Generac Power Systems Switch R 200A User Manual

R-200A Digital Controller  
TECHNICAL  
MANUAL  
A new standard of reliability  
This manual should remain with the unit.  
 
Table of Contents  
R-panel Technical Manual  
Table of Contents  
High Coolant Temp (Red LED Indicator)................7  
Safety Rules ........................................ Inside Front Cover  
Low Coolant Level (Flashing Red  
General Information ......................................................... 2  
High Coolant Temp LED Indicator).....................7  
Introduction...........................................................2  
Overspeed (Red LED Indicator) .............................7  
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  
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  
CONTROL BOARD DIP SWITCH &  
The R-200A Controller incorporates the generator  
control circuitry, the ignition coil driver circuitry and  
the interface circuitry to an external governor driver.  
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 chang-  
es and then push and hold the Set Exercise Switch  
for five seconds.  
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.  
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 gen-  
erator operation. The 2-wire start inputs are labeled  
as 178 and 183 on the wiring terminals inside the  
generator's customer connection panel.  
Both the 1.6L and 2.4L engines use a magnetic  
pickup on the flywheel gear to provide speed informa-  
tion. 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.  
DIP Switch Position 3: Selects the engine operating  
speed in exercise mode.  
The 4.2L engine uses a magnetic pickup on the fly-  
wheel gear to provide speed information. A cam sen-  
sor and a crankshaft sensor provide information to a  
separate ignition coil driver that fires each spark plug  
independently.  
DIP Switch Position 4: Selects the type of Fuel used  
by the generator. The fuel regulator must also be con-  
figured for the correct fuel type.  
DIP Switch Position 5: Selects the engine displace-  
ment when Switch Position 7 is OFF. This position is  
ignored when Switch Position 7 is ON.  
The above generators are configured, at the factory,  
to use either LP Vapor or Natural Gas (NG). The gov-  
ernor gains have been pre-set and are not adjustable.  
The output frequency of the generator main alterna-  
tor is 60Hz.  
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.  
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.  
DIP Switch Position 7: Selects 4.2L displacement  
when ON. When OFF, Switch Position 5 selects dis-  
placement.  
DIP Switch Position 8: Reserved for future use. The  
position of this DIP switch does not affect generator  
operation.  
Switch OFF  
Reserved  
Switch ON  
Position 1  
Position 2  
Position 3  
Position 4  
Position 5  
Position 6  
Reserved  
ATS Mode  
GTS Mode  
Low Speed Exercise  
LP Vapor Fuel (LP)  
2.4L  
Normal Speed Exercise  
Natural Gas Fuel (NG)  
1.6L  
The addition of the 4.2L engine required creation of  
a new series of controller (see Figure 2). This control-  
ler is part number 0G3958C for 1800 rpm units and  
0G3958D for 3600 rpm units. All previous part num-  
bers are replacable with these new controllers.  
45kW (2.4L, 3600 rpm and 35kW (2.4L, 3600 rpm and  
4.2L, 1800 rpm)  
4.2L, 1800 rpm)  
Position 7  
Position 8  
1.6L, 2.4L  
4.2L  
Reserved  
Reserved  
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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.  
Jumper Position*  
Description  
1.6L Selected  
2.4L Selected  
1 & 2  
2 & 3  
* When S2 is used, see decal adjacent to S2. Ignored when Pos 7 is ON.  
Figure 1 — Dip Switch & Jumper Settings  
(Old Revision)  
If the DIP switch and jumper settings are not set  
JUMPER - JMP1  
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).  
3
J4  
1
J5  
U9  
LED Indicators visible through front panel (see Table  
1 and Figure 3).  
