Generac Power Systems Power Zone 410 Owner's Manual
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Generac Power Systems Power Zone 410 Owner's Manual

Generac Power Systems Power Zone 410 Owner's Manual

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Owner's Manual
Power Zone 410® Controller
AUXILIARY SHUTDOWN
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Summary of Contents for Generac Power Systems Power Zone 410

  • Page 1 Owner’s Manual Power Zone 410® Controller AUXILIARY SHUTDOWN SAVE THIS MANUAL FOR FUTURE REFERENCE...
  • Page 2 This product can expose you to chemicals including 1,3–butadiene, a carcinogen and reproductive toxicant, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to: www.p65warnings.ca.gov (W000809) Power Zone 410 ® Controller Owner’s Manual...

  • Page 3: Table Of Contents

    Standard Protections..........9 Section 4: Internal Alarms/Warnings Display..............9 Control Panel ............10 Alarm Displays and Descriptions...... 29 Voltage Regulation (Single or Three-Phase Mod- Power Zone 410 Service Tool .........39 ule Options)............10 Communication Ports..........10 Section 5: Ground Fault Indication (If Qualification Testing..........10 Equipped) Connections ‡...
  • Page 4 This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...

  • Page 5: Section 1: Introduction And Safety

    Introduction hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows: Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high per- DANGER formance, efficient operation, and years of use when maintained correctly.

  • Page 6: General Hazards

    (C000229) (W000101) WARNING Vision loss.Eye protection is required when servicing unit.Failure to do so could result in vision loss or serious injury. (W000377) Power Zone 410 ® Controller Owner’s Manual...

  • Page 7: Fire And Explosion Hazards

    (D000152) WARNING Electrical shock. Disconnect battery ground terminal before working on battery or battery wires.Failure to do so could result in death or serious injury. (W000164) Power Zone 410 ® Controller Owner’s Manual...
  • Page 8 Introduction and Safety This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...

  • Page 9: Section 2: General Information

    Section 2: General Information Introduction • Emergency Stop • On/Off Manual Switch The Power Zone 410 Control Panel is an electronic con- • Not in Auto Flashing Light trol box that functions as an advanced standby generator controller. • Selectable Low Speed Exercise Specialized programs are built into the Power Zone 410 •...

  • Page 10: Control Panel

    § If equipped; not standard on all models • ±0.5% Voltage Regulation Panel Setup • ±0.5% Stability The Power Zone 410 Control Panel controller is setup in • Governor Functionality the factory to match the product it is shipped with and • Speed Control through ECM Integration generally no changes are required.

  • Page 11: Customization

    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. Power Zone 410 ® Controller Owner’s Manual...

  • Page 12: Starting And Stopping Sequence Diagrams

    ESCAPE ENTER SILENCE Auxiliary shutdown USB port and 7.5 A fuse Navigation Use the navigation arrows ( ) to navigate between the screens. Use the ESCAPE button ( ) to go back to Power Zone 410 ® Controller Owner’s Manual...

  • Page 13: Screens

    (remote Modbus command or through dealer edit or press ESC to run menu). in manual only. Figure 2-5. Use page 1 to set the language for the screens. 012980 Figure 2-7. Wizard Screen (Page 3) Power Zone 410 ® Controller Owner’s Manual...

  • Page 14: Engine Screen

    2-11. This screen will display only if Vcode Figure 2-13. Engine Screen (Page 1) settings have never been set. Use page 7 to set the fuel type to liquid propane or natural gas. Power Zone 410 ® Controller Owner’s Manual...

  • Page 15: Power Screen

    Util. Volts BN phase voltage. Util. Volts CN Figure 2-16. Generator Voltages (V) Avg Gen Volts 012994 Figure 2-19. Power Screen (Page 4) 012991 Figure 2-16. Power Screen (Page 1) Power Zone 410 ® Controller Owner’s Manual...

