Generator controller common faults and maintenance experience

 After years of accumulation, the common faults and maintenance experience of generator controller and their processing methods are listed for reference and application by generator maintenance personnel.

 

fault phenomenon

an examination

test result

Fault reason and treatment method

Inaccurate oil pressure and temperature measurement

Is there a dedicated negative line for connecting the sensor?

connected

Reconnect the battery negative to the engine block, especially the rust

Is the sensor connection line screw loose?

none

—Measure the port voltage of the oil pressure sensor, which is required to be less than 0.3V

Low oil pressure alarm

LCD display is low oil pressure switch alarm or low oil pressure alarm

Oil pressure switch

– Port configuration error – Oil pressure switch circuit

No response to start

low oil pressure

Refer to the oil pressure measurement is not allowed to handle

The starter motor rotates, but it cannot be started successfully

Whether the LCD shows the startup status

unusual

Read the operating instructions carefully

Measure the fuel output of the controller for power

none

Controller failure

has output

Check the motor output of the controller

Measure the starter motor output of the controller for power

none

Controller failure

Have

– Starter relay failed – Starter motor damaged or stuck

The starter motor rotates, but it cannot be started successfully

Check whether the actuator operates or whether the output from the governor to the actuator has more than 6VDC

Have

Please refer to the troubleshooting method of the speed control system

none

Check if the governor has power

Whether the governor has power

none

Poor contact of external expansion relay

Have

Please refer to the troubleshooting method of the speed control system

The motor does not separate after starting successfully

Check startup success condition configuration, especially oil pressure for startup success

 

It is strongly recommended to use RPM conditions as separation conditions will be more accurate

startup failure warning

Check for other warning messages during startup

  

Speed signal loss alarm

Check whether there is access to the speed sensor or related lines

normal

 

Check if the speed signal voltage reaches or exceeds 2VAC

low signal voltage

– Clean the iron filings at the detection end of the sensor – Reduce the gap between the sensor and the flywheel – Sensor failure

No idle function

Check the idle line from the governor to the controller

normal

– Check whether the corresponding port configuration of the controller is correct – Check whether the idle delay time of the controller is 0

Unassisted shutdown during operation

Check carefully whether there is an alarm prompt message

none

Controller failure

Mains failure will not start automatically

Check the mains detection circuit

normal

Check the relevant utility failure configuration

A shutdown failure warning occurs

Check if the oil pressure is not 0 after stopping

is 0

Controller failure

Underspeed or undervoltage shutdown during startup

Increase warm-up time

  
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