The Advanced Digital Features is a generator-set controller. It is used on generator sets from Kohler, including the 12RES and 8.5RES.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| AF | Auxiliary fault input shutdown | Indicates a shutdown initiated by pushing the emergency stop switch. (TRES models only) | Check the position of the emergency stop button. (TRES models only) |
| AF | Indicates a shutdown initiated by pushing the emergency stop switch. | Not used on RES models. | Check the position of the emergency stop button. (TRES models only) |
| AF | Input from a customer-supplied switch that closes when the fault is active. The generator set shuts down and will not start when the fault is active (input is grounded). | Check the cause of the auxiliary fault. | |
| HB | Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting. | Check the battery rating and condition. Check the battery charger operation. | |
| HB | High battery voltage warning | Fault code is displayed if the engine starting battery voltage rises above 16 VDC for more than 30 seconds when the engine is running. Not operative during the engine crank cycle, this fault condition does not inhibit engine starting. | Check the battery rating and condition. Check the battery charger operation. |
| HE | High engine temperature shutdown | Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds. This function becomes active after the engine reaches the crank disconnect speed. | Check for blocked air inlets and exhaust outlets. |
| HE | Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds. This protective becomes active after the engine reaches the crank disconnect speed. | Check for blocked air inlets and exhaust outlets. | |
| High engine temperature | Engine runtime, hours | ||
| LB | Fault code is displayed if the engine starting battery voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting. | Check the battery rating and condition. Check the battery charger operation. | Charge or replace the battery. |
| LB | Low battery voltage warning | Fault code is displayed if the engine starting battery voltage falls below 11 VDC for more than 30 seconds when the engine is not running. Not operative during the engine crank cycle, this fault condition does not inhibit engine starting. | |
| LOP | Low oil pressure shutdown | Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This function becomes active 30 seconds after the engine has reached crank disconnect speed (30 second inhibit). Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine. | Check for leaks in the lubrication system. Check the oil level and add oil if the level is low. |
| LOP | Shutdown occurs if a low oil pressure condition exists 7 seconds after the engine has reached crank disconnect speed. | Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine. Check for leaks in the lubrication system. | Check the oil level and add oil if the level is low. |
| Locked rotor | The generator set also shuts down on OC if no engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected. | ||
| Low battery voltage | Crank cycle status | ||
| OC | Overcrank shutdown | Shutdown occurs after 3 unsuccessful starting attempts. The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest. | Check the fuel supply, spark plug, and battery. Check for loose connections. Contact an authorized distributor/dealer for service if problem continues. |
| OC | Shutdown occurs after 3 unsuccessful starting attempts. The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest. The generator set also shuts down after 1 crank attempt if no speed signal is sensed. Shuts down 1 second after the fault is detected. | Check the fuel supply, spark plug, and battery. Check for loose connections. | Contact an authorized distributor/dealer for service if problem continues. |
| OF | Overfrequency shutdown | Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. This function becomes active 10 seconds after engine start (10 second inhibit). | Contact an authorized distributor/dealer for service if problem continues. |
| OF | Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 1 second. This protective becomes active 30 seconds after engine start. | Contact an authorized distributor/dealer for service if problem continues. | |
| OS | Overspeed shutdown | Shutdown occurs if the engine speed exceeds 110% of the normal running speed for more than 0.3 seconds. | Contact an authorized distributor/dealer for service if problem continues. |
| OS | Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 1 second. | Contact an authorized distributor/dealer for service if problem continues. | |
| OU | Overvoltage shutdown | Shutdown occurs if the voltage exceeds 120% of the system nominal voltage for more than 2 seconds. | Contact an authorized distributor/dealer for service if problem continues. |
| OU | Shutdown occurs if the voltage exceeds 120% of the voltage regulator setpoint for more than 1 second. | Contact an authorized distributor/dealer for service if problem continues. | |
