis-

cover any maintenance items that may need service

before the unit is actually needed for emergency

power. In the past, the generator had to be exercised

manually or an external exerciser was attached to the

generator or transfer switch to activate the remote

start once per week for a period of time long enough

for the generator to warm up. With the advent of QT

series of generators, that function was moved into

the generator controller. This allows the QT series

generator to have the QuietTest® mode of exercise as

one of its key features. Normal mode exercise can be

selected instead which can also exercise a Generac

Commercial Transfer Switch (HTS) if desired. These

features are all standard in the PowerManager® H-

100 controller, but require setup by the installer or

end user. The internal exercise can be set up using

GenLink or by using the front panel displays. This

section describes the procedures needed to perform

this setup.

The QuietTest® mode and Normal mode of exercise

run the generator for approximately 20 minutes

starting at a preset day and time once per week when

the key switch is in the AUTO position and internal

exercise is enabled. If the Normal exercise is used

with the option to exercise an HTS selected, the

exercise duration may vary based on the HTS set-

tings. QuietTest® cannot exercise the HTS since the

lower generator frequency and voltage used to reduce

noise levels is incompatible with the standard system

loads.

Click on ”Select Exercise” to enable internal exercise

and allow the changing of the other exercise param-

eters.

If the generator is needed for emergency power while

exercise is running, exercise will be terminated auto-

matically and the system will change to providing

emergency power.

NOTE:

If “transfer on exercise” is selected with an HTS

that is not a “Closed Transition Transfer Switch”,

there will be a momentary (possibly several sec-

onds) interruption in power to the load when

switching from Utility to Emergency power and

when switching back. For this reason, “transfer on

exercise” is normally not selected.

QUIETTEST SETUP USING GENLINK

Connect to the H-100 control panel. Using the

“Configuration” pull down, select “Exercise

Configuration” to display the Exercise Configuration

screen.

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Select the day of week to run the exercise.

Select the time of day to run exercise.

Click on “QuietTest®” to enable the exercise mode

with reduced sound levels. Press “Apply”.

Click on ”Select Exercise” to enable internal exercise

and allow the changing of the other exercise param-

eters.

Setup of QuietTest® is now complete. For this exam-

ple, QuietTest® will start every Wednesday at 10:30

AM and run until about 10:50 AM

NORMAL EXERCISE SETUP USING

GENLINK

Select the day of week to run the exercise.

Connect to the H-100 control panel. Using the

“Configuration” pull down, select “Exercise

Configuration” to display the Exercise Configuration

screen.

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QUIETTEST^®SETUP USING FRONT

PANEL

Press the “MENU” button.

Select the time of day to run exercise.

Move the cursor using the arrow keys to the Exercise/

HTS menu item.

Press the “ENTER” button.

Verify “QuietTest®” is not checked. Press “Apply”.

Setup of Normal exercise is now complete. For this

example, exercise will start every Wednesday at 10:30

AM and run until about 10:50 AM

If exercise of the HTS is desired, Click on “Transfer

on exercise” to enable transferring of the load to the

generator during exercise.

NOTE:

Move the cursor to the “Exercise Enabled” field on

the first line.

This feature is only available in non-QuietTest®

exercise and when an HTS is in the system.

Press the “ENTER” button to enter edit mode.

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Use the up and down arrow keys until a “Y” appears

in the field.

Press the "ENTER" button to exit edit mode.

Move the cursor to the “Time Start” time of day hours

field on the second line.

Press the “ENTER” button to exit edit mode.

Press the “ENTER” button to enter edit mode.

Move the cursor to the “Time Start” day of week field

on the second line.

Use the up and down arrow key until the desired

hour of the day is displayed.

Press the “ENTER” button to enter edit mode.

NOTE:

In a number field the up/down arrows move the

digit up and down while the left/right arrows move

to the adjacent digit.

Use the up and down arrow key until the desired day

of the week is displayed.

Press the “ENTER” button to exit edit mode.

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Move the cursor to the “Time Start” time of day min-

utes field on the second line.

Move the cursor to the “QuietTest Selected” field on

the first line.

Press the “ENTER” button to enter edit mode.

Use the up and down arrow key until a “Y” appears.

Press the “ENTER” button to exit edit mode.

NOTE:

Use the up and down arrow key until the desired

minute of the hour is displayed.

Press the “ENTER” button to exit edit mode.

Move the cursor to the on the bottom line.

Verify that “Xfer On Exercise” field is an “N”.

Otherwise, QuietTest® will be overridden with

normal exercise.

Press the “ENTER” button to move to the second

page.

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Setup of QuietTest® is now complete. For this exam-

ple, QuietTest® will start every Wednesday at 10:30

AM and run until about 10:50 AM

While QuietTest® is running, the “Time Remaining”

will display the approximate number of minutes left

before QuietTest® is completed.

Press the “ENTER” button to enter edit mode.

NORMAL EXERCISE SETUP USING

FRONT PANEL

Press the “MENU” button.

Use the up and down arrow keys until a “Y” appears

in the field.

Move the cursor using the arrow keys to the Exercise/

HTS menu item.

Press the “ENTER” button to exit edit mode.

Press the “ENTER” button.

Move the cursor to the “Time Start” day of week field

on the second line.

Move the cursor to the “Exercise Enabled” field on

the first line.

Press the “ENTER” button to enter edit mode.

