Generac R-200A User Manual

4 (2)

R-200A Digital Controller

TECHNICAL

MANUAL

A new standard of reliability

This manual should remain with the unit.

IMPORTANT SAFETY INSTRUCTIONS

R-panel Technical Manual

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators and potential operators of this equipment.

Study these SAFETY RULES carefully before installing, operating, or servicing this equipment. Become familiar with this manual and all literature pertaining to the generator set and related equipment. This equipment can operate safely, efficiently, and reliably only if it is properly installed, operated, and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the equipment, are, therefore, not all-inclusive. If using a procedure, work method, or operating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method, or operating technique utilized does not render the equipment unsafe.

GENERAL HAZARDS

For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an Authorized Service Dealer or other qualified electrician or installation technician who is familiar with applicable codes, standards, and regulations. The operator also must comply with all such codes, standards, and regulations.

When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

Inspect the equipment regularly, and promptly repair or replace all worn, damaged or defective parts, using only factory-approved parts.

Before performing any maintenance on the generator or any related equipment, disconnect the generator’s battery cables and remove panel fuse to prevent accidental startup. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first. Reconnect that cable last.

ELECTRICAL HAZARDS

Generators produce dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the generator and related equipment are running. Ensure all appropriate covers, guards, and barriers are in place before operating the equipment. If working around an operating unit, stand on an insulated, dry surface to reduce potential shock hazards.

Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

If people must stand on metal or concrete while installing, operating, servicing, adjusting, or repairing this equipment, place insulative mats over a dry wooden platform. Work on the equipment only while standing on such insulative mats.

Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical current (amperage) to which they will be subjected to.

Before installing or servicing this equipment, make sure that all power voltage supplies are positively turned off at their source. Failure to do so will result in hazardous and possibly fatal electrical shock.

When installed with an automatic transfer switch, the generator may crank and start anytime, without warning. To prevent injuries caused by sudden start-up, disable the generator’s automatic start circuit before working on, or around, the unit. Then, place a “Do Not Operate” tag on the generator control panel and on the transfer switch.

In case of an accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as, a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry can conduct electricity, resulting in electric shock, or may get caught in moving components, causing injury.

FIRE HAZARDS

For fire safety, the generator and related equipment must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws, and regulations. Adhere

strictly to local, state, and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the equipment is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations.

Table of Contents

R-panel Technical Manual

Table of Contents

Safety Rules ........................................

Inside Front Cover

General Information .........................................................

 

2

Introduction ...........................................................

 

2

Control Board Dip Switch & Jumper Settings .......

2

Generator Operation ..............................................

 

5

Engine Timing........................................................

 

5

Utility Failure .........................................................

 

5

Manual Mode ......................................................

 

5

Auto Mode...........................................................

 

5

Exercise Mode.....................................................

 

5

Utility Restored ......................................................

 

5

Initial Cranking ......................................................

 

5

Active Alarm...........................................................

 

6

Re-crank ................................................................

 

6

Normal Exercise Mode ...........................................

 

6

Low Speed Exercise ...............................................

 

6

Auto Start ..............................................................

 

6

Manual Start ..........................................................

 

7

System Ready (Green LED Indicator) ....................

7

Low Fuel Pressure (Yellow LED Indicator) .............

7

Low Battery (Red LED Indicator) ...........................

 

7

Low Oil Pressure (Red LED Indicator)...................

7

High Coolant Temp (Red LED Indicator)................

7

Low Coolant Level (Flashing Red

 

High Coolant Temp LED Indicator).....................

7

Overspeed (Red LED Indicator) .............................

7

RPM Signal Failure

 

(Flashing Red Overspeed Indicator)....................

8

RPM Signal Failure During Cranking ..................

8

RPM Signal Failure During Running....................

8

Overcrank (Red LED Indicator) .............................

8

Invalid Dip Switch Setting (All Red LED's On) .......

8

Alarm Cancel .........................................................

8

Automatic Transfer Switch (ATS Mode) .................

8

Engineered Transfer Switch

 

(2-wire Start GTS Mode).....................................

9

Voltage Regulator Adjustment ..............................

10

R-200A J1 Connector (23 Pin,

 

Gray=1800 rpm, White=3600 rpm)..............

11

R-200A J2 Connector (14 Pin White) ................

