®

POWER SYSTEMS, INC.

PowerManager™
Generator Controller
(PM-GC)

This manual should remain with the unit.

DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!
 INTRODUCTION The operator is responsible for proper and safe use
Thank you for purchasing the Modular Power System of the equipment. Generac strongly recommends that
by Generac Power Systems. the operator read this Owner's Manual and thor-
oughly understand all instructions before using this
Every effort was expended to make sure that the equipment. Generac also strongly recommends
information and instructions in this manual were instructing other users to properly start and operate
both accurate and current at the time the manual was the unit. This prepares them if they need to operate
written. However, the manufacturer reserves the right the equipment in an emergency.
to change, alter or otherwise improve this product(s)
at any time without prior notice. ◆ OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
◆ READ THIS MANUAL THOROUGHLY checks, to make sure that all maintenance for safe
If any portion of this manual is not understood, con- operation is performed promptly, and to have the
tact the nearest Generac Authorized Service Dealer equipment checked periodically by a Generac
for starting, operating and servicing procedures. Authorized Service Dealer. Normal maintenance serv-
Throughout this publication, and on tags and ice and replacement of parts are the responsibility of
decals affixed to the generator, DANGER, WARNING, the owner/operator and, as such, are not considered
CAUTION and NOTE blocks are used to alert person- defects in materials or workmanship within the terms
nel to special instructions about a particular service or of the warranty. Individual operating habits and usage
operation that may be hazardous if performed incor- contribute to the need for maintenance service.
rectly or carelessly. Observe them carefully. Their defi- Proper maintenance and care of the generator(s)
nitions are as follows: ensures a minimum number of problems and keep
operating expenses at a minimum. See a Generac
DANGER Authorized Service Dealer for service aids and acces-
sories.
After this heading, read instructions that, if not
strictly complied with, will result in personal injury Operating instructions presented in this manual
or property damage. assume that the standby electric system has been
installed by a Generac Authorized Service Dealer or
other competent, qualified contractor. Installation of
this equipment is not a “do-it-yourself” project.
After this heading, read instructions that, if not
strictly complied with, may result in personal injury ◆ HOW TO OBTAIN SERVICE
or property damage. When the generator requires servicing or repairs,
contact a Generac Authorized Service Dealer for
assistance. Service technicians are factory-trained
After this heading, read instructions that, if not and are capable of handling all service needs.
strictly complied with, could result in damage to When contacting a Generac Authorized Service
equipment and/or property. Dealer about parts and service, always supply the
NOTE: complete model number of the unit as given on the
DATA CARD affixed to the unit.
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing the
service are essential to preventing accidents.
Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type AUTHORIZED DEALER LOCATION
of information each indicates is as follows: To locate the nearest GENERAC
AUTHORIZED DEALER, please call:
This symbol points out important safety informa-
! tion that, if not followed, could endanger personal 1-800-333-1322
safety and/or property of others. or visit our website at:
This symbol points out potential explosion hazard. www.GENERAC.com

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.

Generac® Power Systems, Inc.

 Table of Contents
PM-GC

Introduction ........................Inside Front Cover 3.2.5 Touchscreen Operation ....................6

Read This Manual Thoroughly ........................IFC 3.2.6 Functionality ....................................6
Operation and Maintenance ............................IFC 3.2.7 Software Version Display ................7
How to Obtain Service ....................................IFC 3.3 On Screen Diagnostics ..................................8
Authorized Dealer Locator Number ....................IFC 3.3.1 Main Diagnostics Menu....................8
3.3.2 Digital Diagnostics ..........................8
3.3.3 Analog Diagnostics ..........................9
Safety Rules ........................................................2
3.3.4 Communications Diagnostics ........10
3.4 Alarms and Warnings ..................................10
Section 1 – General Information ..................4 3.5 Programmable Parameters ..........................10
1.1 Equipment Description ................................4 3.5.1 Transfer on Exercise......................10
1.2 Engine Protective Devices ..............................4 3.5.2 Preheat Enabled (If Applicable)......10
1.2.1 Coolant Temperature Sensor ..........4 3.5.3 Preheat Time..................................11
1.2.2 Low Coolant Level Sensor................4 3.5.4 Number of Start Attempts..............11
1.2.3 Oil Pressure Sensor ........................4 3.5.5 Crank Timer ..................................11
1.2.4 Overspeed Shutdown ......................4 3.5.6 Start Detection (RPM) ....................11
1.2.5 Overcrank Shutdown ......................4 3.5.7 Pause Between Cranks Time ..........11
1.2.6 RPM Sensor Loss Shutdown............4 3.5.8 Cool Down Time ............................11
1.3 DC Fuses ......................................................4 3.5.9 Warm Up Time ..............................11
1.4 Control System Components ........................4 3.5.10 Alarm Hold Off Time ....................11
1.4.1 AVR Power Module ..........................4 3.5.11 Load Accept Frequency ..................11
1.4.2 Throttle Actuator Module ................4 3.5.12 Load Accept Voltage ......................11
1.4.3 Battery Charger................................4 3.5.13 Low Voltage Limit ..........................11
3.5.14 High Voltage Limit..........................11
Section 2 – Installation....................................5 3.6 Target Frequency ........................................11
2.1 Field Wiring......................................................5 3.7 Target Voltage Setpoint ................................11
2.1.1 Connecting to the Generac 3.8 Programmable Alarms Setpoints ................11
Generator ..........................................5 3.9 Running Hours ............................................15
2.1.2 Utility Supply Connections 3.10 Exercise ......................................................15
(18.0L and 22.0L only) ......................5 3.11 Serial Communications ..............................15
3.11.1 GenLink® ......................................15
Section 3 – Operation ......................................5 3.12 Additional Panel Components ....................15
3.1 Control Console Components........................5 3.12.1 Alarm Horn....................................15
3.1.1 Off....................................................5 3.12.2 Emergency Stop Switch ................15
3.1.2 Manual ............................................5 3.12.3 Relay/Fuse Box ..............................15
3.1.3 Automatic ........................................5 3.12.4 Voltage Sensing Module ................15
3.2 The Optional Display ....................................6
3.2.1 Connection Details ..........................6 Section 4 – Notes ............................................16
3.2.2 Contrast Adjustment........................6
3.2.3 Calibration ......................................6 Section 5 – Warranty......................Back Cover
3.2.4 Cleaning ..........................................6