U7  
ON  
1
2
Table 1  
SOFTWARE P/N  
REV  
3
4
5
6
7
8
#
DATE XXXX  
J2  
• System Ready  
Green LED  
Yellow LED  
Red LED  
Red LED  
Red LED  
Red LED  
Red LED  
RL1  
• Low Fuel Pressure  
• Low Battery  
• Low Oil Pressure  
• Hi Coolant Temp/Low Coolant Level  
• Over Speed/RPM Sensor Loss  
• Over Crank  
J1  
J3  
POS  
OFF  
ON  
DESCRIPTION  
RESERVED  
1
2
3
4
5
6
7
8
DIP SWITCH  
ATS  
LOW SPD  
LP  
GTS  
NORMAL  
NG  
TRANSFER SWITCH MODE  
EXERCISE MODE  
FUEL TYPE  
Figure 3 — LED Indicators on Front Panel  
2.4L  
1.6L  
ENGINE TYPE  
45kW  
35kW  
kW RATING FOR 2.4L, 3600rpm  
RESERVED  
RESERVED  
OVERCRANK  
Figure 2 — Dip Switch & Jumper Settings  
(New Revision)  
OVERSPEED  
LOW COOLANT LEVEL  
HI COOLANT TEMPERATURE  
LOW OIL PRESSURE  
LOW BATTERY  
8 7 6 5 4 3 2 1  
S1  
J5  
ON  
J1  
LOW FUEL PRESSURE  
SYSTEM READY  
U12  
RL1  
2.4  
1.6  
S2  
U6  
S2  
J2  
C15  
C14  
C13  
J3  
POS  
OFF  
ATS  
ON  
DESCRIPTION  
RESERVED  
TRANSFER SW. MODE  
1
2
3
4
DIP  
SWITCH  
GTS  
LOW SPD NORMAL EXERCISE MODE  
LP  
NG  
FUEL TYPE  
5
6
7
2.4L  
45kW  
1.6L, 2.4L  
1.6L  
35kW  
4.2L  
ENGINE TYPE WHEN POS 7 IS OFF  
kW RATING FOR 2.4L 3600 RPM AND 4.2L, 1800 RPM  
ENGINE SELECT FOR 4.2L  
8
RESERVED  
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General Information  
R-panel Technical Manual  
Switch Position  
Condition  
System  
Ready  
Low  
Fuel  
Low  
Bat  
Low  
Oil  
High  
Temp  
Over  
Speed  
Over  
Crank  
Manual Auto Off  
Generator Switch is  
in the OFF Mode  
OFF  
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
X
X
X
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
O
System Ready for  
Automatic Start  
ON  
O
Generator Switch is  
in the MANUAL Mode  
OFF  
X
OFF  
O
Weekly Exerciser  
is not Set (Note A)  
Flashing Flashing Flashing Flashing  
(---------------------------------------1 sec rate -------------------------------------)  
Flashing  
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Battery Voltage <12.2V  
for > 1 minute  
X
ON  
(Non-Latching)  
Battery Voltage <6V  
For > 0.05 seconds  
OFF  
OFF  
OFF  
OFF  
OFF  
ON  
Unit Shutdown due  
To Low Oil Pressure  
X
X
ON  
Unit Shutdown due  
To High Cooant Temp  
ON  
Unit Shutdown due  
To Engine Overspeed  
X
ON  
Unit Failed to Start  
During it's Crank Cycle  
X
ON  
Utility Voltage is  
< 60% of Nominal  
Flashing  
1 sec rate  
X
Unit Shutdown due  
To Low Coolant Level  
OFF  
OFF  
X
Flashing  
Engine Speed Signal  
Fault/RPM Signal Loss  
X
Flashing  
Control Board is  
In GTS Mode  
Flashing  
5 sec ON, 1 sec OFF  
X
O
O
DIP Switch #5 is  
not set correctly  
OFF  
ON  
ON  
ON  
ON  
ON  
@ = Low Fuel Pressure is a Yellow LED and will be ON when fuel pressure is less than 5 inches Water Column  
X = indicates that the LED can be ON or OFF depending on the Operating Mode (i.e. Manual, OFF or Auto)  
Note A: a RED LED fault indication has priority over the flashing LED's used to indicate exercise time not set  
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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 set-  
tings 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 sec-  
ond engine warm-up timer will be initiated. When  
the warm-up timer expires, the R-200A controller  
will transfer the load to the generator (ATS Mode).  
The transfer of load when the generator is running is  
dependent upon the operating conditions as follows:  
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 MANUAL position the controller will start and  
run the generator.  
In the AUTO position the controller will go into a  
"standby" mode, where the controller will monitor  
the utility voltage and the exercise timer, and deter-  
mine if the generator needs to be started and the load  
transferred.  
MANUAL MODE  
The unit will not transfer if the utility is present, it  
will un-transfer if the utility voltage is above 80% of  
nominal for > 15 seconds and will re-transfer if the  
utility voltage drops below 60% of nominal for >15  
seconds.  
Battery voltage is continuously monitored and a  
warning LED is lit if the battery voltage drops below  
approximately 12.2 volts for longer than one (1) min-  
ute. The LED will turn off when the battery voltage  
goes back above approximately 12.5 volts.  