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NOTE:

In a number field the up/down arrows move the

digit up and down while the left/right arrows move

to the adjacent digit.

Use the up and down arrow key until the desired day

of the week is displayed.

Press the “ENTER” button to exit edit mode.

Press the "ENTER" button to exit edit mode.

Move the cursor to the “Time Start” time of day min-

utes field on the second line.

Move the cursor to the “Time Start” time of day hours

field on the second line.

Press the “ENTER” button to enter edit mode.

Use the up and down arrow key until the desired

minute of the hour is displayed.

Use the up and down arrow key until the desired

hour of the day is displayed.

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Press the “ENTER” button to exit edit mode.

Use the up and down arrow key until a “N” appears.

Move the cursor to the on the bottom line.

Press the “ENTER” button to exit edit mode.

Press the “ENTER” button to move to the second

page.

Setup of Normal Exercise is now complete. For this

example, exercise will start every Wednesday at 10:30

AM and run until about 10:50 AM

While normal exercise is running, the “Time

Remaining” will display the approximate number of

minutes left before exercise is completed.

Move the cursor to the “QuietTest Selected” field on

the first line.

If it is desired to exercise the HTS as well during

the exercise cycle, then continue with the enabling of

“transfer on exercise” described below.

Move the cursor to the “Xfer On Exercise” field on

the third line.

Press the “ENTER” button to enter edit mode.

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‹

DATE AND TIME SETUP USING GENLINK

Connect to the H-100 control panel.

Use the up and down arrow key until a “Y” appears.

Press the “ENTER” button to exit edit mode.

The date and time field is displayed in the lower left

corner of the screen.

Using the mouse cursor, click on the date and time

field.

Setup of Normal Exercise with transfer to load dur-

ing exercise is now complete. For this example, exer-

cise will start every Wednesday at 10:30 AM and run

until about 10:50 AM. However, the HTS settings may

change this time.

While normal exercise is running, the “Time

Remaining” will display the approximate number of

minutes left before exercise is completed.

Any of the fields are editable. Note that hours are

entered as 0 – 23. If the PC being used has reliable

date and time settings, pressing the “Synchronize

with PC!” button will copy the PC date and time into

the H-100 Control Panel. Otherwise, press “Apply”

after making changes. The date and time on the

GenLink screen may take a few seconds to update.

‹

DATE AND TIME SETUP USING FRONT PANEL

Press the “MENU” button.

SET DATE AND TIME

The H-100 Control Panel contains a real time clock to

keep track of date and time. This is used to schedule

internal exercise, time stamp alarm/event log entries,

and time stamp reports. The date and time can be

changed using either GenLink or the front panel

display.

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Press the  button twice.

Press the “ENTER” button.

Press the  button.

There are 5 editable fields on line 3. They are hours,

minutes, month, day, and year. Use the arrow keys

to move to each of the fields needing to be changed.

Press enter to begin edit mode. Use the up and down

arrow keys to slew to the desired value. Press enter

to exit edit mode or use the right or left arrow keys

to leave the field. The date and time setup is com-

pleted.

Press the “ENTER” button.

ADJUST DISPLAY CONTRAST

The display contrast is adjustable to accommodate

different viewing environments. The generator is

shipped from the factory with the contrast set to

20%. This is optimal for most situations. However,

if the user needs to change the contrast, they can

do so by editing the value on the last “Service” page.

Note that changing the contrast can make the screen

nearly unreadable and the contrast setting is saved

across power cycles. Caution should be exercised

while editing this value.

Press the  button and then the  button.

Do the following to change the display contrast:

Press the “MENU” button.

Press the “ENTER” button to enter edit mode.

Press the  button button three times or the  but-

ton once.

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Use the arrow buttons to change the contrast value

(range is 00 to 37). Pressing the “HOME” button

while in edit mode will return the value to the last

entered value.

Press the “ENTER” button to exit edit mode.

The contrast is now set and can only be changed by

editing the value on this page.

ENABLE GENERAC COMMERCIAL

TRANSFER SWITCH (HTS)

The H-100 Control Panel can control up to four HTSs

via the RS-485 communications port. The H-100

Control Panel is shipped without the HTS control

enabled. If the user has an HTS in their system, they

must enable the HTS via GenLink or the front panel.

If the HTS is not enabled, the generator will not

operate automatically with loss of utility. If the H-100

Control Panel enables a non-existent HTS, there will

be a warning indicated.

The lower left corner contains the HTS number. Use

the “Prev” and “Next” buttons to select the appro-

priate switch number - 1 through 4. If enabling the

switch, check the “Switch Connected” check box

in the middle of the screen. If disabling the switch,

uncheck the “Switch Connected” check box. The

remainder of the settings on this page are described

in the HTS manual.

NOTE:

Non-HTS switches use the two-wire start inter-

face and do not need enabling by H-100 Control

Panel.

‹

HTS SETUP USING GENLINK

‹

HTS SETUP USING FRONT PANEL

Connect to the H-100 control panel.

Press the “MENU” button.

Using the “Configuration” pull down, select “Transfer

SwitchConfiguration”todisplaytheHTSConfiguration

screen.

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Press the  button.

Select the appropriate HTS number using the up and

down arrow buttons.

Press the “ENTER” button.

Press the “ENTER” button to exit the edit mode.

Press the  button.

Press the  button to go to the HTS Enable/Disable

field.

Press the “ENTER” button.

Press the “ENTER” button to enter the edit mode.