Generac® Power Systems, Inc. 1

 IMPORTANT SAFETY INSTRUCTIONS
PM-GC

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be
! followed during installation and maintenance of the generator and batteries. The manufac-
turer suggests that these rules for safe operation be copied and posted in potential hazard !
areas. Safety should be stressed to all operators and potential operators of this equipment.

! WARNING: ! ! GENERAL HAZARDS !

The engine exhaust from this product
contains chemicals known to the state • For safety reasons, Generac requires that the
of California to cause cancer, birth installation, initial start-up and maintenance of
defects or other reproductive harm. this equipment is carried out by a Generac
Authorized Dealer.
! WARNING: ! • The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
This product contains or emits chemicals breathed in sufficient concentrations, can cause
known to the state of California to cause unconsciousness or even death. This exhaust sys-
cancer, birth defects or other reproductive harm. tem must be installed properly, in strict compli-
ance with applicable codes and standards.
Study these SAFETY RULES carefully before Following installation, do nothing that might ren-
installing, operating or servicing this equipment. der the system unsafe or in noncompliance with
Become familiar with this Owner’s Manual and with such codes and standards.
the unit. The generator(s) can operate safely, effi- • Keep hands, feet, clothing, etc., away from drive
ciently and reliably only if it is properly installed, belts, fans, and other moving or hot parts. Never
operated and maintained. Many accidents are caused operate the unit with any drive belt or fan guard
by failing to follow simple and fundamental rules or removed.
precautions. • Adequate, unobstructed flow of cooling and venti-
Generac cannot anticipate every possible circum- lating air is critical to correct generator(s) opera-
stance that might involve a hazard. The warnings in tion. Do not alter the installation or allow even par-
this manual, and on tags and decals affixed to the tial blockage of ventilation provisions, as this can
unit are, therefore, not all-inclusive. If using a proce- seriously affect safe operation of the generator(s).
dure, work method or operating technique Generac • When working on this equipment, remain alert at
does not specifically recommend, ensure that it is all times. Never work on the equipment when
safe for others. Also make sure the procedure, work physically or mentally fatigued.
method or operating technique chosen does not ren- • Inspect the generator(s) regularly, and repair or
der the generator(s) unsafe. replace all damaged or defective parts immediate-
ly. Always use factory-authorized parts.
DANGER • Turn off the AC power to the battery charger before
disconnecting the battery to minimize the chance
Despite the safe design of this generator,
! operating this equipment imprudently, neglect-
of equipment damage.
ing its maintenance or being careless can cause • Before performing any maintenance on the genera-
possible injury or death. Only responsible and tor(s), disconnect its battery cables to prevent acci-
capable persons are to operate or maintain this dental start-up. Remove control panel fuse, then
equipment. disconnect the cable from the battery post indicat-
ed by a NEGATIVE, NEG or (–) first. Reconnect
Potentially lethal voltages are generated by that cable last, then reinstall control panel fuse.
these machines. Ensure all steps are taken to • Never use the generator(s) or any of its parts as a
render the machine safe before attempting to step. Stepping on the unit can stress and break
work on the generator(s). parts, and may result in dangerous operating con-
Parts of the generator(s) are rotating and/or ditions from leaking exhaust gases, fuel leakage,
! hot during operation. Exercise care near run- oil leakage, etc.
ning generators.

2 Generac® Power Systems, Inc.

 IMPORTANT SAFETY INSTRUCTIONS
PM-GC

ELECTRICAL HAZARDS FIRE HAZARDS

• All generators covered by this manual produce • For fire safety, the generator(s) must be installed
dangerous electrical voltages and can cause fatal and maintained properly. Installation always must
electrical shock. Utility power delivers extremely comply with applicable codes, standards, laws and
high and dangerous voltages to the transfer switch regulations. Adhere strictly to local, state and
as does the standby generator(s) when it is in national electrical and building codes. Comply
operation. Avoid contact with bare wires, termi- with regulations the Occupational Safety and
nals, connections, etc., while the unit is running. Health Administration (OSHA) has established.
Ensure all appropriate covers, guards and barriers Also, ensure that the generator(s) is installed in
are in place before operating the generator(s). If accordance with the manufacturer’s instructions
working around an operating unit, stand on an and recommendations. Following proper installa-
insulated, dry surface to reduce shock hazard. tion, do nothing that might alter a safe installation
• Do not handle any kind of electrical device while and render the unit in noncompliance with the
standing in water, while barefoot, or while hands aforementioned codes, standards, laws and regu-
or feet are wet. DANGEROUS ELECTRICAL lations.
SHOCK MAY RESULT. • Keep a fire extinguisher near the generator(s) at all
• The National Electrical Code (NEC) requires the times. Extinguishers rated “ABC” by the National
frame and external electrically conductive parts of Fire Protection Association are appropriate for use
the generator(s) to be connected to an approved on the standby electric system. Keep the extin-
earth ground and/or grounding rods. Local electri- guisher properly charged and be familiar with its
cal codes also may require proper grounding of the use. If there are any questions pertaining to fire
generator(s) electrical system. extinguishers, consult the local fire department.
• After installing this standby electrical system, the
generator(s) may crank and start at any time with-
out warning. When this occurs, load circuits are EXPLOSION HAZARDS
transferred to the STANDBY (GENERATOR) power
source. To prevent possible injury if such a start • Do not smoke around the generator(s). Wipe up
and transfer occur, always set the generator’s any fuel or oil spills immediately. Ensure that no
AUTO/OFF/MANUAL switch to its OFF position combustible materials are left in the generator(s)
before working on equipment and remove the 15A compartment, or on or near the generator(s), as
fuse in front panel. FIRE or EXPLOSION may result. Keep the area
• In case of accident caused by electric shock, imme- surrounding the generator(s) clean and free from
diately shut down the source of electrical power. If debris.
this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting imple-
ment, such as a rope or board, to free the victim
from the live conductor. If the victim is uncon-
scious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.