AUTO MODE  
The engine will run if the utility fails for >15 sec-  
onds, will not transfer if the utility is present, will  
un-transfer if the utility is above 80% of nominal for  
>15 seconds, and will stop the engine after a one 1  
minute cool-down time.  
If, however, the battery voltage drops below 6V during  
cranking the low battery LED will stay lit.  
While starting and running the engine, the controller  
will monitor the engine condition and shut the engine  
down on;  
EXERCISE MODE  
• Over Crank  
• Over Speed  
• High Coolant Temperature  
• Low Coolant Level  
• Low Oil Pressure  
The unit will not exercise if the generator is already  
running (in manual or auto mode). The generator  
will only transfer if the utility fails during the exer-  
cise period for >15 seconds, and the switch is in the  
AUTO mode above.  
• Engine Speed Signal Loss/RPM Sensor Loss (the  
overspeed LED flashes to indicate this fault)  
• Dead Battery (battery voltage < 6V during crank-  
ing)  
UTILITY RESTORED  
When the utility returns, a 15 second timer will start.  
At the completion of this time, if the utility supply has  
been above 80% of nominal voltage for the previous  
15 seconds, the control will transfer the load back to  
the utility. When the load is transferred a one (1) min-  
ute cool down timer will start, after which the engine  
will be shutdown.  
ENGINE TIMING  
Nominal engine timing when Natural Gas (NG) fuel  
is selected is:  
• 1.6L engine is 34 degrees BTDC at 3600 rpm; 28  
degrees BTDC at 1800 rpm  
• 2.4L engine is 30 degrees BTDC  
• 4.2L engine is 15 degrees BTDC  
INITIAL CRANKING  
The initial crank cycle will be a 15 second crank fol-  
lowed by a seven (7) second rest. This will be followed  
by 5 additional cycles of seven (7) second cranks fol-  
lowed by seven (7) second rests. If the engine still  
fails to start, the overcrank LED will be illuminated.  
Nominal engine timing when LP fuel is selected is:  
• 1.6L engine is 22 degrees BTDC at 3600 rpm; 20  
degrees BTDC at 1800 rpm  
• 2.4L engine is 21 degrees BTDC  
• 4.2L engine is 15 degrees BTDC  
Based on the above, the maximum number of engine  
crank events is six (6), which is approximately 90  
seconds, prior to illuminating the overcrank LED.  
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General Information  
R-panel Technical Manual  
ACTIVE ALARM  
LOW SPEED EXERCISE  
To select this mode place DIP switch position 3 in the  
OFF position.  
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).  
In Low Speed Exercise mode the normal speed 3600  
rpm generators will exercise at 1800 rpm. The nor-  
mal 1800 rpm generators will exercise at 1400 rpm  
in this mode.  
If the utility fails during the low speed exercise period,  
a 10 second timer will start. If the utility returns to  
a normal operating level, during this 10 second time  
interval the low speed exercise operation will contin-  
ue. If the utility is still not present (i.e. utility voltage  
less than 60% of nominal) when the above 10 second  
timer expires then the low speed exercise mode is  
terminated and the engine will ramp up to its normal  
running speed within five (5) seconds. If the utility  
returns during the five (5) second ramp-up period  
the generator will terminate the exercise mode. If the  
utility is still not present, once the generator is up  
to its normal running speed, then the controller will  
transfer the load to the generator. When the utility  
returns the generator will shutdown.  
RE-CRANK  
If an engine speed signal failure occurs while the gen-  
erator is running the engine will shutdown and then  
attempt a re-crank. A maximum of two re-cranks will  
be attempted after which the overcrank LED will be  
set. If the engine speed signal failure occurred during  
the engine exercise mode the exercise timer will con-  
tinue from where it was at the start of the re-crank  
and is not reset.  
NORMAL EXERCISE MODE  
To select this mode, place DIP switch position 3 in  
the ON position.  
If battery power to the R-200A Controller is lost, the  
weekly exercise time setting will be lost. This is indi-  
cated by all 5 red LED's continually flashing in ATS  
mode. In this state the generator will still start and  
run in MANUAL mode, or automatically start and run  
if utility voltage is lost while in AUTO mode, but it will  
NOT perform a weekly exercise cycle.  
In Normal Exercise Mode the generators will exercise  
at their normal running speed.  
The R-200A controller will start and run the genera-  
tor once every seven (7) days for approximately 12  
minutes. If the utility fails during the exercise period,  
this exercise period is aborted and the R-200A  
Controller transfers the load to the generator output,  
assumes automatic operation and continues to run  
until the utility is returned.  
