PowerZone Generator Guide

Motherboard Info PowerZone 410 A0000660367

Motherboard Info

  • CPU is a Microchip PIC32MZ2048EFM144 214811G
  • Easisest name to Google is PIC32MZEF
  • 32 bit MIPS MCU 2048KB Memory 512kb Ram
  • Software used is potentially genlink?
  • Similar motherboard to Guardian Controllers

CPU programming without official software

  • PIC32 supports ICSP and JTAG progamming
  • Solder JTAG female adapter to development header near CPU.
  • Use ICSP adapter to connect header to PC
  • Adapters like mikroProg will connect to ICSP ribbon cable
  • Typically ICSP is 6 pin or 10 pin
  • Use MPLAB X IDE Software to modify CPU configuration.

Software for PowerZone

  • Program through Ethernet or USB 2.0 Male to Male
  • Use DeepSea DSE Configuration Suite (Unknown if this works) or Web Browser through IP address
  • Controller uses USB 2.0 male to male, non null modem for TX/RX, and controller has a serial adapter built in.
  • Slave ID is 157

How to trace intermittent issues

  • Go to info menu
  • Click alarms

How to go to dealer menu

  • Escape Escape Up Up Down Down

How to Reset Maintenance Warning

  • Method 1:
    Press Back, Up, Up, Down, Down, Back, Back

  • Then go into Maintenance, select Reset, and scroll down.

  • For high fuel warnings, limits can be changed in the maintenance menu too.

How to Reset Codes Forcefully

  • Unplug connectors 7 and 10, then plug them back in.
  • If issues persist, turn off the charger breaker and unhook the battery.

  • Connector 7 is for commercial power for the module!

  • Or, unplug fuse on front of controller and cut charger breaker.

How to Reset Codes Gracefully

  • Connect to controller through USB or Ethernet and reset codes through manufacturer interface

How to Reset PowerZone Pro Codes sometimes

  • Cycle the key to reset the codes.

How to Acknowledge Touchscreen PowerZone Pro Codes

  • Tap on the code or click the check mark button to acknowledge.

PowerZone Pro ECU Shutdown Fault

  • This could be due to a potential overcrank issue.
  • The solution for gas-powered units is unknown.

How to Reset Codes Like ESTOP PRESSED

  • View the codes and acknowledge the code to reset.

  • This advice most likely doesn’t work.

Aux Shutdown Fault

  • Set the circular switch all the way left and the aux switch to the up position.

  • Then, unplug connectors 7 and 10.

How to Acknowledge Generac ATS Codes

  • Press the right button until the code is displayed.
  • Click Acknowledge to clear the code.

  • This advice doesn’t work.

Generator Fail Issues

  • Open the Ethernet module below the control module and test the continuity of the alarm wires.
  • Some major terminal blocks might not be programmed and may require programming or need to be bypassed.

External Charger Fault?

  • Jump the blue and white battery charger fail wires, if the external charger still works.
  • Connector 7 must be plugged in for primary charger to work!

  • The 10 amp charger is optional on the powerzone gens! It can be charged with just the built in module.

How to Lookup Manuals for PowerZone Generators

  • Try searching with the model number and serial number.
  • If neither works, the generator might be too new for Generac to have released manuals.
  • Generac may have pulled some manuals, which is unfortunate.

When to use AUX shutdown

  • When you are working on the generator near moving parts and you don’t want the danger of it kicking on, turn OFF aux shutdown.

Theory about why these controllers have issues

  • Some aren’t programmed right when activated or somehow lose some or all of their programming
  • Clearing codes is a pain
  • Parts are made very cheaply (like rupture sensor) and fail and cause faults

Random

  • Protected hours is how many hours before the warranty is up.

Connector Guide

  • 1 Field
  • 2 Governor Module
  • 3 Coolant/Oil pressure/Fuel Sensors and Canbus
  • 4 Battery/Ground RS485 (Unknown)
  • 5 Fuel alarm, oil temp/level, charger circuit, coolant level, tank rupture sensor, start commmand.
  • 6 Battery/Ground RS485 (Unknown)
  • 7 Commerical Power
  • 8 T1/2/3 Customer Connections S1/2/3
  • 9 Optional Module
  • 10 Main battery power/relay power out

Drawing A0001344265