  • Page 16: Setting Screen

    Figure 2-22. Setting Screen (Page 2) Figure 2-23. Use page 3 to view when the next bat- 013014 tery maintenance is due, perform a lamp test, and enable or disable Chicago code. Figure 2-25. Gateway (Page 1) Power Zone 410 ® Controller Owner’s Manual...

  • Page 17: Info Screen

    2-28. Use this page to view a list of run occur- rences organized by time and date. 013020 Figure 2-30. General Info (Page 1) Figure 2-31. Use page 2 to view battery condition. Power Zone 410 ® Controller Owner’s Manual...

  • Page 18: Alarm Screen

    I/O Extender hardware and firm-ware. 013026 Figure 2-36. Highlight Page Setting 2. See Figure 2-37. Press the ENTER button again to highlight the value if needed. If multiple settings are Power Zone 410 ® Controller Owner’s Manual...

  • Page 19: Battery Charger Logic

    When enabled, if the generator becomes overloaded, pri- or to a shutdown alarm on overload, the generator will de- The Power Zone 410 controller comes equipped with a crease engine speed to create a frequency drop of 3 Hz. 12V 5A internal battery charger. The internal battery...

  • Page 20: Menu Map

    General Information Menu Map Figure 2-38. 019263 Figure 2-38. Power Zone 410 Menu Map Power Zone 410 ® Controller Owner’s Manual...

  • Page 21: Section 3: Input/Output And Connector Info

    0 to 5 V (5 V supplied via 50 mA fuse on J3-12) Oil Pressure J3-14 return Digital Inputs Default Signal Name Range/Level Connection 0 to 5 V (switched 5 V J5-23 coolant+ Coolant Level clock signal) J5-24 coolant Power Zone 410 ® Controller Owner’s Manual...

  • Page 22: Digital Outputs

    Relay Contacts (30 V, 5 Utility Transfer Relay J10-16 A max) Relay Contacts (30 V, 5 J10-14 Generator Transfer Relay A max) J10-15 Open Drain (+VBATT, Throttle Drive (PWM signal) J2-6 1.7 A device limited) Power Zone 410 ® Controller Owner’s Manual...

  • Page 23: Connector Pin Descriptions

    Rocker In (Auxillary Shutdown) 5 V pullup on switch terminal Rocker Loop Switch dry contact Rocker Loop Switch dry contact ExternalChargerFail 5 V pullup CoolantLvl(+) Switched analog input 573V CoolantLvl(-) Switched analog input 573R Power Zone 410 ® Controller Owner’s Manual...

  • Page 24: Can/Current/Analogs

    J10 16 Pin Signal Board Connection Description Wire # +12VBatt On board 7.5 Amp fuse SPLICE 4 +12VBatt On board 7.5 Amp fuse SPLICE 4 +VBatt Externally fuse for 10 A SPLICE 11 Power Zone 410 ® Controller Owner’s Manual...

  • Page 25: Throttle

    Board Connection Description Wire # GND (filtered comms) – – – SHLD +12VBATT – – GND (filtered comms) – SHLD RS4851_N Standard RS-485 RS4851_P Standard RS-485 RS232-RX2 Standard RS-232 – RS232-TX2 Standard RS-232 – Power Zone 410 ® Controller Owner’s Manual...

  • Page 26: Comms2

    J8 8 Pin Signal Board Connection Description Wire # GEN A – GEN B – GEN C – GEN Neutral – UTIL Neutral – UTIL A – UTIL B – UTIL C – Power Zone 410 ® Controller Owner’s Manual...

  • Page 27: Charger

    Input/Output and Connector Info CHARGER J7 2 Pin Signal Board Connection Description Wire # Do not connect if ext charger used Neutral Do not connect if ext charger used Power Zone 410 ® Controller Owner’s Manual...
  • Page 28 Input/Output and Connector Info This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...