In the event of a failure while running in this mode,  
the five (5) red LED's will stop flashing, the indi-  
vidual fault LED will turn on and the engine will be  
shut down. Once the AUTO/OFF/MANUAL switch is  
switched to OFF, the individual fault LED will turn off  
and the five (5) red LED's will begin flashing to show  
that the exercise mode has not yet been set.  
The weekly exercise cycle is set as follows:  
1. Place the AUTO/OFF/MANUAL switch in the  
AUTO position.  
2. Press and hold the "Set Exercise Time " switch for  
five (5) seconds and then release.  
At this time all five (5) red LED's will flash for 10  
seconds, then the engine will start and run for it's  
12 minute exercise period, then shut down. The gen-  
erator will now start and run each week at approxi-  
mately the same time.  
AUTO START  
This unit is designed to automatically start in the  
event of a utility failure. A utility failure is defined as  
the utility voltage being less than approximately 60%  
of nominal, while the utility is considered good when  
it is restored to approximately 80% of its nominal  
value.  
If battery power to the R-200A Controller is lost, the  
weekly exercise time setting will be lost. This is indi-  
cated by all five (5) red LED's continually flashing in  
ATS mode. In this state the generator will still start  
and run in MANUAL mode, or automatically start and  
run if utility voltage is lost while in AUTO mode, but  
it will NOT perform a weekly exercise cycle.  
If the generator is already running under exercise  
when an auto start is required, it will simply transfer  
the load after a 15 second delay and then switch to  
auto operation.  
In the event of a failure while running in this mode,  
the five (5) red LED's will stop flashing, the indi-  
vidual fault LED will turn on and the engine will be  
shut down. Once the AUTO/OFF/MANUAL switch is  
switched to OFF, the individual fault LED will turn off  
and the five (5) red LED's will begin flashing to show  
that the exercise mode has not yet been set.  
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General Information  
R-panel Technical Manual  
LOW BATTERY (RED LED INDICATOR)  
The R-200A controller continually monitors the bat-  
tery voltage and turns on the low battery LED if the  
battery voltage falls below approximately 12.2VDC  
for one minute. A low battery voltage is a non-latch-  
ing alarm and will not shut down the engine, however,  
it is a possible indication of a potential issue with  
the battery or battery charger and should be inves-  
tigated.  
DANGER  
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 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 OPER-  
ATE” tag on the control console.  
The low battery LED will automatically turn off if the  
battery voltage rises above approximately 12.5VDC.  
If the engine is running when the low battery condi-  
tion occurs, the engine will continue to run as long  
as possible.  
MANUAL START  
Allows the user to start and run the generator manu-  
ally. Transfer of the load to the generator will occur  
if the utility is lost while the engine is running in the  
manual mode.  
If the battery voltage drops below 6V at any time dur-  
ing cranking, the crank cycle will be terminated and  
the low battery LED will remain lit. This is a latched  
fault and will shut down the engine.  
SYSTEM READY (GREEN LED  
LOW OIL PRESSURE (RED LED  
INDICATOR)  
INDICATOR)  
Is a positive status indicator and dependent upon the  
following conditions being true:  
Occurs if the oil pressure switch closes while the  
engine is running after the 10 second hold off timer  
expires. This is a latched fault and will shutdown the  
engine.  
1. Switch in the AUTO position.  
2. No other warning indicator present.  
3. Controller is functional.  
HIGH COOLANT TEMP (RED LED  
The System Ready LED will also indicate if utility  
voltage is present at the control board. The system  
ready LED will flash every second (at a 0.5 second  
ON and a 0.5 second OFF rate) when utility voltage is  
not present at the control board when the switch is in  
either the AUTO or MANUAL position. This function  
is ONLY available with DIP Switch Position 2 in the  
OFF position (ATS application).  
INDICATOR)  
Occurs if the high coolant temp switch closes. Checks  
are made after the 10 second hold off timer expires.  
This is a latched fault and will shutdown the engine.  
LOW COOLANT LEVEL (FLASHING RED  
HIGH COOLANT TEMP LED INDICATOR)  
Occurs if the coolant level is low. Checks are made  
after the 10 second hold off timer expires. This is a  
latched fault and will shutdown the engine.  
The system ready LED will also indicate if the genera-  
tor is in the GTS Mode (i.e. DIP Switch Position 2 in  
the ON Position). The system ready LED will flash at  
a five (5) seconds ON and one (1) second OFF rate in  
GTS Mode.  
