R-100 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 install- • Do not handle any kind of electrical device while
ing, operating, or servicing this equipment. Become standing in water, while barefoot, or while hands or
familiar with this manual and all literature pertain- feet are wet. DANGEROUS ELECTRICAL SHOCK
ing to the generator set and related equipment. This MAY RESULT.
equipment can operate safely, efficiently, and reliably • If people must stand on metal or concrete while
only if it is properly installed, operated, and main- installing, operating, servicing, adjusting, or repair-
tained. Many accidents are caused by failing to follow ing this equipment, place insulative mats over a
simple and fundamental rules or precautions. dry wooden platform. Work on the equipment only
The manufacturer cannot anticipate every possible while standing on such insulative mats.
circumstance that might involve a hazard. The warn- • Wire gauge sizes of electrical wiring, cables, and
ings in this manual, and on tags and decals affixed cord sets must be adequate to handle the maxi-
to the equipment, are, therefore, not all-inclusive. If mum electrical current (amperage) to which they
using a procedure, work method, or operating tech- will be subjected to.
nique the manufacturer does not specifically recom- • Before installing or servicing this equipment, make
mend, ensure that it is safe for others. Also make sure sure that all power voltage supplies are positively
the procedure, work method, or operating technique turned off at their source. Failure to do so will result
utilized does not render the equipment unsafe. in hazardous and possibly fatal electrical shock.
• When installed with an automatic transfer switch,
the generator may crank and start anytime, with-
 GENERAL HAZARDS  out warning. To prevent injuries caused by sudden
start-up, disable the generator’s automatic start
• For safety reasons, the manufacturer recommends
that this equipment be installed and serviced by circuit before working on, or around, the unit.
an Authorized Service Dealer or other qualified Then, place a “Do Not Operate” tag on the genera-
electrician or installation technician who is famil- tor control panel and on the transfer switch.
iar with applicable codes, standards, and regula- • In case of an accident caused by electric shock,
tions. The operator also must comply with all such immediately shut down the source of electrical
codes, standards, and regulations. power. If this is not possible, attempt to free the
• When working on this equipment, remain alert victim from the live conductor. AVOID DIRECT
at all times. Never work on the equipment when CONTACT WITH THE VICTIM. Use a nonconduct-
physically or mentally fatigued. ing implement, such as, a rope or board, to free
the victim from the live conductor. If the victim
• Inspect the equipment regularly, and promptly is unconscious, apply first aid and get immediate
repair or replace all worn, damaged or defective medical help.
parts, using only factory-approved parts.
• Never wear jewelry when working on this equip-
• Before performing any maintenance on the gen- ment. Jewelry can conduct electricity, resulting in
erator or any related equipment, disconnect the electric shock, or may get caught in moving com-
generator’s battery cables and remove panel fuse ponents, causing injury.
to prevent accidental startup. Disconnect the cable
from the battery post, indicated by a NEGATIVE,
NEG, or (–) first. Reconnect that cable last.  FIRE HAZARDS 
• For fire safety, the generator and related equip-
 ELECTRICAL HAZARDS  ment must be installed and maintained properly.
Installation always must comply with applicable
• Generators produce dangerous electrical voltages codes, standards, laws, and regulations. Adhere
and can cause fatal electrical shock. Avoid contact strictly to local, state, and national electrical
with bare wires, terminals, connections, etc., while and building codes. Comply with regulations the
the generator and related equipment are running. Occupational Safety and Health Administration
Ensure all appropriate covers, guards, and barri- (OSHA) has established. Also, ensure that the
ers are in place before operating the equipment. equipment is installed in accordance with the
If working around an operating unit, stand on an manufacturer’s instructions and recommenda-
insulated, dry surface to reduce potential shock tions. Following proper installation, do nothing
hazards. that might alter a safe installation and render the
unit in noncompliance with the aforementioned
codes, standards, laws, and regulations.
 Table of Contents
R Panel Technical Manual

Table of Contents Overspeed (Red LED Indicator) ............................. 7

Safety Rules ........................................ Inside Front Cover RPM Signal Failure
(Flashing Red Overspeed Indicator) .................... 7
General Information ......................................................... 2
Introduction ........................................................... 2 RPM Signal Failure During Cranking .................. 8

Control Board Dip Switch Settings ........................ 2 RPM Signal Failure During Running.................... 8

Generator Operation .............................................. 5 Overcrank (Red LED Indicator) ............................. 8

Engine Timing ........................................................ 5 Invalid Cylinder Dip Switch Setting