Generac® Power Systems, Inc. 3

 Section 1 — General Information
PM-GC

1.1 EQUIPMENT DESCRIPTION ◆ 1.2.4 OVERSPEED SHUTDOWN

In a typical standby system, a power outage will be The control system monitors engine speed during
sensed by a transfer switch. A time delay is usually engine cranking, start-up, operation and shutdown.
incorporated in this signal in order to prevent nui- Engine speed signals are delivered to the control sys-
sance tripping of the power system. After the time tem whenever the unit is running. If the engine speed
delay has been met, the transfer equipment will send exceeds a safe, preset value, the system automatical-
a start signal to the generator. Once the generator is ly shuts down the engine.
up to speed and it's voltage and frequency are stable,
the transfer switch will automatically disconnect from
the utility bus and transfer the load to the generator ◆ 1.2.5 OVERCRANK SHUTDOWN
(emergency) bus. When the utility supply returns, the After a pre-specified duration of cranking, this func-
load is transferred back to the utility bus after a pre- tion ends the cranking if the engine has failed to start.
set user selectable time. The generator will then begin
a "cool-down" cycle and shutdown. ◆ 1.2.6 RPM SENSOR LOSS SHUTDOWN
If the speed signal to the control panel is lost, engine
1.2 ENGINE PROTECTIVE DEVICES shutdown will occur.
The standby generator may be required to operate for
long periods of time without an operator on hand to
monitor such engine conditions as coolant tempera- 1.3 DC FUSES
ture, oil pressure or rpm. For that reason, the engine The fuses are located on the inside of the relay box.
has several devices designed to protect it against They protect the panel wiring and components from
potentially damaging conditions by automatically damaging overload. If a fuse is missing or damaged,
shutting down the unit when the oil pressure is too the power module may not start or crank. The fuses
low, the coolant temperature is too high, the coolant must be replaced with fuses of the same size, type,
level is too low, or the engine is running too fast. and rating as originally provided by Generac.

NOTE:
1.4 CONTROL SYSTEM COMPONENTS
Engine protective switches and sensors are men-
tioned here for the reader's convenience. Refer to ◆ 1.4.1 AVR POWER MODULE
the control panel paragraphs for additional auto-
The AVR power module houses the power electronics
matic engine shutdown information.
that drive the field of the alternator. The PM-GC actu-
ally controls the field and the AVR module converts
◆ 1.2.1 COOLANT TEMPERATURE SENSOR the PM-GC output signals to required power levels.
The coolant temperature is monitored by the control The AVR module controls the output voltage and
panel. If coolant temperature rises above a safe, pre- voltage stability of the generator. The Dynamic
set level the control system automatically shuts down response of these parameters can only be adjusted
the engine. via Genlink with the correct security password. Each
engine has its own AVR module.
◆ 1.2.2 LOW COOLANT LEVEL SENSOR
‹ 1.4.2 THROTTLE ACTUATOR MODULE
If the engine coolant level drops below a safe level, it
is possible for the engine to overheat without auto- The Throttle Actuator Module houses the power elec-
matic shutdown. To prevent such overheating, the tronics that drive the throttle actuator. Again, the PM-
engine has a low coolant level sensor. If the level of GC actually controls the throttle actuator and the
engine coolant drops below the level of the low Throttle Actuator Module converts the PM-GC output
coolant level sensor, the control system automatical- signals to required power levels. This module con-
ly shuts down the engine. trols the engine speed and stability, nominally set at
60 hertz. The speed and dynamic response of these
◆ 1.2.3 OIL PRESSURE SENSOR parameters can be adjusted via Genlink. However,
the dynamic response parameters are protected by
The control system monitors engine oil pressure dur- security password.
ing operation. If oil pressure drops below a safe level,
the system automatically shuts down the engine.
‹ 1.4.3 BATTERY CHARGER
The engine is provided with a Generac battery charg-
er. The battery charger must be wired by the cus-
tomer to a separate 120 VAC standard utility supply.