11

2A and 10A Battery Chargers...............................

11

2A, 12VDC Battery Charger ..............................

12

10A, 12VDC Battery Charger ............................

12

Notes...................................................................................

13

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.

1

General Information

R-panel Technical Manual

INTRODUCTION

The R-200A Controller incorporates the generator control circuitry, the ignition coil driver circuitry and the interface circuitry to an external governor driver.

The R-200A Controller can control a;

4-cylinder, 1.6L, 1800 rpm or 3600 rpm engine

4-cylinder, 2.4L, 1800 rpm or 3600 rpm engine

6-cylinder, 4.2L, 1800 rpm engine (with separate ignition coil driver)

The R-200A controller will monitor the utility voltage to determine if stand-by power is required. Should the utility voltage fail, the unit will start and run, detaching from the utility and supplying the customer load from the generator.

Both the 1.6L and 2.4L engines use a magnetic pickup on the flywheel gear to provide speed information. A cam sensor is used to provide engine position information. Each engine uses two coil drivers in a waste spark coil pack for ignition. With a waste spark coil, each high-voltage coil output is connected to two spark plugs resulting in each spark plug being fired during both the compression and exhaust cycle.

The 4.2L engine uses a magnetic pickup on the flywheel gear to provide speed information. A cam sensor and a crankshaft sensor provide information to a separate ignition coil driver that fires each spark plug independently.

The above generators are configured, at the factory, to use either LP Vapor or Natural Gas (NG). The governor gains have been pre-set and are not adjustable. The output frequency of the generator main alternator is 60Hz.

The controller PCB, located on the inside door of the R-200A, may have one of several part numbers. Early 1.6L units will have part number 0G1505A. Early 2.4L units will have part number 0G1505B. Later units have part number 0G1303A for 1800 rpm or, 0G1303B for 3600 rpm. The 0G1303B is a suitable replacement for the 0G1505A and 0G1505B. In later units, or if the engine has emission controls, part number 0G1303C is used for 1800 rpm and 0G1303D is used for 3600 rpm. The latest versions include 30kW, 3600 rpm, 1.6L control and 18kW, 1800 rpm, 1.6L control. Part number 0G1303E is used for 1800 rpm and 0G1303F is used for 3600 rpm. The 0G1303C or 0G1303E will work in place of 0G1303A. The 0G1303D or 0G1303F will work in place of 0G1303B, 0G1505A or 0G1505B.

The addition of the 4.2L engine required creation of a new series of controller (see Figure 2). This controller is part number 0G3958C for 1800 rpm units and 0G3958D for 3600 rpm units. All previous part numbers are replacable with these new controllers.

CONTROL BOARD DIP SWITCH &

JUMPER SETTINGS

The Switch "ON" position location is marked on the DIP switch housing (see Figures 1 and 2.) To activate the DIP Switch settings place the AUTO/OFF/MANUAL switch in the OFF Mode, make the DIP switch changes and then push and hold the Set Exercise Switch for five seconds.

DIP Switch Position 1: Reserved for future use. The position of this DIP Switch does not affect generator operation.

DIP Switch Position 2: Selects the type of transfer switch to be used with the generator. When an "HS" or RTS-type transfer switch is used (ATS Mode) this DIP Switch should be in the OFF Position. When a W-type transfer switch is used (GTS Mode) the generator 2-wire start inputs can be used to control the generator operation. The 2-wire start inputs are labeled as 178 and 183 on the wiring terminals inside the generator's customer connection panel.

DIP Switch Position 3: Selects the engine operating speed in exercise mode.

DIP Switch Position 4: Selects the type of Fuel used by the generator. The fuel regulator must also be configured for the correct fuel type.

DIP Switch Position 5: Selects the engine displacement when Switch Position 7 is OFF. This position is ignored when Switch Position 7 is ON.

DIP Switch Position 6: Selects the alternator kW rating for the 2.4L at 3600 rpm and the 4.2L at 1800 rpm. The position of this DIP switch does not affect generator operation for the 1.6L, or the 1800 rpm 2.4L.

DIP Switch Position 7: Selects 4.2L displacement when ON. When OFF, Switch Position 5 selects displacement.

DIP Switch Position 8: Reserved for future use. The position of this DIP switch does not affect generator operation.