(All Red LED's On).............................................. 8
Utility Failure ......................................................... 5
Alarm Cancel ......................................................... 8
Manual Mode ...................................................... 5
Automatic Transfer Switch (ATS Mode) ................. 8
Auto Mode ........................................................... 5
Engineered Transfer Switch
Exercise Mode ..................................................... 5 (2-wire Start GTS Mode)..................................... 9
Utility Restored ...................................................... 5 Voltage Regulator Adjustment .............................. 10
Initial Cranking ...................................................... 5 R-100 J1 Connector (23 Pin,
Active Alarm ........................................................... 6 Black=1800 rpm, Blue=3600 rpm) .............. 11
Re-crank ................................................................ 6 R-100 J2 Connector (14 Pin White) .................. 11
Normal Exercise Mode ........................................... 6 2A and 10A Battery Chargers............................... 11
Low Speed Exercise ............................................... 6 2A, 12VDC Battery Charger .............................. 12
Auto Start .............................................................. 6 10A, 12VDC Battery Charger ............................ 13
Manual Start .......................................................... 7
System Ready (Green LED Indicator) .................... 7
Low Fuel Pressure (Yellow LED Indicator) ............. 7 AUTHORIZED SERVICE
Low Battery (Red LED Indicator) ........................... 7 DEALER LOCATION
Low Oil Pressure (Red LED Indicator) ................... 7 To locate the nearest AUTHORIZED
High Coolant Temp/Low Coolant Level SERVICE DEALER, please call this number:
(Red LED Indicator)............................................ 7
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER,
or visit the website at www.generac.com.

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 General Information
R Panel Technical Manual

INTRODUCTION CONTROL BOARD DIP SWITCH

The R-100 Controller incorporates the Generator
control circuitry, the ignition coil driver circuitry, the SETTINGS
stepper motor governor driver circuitry and the inter- The Switch "ON" position location is marked on the
face circuitry to an external digital governor driver. DIP Switch housing (see Figure 1.) To activate the DIP
Switch settings place the AUTO/OFF/MANUAL Switch
The R-100 Controller can control a: in the OFF Mode, make the DIP Switch changes and
• 4-cylinder, 1.5L engine having a stepper motor gov- then push and hold the Set Exercise Switch for five
ernor seconds.
• 4-cylinder, 2.5L engine having a stepper motor gov- Switch OFF Switch ON
ernor Position 1 50 Hz 60 Hz
• 6-cylinder, 3.0L engine having a digital governor Position 2 ATS Mode GTS Mode
• 6-cylinder, 3.9L engine having a digital governor ("HS" transfer switch) ("W" transfer switch)
The R-100 controller will monitor the utility voltage Position 3 Low Speed Exercise Normal Speed
to determine if stand-by power is required. Should Exercise
the utility voltage fail, the unit will start and run,
detaching from the utility and supplying the customer Position 4 LP Vapor Fuel (LP) Natural Gas Fuel (NG)
load from the generator. Position 5 1.5L or 3.9L Engine 2.5L or 3.0L Engine
The 2.5L and 3.0L engines use a 36-1 crank sensor Position 6 6 Cylinder Engine 4 Cylinder Engine
to provide engine position and speed information.
The 2.5L engine uses two coil drivers and a waste Position 7 CCW Stepper Rotation CW Stepper Rotation
spark coil pack. The 3.0L engine uses three coil driv- Position 8 Reserved Reserved
ers and a waste spark coil pack. With a waste spark
coil, each high-voltage coil output is connected to two DIP Switch Position 1: Selects the Generator main
spark plugs resulting in each spark plug being fired alternator output frequency. The ability to select the
during both the compression and exhaust cycle. Generator output frequency (i.e. 60Hz or 50Hz) is
The 3.9L engine uses a 164 tooth mag pick-up fly- only available on the 2.5L Generators.
wheel sensor and a +12V distributor hall sensor DIP Switch Position 2: Selects the type of transfer
to provide engine position and speed information. switch to be used with the Generator. When an "HS"
The 3.9L engine uses one coil driver together with or “RTS” type transfer switch is used (ATS Mode) this
a single-fire coil and a distributor sensor. With a DIP Switch should be in the OFF Position. When a
single-fire coil each spark plug is only fired during "W" or “HTS” type transfer switch is used (GTS Mode)
the compression cycle. the Generator 2-Wire start inputs can be used to con-
The 1.5L engine uses a 104 tooth mag pick-up (fly- trol the Generator operation. The 2-Wire start inputs
wheel) sensor to provide engine speed information are labeled as 178 and 183 on the wiring terminals
for the stepper motor governor. The ignition function inside the R-Panel.
and engine timing on the 1.5L generator is deter- DIP Switch Position 3: Selects the engine operating
mined by the distributor. speed in exercise mode.
The R-100 Controller, when a digital governor is DIP Switch Position 4: Selects the type of Fuel used
used, can maintain the engine's steady-state speed at by the Generator. The Fuel Regulator must also be
either 1800 rpm or 3600 rpm (60Hz operation only), configured for the correct Fuel type.
depending on the main alternator and control board
hardware installed in the Generator. DIP Switch Position 5: Selects the engine displace-
ment.
The R-100 Controller, when a Stepper motor Governor
is used, maintains the engine's steady-state speed at DIP Switch Position 6: Selects the number of engine
1800 rpm when 60Hz operation has been selected cylinders.
and 1500rpm when 50Hz operation has been select-
ed.
The Governor gains have been pre-set and are not
adjustable.
All Generators are able to operate with either LP or
Natural Gas (NG). Engine timing for a specific fuel
is selected via a DIP Switch on the R-100 Controller,
except on the 1.5L generator.