4 Generac® Power Systems, Inc.

 Section 2 — Installation
PM-GC

2.1 FIELD WIRING 3.1 CONTROL CONSOLE

COMPONENTS
The PM-GC control module performs all of the gen-
Wiring must comply with ALL local and nation- erator control functions within the system. It controls
! al codes. Only qualified personnel knowledge- engine starting and stopping, engine speed, output
able of these local and national codes should voltage and frequency, and monitors engine perform-
perform any wiring to and from the generator. ance. It can communicate with remote devices via
communication ports. See Figure 1 for a view of the
◆ 2.1.1 CONNECTING TO THE GENERAC operator panel.
GENERATOR The operator panel of the unit acts as the interface to
Connecting to the generator is achieved by connecting the user. By means of an optional backlit ¼ VGA
directly to the main line circuit breaker. The connec- touchscreen display, the user can examine data mon-
tors are capable of accepting conductors ranging itored by the unit. The keyswitch can be used to start
from 350 MCM to 6 AWG. Check all national and and stop the genset. The keyswitch allows the unit to
local codes for proper conductor sizing. The connec- be put into one of three modes.
tor part number and tightening torque are as follows:
Part Number Tightening Torque Wire Range ◆ 3.1.1 OFF
057329 (1-2) 375 in - lb (Al/Cu) 350 MCM - 1 AWG In this mode, the generator will not start.
(1-2) 200 in - lb (Al/Cu) 2 AWG - 6 AWG
◆ 3.1.2 MANUAL
◆ 2.1.2 UTILITY SUPPLY CONNECTIONS (18.0 L In manual mode, the generator will start immediately.
AND 22.0 L ONLY) Manual mode is for limited testing of the unit.
The utility supply connections for the block heater,
battery charger, and any other option is located in the ◆ 3.1.3 AUTOMATIC
AC breaker distribution panel near the back of the Automatic is the normal mode of operation.
generator. Depending on the current rating of the ter-
minal block used, the connector tightening torque The unit will start when the remote start contacts are
values and the acceptable wire ranges are listed as closed.
follows:
Figure 1 — Operator Panel
Connector Tightening Acceptable
Current Rating Torque Wire Range
30 Amp Connectors 5.5 lb.-in. (0.6 Nm) (1-2) 24-10 AWG (CU)
50 Amp Connectors 10.6 lb.-in. (1.2 Nm) (1-2) 22-8 AWG (CU)
65 Amp Connectors 18.0 lb.-in. (2.0 Nm) (1-2) 20-6 AWG (CU)

NOTE:
The current ratings are located directly on the cir-
cuit breaker. The above information is rated for
UL acceptance.

Remove fuses from the battery charger before

! connecting starting batteries. Connect battery,
then replace charger fuses.

Generac® Power Systems, Inc. 5

 Section 3 — Operation
PM-GC

3.2 THE OPTIONAL DISPLAY EITHER

The optional, programmable, remote display can be 1. Switch on the power to the unit.
mounted up to 1000 meters away from the generator. 2. During the initialization phase, a menu will
Only one display per generator is allowed. The dis- appear briefly. Press the CONFIG button.
play has an IP65 front panel with an IP20 rating for 3. Now use the CONTRAST + and - keys to adjust
the rest of the housing. This means that the rear of contrast.
the panel must be protected if it is to be used outside. OR
Normally, it would be mounted to the face of a sealed
enclosure with the supplied screw type clamps. The 1. During normal operation, select the MAINTE-
panel thickness should be <=6mm and the mount- NANCE screen and then use the contrast + and -
ing torque should be <=0.5Nm. The angle of inclina- buttons to adjust the contrast.
tion must be less than 35 degrees from vertical.
‹ 3.2.3 CALIBRATION
Connections to the unit can be made via a single
screened multicore cable and one 9 way D type male As the unit can be mounted at different angles, there
connector, or, via separate signal and power connec- may be calibration required to compensate for paral-
tors(supplied). The second option is recommended lax errors.
for distances of >75m. EITHER
The display is independently programmable and
1. Switch on the power to the unit.
could be customized to display different data from
the same product without altering the PM-GC soft- 2. During the initialization phase, a menu will
ware. Currently, there are three versions of display appear briefly. Press the CONFIG button.
software, one for MPS (SC and IC), one for engine 3. Now use the CALIBRATE button to calibrate the
controllers (PM-PC and PM-GC) then finally one ver- screen
sion for bifuelled engines. 4. Five calibration crosses appear in succession on
the screen, touch them as they appear.
‹ 3.2.1 CONNECTION DETAILS 5. Once this is done, touch the screen within 30 sec-
onds at any position to "accept" the calibration. If
DISPLAY PIN CONNECTION CONTROLLER PIN not completed within 30 seconds, calibration will
1 - - revert to original.
2 - - OR
3 RS485- J1 - 21 1. During normal operation, select the MAINTE-
4 - - NANCE screen and then the "Calibrate
5 - - Touchscreen" button.
6 - - 2. Follow steps 4 and 5 above.
7 - -
8 RS485+ J1 - 20 ‹ 3.2.4 CLEANING
9 - - As a result of normal operation the screen will
TERMINAL CONNECTION WIRE become dirty and should be cleaned with a soft cloth.
+24VDC 24VDC 220C In order to prevent operating the touchscreen during
OV OVDC 0 this time, select the MAINTENANCE page and choose
GROUND 0 the "Clean Screen" option.

The power supply should be in the range 18-30VDC ‹ 3.2.5 TOUCHSCREEN OPERATION
at 0.4A. This is normally supplied from the con-
troller. J1 pin 11 is Ground and pin 12 is +24VDC. Operate the touch screen with a finger only, do not
The case earth screw should be connected to an earth use pens or other pointed objects.
point in the enclosure via a 2.5mm diameter wire.
‹ 3.2.6 FUNCTIONALITY
The multicore cable should have 24AWG cores for
distances up to 75 meters. Above this, 18AWG The display screen has been devised as a way to
should be used. examine data within the PM-GC. Changes to settings
cannot be made from this screen, this can only be
‹ 3.2.2 CONTRAST ADJUSTMENT done via Genlink. Data has been divided into groups
and each group is shown as a button on the menu
Contrast may need to be adjusted depending on the screen. Touching the button will access the main
incident lighting conditions. screen for the group. Some groups, such as diagnos-
tics, may also have sub screens associated with them.
6 Generac® Power Systems, Inc.
 Section 3 — Operation
PM-GC

Each screen has some fixed buttons which allow Figure 5 — Typical Menu Screen
either access to help text for that screen (context sen-
sitive help) (Figure 2), or return to the main menu Touch here for engine parameters. (Also see Figure 6.)
(Figure 3).
Figure 2 — Help Key