 

Switch OFF

Switch ON

 

 

 

Position 1

Reserved

Reserved

 

 

 

Position 2

ATS Mode

GTS Mode

 

 

 

Position 3

Low Speed Exercise

Normal Speed Exercise

 

 

 

Position 4

LP Vapor Fuel (LP)

Natural Gas Fuel (NG)

 

 

 

Position 5

2.4L

1.6L

 

 

 

Position 6

45kW (2.4L, 3600 rpm and

35kW (2.4L, 3600 rpm and

 

4.2L, 1800 rpm)

4.2L, 1800 rpm)

 

 

 

Position 7

1.6L, 2.4L

4.2L

 

 

 

Position 8

Reserved

Reserved

 

 

 

2

Generac R-200A User Manual

General Information

Jumper JMP1/S2: Selects the engine displacement. Set to position 1 and 2 for 1.6L. Set to position 2 and 3 for 2.4L. The jumper is not used on PCB's 0G1505A or 0G1505B. On later revisions, JMP1 is replaced by S2. S2 has no effect on 4.2L operation and is ignored when DIP Switch Position 7 is ON.

Figure 1 — Dip Switch & Jumper Settings

(Old Revision)

JUMPER - JMP1

3

J4

1

J5

U9

R-panel Technical Manual

Jumper Position*

Description

1 & 2

1.6L Selected

 

 

2 & 3

2.4L Selected

 

 

* When S2 is used, see decal adjacent to S2. Ignored when Pos 7 is ON.

If the DIP switch and jumper settings are not set correctly, the generator engine may run rough, not start or not provide rated power. When LP fuel is used it is very important that DIP Switch Position 4 be in the LP fuel position (switch OFF).

LED Indicators visible through front panel (see Table 1 and Figure 3).

U7

ON

 

1

 

SOFTWARE P/N

2

 

3

 

REV #

4

 

DATE XXXX

5

 

 

6

J2

 

7

 

8

 

 

RL1

 

J1

 

 

 

 

J3

 

POS

OFF

ON

DESCRIPTION

DIP SWITCH

1

 

 

RESERVED

 

2

ATS

GTS

TRANSFER SWITCH MODE

 

3

LOW SPD

NORMAL

EXERCISE MODE

 

4

LP

NG

FUEL TYPE

 

5

2.4L

1.6L

ENGINE TYPE

 

6

45kW

35kW

kW RATING FOR 2.4L, 3600rpm

 

7

 

 

RESERVED

 

8

 

 

RESERVED

Figure 2 — Dip Switch & Jumper Settings

(New Revision)

 

 

 

 

8 7 6 5 4 3 2 1

 

 

 

 

 

S1

J5

 

 

 

 

ON

 

 

J1

 

 

U12

 

 

 

 

 

 

 

RL1

 

 

 

 

 

 

2.4

 

 

 

 

 

1.6

 

 

 

 

 

S2

 

 

 

 

 

 

U6

 

 

 

 

 

S2

 

 

 

 

 

 

J2

 

 

C15

C14

C13

 

 

 

 

 

 

J3

 

POS

OFF

ON

DESCRIPTION

 

DIP

1

 

 

RESERVED

 

2

ATS

GTS

TRANSFER SW. MODE

SWITCH

3

LOW SPD

NORMAL EXERCISE MODE

 

 

 

 

4

LP

NG

FUEL TYPE

 

 

5

2.4L

1.6L

ENGINE TYPE WHEN POS 7 IS OFF

 

6

45kW

35kW

kW RATING FOR 2.4L 3600 RPM AND 4.2L, 1800 RPM

 

7

1.6L, 2.4L

4.2L

ENGINE SELECT FOR 4.2L

 

8

 

 

RESERVED

 

Table 1

• System Ready

Green LED

• Low Fuel Pressure

Yellow LED

• Low Battery

Red LED

• Low Oil Pressure

Red LED

• Hi Coolant Temp/Low Coolant Level

Red LED

• Over Speed/RPM Sensor Loss

Red LED

• Over Crank

Red LED

Figure 3 — LED Indicators on Front Panel

OVERCRANK

OVERSPEED

LOW COOLANT LEVEL

HI COOLANT TEMPERATURE

LOW OIL PRESSURE

LOW BATTERY

LOW FUEL PRESSURE

SYSTEM READY

3

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