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 General Information
R Panel Technical Manual

DIP Switch Position 7: Selects the direction of rota-

tion of the Stepper motor Governor and should be
set for CCW Stepper rotation (DIP Switch OFF) for
the 2.5L Generator. Rotation is observed looking at  IfthetheGenerator
DIP switch settings are not set correctly,
engine may run rough, not start
the stepper shaft as it moves from closed throttle to
open throttle. or not provide rated power. When LP fuel is
being used it is very important that DIP Switch
DIP Switch Position 8: The position of this DIP Position 4 be in the LP fuel position (switch
switch (ON or OFF) does not affect Generator opera- OFF).
tion.
LED Indicators visible through Front Panel (see Table
1 and Figure 2).
Figure 1 — Dip Switch Settings
C80 U15
J4 Table 1
R145

R143
R144

C79

R147

Q12
J5
R142

R140
R141

C75
C74

System Ready Green LED

R175
R139
C77
R137 R123

C71
R126
R125
R128
Z12 R127
R115
R131
R136

R124 R109
R120

C76 U13
C69

R121 U14 C68 R117 R118 R119 C67 C66

D41 R116 D42 R110

Low Fuel Pressure Yellow LED

R132
R133
R135
R134

T8 C72
C73
R130

R129

R107

U12
R112
R111

T7 C60 R104
C70 R122
R102 R100

C63 D40 Q9 R113 R114

C61
R105

C65

D39 Z8 U10
R106

C59

R151
C57
C81

Low Battery Red LED

C64 C58 D38 R92 U8 D37 R101
R96

R95 R94
C56 C62 R98
D35

C78
R99

T6
R90

C54 U11 R89

T5 C48 X1 R88 C53
C55 R93 C47 R108 D34

Low Oil Pressure Red LED

C52

D33 R82 R79 R103

C51

U9 R97
R85
R86
D36

R80 R91
D32
C50
R84

C49 R83 R77 C39 R87 D31

J6
C89

R76 Z7
R81
C45

C42
Z6

C40
C46 C44 D30
R73

Hi Coolant Temp/Low Coolant Level Red LED

C41

C82

C38 D29
R148
R152
R68

U7
R78 D25
U6
R75
R74

R149 C34

D26 R67
D27
R158
R69

Over Speed/RPM Sensor Loss Red LED

R72
R70
R71

L3 C37 C36
R61

R66 R55 R63

R54 L2
R64 C35
R52
ON
R62

T2 D22 D21 R50 S1 D24 D28

U5 Z5 D23

Over Crank Red LED

R45 C33 Z4
R155

R57
C30

C31
C32

1 C24
R56 D20

2
T1 C25 L1
R153
SOFTWARE
R53

3
C27 C26
R48

C29 R49 C28 R167 R51

Z3
REV # 4
D19
R46
R154

DATE XXXX 5 R44 C22

F1
6
7
D16 D15 U4 D18 D17
C23
D14 D12
J2
Figure 2 — LED Indicators on Front Panel
R41

R37
R42

C20

U3 C21 C19

R150 RL1
R43
R39
8
C15

R38
D13 C14
C18 R36
C16
C17

R35
R34

U2 Z1

Z2 C9 C8
J1 D10
D11
R20
R21
R32

R30

C13
R31
R33

R28
R29

R26
C10

R27

R25 D8
C11 R19 R18
C12
R23

R22

C6
R24

C5 Q7 Q6 Q5
R17

C4 R16 D9
R12

Q8 C7 D5
R14

R15 R13 R11

C3 D4 C2
Z9 D2 R10
R9

R3
R8

R6 R4 C1 R7
R5 D3
D7 D6

OVERCRANK
R2
Q4 Q2 J3
Q3

Q1 U1 D1
R1

OVERSPEED
POS OFF ON DESCRIPTION LOW COOLANT LEVEL
DIP SWITCH 1 50 60 FREQ. HZ HI COOLANT TEMPERATURE
2 ATS GTS TRANSFER SWITCH MODE
3 LOW SPD NORMAL EXERCISE MODE LOW OIL PRESSURE
4 LP NG FUEL TYPE LOW BATTERY
5 1.5/3.9L 2.5/3.0L ENGINE TYPE
6 6 CYL 4 CYL # OF CYLINDERS LOW FUEL PRESSURE
7 CCW CW STEPPER ROTATION SYSTEM READY
8 RESERVED

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 General Information
R Panel Technical Manual

Switch Position
Condition System Low Low Low High Over Over Manual Auto Off
Ready Fuel Bat Oil Temp Speed Crank

Generator Switch is OFF @ X OFF OFF OFF OFF O

in the OFF Mode

System Ready for ON @ X OFF OFF OFF OFF O

Automatic Start

Generator Switch is OFF @ X OFF OFF OFF OFF O

in the MANUAL Mode

Weekly Exerciser X @ Flashing Flashing Flashing Flashing Flashing O O O

is not Set (Note A) (---------------------------------------1 sec rate -------------------------------------)

Battery Voltage <12.2V X @ ON O O O

for > 1 minute (Non-Latching)

