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 22 kW, Generac 24 KW, Generac 26 kW, Generac 28 kW, Generac Air-Cooled Residential Standby Generator.
| Code | Meaning | Remedy |
|---|---|---|
| 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 | |
| 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 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 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, runs rough. | 1. Flame arrestor (air cleaner) plugged or damaged. 2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. | |
| 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 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 | |
| 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. | |
| No AC output from generator. | Defective Control Module circuit board | Replace board.* |
| 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. | |
| Unstable Voltage or Incorrect Output Which is Not Triggering a Shutdown | TEST 1 - CHECK AC OUTPUT VOLTAGE, ERRATIC -> PROCEED TO PROBLEM 3 | |
| Voltage and Frequency Drop Excessively When Loads Are Applied | TEST 14 - CHECK VOLTAGE AND FREQUENCY UNDER LOAD, BOTH LOW -> TEST 15 - CHECK FOR OVERLOAD CONDITION, NOT OVERLOADED -> GOOD -> IF RECONFIGURED TO LP GAS, VERIFY THAT PROPER PROCEDURE WAS FOLLOWED (REFER TO INSTALLATION MANUAL), GOOD -> OVERLOADED -> DISCONTINUE TESTING, REDUCE LOADS TO UNIT’S RATED CAPACITY, TEST 12 - CHECK STEPPER MOTOR CONTROL, GOOD -> BAD -> REPAIR OR REPLACE, LOOK FOR A SHORTED CONDITION IN A CONNECTED LOAD OR IN ONE OF THE LOAD CIRCUITS, GOOD -> TEST 7 - CHECK STATOR AC POWER WINDINGS, ENGINE CONDITION GOOD -> REPAIR OR REPLACE, BAD -> TEST 16 - CHECK ENGINE CONDITION, GOOD -> GO TO “PROBLEM 18 - ENGINE STARTS HARD AND RUNS ROUGH/LACKS POWER” SECTION 4.3 |
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.