This is the HTS enabling/disabling page. The HTS

number needs to be selected first.

Select the Enabled / Disabled using the up and down

arrow buttons.

Press the  button to go to the HTS # field.

Press the “ENTER” button to enter the edit mode.

Press the “ENTER” button to exit the edit mode.

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In an H-100 Control Panel system with HTS switches,

the annunciator will indicate Line Power or Generator

Power based on the status reported from the selected

HTS. The selected HTS is the HTS number that was

selected using the H-100 control front panel. The

number is selected on either of the Exercise/HTS

pages (3-4) or (4-4). The two designated H-100 con-

trol panel inputs Input #7 and Input #8 are free to

be used for other functions and will not affect the

annunciator as long as at least one HTS is connected

and enabled.

For this example, HTS number 1 is now enabled. If

HTS #1 is not connected or if the HTS is not #1,

there will be a communications error indicated.

NEW GENERATION GENLINK (NGG)

An all new version of GenLink has been released

for support of the H-100 Control Panel. It uses the

industry standard Modbus protocol for communica-

tions and acts as a Modbus master. GenLink runs

on PC platforms running Windows 98 (but will not

support future Internet applications), Windows NT

4.0, Windows 200 and XP. We recommend an Intel

Pentium 4 processor (1.0gHz+) with a minimum

64MB memory and 20GB hard drive. plus 56k

Zonet PCMCIA based modem. For details about

GenLink, refer to the New Generation GenLink man-

ual. Addtional features include:

COMMUNICATIONS

There are 2 ports on the H-100 Control Panel, an

RS-232 port and an RS-485. Each port can be recon-

figured as to its function, however there can only be

one master Modbus port. All ports can have their

baud rate, parity and stop bits changed. For Modbus

ports, the address can also be changed via GenLink,

but each address in a connected system must be

unique. Normally the RS-232 port will be configured

as a Modbus slave to communicate with GenLink and

the optional Modem. The RS-485 port will act as a

master for connection to up to two remote annuncia-

tors/remote relay panels and up to four HTSs. The

RS-485 port can be reconfigured via GenLink to be a

deep diagnostic port.

‹

GENLINK RELAY CONTROL

There is a “Radio Button” displayed on the main

GenLink display screen. This button will set or reset

output function 106 which in turn can be made to

drive a relay or any combination of things (via the

ILC). The function can be renamed and this new

name will appear above the radio button.

REMOTE ANNUNCIATOR CONNECTION

(OPTION)

The H-100 Control panel RS-485 port is normally

configured as Modbus Master, 4800 baud, no parity,

and two stop bits. This is the required configuration

for the remote annunciator. However, the remote

annunciator is often shipped configured as a Modbus

Master (active mode). A wire jumper must be added

in the remote annunciator to configure it as the

Modbus Slave (passive mode). A total of up to two

remote annunciators and remote relay panels can be

attached to the RS-485 bus. See the remote annun-

ciator/relay panel manual for details.

‹

SET ENGINE HOURS

In the event that a controller has to be replaced, the

engine hours on the new controller can be set to

match the controller it is replacing. This can only be

done at the factory.

‹

ABSOLUTE MAXIMUM RATINGS

Supply Voltage rating

Power consumption

5 - 30V dc continuous

0.45A typical

In an H-100 Control Panel system without HTS

switches, the annunciator will indicate Line Power or

Generator Power based on two designated H-100 con-

trol panel spare inputs Input #7 (Also labeled DI3)

and Input #8 (Also labeled DI4). These inputs can be

used for other functions as desired, but will always

operate the annunciator lights. Input #7 should be

connected to Line Power indication. Input #8 should

be connected to Generator Power indication.

‹

ENVIRONMENTAL RATINGS

Temperature

Relative humidity

Sealing

0 - 50 deg. C

20 - 95%, non condensing

IP65

ESD

As per manufacturer's

spec.

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Appendix A

H-100 Control Panel Technical Manual

THERMISTOR:

PRESSURE:

POLY_3RD:

APPENDIX A — ANALOG FUNCTIONS

The User Configurable Analog Inputs have several

parameters that affect the value interpreted from

the A/D reading. In general, the following equation

determines the final User Configurable Analog Input

result:

Third order polynomial with 4 coefficients and a scal-

ing factor

X = raw_analog

(AX3 + BX2 + CX + D) * S

Where:

Result = Scale (Function (Calibrate (Raw A/D read-

ing)))

For functions that require 4 coefficients for a polyno-

mial, the calibration factor has to be incorporated in

the polynomial coefficients. In this case, the follow-

ing equation determines the final User Configurable

Analog Input result:

A, B, C, D are polynomial coefficients

S is the scaling factor

Coefficient 3 = A * 10243

Coefficient 2 = B * 10242

Coefficient 1 = C * 1024

Calibration = D

Result = Scale (Function (Raw A/D reading))

The RMS Analog Inputs have a calibration parameter

and a scaling parameter that affect the value inter-

preted from the A/D reading. The following equation

determines the final RMS Analog Input result:

Scaling

= S * 1024

POLY_2ND:

Second order polynomial with 3 coefficients, a scal-

ing factor, and a calibration factor

Result = Scale (Calibrate (RMS Function (Raw A/D

reading)))

X = M * raw_analog

(AX2 + BX + C) * S

Where:

Although the calibration and scaling adjustments

exist for the remaining Analog Inputs (i.e. derived

channels), it is unlikely they will be used. The

remaining Analog Inputs are derived from other ana-

log inputs that have already been adjusted. If further

adjustment is needed, then the following equation

determines the final Analog Input result:

M is the calibration factor

A, B, C are polynomial coefficients

S is the scaling factor

Calibration = M * 1024

Coefficient 3 = A * 10242

Coefficient 2 = B * 1024

Coefficient 1 = C

Result = Scale (Calibrate (RMS Function (Raw A/D

reading)))

These derived inputs have more complex interactions

with the hardware, so care should be taken if adjust-

ments are used.