Battery Voltage <6V OFF @ ON O O

For > 0.05 seconds

Unit Shutdown due OFF @ X ON O O

To Low Oil Pressure

Unit Shutdown due

To High Temperature OFF @ X ON O O
or Low Coolan.t Level

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

Engine Speed Signal OFF @ X Flashing O O

Fault/RPM Signal Loss

Control Board is Flashing @ X O O O

In GTS Mode 5 sec ON, 1 sec OFF

DIP Switch #6 is OFF @ ON ON ON ON ON O O O

not set correctly

@ = 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-100 Controller monitors the front panel switch When the utility fails, a 15 second timer will start.
position and reads the DIP Switch position settings If the utility is still gone when the timer expires the
when the control board is initially powered-up. engine will crank and start. Once started a 10 sec-
In the OFF position the software will only be incre- ond engine warm-up timer will be initiated. When
menting the exercise timer and monitoring the bat- the warm-up timer expires, the R-100 controller will
tery voltage and low fuel pressure sensor. transfer the load to the generator (ATS Mode). The
transfer of load when the generator is running is
In the MANUAL position the software will start and dependent upon the operating conditions as follows:
run the generator.
In the AUTO position the software will go into a ‹ MANUAL MODE
"standby" mode, where the software will monitor the
The unit will not transfer if the Utility is present,
utility voltage and the exercise timer, and determine
will un-transfer if the Utility voltage is above 80% of
if the generator needs to be started and the load
nominal for > 15 seconds and will re-transfer if the
transferred.
Utility voltage drops below 60% of nominal for >15
Battery voltage is continuously monitored and a seconds.
warning LED is lit if the battery voltage drops below
approximately 12.2 volts for longer than 1 minute.
The LED will turn off when the battery voltage goes
‹ AUTO MODE
back above approximately 12.5 volts. The engine will run if the utility fails for >15 sec-
onds, will not transfer if the utility is present, will
If, however, the battery voltage drops below 6V during
un-transfer if the utility is above 80% of nominal for
cranking the low battery LED will stay lit.
>15 seconds, and will stop the engine after a one 1
While starting and running the engine, the software minute cool-down time.
will monitor the engine condition and shut the engine
down on; ‹ EXERCISE MODE
• Over Crank The unit will not exercise if the generator is already
• Over Speed running (in manual or auto mode). The Generator
• High Coolant Temperature will only transfer if the utility fails during the exer-
• Low Coolant Level cise period for >15 seconds, and the switch is in the
• Low Oil Pressure 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-
UTILITY RESTORED
When the utility returns, a 15 second timer will start.
ing) At the completion of this time, if the utility supply has
been above 80% of nominal voltage for the previous
ENGINE TIMING 15 seconds, the control will transfer the load back to
Nominal engine timing when Natural Gas (NG) fuel the utility. When the load is transferred a 1 minute
is selected is; cool down timer will start, after which the engine will
be shutdown.
• 1.5L, 3600rpm engine is 43 degrees BTDC
• 2.5L, 1800rpm engine is 30 degrees BTDC
• 3.0L, 1800rpm engine is 28 degrees BTDC INITIAL CRANKING
• 3.9L, 1800rpm engine is 30 degrees BTDC The initial crank cycle will be a 15 second crank fol-
• 3.0L, 3600rpm engine is 36 degrees BTDC lowed by a 7 second rest. This will be followed by 5
• 3.9L, 3600rpm engine is 36 degrees BTDC additional cycles of 7 second cranks followed by 7
second rests. If the engine still fails to start, the over-
Nominal engine timing when LP fuel is selected is; crank LED will be illuminated.
• 1.5L, 3600rpm engine is 43 degrees BTDC Based on the above, the maximum number of engine
• 2.5L, 1800rpm engine is 24 degrees BTDC crank events is six (6), which is approximately 90
• 3.0L, 1800rpm engine is 21 degrees BTDC seconds, prior to illuminating the overcrank LED.
• 3.9L, 1800rpm engine is 23 degrees BTDC
• 3.0L, 3600rpm engine is 25 degrees BTDC
• 3.9L, 3600rpm engine is 22 degrees BTDC

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 General Information
R Panel Technical Manual