Figure 3 — Return to Main Menu Key

Figure 6 — Typical Parameter Screen - Engine

Prameters

‹ 3.2.7 SOFTWARE VERSION DISPLAY

Help Key
The software version number for the PM-GC, and the
version number for the display software, are located
on the status page which is accessed via the "SYS-
TEM STATUS" touch button. This should always be
referred to when requesting help or service from
Generac and it's dealers.
Figure 4 — System Status Screen • ENGINE PARAMETERS: Temperatures, pressures,
rpm, etc.
• GENERATOR PARAMETERS: Voltages, frequency,
power, etc.
• UTILITY PARAMETERS: Voltages, frequency,
power, etc.
• CURRENT ALARMS: Displays any current alarms/
warnings
• SYSTEM STATUS: Displays what the system is
currently doing
• SPARE CHANNELS: Shows the measurements
taken on some spare channels
• SYNCHROSCOPE: Shows the synchroscope (active
in PM-PC only)
PM-PC software version v1.00 • TRANSFER SWITCH: A mimic diagram of the
LOCAL contactor (not the main transfer switch,
active in PM-PC only)
Software Version Numbers • DIAGNOSTICS: Diagnostic options are displayed
here.
Generac® Power Systems, Inc. 7
 Section 3 — Operation
PM-GC

• MAINTENANCE SCHEDULE: A display of percent- ‹ 3.3.1 MAIN DIAGNOSTICS MENU

age remaining before maintenance is required.
See Figure 8.
Figure 7 — TYPICAL HELP SCREEN - ANALOG
HELP ‹ 3.3.2 DIGITAL DIAGNOSTICS
Inputs to the controller are internally pulled to 5VDC,
so to activate an input, short it to ground. This will be
seen as a '1' (meaning active) on the diagnostic screen.
To test equipment that is connected to a digital input,
such as a digital sensor, first display the diagnostics
menu shown above, then operate the sensor or short it
out. Only one of the inputs should change to a '1'.
Inputs are numbered 1-32 to correspond with the cir-
cuit diagram. Refer to this diagram to see that the cor-
rect input has operated.
Outputs from the controller are generally open col-
lector, meaning that they sink current through a load
and will NOT change any voltage on them when they
are activated, unless they are connected to a load.
The main diagnostics display shows the current state
Return to Last Screen of the outputs which will change as the normal con-
trol program is still running. For example, if the
engine cranks while viewing this page, some outputs
3.3 ON SCREEN DIAGNOSTICS will turn on. Note that the update rate for the screen
Generac provides diagnostics through both the front is only about one to two seconds, so any fast chang-
panel display and remotely through Genlink. The fol- ing outputs will not be seen. The state of an output
lowing text refers exclusively to the front panel dis- can be overridden for a limited time with the
play. “Operate” button. First, select which output to oper-
The main diagnostic screen allows access to the sub ate with the aid of the circuit diagram (outputs 1-32),
screens and also acts as the diagnostic screen for dig- then press the operate button to turn it on or off for
ital I/O. All of the raw unprocessed digital inputs are three seconds. Use this feature to test things like the
displayed on this screen. Any digital output can be crank relay, etc.
overridden on this screen.

Figure 8 — Main Diagnostics Menu

The state of the digital

inputs (1=Active). Access to analog
diagnostics.

The state of the digital Access to communications

outputs (1=Active). diagnostics.

Output channel to test Used to reprogram the

(via operate button). display.

Select output channel Operate (override) output

to override. for three seconds.
8 Generac® Power Systems, Inc.
 Section 3 — Operation
PM-GC

‹ 3.3.3 ANALOG DIAGNOSTICS CHANNEL FUNCTION

1 Utility current sense A
By selecting the analog submenu, the sensors con-
nected to each of the analog channels can be interro- 2 Utility current sense B
gated (Figure 9). The reading displayed is "raw" un- 3 Utility current sense C
processed data and is a decimal number ranging 4 Generator current sense A
from 0 - 1023 representing a voltage on the input
5 Generator current sense B
channel of the 10 bit ADC. Some channels have dif-
ferent scaling associated with them in hardware. The 6 Generator current sense C
channels are numbered and scaled as shown below: 7 Utility voltage sense A
8 Utility voltage sense B
Figure 9 — Analog Diagnostics Menu
9 Utility voltage sense C
10 Generator voltage sense A
11 Generator voltage sense B
12 Generator voltage sense C
13 4 - 20ma User config. channel 1
14 4 - 20ma User config. channel 2
15 4 - 20ma User config. channel 3
16 4 - 20ma User config. channel 4
17 4 - 20ma User config. channel 5
18 4 - 20ma User config. channel 6
19 4 - 20ma User config. channel 7
20 4 - 20ma User config. channel 8
21 4 - 20ma User config. channel 9
22 4 - 20ma User config. channel 10
Use the analog help button (or GenLink) to show
which user configurable channels are connected to 23 4 - 20ma User config. channel 11
which sensors. 24 4 - 20ma User config. channel 12
25 4 - 20ma User config. channel 13
26 4 - 20ma User config. channel 14
27 4 - 20ma User config. channel 15
28 4 - 20ma User config. channel 16
29 4 - 20ma User config. channel 17
30 BATTERY GROUND
31 BATTERY +
32 Internal +12 VDC supply
33 Internal +5VDC supply
34 Internal -12VDC supply
35 Internal +24VDC supply
36 Internal +2.6VDC supply
37 Internal +10VDC supply
38 -
39 GROUND
40 GROUND
41 VDC reference low
42 VDC reference High