Scaling

LINEAR:

POLY_1ST:

= S * 1024

The conversion functions are described below. One of

these functions is a 16 bit floating point polynomial

- GEN_FP_POLY. This function should only be used

as an extreme last resort as it is processor time inten-

sive. The other integer polynomial functions should

be sufficient for converting the A/D input data.

First order polynomial with 2 coefficients, a scaling

factor, and a calibration factor

X = M * raw_analog

(AX + B) * S

Where:

The coefficients for the conversion functions need to

be adjusted for working in the A/D counts realm as

opposed to the voltage realm. Multiply A/D reading

voltage by 1023/5 to convert to A/D reading counts.

Also, the coefficient scaling is in powers of 2 to

expedite processing of math operations using shifts

instead of multiply and divide. The following types

of Analog Input functions are implemented in the

firmware.

M is the calibration factor

A, B are polynomial coefficients

S is the scaling factor

Calibration = M * 1024

Coefficient 2 = A * 1024

Coefficient 1 = B

Scaling

= S * 1024

POLY_1ST_N1:

First order polynomial with 3 coefficients, a scaling

factor, and a calibration factor

X = M * raw_analog

(A + BX + CX-1) * S

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Appendix A

H-100 Control Panel Technical Manual

Where:

M is the calibration factor

CURRENT:

CAL_SCALE:

A, B, C are polynomial coefficients

S is the scaling factor

Calibration = M * 1024

Coefficient 3 = C

Coefficient 2 = B * 1024

Coefficient 1 = A

Implements a scaling factor and a calibration factor

X = M * raw_analog

X * S

Where:

M is the calibration factor

S is the scaling factor

Calibration = M * 1024

Scaling

= S * 1024

POLY_1ST_N2:

Scaling

= S * 1024

First order polynomial with 4 coefficients and a scal-

ing factor

GEN_FP_POLY:

Third order polynomial with 4 coefficients

X = raw_analog

(A + BX + CX-1 + DX-2) * S

Where:

X = raw_analog

AX3 + BX2 + CX + D

Where:

A, B, C, D are polynomial coefficients

S is the scaling factor

Coefficient 3 = D

Coefficient 2 = C

Coefficient 1 = B * 1024

Calibration = A

A, B, C, D are 16 bit floating point polynomial

coefficients

Coefficient 3 = A

Coefficient 2 = B

Coefficient 1 = C

Calibration = D

Scaling

= S * 1024

Amplitudes from 0.00000005961 (256 E-16) to

1,098,437,885,952 (1023 E+15) are possible with

this representation with at least 9 significant bits.

CFM_SENSOR:

First order polynomial with 4 coefficients and a scal-

ing factor

X = raw_analog - learned_offset

(A + BX + CX-1 + DX-2) * S

Where:

A, B, C, D are polynomial coefficients

S is the scaling factor

Coefficient 3 = D/32

Coefficient 2 = C

Coefficient 1 = B * 32768

Calibration = A * 64

Scaling

= S * 1024

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Appendix B

H-100 Control Panel Technical Manual

APPENDIX B — H-100 GENERAL I/O AND CONNECTOR INFORMATION

‹

H-100 ANALOG INPUTS

Number Default Signal Name

Default Signal Name

Oil Temperature

Type

4-20 ma

Connector Pin

J1-9 source,

J1-8 return

OIL TEMP

COOLANT TEMP

OIL PRESSURE

Coolant Temperature

Oil Pressure

4-20 ma

J1-15 source,

J1-31 return

J1-20 source,

J1-19 return

J1-30 source,

J1-29 return

J1-7 source,

J1-6 return

COOLANT LEVEL

Coolant Level

USER CFG 05

FUEL LEVEL

USER CFG 06

FUEL PRESSURE

INLET TEMP

USER CFG 07

THROT POS

USER CFG 08

EMISSIONS

FLUID BASIN

USER CFG 09

BAT CHARGE CUR

BATTERY VOLTS

Analog Input #5

Fuel Level

Analog Input #6

Fuel Pressure,

Inlet Temperature

Analog Input #7

Throttle Position

Analog Input #8

Emissions Sensor,

Fluid Basin Level

Analog Input #9

Battery Charge Current

Battery Voltage

J1-28 source,

J1-27 return

4-20 ma

0-1 Volt

J1-18 source,

J1-17 return

J1-5 source,

J1-5 return

0-10 Volt

J1-16 return

0-30 Volt

J1-35 ( + )

J1-12 ( - )

J2-12 ( + )

J2-11 ( - )

J2-35 ( + )

J2-34 ( - )

J2-10 ( + )