ACTIVE ALARM Once the AUTO/OFF/MANUAL switch is switched

to OFF, the individual fault LED will turn off and
Low Oil pressure, High coolant temp/Low coolant
level, Overspeed, Overcrank, Engine Speed signal the 5 red LED's will begin flashing to show that the
loss and a Dead Battery indication will all be latched Exercise Mode has not yet been set.
shutdowns. In the event one of these conditions
occurs, the unit will be shut down, the appropriate
LED will be illuminated, the alarm relay output will
LOW SPEED EXERCISE
To select this mode place DIP Switch Position 3 in
be activated and the unit will not start again without the OFF Position.
manual intervention (see Re-Crank below).
In low speed exercise mode a 3.0L or 3.9L, 3600 rpm
engine will exercise at 1800 rpm and a 3.0L or 3.9L,
RE-CRANK 1800 rpm engine will exercise at 1400 rpm.
If an engine speed signal failure occurs while the gen-
A 2.5L, 1800rpm engine will exercise at 1400rpm in
erator is running the engine will shutdown and then
low speed exercise mode.
attempt a re-Crank. A maximum of two Re-Cranks
will be attempted after which the overcrank LED will If the utility fails during the low speed exercise peri-
be set. If the engine speed signal failure occurred od, a 10 second timer will start. If the utility returns
during the engine Exercise Mode the exercise timer to a normal operating level, during this 10 second
will continue from where it was at the start of the Re- time interval the low speed exercise operation will
Crank and is not reset. continue. 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
NORMAL EXERCISE MODE mode is terminated and the engine will ramp up to
To select this mode place DIP Switch Position 3 in its normal running speed within 5 seconds. If the
the ON position utility returns during the 5 second ramp-up period
In Normal Exercise Mode a Generator will exercise the generator will terminate the exercise mode. If the
at the engine's rated speed (i.e. a 3600rpm engine utility is still not present, once the generator is up
will exercise at 3600rpm, an 1800rpm engine will to its normal running speed, then the controller will
exercise at 1800rpm). transfer the load to the generator. When the utility
returns the generator will shutdown.
The R-100 Controller will start and run the genera-
tor once every 7 days for approximately 12 minutes. If battery power to the R-100 Controller is lost, the
If the utility fails during the exercise period, this weekly exercise time setting will be lost. This is indi-
exercise period is aborted and the R-100 Controller cated by all 5 red LED's continually flashing in ATS
transfers the load to the generator output, assumes mode. In this state the generator will still start and
automatic operation and continues to run until the run in MANUAL mode, or automatically start and run
utility is returned. if utility voltage is lost while in AUTO mode, but it
will NOT perform a weekly exercise cycle.
The weekly exercise cycle is set as follows:
In the event of a failure while running in this mode,
1. Place the AUTO/OFF/MANUAL switch in the the 5 red LED's will stop flashing, the individual fault
AUTO position LED will turn on and the engine will be shut down.
2. Press and hold the "Set Exercise Time " switch for Once the AUTO/OFF/MANUAL switch is switched
5 seconds and then release. to OFF, the individual fault LED will turn off and
At this time all 5 red LED's will flash for 10 seconds, the 5 red LED's will begin flashing to show that the
then the engine will start and run for it's 12 minute Exercise Mode has not yet been set.
exercise period, then shut down. The generator will
now start and run each week at approximately the
same time. AUTO START
This unit is designed to automatically start in the
If battery power to the R-100 Controller is lost, the event of a utility failure. A utility failure is defined as
weekly exercise time setting will be lost. This is indi- the utility voltage being less than approximately 60%
cated by all 5 red LED's continually flashing in ATS of nominal, while the utility is considered good when
mode. In this state the generator will still start and it is restored to approximately 80% or more of its
run in MANUAL mode, or automatically start and run nominal value.
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
In the event of a failure while running in this mode, the load after a 15 second delay and then switch to
the 5 red LED's will stop flashing, the individual fault Auto operation.
LED will turn on and the engine will be shut down.
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 General Information
R Panel Technical Manual

DANGER LOW BATTERY (RED LED INDICATOR)

The R-100 Controller continually monitors the bat-
 With the switch set to AUTO, the engine can
crank and start suddenly without warning. Such
tery voltage and turns on the low battery LED if the
battery voltage falls below approximately 12.2VDC
automatic start up normally occurs when utility for one minute. A low battery voltage is a non-latch-
source voltage drops below a pre-set level. To ing alarm and will not shut down the engine, however,
prevent possible injury that might be caused by it is a possible indication of a potential issue with
such sudden starts, set the AUTO/ OFF/MANUAL the battery or battery charger and should be inves-
switch to OFF and remove the NEGATIVE battery tigated.
cable from the battery before working on or The low battery LED will automatically turn off if the
around the unit. Then, place a “DO NOT OPER- battery voltage rises above approximately 12.5VDC.
ATE” tag on the control console. If the engine is running when the low battery condi-
tion occurs, the engine will continue to run as long
MANUAL START as possible.
Allows the user to start and run the generator manu- If the battery voltage drops below 6V at any time dur-
ally. Transfer of the load to the generator will occur ing cranking, the crank cycle will be terminated and
if the utility is lost while the engine is running in the the low battery LED will remain lit. This is a latched
manual mode. 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 Occurs if the oil pressure switch closes while the
following conditions being true: engine is running after the 10 second hold off timer
1. Switch in the AUTO position. expires. This is a latched fault and will shutdown the
engine.
2. No other warning indicator present.
3. Controller is functional.
The System Ready LED will also indicate if utility HIGH COOLANT TEMP/LOW COOLANT
voltage is present at the control board. The system
ready LED will flash every second (at a 0.5 second
LEVEL (RED LED INDICATOR)
Occurs if either the high coolant temp switch closes,
ON and a 0.5 second OFF rate) when utility voltage is
or the low coolant level switch is in air. The two sen-
not present at the control board when the switch is in
sors are wired in parallel on the engine. Checks are
either the AUTO or MANUAL position. This function
made after the 10 second hold off timer expires. This
is ONLY available with DIP Switch Position 2 in the
is a latched fault and will shutdown the engine.
OFF position (ATS application).
The System Ready LED will also indicate if the
Generator is in the GTS Mode (i.e. DIP Switch OVERSPEED (RED LED INDICATOR)
Position 2 in the ON Position). The system ready LED An overspeed shutdown will occur if the engine speed
will flash at a 5 seconds ON and 1 second OFF rate is greater than 4320 rpm for 3 seconds with a 3600
in GTS Mode. rpm engine or greater than 2160 rpm with an 1800
rpm engine. An Overspeed condition will shutdown
the engine and activate the over speed LED. An imme-
LOW FUEL PRESSURE (YELLOW LED diate overspeed shutdown will occur if the engine
speed is greater than 4500rpm with a 3600rpm
INDICATOR) engine or greater than 2250 rpm with an 1800 rpm
The yellow low fuel pressure LED will turn ON if the engine.
fuel supply pressure drops below approximately five
inches water column (i.e. occurs when the low fuel
pressure sensing switch on the fuel regulator opens). RPM SIGNAL FAILURE (FLASHING RED
This is a non-latched fault (visual LED warning only)
and does not trigger the controller alarm output. Low OVERSPEED INDICATOR)
fuel pressure sensing is active in all generator operat- If the R-100 controller does not receive a signal
ing modes (i.e. MANUAL, OFF and AUTO). from the engine crank or flywheel sensor, the R-100
controller cannot maintain the generator output fre-
quency or monitor for an overspeed condition. If this
signal is lost the R-100 controller will shut down the
engine as follows:
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R Panel Technical Manual

