Generator Controller

Problem Items to Check, Troubleshooting Steps, Remedies

No power-up

Fuse - position 11Ensure the controller power switch below the controller is turned on.

Ensure the control power disconnect switch on the 24 VDC distribution panel is turned on.

Check the fuse that provides power to the generator controller (Position 11) in the 24VDC distribution panel.

Verify that the battery connections are secure and that the battery voltage is close to the nominal level.

Check the corresponding wire and terminal connections at the back of the fuse panel.

Check the battery power connections at the back of the generator controller, terminals 2 and 3. Verify that there is battery voltage measured on these terminals with respect to ground.

LCD display is faint and slow to respond

This can occur to the generator controller if the ambient temperature falls below -20°C (e.g. if the generator unit has been stored outside in temperatures at or below -20°C, the controller display will exhibit this behavior).

Controller is in ‘Editor Mode’

If the generator controller is in ‘Editor Mode’, press and hold the checked button to exit and return to normal user mode (hold the checked button for approximately 3 seconds).

The editor mode should not be accessed without direction from (Undefined variable: General.CompanyName)

Electrical trip - Overload

The generator has been subjected to an excessive load above the threshold configured in the generator controller for the allowable time limit. The generator controller will perform an electrical trip followed by an engine shutdown.

A pre-alarm warning will be activated before the electrical trip occurs.

Possible causes:

  • Excessive continuous overload on generator.

Remedies:

  • Reduce the load on the generator.

Electrical trip –

High inlet air temperature

The inlet air temperature has reached or exceeded the threshold configured in the generator controller, and has caused an electrical trip. The main contactor is opened and the engine goes through a cool-down period prior to shutting down.

Possible causes:

  • Restricted air flow through the generator.
  • Excessive engine overheating.

Items to check:

  • Check that the air inlet and outlets are clear and unobstructed.
  • Ensure that the engine radiator fan is operating correctly.
  • Ensure that the air damper system is functioning correctly to regulate ambient temperature inside the unit.

Electrical trip –

Overcurrent

The generator current has reached or exceeded the maximum threshold for the allowable time limit.

Possible causes:

  • Unbalanced loads operating close to the full output capabilities of the generator.
  • Excessive load demand put on generator.
  • Mechanical problem with load, e.g. worn bearings causing excessive friction on a motor.
  • Large motor starting attempts.

Ensure that the load is appropriate for the generator. Motors typically require three times their rated current when starting.

Electrical trip –

Bus not live

The generator controller has not been able to measure or verify the bus voltage after closing the contactor, and has caused an electrical trip.

Possible causes:

  • One or more of the bus metering fuses for the generator controller is at fault.
  • Controllers are blown or not installed.
  • Main contactor failed to close.
  • Failure on any part of the contactor control circuit for generator 1 and 2 (control transformer fuses, fuse holders, contactor control relays and/or wiring).
  • Controller plant power fuse is blown (provides power to the contactor control output on the generator controllers in addition to providing power to the engine glow plug and crank relays).

Electrical trip –

Undervoltage

The generator output voltage has reached or fallen below the threshold configured in the generator controller, and has caused an electrical trip.

Possible causes:

  • Excessive load applied to the generator to the extent that the generator controller cannot maintain control of the engine governor to maintain the nominal speed /frequency of the generator.

Remedies:

  • Reduce the load on the generator.

 

Electrical trip –

Underfrequency

The frequency of the generator has reached or fallen below the threshold configured in the generator controller, and has caused an electrical trip.

Possible causes:

  • Excessive load applied to the generator (e.g. large motor starts, increased or sudden load demand put on generator).
  • Fuel supply problem with engine.
  • Problems or failure with an engine component such as fuel pump, injectors or Engine ECU. Review unit for fault codes.

Remedies:

  • Reduce the load demand on the generator.
  • Troubleshoot engine governor as per the engine manufacturer's specifications.

Manufacturers’ procedures:

  • Ensure the fuel system is intact, with no leaks or restricted lines.

NOTE  When the generator is closed onto the BUS, the generator controller can control the engine governor and make quick adjustments to help maintain and recover engine speed in response to changes in the load. If an excessive load is applied to the generator, the generator controller's adjustment of the governor may not be enough for the engine to recover before an underfrequency electrical trip occurs.