J2-9 ( - )

n/a

CURRENT PHS A

CURRENT PHS B

CURRENT PHS C

Phase A Current – single & three phase

Phase B Current – single & three phase

Phase C Current – three phase

0-3 ARMS

CURRENT NEUTRAL

AVRG CURRENT

VOLT PHS A-B

VOLT PHS A-N

VOLT PHS B-C

VOLT PHS B-N

VOLT PHS C-A

VOLT PHS A-B

AVRG VOLTAGE

TOTAL POWER KW

TOTAL PF

Current in Neutral – single phase

Average System Current

Derived

0-28.8 VRMS

n/a

J2-6

Line-to-Line AB Voltage – three phase

Line-to-Neutral AN Voltage – single

Line-to-Line BC Voltage – three phase

Line-to-Neutral BN Voltage – single

Line-to-Line CA Voltage – three phase

Line-to-Line AB Voltage – single phase

Average Line-to-Line System Voltage

Total System Real Power

0-28.8 VRMS

J2-29

0-28.8 VRMS

Derived

J2-17

n/a

Total System Power Factor

Generator Frequency

Engine RPM

GEN FREQUENCY

ENGINE RPM

Derived

Hall Affect

n/a

J1-24 ( - )

J1-25 ( + )

n/a

O2 DUTY CYCLE

Oxygen Sensor Measured Duty Cycle

Derived

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Appendix B

H-100 Control Panel Technical Manual

‹

H-100 DIGITAL OUTPUTS

H-100

GenLink

Number

Signal Description

Starter Relay (reserved)

Fuel Relay (reserved)

Fault Relay (reserved)

Connector Pin

J1-23

J1-11

J1-34

13.3L Gas Relay (reserved for ILC on 13.3L gas)

Auxiliary #1

J1-22

J2-23

Auxiliary #2

J2-22

Auxiliary #3

J2-33

Auxiliary #4

J2-21

13.3L Ignition Module (reserved for ILC on 13.3L gas)

Overspeed Shutdown (reserved – no software control)

Throttle Driver PWM (reserved for H-100 governed generators)

PreHeat Relay – diesel only (reserved)

Air/Fuel Ratio PWM – gas only (reserved)

AVR Field Control (reserved)

J2-32

J1-10

J1-33

J1-21

n/a

J2-20

J2-8

AVR Field Control (reserved)

‹

H-100 DIGITAL INPUTS

Number

Default Signal Name

AUTO SWITCH

Signal Description

Key Switch in AUTO

Key Switch in MANUAL

Emergency Stop Status

Remote Start

DI-1,

Battery Charger Fail

DI-2,

Ruptured Basin,

Propane Gas Leak,

Low Fuel Pressure

DI-3,

Line Power

DI-4,

Connector Pin

J2-5

J2-28

J2-16

J2-4

MANUAL SWITCH

EMERGENCY STOP

REMOTE START

DI1/USR CFG 05

BAT CHRGR FAIL

DI2/USR CFG 06

RUPTURED BASIN

PROP GAS LEAK

DI2/FUEL PRESSURE

DI3/USR CFG 07

DI3/LINE POWER

DI4/USR CFG 08

DI4/GEN POWER

MODEM DCD

J2-27

J2-15

J2-3

J2-26

J1-14

Generator Power

Modem DCD

USR CFG 09

MODEM ENABLED

GEN OVERSPEED

User conﬁgurable (reserved if Modem)

Modem Enable

Generator Overspeed Detected

J1-26

Internal

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Appendix B

H-100 Control Panel Technical Manual

‹

H-100 DIGITAL OUTPUT FUNCTIONS

Number

Default Function Name

COMMON ALARM

COMMON WARNING

GEN RUNNING

Function Description

An alarm is active

A warning is active

Generator is running

ALARMS ENABLED

READY FOR LOAD

GEN READY TO RUN

GEN STOPPED-ALRM

GEN STOPPED

All alarm hold off delays have expired, so all alarms are enabled

Generator is warmed up and ready to accept power loading

Generator is ready to start

Generator stopped due to a shutdown alarm

Generator is stopped

GEN IN MANUAL

GEN IN AUTO

GEN IN OFF

Generator in MANUAL mode ( key switch in MANUAL or ILC overriden)

Generator in AUTO mode ( key switch in AUTO or ILC overriden )

Generator in OFF mode ( key switch in OFF or ILC overriden )