‹ RPM SIGNAL FAILURE DURING CRANKING ALARM CANCEL

The engine control board (R-100 controller) will When the generator is shut down on a latched fault or
monitor the engine speed signal during engine crank- latching alarm, the AUTO/OFF/MANUAL switch must
ing. If the control board does not see a valid signal be set to the OFF position to turn off the correspond-
within the first four seconds of each crank cycle it ing fault LED. Prior to moving the switch to the OFF
will stop the crank cycle, lock out on a shut down position, record which LEDs are ON or FLASHING
fault and flash the overspeed LED. and the date on the back cover of this manual.

‹ RPM SIGNAL FAILURE DURING RUNNING AUTOMATIC TRANSFER SWITCH (ATS

Running mode is handled differently because there MODE)
is always the possibility the engine could slow down When this generator, along with an RTS-type or HS-
or stop running do to a temporary overload. To avoid type automatic transfer switch has been installed and
shutting down and latching out on a temporary prob- connected, a circuit board in the generator control
lem the following is done. If the engine is up and panel constantly monitors the utility voltage and con-
running, and the control board stops receiving a valid trols the operation of the transfer switch.
engine speed input signal it will respond as follows:
To implement this mode of operation, Position 2 of
1. It will close the throttle the eight-position DIP switch, which is located on the
2. It will shut down the engine by turning off the fuel generator circuit board (see Figure 1), must be in the
supply OFF position. In ATS Mode utility voltage sensing,
3. It will wait for 15 seconds to ensure the engine weekly exercising, and load transferring is under the
has stopped control of the generator.
4. It will then energize the starter and monitor the Should the utility voltage drop below a preset value,
engine speed signal and remain at this low voltage for a preset amount
A. If the control board does not see the engine of time, the generator cranks and starts. After the
speed signal it will stop the crank cycle, lock out generator starts, the transfer switch transfers the
on fault, and flash the overspeed LED. load circuits to the generator so the generator can
B. If the control board does see the engine speed power them. When the utility source voltage has been
input signal during cranking it will start and run restored, the transfer switch re-transfers the load
the engine normally. If the engine speed signal is circuits back to the utility source voltage and the gen-
again lost while running it will repeat the above erator shuts down.
procedure one more time.
The transfer switch is controlled by the generator
C. If the failure should repeat a third time, the con- circuit board via control wires 23 and 194. Wire 23
trol board will shut down the engine, lock out on connects the relay driver output (collector of an NPN
fault, and flash the over speed LED. transistor) on the generator circuit board to the "low
side" (Terminal 23) of the transfer relay coil in the
OVERCRANK (RED LED INDICATOR) transfer switch. Wire 194 connects positive battery
Occurs if the engine has not started within the total voltage from the generator circuit board to the "high
90 second crank cycle. This is a latched fault and will side" (Terminal 194) of the transfer relay coil in the
shutdown the engine. transfer switch.

INVALID CYLINDER DIP SWITCH

SETTING (ALL RED LED’S ON)  Ifthegenerator wires 23 and 194 are not wired to
correct terminals in the transfer switch, the
All five RED LED’s on the front panel will be ON all
circuit board in the generator control panel will
the time if the DIP switch setting for the number of
be damaged.
engine cylinders is not set correctly. For example, if
DIP switch position 6 is set to 4 cylinders and the In order for the generator utility voltage sensing
controller is actually installed on a six-cylinder gen- function to work, it is necessary to provide a 5 amp
erator, then all five RED LED’s will be ON until the fused 240 VAC or 208 VAC or 480 VAC utility source
correct DIP switch setting is used. 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 2).