Generac® Power Systems, Inc. 9

 Section 3 — Operation
PM-GC

‹ 3.3.4 COMMUNICATIONS DIAGNOSTICS goes away AND the alarm has been acknowledged.
For shutdown alarms, the alarm cannot be cleared
After a port has been selected to test (press the help unless the keyswitch is in the OFF position (the audi-
button for a description of the ports), the pseudo ble alarm can be silenced though).
LED's will show if data is being transmitted to the
port and/or received from the port. In the case of When a warning occurs, the display will automatical-
ports with protocols such as Modbus, the error LED ly switch to the "current alarm" page where it will be
will light if the messages are corrupt. The status lines displayed in the list of current alarms. The audible
will also show diagnostic messages to help solve any alarm will sound. When the warning condition goes
communication problems (Figure 10). away, the message will disappear and the audible
alarm will turn off.
• LINE 1: shows the type of port protocol that has
been selected. If this is incorrect, it can be changed Genlink duplicates the "alarm acknowledge " button
from the Genlink configuration menu. on it's display, and can also clear the alarm inde-
pendently of the keyswitch position by using the
• LINE 2: shows the settings for the port (for exam-
"Reset" button. This Feature allows geographically
ple, baud rate, bits per character, stop bits and
remote systems to be re-started without human inter-
parity). Again, this can be changed via Genlink.
vention to turn the keyswitch.
• LINE 3: shows any error information available (for
example, modbus address errors). The latched warning function can be mimicked by
selecting a non shutdown alarm.
Figure 10 — Communications Diagnostics All alarms and warnings will be entered in the alarm
log (see the Genlink or technical manual for details
These LED’s light if data is transmitted,
about the alarm log). Individual channels alarms or
Select which port to received, or an error occurs.
warnings can both utilize the dialout function. The
test (0-3)
Dialout feature can inform a remote PC of a fault con-
dition. Each alarm can be configured to be a shut-
down alarm or not.
There are further conditions imposed when an
alarm/warning can become active, details of these are
described in the technical manual for the PM-DCP
Status system or via Genlink on line help. Generally, these
messages incorporate timers, engine run status, etc.

3.5 PROGRAMMABLE PARAMETERS

The PM-GC allows the user to configure various
options to control the generator starting and stopping
cycles and operating settings for the generator.
3.4 ALARMS AND WARNINGS Parameters can be changed only via Genlink, and this
The PM-GC has a built-in alarm system to alert serv- is limited to parameters that have no security protec-
ice personnel of operational conditions which require tion. A description of these programmable parame-
attention. Only alarms (not warnings) can shut down ters follows.
the engine. The alarm and warning conditions are set
via Genlink, which can also change the actions that ‹ 3.5.1
are taken when an alarm/warning occurs.
TRANSFER ON EXERCISE
This parameter is currently not used.
When a new alarm occurs, the display will automati-
cally switch to the "current alarm" page where it will
be displayed in the list of current alarms. If the alarm ‹ 3.5.2 PREHEAT ENABLED (IF APPLICABLE)
is a shutdown alarm, "shutdown" will also be dis- This parameter determines how the preheat function
played alongside the alarm. All alarms will also dis- works. The preheat can be fully disabled, enabled
play the " * " symbol if they are unacknowledged (this before starting only (for the duration of the preheat
also means that the audible alarm is sounding and time), or before and during starting (for the duration
the alarm LED will be flashing to indicate a new of the preheat time and also while the starter is
alarm). When the alarm acknowledge button is engaged). If the user wants to engage the preheat dur-
pressed, the audible alarm will be silenced and the ing starting but not before it is possible to set the pre-
LED will stop flashing, it will remain lit if the alarm heat time to zero.
condition is still present. The alarm message and lit
LED will only disappear when the alarm condition
10 Generac® Power Systems, Inc.
 Section 3 — Operation
PM-GC

‹ 3.5.3 PREHEAT TIME ‹ 3.5.9 WARM UP TIME

When a start command is received, the engine may Some applications require that the generator run for
require preheating before the generator attempts to a given time before a load is applied. This parameter
start. If the preheat function is enabled, this parame- allows the user to set that time. Normally, it will be
ter allows the user to determine the time that the pre- set to zero seconds. The generator is ready to accept
heat contact closes before activating the starter sole- load when this timer expires.
noid.
‹ 3.5.10 ALARM HOLD OFF TIME
‹ 3.5.4 NUMBER OF START ATTEMPTS Once the engine has started, some alarm functions
This parameter will determine how many times the (such as low oil pressure and under speed) are not
engine will crank in an attempt to start the engine. activated immediately since the engine must be given
For example, if it is set to two (2), the engine will time to reach a stable condition. This parameter
crank two (2) times with a pause in between each determines the time that elapses before the hold off
crank cycle. If it fails to start, an overcrank alarm will alarms are activated.
be displayed.
‹ 3.5.11 LOAD ACCEPT FREQUENCY
‹ 3.5.5 CRANK TIMER This is the minimum frequency the generator must
Once a start command has been received and the reach before the system will accept load.
preheat time has expired (if enabled), the starter
solenoid will be engaged. This parameter allows the ‹ 3.5.12 LOAD ACCEPT VOLTAGE
user to determine how long the starter solenoid is
engaged before the start attempt is regarded as hav- This is the minimum voltage the generator must
ing failed. If the generator does not start within this reach before the system will accept load.
time, the generator will wait for a preset time before
attempting to start again. The user also can program ‹ 3.5.13 LOW VOLTAGE LIMIT
the number of start attempts.
This parameter normally sets the tolerance limits for
utility voltage in a single standby system.
‹ 3.5.6 START DETECTION (RPM)
This is the speed at which the engine should be self ‹ 3.5.14 HIGH VOLTAGE LIMIT
sustaining and the point at which the starter disen-
gages. It is changeable by the user and is normally set This parameter normally sets the tolerance limits for
to 500 rpm. utility voltage in a single standby system.

‹ 3.5.7 PAUSE BETWEEN CRANKS TIME 3.6 TARGET FREQUENCY

This parameter sets the nominal output frequency.
If the generator does not start within the pro-
grammed start time, it will pause before trying to
start again. This parameter determines the length of 3.7 TARGET VOLTAGE SETPOINT
that pause. This parameter sets the nominal output AC voltage.

