The Power Zone 200 is a generator-set controller. It is used on generator sets from Generac, including the G007258-0, G007259-0, G007323-0 and G007324-0.
Also fitted to: Generac 10 kW, Generac 14 kW, Generac 18 kW, Generac 22 kW, Generac 24 kW, Generac 26 kW, Generac 28 kW, Generac G007258-0 / G007323-0, Generac G007259-0 / G007324-0.
| Code | Meaning | Remedy |
|---|---|---|
| 0 | Utility failure | Crank and start engine, transfer load to Generator if Utility returns above 75% nominal for 15 seconds |
| 000001 | DANGER | |
| 1 | Engine won’t crank. | |
| 10 | Defective Low Coolant Level Switch | |
| 11 | Defective AUTO/OFF/MANUAL switch | |
| 12 | Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board. | |
| 13 | Engine starts then shuts down. | |
| 1501 | RPM Sensor ALARM | |
| 1900 | Prolonged Over-Voltage Undervoltage | |
| 1901 | Instantaneous Undervoltage | |
| 1902 | Undervoltage | |
| 2 | Engine cranks but won't start | |
| 2099 | Wiring Error ALARM | |
| 2100 | Stepper Overcurrent ALARM | |
| 2102 | Overloaded ALARM | |
| 2399 | Overload Remove Load ALARM | |
| 3 | Engine starts hard, runs rough. | |
| 4 | Engine oil level is low. | |
| 5 | Engine is overheated. | |
| 6 | Defective Low Oil Pressure Switch | |
| 7 | Defective Coolant Temperature Switch | |
| 8 | Defective Control Module circuit board | |
| 9 | Coolant Level is Low. | |
| Battery is Dead | Problem 22 – Battery is Dead | Test 45 – Check Battery and Cables |
| Evolution E-Code 2400 | Engine Will Not Crank When Utility Power Source Fails | Test 44 – Check 7.5 Amp Fuse Evolution Alarm Code 2400 |
| Generator Will Not Exercise | Problem 20 – Generator Will Not Exercise | Test 45 – Check Battery and Cables |
| No Low Speed Exercise | Problem 21 – No Low Speed Exercise | |
| Problem 18 | Shutdown Alarm/Fault Occurred | |
| Safety004 | Not stated | Engine shutdown; restart after temperature returns to safe operating level; add oil and reset generator control board |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine cranks but will not start | No fuel. Faulty fuel solenoid (FS). Harness/wiring issue. Faulty spark plug(s). Valve clearance out of adjustment, if applicable. See Engine. | Replenish fuel / turn on fuel valve. Contact an IASD for assistance. Clean; inspect spark plug gap; replace spark plug(s) if necessary. Inspect and adjust valve clearance. |
| Engine cranks but will not start. | 1. Out of fuel. 2. Defective fuel solenoid (FS). 3. Defective spark plug(s). 4. Valve lash out of adjustment. | 1. Replenish fuel / Turn on fuel valve. 2. * 3. Clean, re-gap or replace plug(s). 4. Reset valve lash. |
| Engine cranks but won't start | 1. Out of fuel. 2. Fuel solenoid (FS) is defective 3. Open Wire #14A from Engine Control circuit board. 4. Spark plugs defective. 5. Door on tank not closed. | 1. Replenish fuel. 2. Replace solenoid.* 3. Reconnect wire. 4. Clean, regap or replace plugs. 5. Close door on tank. |
| Engine damage. | Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. | |
| Engine oil level is low. | 1. Engine starts then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run | |
| Engine speed and frequency drop excessively under load | Engine may be underpowered; result of dirty air cleaner, loss of engine compression, faulty fuel settings, or incorrect ignition timing | Refer to Section 4.5 Diagnostic Tests for repair procedures |