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R Panel Technical Manual

Figure 2 - Connection Diagram (ATS Mode)

FROM UTILITY TO LOAD
FEEDER CIRCUITS
MAIN LINE
CIRCUIT
BREAKER
OR FUSE GENERATOR
LOAD
FUSE N1 N2 DISTRIBUTION CHARGER
120 VAC
N1 T1 PANEL
N2 T2 LINE
NEU
FUSE GND

RTS-TYPE 194 194

23 23
OR
HS-TYPE
TRANSFER 178
183
SWITCH N2 N1
E1 E2 E1 E2

In order for the generator battery charger function Generator Control Board DIP Switch Position 2 ON =
to work, it is necessary to provide a 120Vac util- 2-Wire Start GTS Mode:
ity source connection to the generator wiring panel • The generator control board will NOT monitor the
LINE, NEUTRAL and GND terminals (see figure 2). utility
Transfer Switch terminals N1 and N2 (also called • The generator control board will NOT perform a
Utility 1 and Utility 2) are the input utility AC power weekly exercise. (In GTS Mode The Green System
connections to the Transfer Switch. Transfer Switch Ready LED will be ON for 5 seconds and OFF for
terminals T1 and T2 (also called Load 1 and Load 1 second)
2) are the transfer switch AC output power termi- • The generator control board will NOT activate the
nals that go to the load circuit distribution panel. transfer output
Transfer Switch terminals E1 and E2 are the AC The generator control board WILL monitor all engine
power terminals that come from the generator's main conditions and shut down on all the faults listed in
alternator. this document.
For the W Type transfer switch to control utility volt-
ENGINEERED TRANSFER SWITCH age sensing, weekly exercising and load transferring,
suitable wiring must also be connected from the
(2-WIRE START GTS MODE) transfer switch 178 and 183, 2-Wire Start terminals
When required, the generator can be installed with
to the corresponding generator 178 and 183 2-Wire
an engineered W or HTS type transfer switch which
Start terminals. Recommended wire gauge sizes for
controls utility voltage sensing, weekly exercising and
the 2-Wire Start wiring depend on the length of the
load transferring.
wire (see wiring length chart).
When Position 2 of the eight-position DIP switch, MAXIMUM WIRE LENGTH RECOMMENDED WIRE
which is located on the generator circuit board (See SIZE
Figure 1), is in the ON position then utility voltage 460 feet (140M) No. 18 AWG.
sensing, weekly exercising and load transferring is 461 TO 730 feet (223M) No 16 AWG.
under the control of the Engineered W Type transfer 731 to 1,160 feet (354m) No 14 AWG.
switch (GTS Mode). 1,161 to 1,850 feet (565m) No 12 AWG.
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R Panel Technical Manual

Figure 3 - Connection Diagram (GTS Mode)

FROM UTILITY TO LOAD

FEEDER CIRCUITS
MAIN LINE
CIRCUIT
BREAKER
OR FUSE GENERATOR
LOAD
FUSE N1 N2 DISTRIBUTION CHARGER
N1 T1 120 VAC
PANEL
N2 T2 LINE
HTS-TYPE NEU
FUSE GND
OR
W-TYPE 194
TRANSFER 23
SWITCH
178 178
183 183
N2 N1
E1 E2 E1 E2

Route the 2-Wire Start control wires through suit- MANUAL: The control board will start and run the
able, approved conduit which is separate from the AC generator whenever the switch is in the manual posi-
power leads. Connection of wire 178 to wire 183 by tion.
relay contact closure action (volt free switch contacts)
AUTO: The control board will monitor the 2-wire
in the transfer switch must result in generator engine
start circuit. When the 2-wire start wire 178 is con-
cranking and startup (See Figure 3).
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
 Do NOT connect battery voltage, utility voltage
(N1/N2) or load voltage (T1/T2) to either the board will stop the generator.
178 or the 183 2-Wire start terminals as this will When the control board is in AUTO, MANUAL or OFF
damage the generator control board. (GTS Mode) the GREEN System Ready LED will flash
In order for the generator battery charger function (5 seconds ON, 1 second OFF) to indicate that the
to work, it is necessary to provide a 120Vac util- Transfer Switch is performing the utility monitoring
ity source connection to the generator wiring panel and transfer functions.
LINE, NEUTRAL and GND terminals (see figure 3).
When in GTS mode, the control board will respond VOLTAGE REGULATOR ADJUSTMENT
as follows based on the AUTO/OFF/MANUAL switch Four adjustment potentiometers are provided on the
position. voltage regulator installed in the control panel (see
OFF: The generator will not start and run in this Figure 4). These are Voltage Adjust, Gain, Stability,
position. Only the System Ready LED and the Low Underfrequency Adjust.
Battery LED are active in the GTS OFF Mode. The voltage regulator potentiometers have been set at
the factory and should NOT be adjusted.
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R Panel Technical Manual

Figure 4 — Voltage Regulator ‹ R-100 J2 CONNECTOR (14 PIN WHITE)