OVERSPEED (RED LED INDICATOR)  
An overspeed shutdown will occur if the engine speed  
is greater than 4300 rpm for a 3600 rpm engine;  
2160 rpm for an 1800 rpm engine; 2250 rpm for an  
1800 rpm engine, for three (3) seconds. An overspeed  
condition will shutdown the engine and activate the  
over speed LED. An immediate overspeed shutdown  
will occur if the engine speed is greater than 4500  
rpm for a 3600 rpm engine.  
LOW FUEL PRESSURE (YELLOW LED  
INDICATOR)  
The yellow low fuel pressure LED will turn ON if the  
fuel supply pressure drops below approximately five  
(5) inches water column (i.e. occurs when the low fuel  
pressure sensing switch on the fuel regulator opens).  
This is a non-latched fault (visual LED warning only)  
and does not trigger the controller alarm output. Low  
fuel pressure sensing is active in all generator operat-  
ing modes (i.e. MANUAL, OFF and AUTO).  
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General Information  
R-panel Technical Manual  
RPM SIGNAL FAILURE (FLASHING RED  
INVALID DIP SWITCH SETTING  
OVERSPEED INDICATOR)  
(ALL RED LED’S ON)  
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:  
All five (5) RED LED’s on the front panel will be ON  
all the time if DIP switch position 5 is not set cor-  
rectly.  
ALARM CANCEL  
When the generator is shut down on a latched fault or  
latching alarm, the AUTO/OFF/MANUAL switch must  
be set to the OFF position to turn off the correspond-  
ing fault LED. Prior to moving the switch to the OFF  
position, record which LEDs are ON or FLASHING  
and the date on the back cover of this manual.  
RPM SIGNAL FAILURE DURING CRANKING  
The engine control board (R-200A controller) will  
monitor the engine speed signal during engine crank-  
ing. If the control board does not see a valid signal  
within the first four seconds of each crank cycle it  
will stop the crank cycle, lock out on a shut down  
fault and flash the overspeed LED.  
AUTOMATIC TRANSFER SWITCH (ATS  
MODE)  
When this generator, along with an RTS-type or HS-  
type automatic transfer switch has been installed and  
connected, a circuit board in the generator control  
panel constantly monitors the utility voltage and con-  
trols the operation of the transfer switch.  
RPM SIGNAL FAILURE DURING RUNNING  
Running mode is handled differently because there  
is always the possibility the engine could slow down  
or stop running due to a temporary overload. To  
avoid shutting down and latching out on a temporary  
problem the following is done. If the engine is up and  
running, and the control board stops receiving a valid  
engine speed input signal it will respond as follows:  
To implement this mode of operation, Position 2 of  
the eight-position DIP switch, which is located on the  
generator circuit board (see Figures 1 and 2), must  
be in the OFF position. In ATS Mode utility voltage  
sensing, weekly exercising, and load transferring is  
under the control of the generator.  
1. It will close the throttle.  
2. It will shut down the engine by turning off the fuel  
Should the utility voltage drop below a preset value,  
and remain at this low voltage for a preset amount  
of time, the generator cranks and starts. After the  
generator starts, the transfer switch transfers the  
load circuits to the generator so the generator can  
power them. When the utility source voltage has been  
restored, the transfer switch re-transfers the load  
circuits back to the utility source voltage and the gen-  
erator shuts down.  
supply.  
3. It will wait for 15 seconds to ensure the engine  
has stopped.  
4. It will then energize the starter and monitor the  
engine speed signal.  
A. If the control board does not see the engine  
speed signal it will stop the crank cycle, lock out  
on fault, and flash the overspeed LED.  
B. If the control board does see the engine speed  
input signal during cranking it will start and run  
the engine normally. If the engine speed signal is  
again lost while running it will repeat the above  
procedure one more time.  
The transfer switch is controlled by the generator  
circuit board via control wires 23 and 194. Wire 23  
connects the collector of an NPN transistor on the  
generator circuit board to the “low side” (Terminal  
23) of the transfer relay coil in the transfer switch.  
Wire 194 connects positive battery voltage from the  
generator circuit board to the “high side” (Terminal  
194) of the transfer relay coil in the transfer switch.  
C. If the failure should repeat a third time, the con-  
trol board will shut down the engine, lock out on  
fault, and flash the over speed LED.  
In order for the generator utility voltage sensing  
function to work, it is necessary to provide a 5 amp  
fused 240VAC for 240V or 480V systems or 208VAC  
utility source connection (depending on the generator  
being used) from the transfer switch main N1 and N2  
terminals to the generator wiring panel N1 and N2  
terminals (See Figure 4).  