| Engine starts hard and runs rough | Plugged or damaged air cleaner. Faulty spark plug(s). Incorrect fuel pressure. Fuel selector in wrong position. Valve clearance out of adjustment, if applicable. See Engine. | Inspect and clean air cleaner. Clean; inspect spark plug gap; replace spark plug(s) if necessary. Verify fuel pressure to regulator is 10–12 in water column (2.49–2.99 kPa) for LP gas, and 3.5–7.0 in water column (0.87–1.74 kPa) for NG. Set fuel conversion valve to correct position and program controller for fuel type. Inspect and adjust valve clearance. |
| Engine starts hard and runs rough. | 1. Air cleaner plugged or damaged. 2. Defective spark plug(s). 3. Fuel regulator not set. 4. Fuel pressure incorrect. 5. Fuel selector in wrong position. 6. Choke remains closed. | 1. Check / replace air cleaner. 2. Clean, re-gap or replace plug(s). 3. Set fuel regulator. 4. Confirm fuel pressure to regulator is 10-12” water column (19-22mm mercury) for LP, and 3.5 - 7” water column (9-13mm mercury) for natural gas. 5. Move selector to correct position. 6. Verify choke plate moves freely. |
| Engine starts hard, runs rough. | 1. Flame arrestor (air cleaner) plugged or damaged. 2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. | |
| Engine will not crank | Blown fuse. Loose, corroded, or faulty battery cables. Faulty starter contact. | Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an IASD if fuse continues to blow. Tighten, clean, or replace as necessary.* Contact an IASD for assistance. |
| Engine will not crank. | 1. Fuse blown. 2. Loose, corroded or defective battery cables. 3. Defective starter contact. 4. Defective starter motor. 5. Dead Battery. | 1. Correct short circuit condition by replacing 7.5 Amp fuse in generator control panel. 2. Tighten, clean or replace as necessary.* 3. *See #2. 4. *See #2. 5. Charge or replace battery. |
| Engine won’t crank. | 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. | 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* |
| Generator Produces High Voltage | TEST 1 - CHECK AC OUTPUT VOLTAGE, HIGH -> TEST 11 - CHECK AC OUTPUT FREQUENCY, HIGH -> TEST 12 - CHECK STEPPER MOTOR CONTROL, REFER TO PROBLEM 1, TEST 3 - CALIBRATE VOLTAGE, VOLTAGE OUTPUT AT BREAKER IS BELOW 220 OR ABOVE 270 VOLTS -> VOLTAGE OUTPUT AT BREAKER IS BETWEEN 220-270 VAC -> FREQUENCY O.K., BUT VOLTAGE INCORRECT -> FREQUENCY AND VOLTAGE O.K. -> STOP TESTS | |
| Generator Produces High Voltage at No-Load | TEST 14 - CHECK AC OUTPUT FREQUENCY TEST 16 - CHECK STEPPER MOTOR CONTROL TEST 2 - CHECK AC OUTPUT VOLTAGE | |
| Generator Produces Low Voltage at No-Load | TEST 14 - CHECK AC OUTPUT FREQUENCY TEST 16 - CHECK STEPPER MOTOR CONTROL TEST 2 - CHECK AC OUTPUT VOLTAGE | |
| Generator Produces Zero Voltage or Residual Voltage | TEST 1 - CHECK MAIN CIRCUIT BREAKER TEST 4 - PERFORM FIXED EXCITATION / ROTOR AMP DRAW PERFORM STATOR INSULATION RESISTANCE TEST - SECTION 1.4 PERFORM ROTOR INSULATION RESISTANCE TEST - SECTION 1.4 TEST 7 - TEST STATOR TEST 5 - WIRE CONTINUITY TEST 6 - FIELD BOOST TEST 11 - CHECK ROTOR RESISTANCE CHECK VOM FUSES TEST 12 - CHECK BRUSHES & SLIP RINGS TEST 13 - TEST ROTOR ASSEMBLY REPAIR OR REPLACE FUSES | |