| Overcrank | Remote two-wire start/stop capability | ||
| Overfrequency | Digital voltage regulation: ±1.5% RMS no-load to full-load | ||
| Overspeed | Automatic start for programmed cranking cycle | ||
| UF | Shutdown occurs when the governed frequency falls 1 Hz below the system’s frequency setpoint for more than 1 second. | Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if problem continues. | |
| UF | Underfrequency shutdown | Shutdown occurs if the governed frequency falls below 54 Hz for more than 5 seconds. Shutdown also occurs if the governed frequency falls below 56.5 Hz for more than 60 seconds. This function becomes active 10 seconds after engine start. (10 second inhibit). | Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if problem continues. |
| UU | Shutdown occurs if the voltage falls below 80% of the voltage regulator setpoint for more than 1 second. This protective becomes active 30 seconds after engine start. | Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if problem continues. | |
| UU | Undervoltage shutdown | Shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than 10 seconds. | Reduce the load and restart the generator set. Contact an authorized distributor/dealer for service if problem continues. |
| Underfrequency | Master control switch mounted on the junction box: Run/Off-Reset/Auto | ||
| Undervoltage | Upgradeable application software |
| Symptom | Cause | Remedy |
|---|---|---|
| Accidental starting | Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. | |
| Alternator or control system problem | Perform separate excitation procedure to isolate the problem to the alternator or the control system. Then troubleshoot the alternator or control system components as follows. | |
| Auxiliary winding fuse (F1) blown | Replace the fuse. Contact an authorized distributor/dealer for service if fuse blows repeatedly. | |
| Battery acid is electrically conductive and corrosive. | Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. | |
| Battery short circuit | Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. | |
| Battery short circuits | Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. | |
| Battery short circuits can cause bodily injury and/or equipment damage. | Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. | |
| Battery short circuits. | Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. | |
| Broken or damaged vibromount(s) | Check and replace as necessary. | |
| Brushes problem | Inspect brushes and replace if worn. Check for brushes sticking in brush holder or broken brush spring. | |
| Controller LED display is off | No power to the controller: Controller fuse (F3) is blown. | Replace the fuse. If the fuse blows again, contact an authorized distributor/dealer. Low or no battery voltage. Check connections. Check the engine starting battery and battery charger. See Figure 4-3. |
| Controller fuse (F3) blown | Replace the fuse. If the fuse blows again, contact an authorized distributor/dealer. | |
| Engine malfunction | Contact an authorized distributor/dealer. | |
| Engine not running at rated rpm | Check controller settings for unit configuration (UC) and engine type (EC). Adjust governor speed. | |
| Engine not running smoothly | See “Generator set operates erratically,” this table | |
| Engine overheated | Check air intake, fuel adjustment, oil level, air inlet/outlet. | |
| Engine overloaded | Reduce electrical load. | |
| Engine power loss | Refer to the Engine Service Manual for troubleshooting and repair instructions. | |
| Excessive engine/generator vibration | Check, rotor, crankshaft, bearing, etc. (disassembly of engine and/or alternator may be required). | |
| Exhaust piping or air inlets/outlets not securely installed | Inspect for loose parts and secure if necessary. | |
| Fuel valve/fuel regulator | Check regulator/valve operation. | |
| Fuse blows repeatedly | Replace Auxiliary winding fuse (F1). Contact an authorized distributor/dealer if the fuse blows again. | |
| Gas fuel leaks can cause an explosion. | Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. | |
| Generator does not start | Low battery voltage or faulty starter motor | Check the battery and ensure it is fully charged. If necessary, replace the battery. Check the starter motor for proper operation. |
| Generator overloaded | Reduce load. | |
| Generator set cranks but does not start | No fuel | Open (turn on) manual fuel valve. Check fuel supply tank (LP). |
| Generator set does not crank | Weak or dead battery | Recharge or replace battery. If battery is weak or dead, check battery charger fuse, power supply, and operation. |
| Generator set master switch in the OFF/RESET position | Move generator set master switch to the AUTO or RUN position. | |
| Generator set stops suddenly. | Low oil pressure shutdown | Check the oil level. Check for signs of oil leaks. Out of fuel Check fuel supply. Overcrank shutdown Reset the controller. If the overcrank fault occurs again, contact an authorized distributor/dealer. |
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.