Generac R-200A User Manual
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 gen-
•
erator 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 equip-
•
ment. 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 equip-
•
ment 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
Table of Contents
R-panel Technical Manual
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
4.2L, 1800 rpm)
Position 7 1.6L, 2.4L 4.2L
Position 8 Reserved Reserved
35kW (2.4L, 3600 rpm and
4.2L, 1800 rpm)
2
General Information
R-panel Technical Manual
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
J1
DIP SWITCH
3
1
SOFTWARE P/N
REV #
DATE XXXX
J5
RL1
POS
1
2
43LP
5
6
7
8
LOW SPD
45kW
ON
1
2
3
4
5
6
7
8
OFF
ON
ATS GTS
NORMAL
NG
1.6L
2.4L
35kW
J4
U7
TRANSFER SWITCH MODE
EXERCISE MODE
kW RATING FOR 2.4L, 3600rpm
DESCRIPTION
RESERVED
FUEL TYPE
ENGINE TYPE
RESERVED
RESERVED
U9
J2
J3
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).
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
Figure 2 — Dip Switch & Jumper Settings
(New Revision)
8 7 6 5 4 3 2 1
S1
J5
ON
J1
RL1
2.4
1.6
S2
U6
S2
C13C14C15
POS OFF ON DESCRIPTION
DIP
SWITCH
1
2
ATS
3
LOW SPD
4
LP
5
2.4L
6
45kW
7
1.6L, 2.4L 4.2L
8
RESERVED
GTS
TRANSFER SW. MODE
NORMAL
EXERCISE MODE
NG
FUEL TYPE
1.6L
ENGINE TYPE WHEN POS 7 IS OFF
35kW
kW RATING FOR 2.4L 3600 RPM AND 4.2L, 1800 RPM
ENGINE SELECT FOR 4.2L
RESERVED
J3
U12
OVERCRANK
OVERSPEED
LOW COOLANT LEVEL
HI COOLANT TEMPERATURE
LOW OIL PRESSURE
LOW BATTERY
LOW FUEL PRESSURE
SYSTEM READY
J2
3
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