OVERCRANK (RED LED INDICATOR)  
Occurs if the engine has not started within the total  
90 second crank cycle. This is a latched fault and will  
shut down the engine.  
8
 
General Information  
R-panel Technical Manual  
Figure 4 - Connection Diagram (ATS Mode)  
FROM UTILITY  
TO LOAD  
FEEDER CIRCUITS  
MAIN LINE  
CIRCUIT  
BREAKER  
OR FUSE  
GENERATOR  
CHARGER  
LOAD  
DISTRIBUTION  
PANEL  
N1 N2 (N3)  
FUSE  
FUSE  
T1  
T2  
(T3)  
120 VAC  
LINE  
NEU  
GND  
N1  
N2  
194  
23  
194  
23  
RTS-TYPE  
OR  
HS-TYPE  
TRANSFER  
SWITCH  
178  
183  
N2 N1  
E1 E2 (E3)  
E1 E2 (E3)  
Generator control board DIP switch position 2 ON =  
2-wire Start GTS Mode:  
• The generator control board will NOT monitor the  
utility.  
• The generator control board will NOT perform a  
weekly exercise. (In GTS mode the green system  
ready LED will be ON for five (5) seconds and OFF  
for one (1) second).  
Be very careful when connecting high-voltage  
wires labeled N1 and N2 and low-voltage wires  
labeled 23 and 194 in both the generator wiring  
panel and the transfer switch wiring panel. The  
control board will be damaged if these wires are  
not connected correctly.  
• The generator control board will NOT activate the  
In order for the generator battery charger function  
to work, it is necessary to provide a 120VAC util-  
ity source connection to the generator wiring panel  
LINE, NEUTRAL and GND terminals (see Figure 4).  
transfer output.  
• The generator control board WILL monitor all  
engine conditions and shut down on all the faults  
listed in this document.  
For the W-type transfer switch to control utility volt-  
age sensing, weekly exercising and load transferring,  
suitable wiring must also be connected from the  
transfer switch 178 and 183, 2-wire start terminals  
to the corresponding generator 178 and 183 2-wire  
start terminals. Recommended wire gauge sizes for  
the 2-wire start wiring depend on the length of the  
wire (see wiring length chart).  
ENGINEERED TRANSFER SWITCH  
(2-WIRE START GTS MODE)  
When required, the generator can be installed with  
an engineered W-type transfer switch which controls  
utility voltage sensing, weekly exercising and load  
transferring.  
When Position 2 of the eight-position DIP switch,  
which is located on the generator circuit board (see  
Figures 1 and 2), is in the ON position then utility  
voltage sensing, weekly exercising and load transfer-  
ring is under the control of the engineered W-type  
transfer switch (GTS Mode).  
MAXIMUM WIRE LENGTH  
460 feet (140M)  
RECOMMENDED WIRE SIZE  
No. 18 AWG.  
461 TO 730 feet (223M)  
731 to 1,160 feet (354m)  
1,161 to 1,850 feet (565m)  
No 16 AWG.  
No 14 AWG.  
No 12 AWG.  
9
 
General Information  
R-panel Technical Manual  
Figure 5 - Connection Diagram (GTS Mode)  
FROM UTILITY  
TO LOAD  
FEEDER CIRCUITS  
MAIN LINE  
CIRCUIT  
BREAKER  
OR FUSE  
GENERATOR  
CHARGER  
120 VAC  
LOAD  
DISTRIBUTION  
PANEL  
N1 N2 (N3)  
T1  
T2  
(T3)  
LINE  
NEU  
GND  
W-TYPE  
TRANSFER  
SWITCH  
194  
23  
178  
183  
178  
183  
N2 N1  
E1 E2 (E3)  
E1 E2 (E3)  
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).  
MANUAL: The control board will start and run the  
generator whenever the switch is in the manual posi-  
tion.  
AUTO: The control board will monitor the 2-wire  
start circuit. When the 2-wire start wire 178 is con-  
nected to 2-wire start wire 183, via a relay contact  
closure in the W-type transfer switch, the control  
board will start and run the generator. When the  
2-wire start wire connection is opened the control  
board will stop the generator.  
Do NOT connect battery voltage, utility voltage  
(N1/N2) or load voltage (T1/T2) to either the  
178 or the 183 2-wire start terminals as this will  
damage the generator control board.  
