Generac Power Systems R-200 Technical Manual Download Page 2

   

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 install-
ing, operating, or servicing this equipment. Become 
familiar with this manual and all literature pertain-
ing to the generator set and related equipment. This 
equipment can operate safely, efficiently, and reliably 
only if it is properly installed, operated, and main-
tained. 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 warn-
ings 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 tech-
nique the manufacturer does not specifically recom-
mend, 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 famil-
iar with applicable codes, standards, and regula-
tions. 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 barri-
ers 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 repair-
ing 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 maxi-
mum 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, with-
out 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 genera-
tor 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 nonconduct-
ing 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 com-
ponents, 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 recommenda-
tions. 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.

Summary of Contents for R-200

Page 1: ...TECHNICAL MANUAL This manual should remain with the unit R 200 Digital Controller A new standard of reliability ...

Page 2: ...s and barri ers 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 adjus...

Page 3: ...ed 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 Cylinder 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 ...

Page 4: ...ing see Figure 1 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...

Page 5: ...tart 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 2 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 ...

Page 6: ...down due OFF X ON O O To Low Oil Pressure Unit Shutdown due OFF X ON O O To High Cooant Temp Unit Shutdown due OFF X ON O O To Engine Overspeed Unit Failed to Start OFF X ON O O During it s Crank Cycle Utility Voltage is Flashing X O O 60 of Nominal 1 sec rate Unit Shutdown due OFF X Flashing O O To Low Coolant Level Engine Speed Signal OFF X Flashing O O Fault RPM Signal Loss Control Board is Fla...

Page 7: ...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 200 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 MANUAL MODE The unit will not transfer if the utility is present will...

Page 8: ... 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 LOW SPEED EXERCISE To select this mode place DIP switch position 3 in the OFF position In Low Speed Exercise mode the 2 4...

Page 9: ... 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 LOW BATTERY RED LED INDICATOR The R 200 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 lat...

Page 10: ...front panel will be ON all the time if DIP switch position 5 and DIP switch position 6 are not set correctly 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 ...

Page 11: ... 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 The generator control board will NOT activate the 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...

Page 12: ...tch 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 When the control board is in AUTO MANUA...

Page 13: ...act in W type transfer switch 5 Momentary Open Switch Input B 6 2 wire Start Return from relay contact in W type transfer switch 7 Manual Auto Input BS 8 19 5VAC Utility Sense Input 9 Alarm Relay Driver Output minimum coil resistance is 90 ohms 10 Transfer Relay Driver Output minimum coil resistance is 60 ohms 11 Manual Input 12 19 5VAC Utility Sense Return 13 Reserved Do not connect any wires to ...

Page 14: ...on 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 Battery electrolyte fluid is an extremely corro sive sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothin...

Page 15: ... 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 Contro...

Page 16: ...Part No 0F9784 GENERAC POWER SYSTEMS INC P O BOX 8 WAUKESHA WI 53187 Revision B 06 07 06 Printed in U S A ...

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