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 |