‹ 3.5.8 COOL DOWN TIME 3.8 PROGRAMMABLE ALARMS

This parameter determines the length of time that the SETPOINTS
generator continues to run after a stop command is The following table shows a typical default setup for
sent in AUTO mode in order to cool down the engine alarms, the settings are protected from editing by a
with no load. security system involving one time passwords, con-
tact Generac for details and advice if these settings
NOTE: need to be changed.
If the key-switch is turned to the OFF position
when the generator is running, it will stop imme-
diately regardless of this setting.

Generac® Power Systems, Inc. 11

 Section 3 — Operation
PM-GC

High Oil Temperature (Deg. F) Warning Alarm Units Comment

Setpoint
Shutdown N Y
Dialout N Y
Common alarm Y Y
Alarm log N Y
Sensor failure detection Y Y
Shutdown on sensor failure Y Y
Delay 0 0 seconds
Active Hold of Hold off
Hysteresis 2 2 Deg. F

High Coolant Temperature (Deg. F)

Setpoint
Shutdown N Y
Dialout N Y
Common alarm Y Y
Alarm log N Y
Sensor failure detection Y Y
Shutdown on sensor failure Y Y
Delay 0 0 seconds
Active Hold off Hold off
Hysteresis 2 2 Deg. F

Low Coolant Temperature (Deg. F)

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log N
Sensor failure detection Y
Shutdown on sensor failure Y
Delay 0 seconds
Active Hold off
Hysteresis 2 2 Deg. F

Low Oil Pressure (psi)

Setpoint
Shutdown N Y
Dialout N Y
Common alarm Y Y
Alarm log N Y
Sensor failure detection Y Y
Shutdown on sensor failure Y Y
Delay 0 0 seconds
Active Hold off Hold off
Hysteresis 3 3 PSI

Low Coolant Level

Setpoint
Shutdown Y
Dialout Y
Common alarm Y
Alarm log Y
Sensor failure detection Y
Shutdown on sensor failure Y
Delay 0
Active Always
Hysteresis 30
12 Generac® Power Systems, Inc.
 Section 3 — Operation
PM-GC

Low Battery Voltage (1/100ths volt) Warning Alarm Units Comment

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 60 seconds seconds
Active Hold off
Hysteresis 200 1/100ths volt

High Battery voltage (1/100ths volt)

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 0 seconds
Active Hold off
Hysteresis 200 1/100ths volt

High Gen. Voltage A,B,C (Volts RMS)

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log Y
Sensor failure detection N
Shutdown on sensor failure N
Delay 0.5 seconds seconds
Active Hold off
Hysteresis 10 Vrms

Low Gen. Voltage A,B,C (Volts RMS)

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log Y
Sensor failure detection N
Shutdown on sensor failure N
Delay 0.5 seconds seconds
Active Hold off
Hysteresis 10 Vrms

Over Speed (rpm)

Setpoint
Shutdown Y
Dialout Y
Common alarm Y
Alarm log Y
Sensor failure detection Y
Shutdown on sensor failure Y
Delay 0.1 seconds seconds
Active Immediate
Hysteresis 20 RPM
Generac® Power Systems, Inc. 13
 Section 3 — Operation
PM-GC

Under Speed (rpm) Warning Alarm Units Comment

Setpoint
Shutdown N
Dialout N
Common alarm Y
Alarm log N
Sensor failure detection Y
Shutdown on sensor failure Y
Delay 0.5 seconds seconds
Active Hold off
Hysteresis 20 RPM

Over Frequency (1/10ths Hz)

Setpoint 1/10ths Hz
Shutdown Y
Dialout Y
Common alarm Y
Alarm log Y
Sensor failure detection N
Shutdown on sensor failure N
Delay 0.2 seconds seconds
Active Hold off
Hysteresis 5 1/10ths Hz

Under Frequency (1/10ths Hz)

Setpoint 1/10ths Hz
Shutdown N
Dialout N
Common alarm Y
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 0.5 seconds seconds
Active Hold off
Hysteresis 5 1/10ths Hz

High Fuel level (%) Warning Alarm Units Disabled unless probe fitted
Setpoint %
Shutdown N
Dialout N
Common alarm N
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 2 seconds seconds
Active Always
Hysteresis 2 %\

Low Fuel level (%) Warning Alarm Units Disabled unless probe fitted
Setpoint %
Shutdown N
Dialout N
Common alarm N
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 2 seconds seconds
Active Always
Hysteresis 2 %
14 Generac® Power Systems, Inc.
 Section 3 — Operation
PM-GC

Critical Low Fuel level (%) Warning Alarm Units Disabled unless probe fitted
Setpoint %
Shutdown N
Dialout N
Common alarm N
Alarm log N
Sensor failure detection N
Shutdown on sensor failure N
Delay 2 seconds seconds
Active Always
Hysteresis 2 %

3.9 RUNNING HOURS communications will normally be via the GenLink®

The PM-GC keeps track of how many hours the connection port situated on the relay box. The ver-
engine has been running. This is displayed in hours sion of Genlink that works with PM-GC systems is
and tenths of hours. Any run of less than six minutes not the same as older versions of Genlink, It is called
duration will not be recorded. This parameter is for “GENLINK - DCP”.
display only.
3.12 ADDITIONAL PANEL
3.10 EXERCISE COMPONENTS
The generator should be programmed to exercise via In addition to the control module, the PM-GC con-
the remote start contact or, the PLC function. tains the following components (see Figure 9):