Generator has unsuccessfully tried to start the designated number of times

Oil pressure too high for a stopped engine

OVERCRANK ALARM

OIL INHIBIT ALRM

ANNUNC SPR LIGHT

OIL TEMP HI ALRM

OIL TEMP LO ALRM

OIL TEMP HI WARN

OIL TEMP LO WARN

OIL TEMP FAULT

COOL TMP HI ALRM

COOL TMP LO ALRM

COOL TMP HI WARN

COOL TMP LO WARN

COOL TMP FAULT

OIL PRES HI ALRM

OIL PRES LO ALRM

OIL PRES HI WARN

OIL PRES LO WARN

OIL PRES FAULT

COOL LVL HI ALRM

COOL LVL LO ALRM

COOL LVL HI WARN

COOL LVL LO WARN

COOL LVL FAULT

ANALOG 5 HI ALRM

FUEL LVL HI ALRM

ANALOG 5 LO ALRM

FUEL LVL LO ALRM

ANALOG 5 HI WARN

FUEL LVL HI WARN

ANALOG 5 LO WARN

FUEL LVL LO WARN

ANALOG 5 FAULT

FUEL LVL FAULT

ANALOG 6 HI ALRM

FUEL PRS HI ALRM

INLT TMP HI ALRM

ANALOG 6 LO ALRM

FUEL PRS LO ALRM

INLT TMP LO ALRM

ILC controlled: this function operates the spare remote annunciator light

Oil Temperature has gone above maximum alarm limit

Oil Temperature has gone below minimum alarm limit

Oil Temperature has gone above maximum warning limit

Oil Temperature has gone below maximum warning limit

Oil Temperature sensor exceeds nominal limits for valid sensor reading

Coolant Temperature has gone above maximum alarm limit

Coolant Temperature has gone below minimum alarm limit

Coolant Temperature has gone above maximum warning limit

Coolant Temperature has gone below maximum warning limit

Coolant Temperature sensor exceeds nominal limits for valid sensor reading

Oil Pressure has gone above maximum alarm limit

Oil Pressure has gone below minimum alarm limit

Oil Pressure has gone above maximum warning limit

Oil Pressure has gone below maximum warning limit

Oil Pressure sensor exceeds nominal limits for valid sensor reading

Coolant Level has gone above maximum alarm limit

Coolant Level has gone below minimum alarm limit

Coolant Level has gone above maximum warning limit

Coolant Level has gone below maximum warning limit

Coolant Level sensor exceeds nominal limits for valid sensor reading

Analog Input #5 has gone above maximum alarm limit

Fuel Level

Analog Input #5 has gone below minimum alarm limit

Fuel Level

Analog Input #5 has gone above maximum warning limit

Fuel Level

Analog Input #5 has gone below maximum warning limit

Fuel Level

Analog Input #5 sensor exceeds nominal limits for valid sensor reading

Fuel Level

Analog Input #6 has gone above maximum alarm limit

Fuel Pressure

Inlet Air Temperature

Analog Input #6 has gone below minimum alarm limit

Fuel Pressure

Inlet Air Temperature

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Appendix B

H-100 Control Panel Technical Manual

Number

Default Function Name

ANALOG 6 HI WARN

FUEL PRS HI WARN

INLT TMP HI WARN

ANALOG 6 LO WARN

FUEL PRS LO WARN

INLT TMP LO WARN

ANALOG 6 FAULT

FUEL PRS FAULT

Function Description

Analog Input #6 has gone above maximum warning limit

Fuel Pressure

Inlet Air Temperature

Analog Input #6 has gone below maximum warning limit

Fuel Pressure

Inlet Air Temperature

Analog Input #6 sensor exceeds nominal limits for valid sensor reading

Fuel Pressure

INLT TMP FAULT

Inlet Air Temperature

ANALOG 7 HI ALRM

GOV POS HI ALARM

ANALOG 7 LO ALRM

GOV POS LO ALARM

ANALOG 7 HI WARN

GOV POS HI WARN

ANALOG 7 LO WARN

GOV POS LO WARN

ANALOG 7 FAULT

GOV POS FAULT

ANALOG 8 HI ALRM

OXYGEN HI ALARM

FLUID BS HI ALRM

ANALOG 8 LO ALRM

OXYGEN LO ALRM

FLUID BS LO ALRM

ANALOG 8 HI WARN

OXYGEN HI WARN

FLUID BS HI WARN

ANALOG 8 LO WARN

OXYGEN LO WARN

FLUID BS LO WARN

ANALOG 8 FAULT

O2 SENSOR FAULT

FLUID BS FAULT

Analog Input #7 has gone above maximum alarm limit

Throttle Position

Analog Input #7 has gone below minimum alarm limit

Throttle Position

Analog Input #7 has gone above maximum warning limit

Throttle Position

Analog Input #7 has gone below maximum warning limit

Throttle Position

Analog Input #7 sensor exceeds nominal limits for valid sensor reading

Throttle Position

Analog Input #8 has gone above maximum alarm limit

Emissions Sensor

Fluid Basin

Analog Input #8 has gone below minimum alarm limit

Emissions Sensor

Fluid Basin

Analog Input #8 has gone above maximum warning limit

Emissions Sensor

Fluid Basin

Analog Input #8 has gone below maximum warning limit

Emissions Sensor

Fluid Basin

Analog Input #8 sensor exceeds nominal limits for valid sensor reading

Emissions Sensor

Fluid Basin

ANALOG 9 HI ALRM

CHG CURR HI ALRM

ANALOG 9 LO ALRM

CHG CURR LO ALRM

ANALOG 9 HI WARN

CHG CURR HI WARN

ANALOG 9 LO WARN

CHG CURR LO WARN

ANALOG 9 FAULT

CHG CURR FAULT

BAT VOLT HI ALRM

BAT VOLT LO ALRM

BAT VOLT HI WARN

Analog Input #9 has gone above maximum alarm limit

Battery Charge Current

Analog Input #9 has gone below minimum alarm limit

Battery Charge Current

Analog Input #9 has gone above maximum warning limit

Battery Charge Current

Analog Input #9 has gone below maximum warning limit

Battery Charge Current

Analog Input #9 sensor exceeds nominal limits for valid sensor reading