When the control board is in AUTO, MANUAL or OFF  
(GTS mode) the GREEN System Ready LED will flash  
(five (5) seconds ON, one (1) second OFF) to indi-  
cate that the transfer switch is performing the utility  
monitoring and transfer functions.  
In order for the generator battery charger function  
to work, it is necessary to provide a 120Vac util-  
ity source connection to the generator wiring panel  
LINE, NEUTRAL and GND terminals (see Figure 5).  
When in GTS mode, the control board will respond  
as follows based on the AUTO/OFF/MANUAL switch  
position.  
VOLTAGE REGULATOR ADJUSTMENT  
Although adjustment potentiometers are provided on  
the voltage regulator installed in the control panel,  
the voltage regulator potentiometers have been set at  
the factory and should NOT be re-adjusted.  
OFF: The generator will not start and run in this  
position. Only the System Ready LED and the Low  
Battery LED are active in the GTS OFF mode.  
10  
 
General Information  
R-panel Technical Manual  
R-200A J1 CONNECTOR (23 PIN, GRAY=1800  
RPM, WHITE=3600 RPM)  
Refer to the individual generator wiring dia-  
grams and schematics for additional informa-  
tion.  
Pin #  
1
2
Governor 12V Supply  
Reserved (Do not connect any wires to this  
pin.)  
2A AND 10A BATTERY CHARGERS  
There are two types of battery chargers. A 2 Amp bat-  
tery charger and a 10 Amp battery charger.  
3
4
5
6
7
8
9
GND-B to Governor Driver  
Hi-Coolant Temp Input  
0V to Governor Driver  
5V Supply to Governor Driver  
Distributor (Hall Sensor) 12V Sensor Supply  
Low Coolant Level Input  
Crank Signal Input  
The 2 Amp battery charger is a "float" type charger. A  
"float" type charger will charge the battery at its maxi-  
mum output current rating until the battery voltage  
reaches a "float" voltage and then the charge current  
will decrease to maintain the battery at that "float"  
voltage.  
10 Crank Signal Return  
11 Low Fuel Pressure Input  
12 Governor Position Feedback Input  
13 Reserved (Do not connect any wires to this  
pin.)  
14 Coil + (Supply voltage to engine coil pack.)  
15 Coil A Driver  
The 10 Amp battery charger is an "equalize" type  
charger. An "equalize" type charger will charge the  
battery at its maximum output current rating until  
the battery voltage reaches an "equalize" voltage and  
then the charge current will decrease to maintain the  
battery at a lower "float" voltage.  
16 2.4L Distributor Sensor Return  
17 2.4L Distributor Sensor Input  
18 Governor PWM Output  
19 Governor Enable Output  
20 Lo Oil Pressure Input  
21 2.4L Flywheel Sensor Screen  
22 Coil C Driver  
23 Coil B Driver  
The 2 Amp charger incorporates fuses on both the  
input AC line and the battery charger output. The  
input AC line fuse is a Littelfuse 2 Amp, Slo-Blo Fuse,  
5x20mm, P/N 218002. The AC line fuse is located on  
the charger printed-circuit board. The output DC bat-  
tery fuse is a Littelfuse 5 Amp, Mini-Blade Fuse, P/N  
297005. The battery fuse is located on the charger  
printed-circuit board.  
The 10 Amp charger incorporates fuses on both the  
input ac line and the battery charger output. The  
input AC line fuse is a Littelfuse 5 Amp, Slo-Blo Fuse,  
5x20mm, P/N 218005. The AC line fuse is located  
on the charger printed-circuit board. The output DC  
battery fuse is a Littelfuse 15 Amp, ATO Fuse, P/N  
257015. The battery fuse is located on the charger  
printed-circuit board.  
Pin #  
R-200A J2 CONNECTOR (14 PIN WHITE)  
1
2
Reserved  
Start (Crank) Relay Driver Output (minimum  
coil resistance is 90 ohms)  
Fuel (Run) Relay Driver Output (minimum  
coil resistance is 90 ohms)  
2-wire Start Input (from relay contact in W-  
type transfer switch)  
Momentary Open Switch Input (B+)  
2-wire Start Return (from relay contact in W-  
type transfer switch)  
3
4
These chargers require that the battery be connected  
to the charger in order to turn on. The battery voltage  
must also be above a certain "boost" voltage for the  
charger to turn-on.  
5
6
The boost voltage required is approximately 11 volts  
for a 12V system. If the battery open-circuit voltage is  
less than the above boost voltage, it is recommended  
that the battery be checked.  