Pin #
1 Reserved (Do not connect any wires to this
pin)
2 Start (Crank) Relay Driver Output (minimum
coil resistance is 90 ohms)
3 Fuel (Run) Relay Driver Output (minimum
coil resistance is 90 ohms)
4 2-Wire Start Input (from relay contact 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
‹ R-100 J1 CONNECTOR (23 PIN, resistance is 90 ohms)
10 Transfer Relay Driver Output (minimum coil
BLACK=1800RPM, BLUE=3600RPM) resistance is 90 ohms)
Pin # 11 Manual Input
1 Digital 12V Supply 12 19.5VAC Utility Sense Return
2 Reserved (Do not connect any wires to this 13 Reserved (Do not connect any wires to this
pin) pin)
3 GND-B to Digital Driver 14 GND-B (Battery Ground)
4 Hi-Coolant Temp/Lo Coolant Level Input
5 0V to Digital Driver
6 5V Supply to Digital Driver
7 Distributor (Hall Sensor) 12V Sensor Supply  Refer to the individual Generator wiring dia-
grams and schematics for additional informa-
8 Reserved (Do not connect any wires to this tion.
pin)
9 2.5L/3.0L Crank Signal Input or 3.9L
Flywheel Sensor Input
2A AND 10A BATTERY CHARGERS
There are two types of battery chargers. A 2 Amp
10 2.5L/3.0L Crank Signal Return or 3.9L battery charger and a 10 Amp battery charger. Each
Flywheel Sensor Return charger type is available as either a 12V or 24V char-
11 Low Fuel Pressure Input ger, as appropriate for the Generator's DC electrical
12 Digital Position Feedback Input system voltage.
13 Reserved (Do not connect any wires to this The 2 Amp battery chargers are "float" type char-
pin) gers. A "float" type charger will charge the battery at
14 Coil + (Supply voltage to engine coil pack) its maximum output current rating until the battery
15 Coil A Driver voltage reaches a "float" voltage and then the charge
16 3.9L Distributor Sensor Return current will decrease to maintain the battery at that
17 3.9L Distributor Sensor Input "float" voltage.
18 Digital PWM Output The 10 Amp battery chargers are "equalize" type
19 Digital Enable Output chargers. An "equalize" type charger will charge the
20 Lo Oil Pressure Input battery at its maximum output current rating until
the battery voltage reaches an "equalize" voltage and
21 3.9L Flywheel Sensor Screen or 3.0L Crank then the charge current will decrease to maintain the
Sensor Screen battery at a lower "float" voltage.
22 Coil C Driver
23 Coil B Driver

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 General Information
R Panel Technical Manual

The 2 Amp chargers incorporate 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,
 Do not use any jumper cables or booster battery
to crank and start the generator engine. If the
5x20mm, P/N 218002. The AC line fuse is located on battery has completely discharged, remove it
the charger printed-circuit board. The output DC bat- from the generator for recharging.
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 chargers incorporate fuses on both the  Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position, before connecting the battery
input ac line and the battery charger output. The cables. If the switch is set to AUTO or MANUAL,
input AC line fuse is a Littelfuse 5 Amp, Slo-Blo Fuse, the generator can crank and start as soon as the
5x20mm, P/N 218005. The AC line fuse is located battery cables are connected.
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
 Be sure the utility power supply to the battery
charger is turned off, or sparking may occur at
printed-circuit board. the battery posts as the cables are attached and
cause an explosion.
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 ‹ 2A, 12VDC BATTERY CHARGER
charger to turn-on. Nominal Input AC Line Voltage .......................... 120Vac
The boost voltage required is approximately 11 volts Operating AC Line Voltage Range ................... 108Vac to
for a 12V system and 22 volts for a 24V system. If 132Vac
the battery open-circuit voltage is less than the above Input AC Line Frequency ..............................50 or 60Hz
boost voltage, it is recommended that the battery be AC Line Fuse ......................... 2 Amp Slo-Blo, 5x20mm,
checked. Littelfuse P/N 218002
Battery Fuse ........................................5 Amp, Littelfuse
If the voltage of the Generator's 12V battery exceeds Mini-Blade Fuse P/N 297005
15VDC, during normal charging operation, the bat- Nominal Charge Rate ........................................ 2 Amps
tery should be checked. Typical battery voltages, Float Voltage (typ) ..........................................13.8 Volts
when a 12V battery is being charged, should be in the Battery Undervoltage Shutdown (typ) .............. 11 Volts
13VDC to 15VDC range.
The 2 Amp and 10 Amp chargers are UL recognized LED Indicators
for use in the R-Panel enclosure and are not to be AC Line Voltage > 108Vac ................Green LED ON
operated outside the R-Panel enclosure. Battery Connected & Charging .........Yellow LED ON
(the Green LED must be ON to obtain a valid bat-
DANGER tery charging indication,
Yellow LED ON if charge current > approx 0.5
 Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
Amps)
Battery Current Drain (AC Power OFF) ........ 30mA (typ)
around the battery for several hours after charg- AC Line Connection........................... via terminal block
ing. The slightest spark can ignite the gas and (AC Hot, AC Neut & GND)
cause an explosion. Such an explosion can shat- Battery Connections .......................... via terminal block
ter the battery and cause blindness or other (Pos +, Neg -)
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,
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.

12
 General Information
R Panel Technical Manual

‹ 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
Battery Fuse ............................ 15 Amp, Littelfuse ATO
Blade P/N 257015
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)

13
 GENERAC® POWER SYSTEMS, INC.
P.O. BOX 8
WAUKESHA, WI 53187
Part No. 0F6402 Revision C (10/20/05) Printed in U.S.A.