Battery Charge Current

Battery Voltage has gone above maximum alarm limit

Battery Voltage has gone below minimum alarm limit

Battery Voltage has gone above maximum warning limit

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Appendix B

H-100 Control Panel Technical Manual

Number

Default Function Name

Function Description

BAT VOLT LO WARN

AVG CURR HI ALRM

AVG CURR LO ALRM

AVG CURR HI WARN

AVG CURR LO WARN

AVG VOLT HI ALRM

AVG VOLT LO ALRM

AVG VOLT HI WARN

AVG VOLT LO WARN

TOT PWR HI ALARM

TOT PWR LO ALARM

TOT PWR HI WARN

TOT PWR LO WARN

GEN FREQ HI ALRM

GEN FREQ LO ALRM

GEN FREQ HI WARN

GEN FREQ LO WARN

GEN FREQ FAULT

ENG RPM HI ALARM

ENG RPM LO ALARM

ENG RPM HI WARN

ENG RPM LO WARN

ENG RPM FAULT

Battery Voltage has gone below maximum warning limit

Average Current has gone above maximum alarm limit

Average Current has gone below minimum alarm limit

Average Current has gone above maximum warning limit

Average Current has gone below maximum warning limit

Average Voltage has gone above maximum alarm limit

Average Voltage has gone below minimum alarm limit

Average Voltage has gone above maximum warning limit

Average Voltage has gone below maximum warning limit

Total Real Power has gone above maximum alarm limit

Total Real Power has gone below minimum alarm limit

Total Real Power has gone above maximum warning limit

Total Real Power has gone below maximum warning limit

Generator Frequency has gone above maximum alarm limit

Generator Frequency has gone below minimum alarm limit

Generator Frequency has gone above maximum warning limit

Generator Frequency has gone below maximum warning limit

Generator Frequency exceeds nominal limits for valid sensor reading

Engine RPM has gone above maximum alarm limit

Engine RPM has gone below minimum alarm limit

Engine RPM has gone above maximum warning limit

Engine RPM has gone below maximum warning limit

Engine RPM exceeds nominal limits for valid sensor reading

Key Switch in AUTO digital input active

SWITCH IN AUTO

SWITCH IN MANUAL

E-STOP ACTIVE

REMOTE START ACT

DIG INPUT 05 ACT

BATT CHARGE FAIL

DIG INPUT 06 ACT

RUPTURED BASIN

PROP LEAK ACT

Key Switch in MANUAL digital input active

Emergency Stop Status digital input active

Remote Start digital input active

DI-1, Digital Input #5 active

Battery Charger Fail digital input active

DI-2, Digital Input #6 active

Ruptured Basin digital input active,

Propane Gas Leak digital input active,

LOW FUEL PRS ACT

DIG INPUT 07 ACT

LINE POWER ACT

DIG INPUT 08 ACT

GEN POWER ACT

DIG INPUT 09 ACT

MODEM DCD ACT

MODEM ENAB ACT

ILC ALR/WRN #1

ILC ALR/WRN #2

IN WARM UP

IN COOL DOWN

CRANKING

Low Fuel Pressure digital input active

DI-3, Digital Input #7 active

Line Power digital input active

DI-4, Digital Input #8 active

Generator Power digital input active

Digital Input #9 active

Modem Carrier Detect digital input active

Modem Enable digital input active

ILC controlled: ILC warning or alarm signal # 1

ILC controlled: ILC warning or alarm signal # 2

Generator is running, but not fully warmed up yet

Generator is running, but cooling down before shutting off.

Generator is starting – the starter is engaged

Maintenance item has expired

100

101

102

NEED SERVICE

SHUTDOWN GENSET

Shutdown alarm is active

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Appendix B

H-100 Control Panel Technical Manual

Number

103

104

105

106

107

108

109

110

111

Default Function Name

CHCK V PHS ROT

CHCK C PHS ROT

FAULT RLY ACTIVE

USR CONFIG 106

INT EXERCISE ACT

CHECK FOR ILC

USR CONFIG 109

USR CONFIG 110

USR CONFIG 111

USR CONFIG 112

USR CONFIG 113

USR CONFIG 114

USR CONFIG 115

USR CONFIG 116

USR CONFIG 117

USR CONFIG 118

USR CONFIG 119

USR CONFIG 120

Function Description

Detected voltage phase rotation as not being A-B-C

Detected current phase rotation as not being A-B-C and not matching voltage

Audible alarm/warning signal is active.

GenLink controlled: GenLink front panel radio button selected

Internal Exercise is active – includes QuietTest®

Indicates the ILC is not running

Available for ILC use

112

113

114

115

116

117

118

119

120

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Appendix B

H-100 Control Panel Technical Manual

‹

H-100 CONNECTOR PIN DESCRIPTIONS

Wire

Signal

CAN (rtn)

CAN (+)

Gnd

Description

CAN Bus

Wire

391

Signal

Description

Diagnostic/Rem-An/HTS

GenLink

RS485 (-)

RS232 (tx)

IN (DB) 7

IN (DB) 4

CAN Bus (+)

Modem Power (-)

Emissions Sensor/

Fluid Basin Level

Emissions Sensor/

Fluid Basin Level

Fuel Level

388

810

805

IN7

DI-3/Line Power

Remote Start

AN8 (rtn)

183

804

AN8 (+) 0-1V

174

IN (DB) 1

Key Switch in AUTO

575R

575V

523R

523V

R15B

256

AN5 (rtn)

224

227

Vsense 1

Gnd

Phase AB Voltage

Vsense PCB Ground

AVR Gate trigger ‘B’

Phase C Current

AN5 (+) 4-20mA

AN1 (rtn)

Fuel Level

Oil Temperature

Overspd Shutdown

Fuel Relay

403

OUT (OC) 14

CT3 (-)