3.11 SERIAL COMMUNICATIONS ‹ 3.12.1 ALARM HORN

The control panel has two RS232 and two RS485 This horn sounds an audible warning when an alarm
communication ports. In the MPS system, one RS485 condition exists. See the "Alarms" section for further
port is used to communicate to the PowerManager. information.
For a PM-GC controller, the ports are normally con-
figured as follows:
‹ 3.12.2 EMERGENCY STOP SWITCH
**1 x RS485 — Spare - can be connected to remote
annunciator(s) or relay panel(s). When pressed, this switch will automatically shut
down the entire generator set. The operator must
1 x RS485 — Touchscreen display twist the switch to pop out to its original position to
1 x RS232 — GenLink® (modbus slave) reset it and allow for generator operation.
*1 x RS232 — Deep diagnostics
‹ 3.12.3 RELAY/FUSE BOX
* This port can be reconfigured to be a modbus slave
if required. An external RS232/485 converter is The relay box houses all slave relays for engine com-
available. ponents (for example, starter relay, run relay, pre-
**This port can be configured as a modbus slave heat relay, etc.). The DC panel fuses are also mount-
RS485 port for connection to external devices. ed inside this box.
Multiple annunciators can be connected to the same
port, but they will all annunciate the same thing - ‹ 3.12.4 VOLTAGE SENSING MODULE
either communal results or individual results. This circuit monitors the three-phase alternator out-
Apart from the display port, communications are put voltages. These high voltages (480, 208 etc.) at
done via Modbus RTU protocol. the input to the circuits, are electronically condi-
tioned to produce low voltage outputs (typically 5v
‹ 3.11.1 GENLINK® rms) which are proportional to the alternator and
bus voltages. The outputs are used by the PM-GC
The control panel can communicate with GenLink® control module to determine the phase and ampli-
which is a PC based program allowing both the inter- tude of the source.
rogation of the generator and remote programming of
its parameters. The user will be able to start and stop
the generator if it is in AUTO mode. GenLink®
Generac® Power Systems, Inc. 15
 Section 4 — Notes
PM-GC

16 Generac® Power Systems, Inc.

Section 4 — Notes
PM-GC

Generac® Power Systems, Inc. 17

 Section 5 — Warranty
PM-GC

GENERAC POWER SYSTEMS STANDARD TWO-YEAR LIMITED WARRANTY

FOR GENERAC TRANSFER SWITCH SYSTEMS
NOTE: ALL UNITS MUST HAVE A START-UP INSPECTION PERFORMED BY AN AUTHORIZED GENERAC DEALER.
For a period of 2 (two) years from the date of sale/start date, Generac Power Systems, Inc. will, at its option, repair or
replace any part(s) which, upon examination, inspection, and testing by Generac Power Systems or a Generac Power
Systems Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with
the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must examined by
the nearest Generac Power Systems Authorized Warranty Service Facility. All transportation costs under the warranty,
including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to
Generac Power Systems Transfer Switch applications, as Generac Power Systems, Inc. have defined Transfer Switch
applications. A scheduled maintenance agreement with a local Authorized Generac Power Systems Dealer is highly recom-
mended to verify adequate service has been performed on the unit throughout the warranty period.

WARRANTY SCHEDULE
• YEAR ONE — 100% (one hundred percent) coverage on mileage*, labor, and parts listed.
• ALL COMPONENTS
• YEAR TWO — 100% (one hundred percent) coverage on parts listed.
• ALL COMPONENTS — *PARTS ONLY
• *Travel allowance is limited to 300 miles maximum, or 7.5 hours maximum (per occurrence), round trip, to the nearest
authorized Generac Service Facility.
• A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a
non Generac genset is substituted for use and directly causes damage to the Generac Transfer Switch, no warranty
coverage shall apply.
• All warranty expense allowances are subject to the conditions defined in Generac Power Systems Warranty, Policies, and
Procedures Flat Rate Manual.
• Units that have been resold are not covered under the Generac Power Systems Warranty, as this Warranty is not transferable.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
1. Unit enclosure is only covered against rust or corrosion the first year of the warranty provision.
2. Use of Non-Generac replacement part(s) will void the warranty in its entirety.
3. Failures due, but not limited to, normal wear and tear, accident, misuse, abuse, negligence, or improper installation or
sizing.
4. Failures caused by any external cause or act of God such as collision, fire, theft, freezing, vandalism, riot or wars, lightning,
earthquake, windstorm, hail, volcanic eruption, water or flood, tornado, hurricane, terrorist acts or nuclear holocaust.
5. Products that are modified or altered in a manner not authorized by Generac Power Systems in writing.
6. Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in
repair or replacement of the defective part(s).
7. Failure due to misapplication, misrepresentation, or bi-fuel conversion.
8. Telephone, facsimile, cell phone, satellite, internet, or other communication expenses.
9. Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific
unit warranty period.
10. Rental equipment used while warranty repairs are being performed i.e. rental generators, cranes, etc..
11. Overtime labor or more than one person performing repairs.
12. Any and all expenses incurred investigating performance complaints unless defective Generac materials and or work-
manship were the direct cause of the problem.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, SPECIFICALLY, GENERAC
POWER SYSTEMS MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICU-
LAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may
not apply to you.
GENERAC POWER SYSTEMS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED
ABOVE. IN NO EVENT SHALL GENERAC POWER SYSTEMS BE LIABLE FOR ANY INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC POWER SYSTEMS, INC. NEGLIGENCE.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may
not apply to you. Purchaser/owner agrees to make no claims against Generac Power Systems, Inc. based on negligence.
This warranty gives you specific legal rights. You also may have other rights that vary from state to state.
GENERAC® POWER SYSTEMS, INC. • P.O. BOX 8 • WAUKESHA, WI 53187
PH: (262) 544-4811 • FAX: (262) 544-4851
Bulletin 0166260SBY / Printed in USA 1.04

Part No. 0F0545 Revision 0 (03/26/04) Printed in U.S.A.