| Generator Shuts Down for Under Voltage | Perform FBCT, Preliminary Output Voltage Test (if Evolution non-Synergy with Firmware v1.12 or higher), TEST 4 - Fixed Excitation / Rotor Amp Draw, RE-TEST, REPLACE CONTROLLER if necessary, CHECK DMM FUSES, TEST 5 - SENSING CIRCUIT WIRES 11 AND 44, BAD -> TEST 6 - EXCITATION WINDING CIRCUIT 2 AND 6, BAD -> TEST 8 - RESISTANCE CHECK OF ROTOR CIRCUIT, GOOD -> TEST 7 - TEST STATOR, BAD -> PERFORM STATOR INSULATION RESISTANCE, REPLACE STATOR ONLY if necessary, TEST 10 - TEST ROTOR ASSEMBLY, BAD -> REPLACE ROTOR AND STATOR, BAD -> REPAIR OR REPLACE, BAD -> ROTOR CIRCUIT FAILURE, TEST 9 - CHECK BRUSHES & SLIP RINGS, GOOD -> BAD -> TEST 10 - TEST ROTOR ASSEMBLY, GOOD -> TEST 7 - TEST STATOR, BAD -> REPLACE ROTOR ONLY, BAD -> REPLACE ROTOR AND STATOR, PERFORM ROTOR INSULATION RESISTANCE TEST | |
| Generator is set to OFF, but the engine continues to run. | 1. Controller wired incorrectly 2. Defective control board. | 1. Repair wiring or replace controller* 2. Replace controller |
| High Temperature ALARM | Check the inlet/outlet for debris. Check temperature sensor and wiring. | |
| Low Oil Pressure ALARM | Occurred while running The default Extended alarm for low oil pressure. Check oil level and pressure. | |
| NOT ACTIVATED! | Press ESC and then ENTER to reset Install Wizard. | |
| No AC output from generator | Generator MLCB (generator disconnect) is OFF (OPEN). Generator internal failure. | Set generator MLCB (generator disconnect) to ON (CLOSED). Contact an IASD for assistance. |
| No AC output from generator. | Defective Control Module circuit board | Replace board.* |
| No transfer to standby after utility source failure | Generator MLCB (generator disconnect) is OFF (OPEN). Faulty transfer switch coil. Faulty transfer relay. Faulty control logic board. | Set generator MLCB (generator disconnect) to ON (CLOSED). Contact an IASD for assistance. Transfer relay circuit open. Contact an IASD for assistance. |
| No transfer to standby after utility source failure. | 1. Defective transfer switch coil. 2. Defective transfer relay. 3. Transfer relay circuit open. 4. Defective control logic board. | 1. * 2. * 3. * 4. * |
| Over-crank fault during initial start-up | Reset control board by pushing OFF button and ENTER key, restart up to two more times if necessary. If unit fails to start, contact a local dealer for assistance | |
| Overspeed ALARM | Prolonged (60 Hz on a 50 Hz unit, 72Hz on 60Hz unit) Over specified Hz for 3 seconds. Possible cause: Stepper motor/mixer body assembly issue. | |
| Unit consumes large amounts of oil | Excessive engine oil. Faulty engine breather. Incorrect type or viscosity of oil. Damaged gasket, seal, or hose. | Adjust oil to correct level. See Checking Engine Oil Level. Contact an IASD for assistance. See Engine Oil Requirements. Inspect for oil leaks. |
| Unit consumes large amounts of oil. | 1. Engine over filled with oil. 2. Engine breather defective. 3. Improper type or viscosity of oil. 4. Damaged gasket, seal or hose. | 1. Adjust oil to proper level. 2. * 3. See “Engine Oil Recommendations”. 4. Check for oil leaks. |
| Unit is set to OFF, but engine continues to run | Controller wired incorrectly. | Contact an IASD for assistance. |
| Unstable Voltage or Incorrect Output Which is Not Triggering a Shutdown | TEST 1 - CHECK AC OUTPUT VOLTAGE, ERRATIC -> PROCEED TO PROBLEM 3 |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.