AN1 (+) 4-20mA

OUT (OC) 10

OUT (OC) 2

- Batt (12/24V)

CAN (-)

399C

398C

399A

398A

390

CT3 (+)

Phase C Current

CT1 (-)

Phase A Current

Panel Power (-)

CAN Bus (-)

CT1 (+)

Phase A Current

RS485 (+)

RS232 (rx)

IN (DB) 6

Diagnostic/Rem-An/HTS

GenLink

811

IN (DB) 9

Modem DCD

Coolant

387

68V

AN2 (+) 4-20mA

567/601

DI-2/Ruptured Basin/

Low Fuel Pressure

Emergency Stop

Phase CA Voltage

Vsense PCB

Temperature

803

766R

766V

69R

AN9(+) 0-5V

AN7 (rtn)

Battery Charger Cur

Throttle Position

Oil Pressure

R15

226

IN (DB) 3

Vsense 3

AN7 (+) 4-20mA

AN3 (rtn)

+12V (500 mA)

Gnd

405

404

AVR PCB Power (-)

AVR Gate trigger ‘A’

Auxiliary 4 Output

69V

AN3 (+) 4-20mA

OUT (OC)12 (PWM)

Oil Pressure

OUT (OC) 13

OUT (OC) 8

221/808

Preheat/Air

OC8

/Fuel Solenoid

13.3 Gas Relay

Starter Relay

242

56A

0/shld

OUT (OC) 4

OUT (OC) 1

RPM sensor (-)

RPM sensor (+)

IN (DB) 10

OC6

OC5

SHLD

389

OUT (OC) 6

OUT (OC) 5

RS485 (shield)

RS232 (com)

IN (DB) 8

Auxiliary 2 Output

Auxiliary 1 Output

Diagnostic/Rem-An/HTS

GenLink

Engine RPM

812

Modem Enable

Fuel Press/Ign. Alarm/

Inlet Temp

IN8

DI-4/Generator Power

DI-1/Battery Charger Fail

27 AI1R/806/

754R

AN6 (rtn)

505

IN (DB) 5

AI1S/

754V

573R

573V

68R

AN6 (+) 4-20mA

Fuel Press/

175

IN (DB) 2

Key Switch in MANUAL

Inlet Temp

AN4 (rtn)

Coolant Level

Coolant Temp

Modem Power (+)

Throttle Driver

Fault Relay

225

406

Vsense 2

Phase BC Voltage

AVR Zero Crossing Input

AVR PCB Power (+)

13.3 Ignition Power

Auxiliary 3 Output

Phase B Current

AN4 (+) 4-20mA

AN2 (rtn)

AVR Zero Crossing

+12V (300 mA)

OUT (OC) 9

OUT (OC) 7

CT2 ( - )

194

809

+12V (300mA)

OUT (OC)11 (PWM)

OUT (OC) 3

OC9/25

OC7

769

445

399B

398B

35 15B/220B

+ Batt ( 12/24V )

Panel Power ( + )

CT2 ( + )

Phase B Current

KEY:

AN #1-7 (+)

AN #1-7 (rtn)

Vsense #1-3

CT #1-3

= Analog 12V ( 50 mA ) source

OUT (O/C) #1-14 = Digital OUTput, Open Collector (includes

PWM Outputs, AVR Gates)

IN (DB) #1-10

= General purpose analog input ( 4 - 20 mA )

= Voltage sensing input ( 0 - 28.8 VAC)

= Current Transformer input ( 0 - 3 AAC)

= Digital INput, Buffered (Schmitt Trigger)

“Pulled up”

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Appendix C

H-100 Control Panel Technical Manual

APPENDIX C — MISCELLANEOUS H-100 INTERNAL ALARMS/WARNINGS

“Strt Inhib:Oil”

“Overcrank”

– Oil pressure is higher than expected for a stopped engine.

– Generator has attempted to start the designated number of times without success.

“Mult Def Digtl”

– More than one Digital Output Function is assigned to the same Digital Output; or A Digital

Output Function is assigned to a reserved Digital Output.

“Mult Def Analg”

– More than one Analog Input is assigned to the same Analog Output; or An Analog Input is

assigned to a reserved Analog Output.

“WatchDog Fail”

“HW Overspeed”

“System Reset”

“i2t Gen Tmp HI”

– Firmware was unable to complete all its tasks in the allotted time.

– Hardware Generator Overspeed circuit has detected a generator overspeed condition.

– Microprocessor has reset unexpectedly.

– i2t logic has determined alternator temperature is too high.

“300% Rated Cur” – >300% rated current short present – current is being controlled to 300%.

“Eng Stall RPM” – Engine has stalled unexpectedly.

“No HTS # Comms” – HTS number ‘#’ is not communicating.

“HTS # SW Fault” – HTS number ‘#’ failed in its switching attempt.

“HTS # Not Sync” – HTS number ‘#’ was unable to synchronize with utility in the allotted time.

“HTS # Batt Low” – HTS number ‘#’ battery is weak and possibly needs replacing.

“No HTS # Batt”

– HTS number ‘#’ battery is not connected.

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Notes

H-100 Control Panel Technical Manual

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Notes

H-100 Control Panel Technical Manual

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GENERAC POWER SYSTEMS, INC.

P.O. BOX 8

WAUKESHA, WI 53187

Part No. 0F3750

Revision A (03/13/06)

Printed in U.S.A.

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