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Generac Power Systems Digital Controller R-200A manual

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Table of contents for the manual

  • Page 1

    TECHNICAL MANU AL This manual should remain with the unit. R-200A Digital Contr oller A ne w standar d of reliability[...]

  • Page 2

    IM PORT ANT SAFETY INSTRUCTIONS R-panel T echnical Manual  SA VE 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 install- ing, ope[...]

  • Page 3

    T able of Contents R-panel T echnical Manual 1 Safety Rules ........................................ Inside Front Cover General Information ......................................................... 2 Introduction ........................................................... 2 Control Board Dip Switch & Jumper Settings ....... 2 Generator Operatio[...]

  • Page 4

    I NTRODUCTION 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 (w[...]

  • Page 5

    3 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 P osition 7 is ON . Figure 1 — Dip Switch & Jumper Setting[...]

  • Page 6

    4 General Information R-panel T echnical Manual Switch P osition Condition System Low Low Low High Over Over Manual A uto Off Ready Fuel Bat Oil T emp Speed Crank Generator Switch is OFF @ X OFF OFF OFF OFF O in the OFF Mode System Ready f or ON @ X OFF OFF OFF OFF O A utomatic Star t Generator Switch is OFF @ X OFF OFF OFF OFF O in the MANU AL Mod[...]

  • Page 7

    5 GEN ER A T OR OP ER A TION The R-200A controller monitors the front panel switch position and reads the DIP switch position set - tings when the control board is initially powered-up. In the OFF position the controller will only be incre - menting the exercise timer and monitoring the bat - tery voltage and low fuel pressure sensor . In the MANU [...]

  • Page 8

    6 General Information R-panel T echnical Manual A CTIVE AL AR M Low Oil Pressure, High Coolant T emp, 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[...]

  • Page 9

    7 D ANGER  With the switch set to AUTO, the engine can crank and start suddenly without warning. Such automatic start up normally occurs when utility source voltage dr ops below a pre-set level. T o prevent possible injury that might be caused by such sudden starts, set the AUTO/ OFF/MANUAL switch to OFF and remove the NEGA TIVE battery cable fr[...]

  • Page 10

    8 R P M SIGNAL F AI L UR E (F LASHI NG R ED O VERSP EED I N DICA T OR) If the R-200A controller does not receive a signal from the engine flywheel sensor , the R-200A control- ler cannot maintain the generator output frequency or monitor for an overspeed condition. If this sig- nal is lost the R-200A controller will shut down the engine as follows:[...]

  • Page 11

    9  Be very careful when connecting high-voltage wires labeled N1 and N2 and low-voltage wir es labeled 23 and 194 in both the generator wiring panel and the transfer switch wiring panel. The control boar d will be damaged if these wires ar e not connected correctly . In order for the generator battery charger function to work, it is necessary to[...]

  • Page 12

    10 Route the 2-wire start control wires through suit - able, approved conduit which is separate from the AC power leads. Connection of wire 178 to wire 183 by relay contact closure action (volt free switch con- tacts) in the transfer switch must result in generator engine cranking and startup (see Figure 5).  Do NOT connect battery voltage, util[...]

  • Page 13

    11 R-200A J1 C ONN ECT OR (23 PI N, GR A Y=1 800 R PM, WH ITE=3600 RP M) Pin # 1 Governor 12V Supply 2 Reserved (Do not connect any wires to this pin.) 3 GND -B to Governor Driver 4 Hi-Coolant T emp Input 5 0V to Governor Driver 6 5V Supply to Governor Driver 7 Distributor (Hall Sensor) 12V Sensor Supply 8 Low Coolant Level Input 9 Crank Signal Inp[...]

  • Page 14

    12 D ANGER  Storage batteries give off explosive hydr ogen gas. This gas can form an explosive mixture around the battery for several hours after charg- ing. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shat- ter the battery and cause blindness or other injury . Any area that houses a storage battery must [...]

  • Page 15

    13 Notes R-panel T echnical Manual[...]

  • Page 16

    Part No. 0G1341 GENERAC ® POWER SY STEMS, INC. P .O. BOX 8 W AUKESHA, WI 53187 Revision E (06/19/07) Printed in U.S.A.[...]