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.
Table of Contents R-panel Technical Manual Table of Contents Safety Rules ........................................ Inside Front Cover High Coolant Temp (Red LED Indicator)................ 7 General Information ......................................................... 2 Introduction ........................................................... 2 Low Coolant Level (Flashing Red High Coolant Temp LED Indicator) ..................... 7 Control Board Dip Switch & Jumper Settings .......
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.
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 Position* Description 1&2 1.6L Selected 2&3 2.
General Information R-panel Technical Manual Condition Switch Position Manual Auto Off System Ready Low Fuel Low Bat Low Oil High Temp Over Speed Over Crank Generator Switch is in the OFF Mode OFF @ X OFF OFF OFF OFF System Ready for Automatic Start ON @ X OFF OFF OFF OFF Generator Switch is in the MANUAL Mode OFF @ X OFF OFF OFF OFF O Weekly Exerciser is not Set (Note A) X @ Flashing Flashing Flashing O O O Battery Voltage <12.
General Information R-panel Technical Manual GENERATOR OPERATION UTILITY FAILURE The R-200A controller monitors the front panel switch position and reads the DIP switch position settings when the control board is initially powered-up. When the utility fails, a 15 second timer will start. If the utility is still gone when the timer expires the engine will crank and start. Once started a 10 second engine warm-up timer will be initiated.
General Information R-panel Technical Manual ACTIVE ALARM LOW SPEED EXERCISE Low Oil Pressure, High Coolant Temp, Low Coolant Level, Overspeed, Overcrank, Engine Speed Signal Loss and a Dead Battery indication will all be latched shutdowns. In the event one of these conditions occurs, the unit will be shut down, the appropriate LED will be illuminated, and the unit will not start again without manual intervention (see Re-Crank below). To select this mode place DIP switch position 3 in the OFF position.
General Information R-panel Technical Manual DANGER the switch set to AUTO, the engine can With crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage drops below a pre-set level. To prevent possible injury that might be caused by such sudden starts, set the AUTO/ OFF/MANUAL switch to OFF and remove the NEGATIVE battery cable from the battery before working on or around the unit. Then, place a “DO NOT OPERATE” tag on the control console.
General Information R-panel Technical Manual RPM SIGNAL FAILURE (FLASHING RED OVERSPEED INDICATOR) INVALID DIP SWITCH SETTING (ALL RED LED’S ON) If the R-200A controller does not receive a signal from the engine flywheel sensor, the R-200A controller cannot maintain the generator output frequency or monitor for an overspeed condition.
General Information R-panel Technical Manual Figure 4 - Connection Diagram (ATS Mode) FROM UTILITY MAIN LINE CIRCUIT BREAKER OR FUSE N1 N2 (N3) FUSE N1 N2 FUSE RTS-TYPE OR HS-TYPE TRANSFER SWITCH T1 T2 (T3) TO LOAD FEEDER CIRCUITS GENERATOR LOAD DISTRIBUTION PANEL CHARGER 120 VAC LINE NEU GND 194 23 194 23 E1 E2 (E3) 178 183 N2 N1 E1 E2 (E3) Generator control board DIP switch position 2 ON = 2-wire Start GTS Mode: very careful when connecting high-voltage Be wires labeled N1 and N2 and low-vo
General Information R-panel Technical Manual Figure 5 - Connection Diagram (GTS Mode) FROM UTILITY TO LOAD FEEDER CIRCUITS MAIN LINE CIRCUIT BREAKER OR FUSE N1 N2 (N3) T1 T2 (T3) W-TYPE TRANSFER SWITCH CHARGER 120 VAC LINE NEU GND 194 23 178 183 E1 E2 (E3) Route the 2-wire start control wires through suitable, approved conduit which is separate from the AC power leads.
General Information R-panel Technical Manual R-200A J1 CONNECTOR (23 PIN, GRAY=1800 RPM, WHITE=3600 RPM) Pin # 1 Governor 12V Supply 2 Reserved (Do not connect any wires to this pin.
General Information R-panel Technical Manual DANGER Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.
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GENERAC® POWER SYSTEMS, INC. P.O. BOX 8 WAUKESHA, WI 53187 Part No. 0G1341 Revision E (06/19/07) Printed in U.S.A.