  • Page 29: Section 4: Internal Alarms/Warnings

    Frequency (DPE measured) > 20% of target frequency for 5 seconds. 1208 Occurred while running—DefaultThe default extended alarm for low oil 1300 Low Oil Pressure pressure. Check the oil level. 1301 Low Oil Pressure Check the oil level. Power Zone 410 ® Controller Owner’s Manual...
  • Page 30 Possible cause: loose wiring, field boost hardware failure Single Zero Cross missing Undervoltage Undervoltage due to faulty excitation winding, or zero cross circuit, or circuit 1906 in general. One zero cross missing for greater than 1.5 seconds. Power Zone 410 ® Controller Owner’s Manual...
  • Page 31 No response from I/O Extender for 3 seconds after a hold-off duration of 30 2675 Comm seconds. I/O Ext. 2 Loss of No response from I/O Extender for 3 seconds after a hold-off duration of 30 2676 Comm seconds. Power Zone 410 ® Controller Owner’s Manual...
  • Page 32 (stuck open/closed) for 4 minutes. Lid Open/Theft Lid or door is open. 2745 Alarm Controller wrote to the SPI Flash more than 500 times in less than 4 2746 SPI Flash Abuse minutes. Power Zone 410 ® Controller Owner’s Manual...
  • Page 33 AUX shutdown. The system detected an auxiliary shutdown or onboard rocker switch on Auxiliary Power Zone 410 front panel button was pressed and prompted a shutdown. 2801 Shutdown Shutdown detected when pressed for greater than 300 ms...
  • Page 34 Engine Intake Low MAP — Data valid but below normal operating range; high severe 3401 Manifold #1 level. Pressure Engine Intake MAP Fault — Data erratic, intermittent, or incorrect. 3402 Manifold #1 Pressure Power Zone 410 ® Controller Owner’s Manual...
  • Page 35 Air Filter Sensor Fault — Voltage above normal range; shorted to high 3603 Differential source. Pressure Engine Air Filter 1 Air Filter Sensor Fault — Voltage below normal range; shorted to low 3604 Differential source; open circuit. Pressure Power Zone 410 ® Controller Owner’s Manual...
  • Page 36 Fuel System Fault — Voltage below normal range; shorted to low source; Engine Fuel Shut- 4004 open circuit. off 1 Control Crankshaft Sensor Fault — Data valid but above normal operating range; Engine Position 4100 high severe level. Sensor Power Zone 410 ® Controller Owner’s Manual...
  • Page 37 Engine Knock Sensor — Data valid but above normal operating range; Engine Knock 1 4415 least severe level. Engine Knock Sensor — Data valid but below normal operating range; Engine Knock 1 4417 least severe level. Power Zone 410 ® Controller Owner’s Manual...
  • Page 38 Engine Fuel Valve Fuel Mixer — Mechanical system not responding correctly. 4907 1 Position Engine Fuel Valve Fuel Mixer — Data valid but above normal operating range; least severe 4915 1 Position level. Power Zone 410 ® Controller Owner’s Manual...

  • Page 39: Power Zone 410 Service Tool

    The Manifold inlet temperature reached its maximum threshold limit. 7620 take Temp Power Zone 410 Service Tool Additional interfacing for configuration and setup is avail- able to an IASD using the Power Zone 410 Service Tool. Power Zone 410 ® Controller Owner’s Manual...
  • Page 40 Internal Alarms/Warnings This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...

  • Page 41: Section 5: Ground Fault Indication (If Equipped)

    This section describes the Ground Fault Indication (GFI) feature. To enable this feature, contact an IASD. Power Zone 410 generators have CTs on all phases to provide phase current measurements. This data is used to calculate system current, powers, and power factor (PF).
  • Page 42 Ground Fault Indication (If Equipped) This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...
  • Page 43 Ground Fault Indication (If Equipped) This page intentionally left blank. Power Zone 410 ® Controller Owner’s Manual...
  • Page 44 Part No. A0001458309 Rev. C 05/20/2024 Generac Power Systems, Inc. © 2024 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved. Waukesha, WI 53189 Specifications are subject to change without notice. 1–888–GENERAC (1–888–436–3722) No reproduction allowed in any form without prior written www.generac.com...

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