7
8
9
Manual/Auto Input (+BS)  
19.5VAC Utility Sense Input  
Reserved  
If the voltage of the generator's 12V battery exceeds  
15VDC, during normal charging operation, the bat-  
tery should be checked. Typical battery voltages,  
when a 12V battery is being charged, should be in the  
13VDC to 15VDC range.  
10 Transfer Switch Relay Driver Output (mini-  
mum coil resistance is 60 ohms)  
11 Manual Input  
12 19.5VAC Utility Sense Return  
13 Reserved  
The 2 Amp and 10 Amp chargers are UL recognized  
for use in the R-panel enclosure and are not to be  
operated outside the R-panel enclosure.  
14 GND-B (Battery Ground)  
11  
 
General Information  
R-panel Technical Manual  
2A, 12VDC BATTERY CHARGER  
DANGER  
Nominal Input AC Line Voltage .......................... 120Vac  
Operating AC Line Voltage Range ...................108Vac to  
Storage batteries give off explosive hydrogen  
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 be properly ventilated. Do not allow smok-  
ing, open flame, sparks or any spark producing  
tools or equipment near the battery.  
132Vac  
Input AC Line Frequency..............................50 or 60Hz  
AC Line Fuse......................... 2 Amp Slo-Blo, 5x20mm,  
Littelfuse P/N 218002  
Battery Fuse ........................................5 Amp, Littelfuse  
Mini-Blade Fuse P/N 297005  
Nominal Charge Rate ........................................ 2 Amps  
Float Voltage (type).........................................13.4 Volts  
Battery Undervoltage Shutdown (typ).............. 11 Volts  
LED Indicators  
Battery electrolyte fluid is an extremely corro-  
sive sulfuric acid solution that can cause severe  
burns. Do not permit fluid to contact eyes, skin,  
clothing, painted surfaces, etc. Wear protective  
goggles, protective clothing and gloves when  
handling a battery. If fluid is spilled, flush the  
affected area immediately with clear water.  
AC Line Voltage > 108Vac................Green LED ON  
Battery Connected & Charging.........Yellow LED ON  
(the Green LED must be ON to obtain a valid bat-  
tery charging indication,  
Yellow LED ON if charge current > approx 0.5  
Amps)  
Battery Current Drain (AC Power OFF)........30mA (typ)  
Do not use any jumper cables or booster battery  
to crank and start the generator engine. If the  
battery has completely discharged, remove it  
from the generator for recharging.  
AC Line Connection...........................via terminal block  
(AC Hot, AC Neut & GND)  
Battery Connections..........................via terminal block  
(Pos +, Neg -)  
10A, 12VDC BATTERY CHARGER  
Nominal Input AC Line Voltage ........................ 120Vac  
Operating AC Line Voltage Range ......108Vac to 132Vac  
Input AC Line Frequency.............................50 or 60Hz  
AC Line Fuse......................................5 Amp, 5x20mm,  
Littelfuse P/N 218005  
Be sure the AUTO/OFF/MANUAL switch is set to  
the OFF position, before connecting the battery  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
Battery Fuse ..............................15 Amp, Littelfuse ATO  
Blade P/N 257015  
Be sure the utility power supply to the battery  
charger is turned off, or sparking may occur at  
the battery posts as the cables are attached and  
cause an explosion.  
Nominal Charge Rate ..................................... 10 Amps  
Equalize Voltage (typ)....................................13.8 Volts  
Float Voltage (typ) .........................................13.0 Volts  
Current at Equalize to Float Transition (typ) .. 5 Amps  
Battery Undervoltage Shutdown (typ)...............11 Volts  
LED Indicators  
AC Line Voltage > 108Vac...............Green LED ON  
Battery Connected & Charging........Yellow LED ON  
the Green LED must be ON to obtain a valid  
battery charging indication,  
Yellow LED ON if charge current > approx 2  
Amps)  
Battery Current Drain (AC Power OFF).......30mA (typ)  
AC Line Connections.........................via terminal block  
(AC Hot, AC Neut & GND)  
Battery Connections..........................via terminal block  
(Pos +, Neg -)  
Control Connections ......................AC Power Fail Relay,  
Form C, 2Amps, 12Vdc  
(N.O. Contact closes when ac line voltage is applied)  
(N.O. Contact opens when ac line voltage is removed)  
12  
 
Notes  
R-panel Technical Manual  
13  
 
®
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 8  
WAUKESHA, WI 53187  
Part No. 0G1341  
Revision E (06/19/07)  
Printed in U.S.A.  
 

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