The Power Zone is a generator-set controller. It is used on generator sets from Generac, John Deere and Magnum, including the MDG100DF4, MDG150, MDG175 and MDG250.
Used across brands: Generac, John Deere, Magnum
Also fitted to: Generac MDG20IF4 • MLG20IF4, Generac SG750/MG750.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 00230 | EMERGENCY STOP | ||
| 00383 | Exhaust Filter Cleaning enabled. | ||
| 1 | To Service | Oil Maintenance | |
| 1049 VSCF | Overload RED Unit shuts down during operation. | Check the LEDs/Screen for alarms. Generator output is shorted or severely overloaded. Identify and clear the overload, and then restart. | |
| 1051 VSCF | High Battery YELLOW LED illuminated in any state. | Check the LEDs/Screen for alarms. Voltage supply to the AVR is high. If an external battery charger is in use, contact installing dealer to correct installation. If an external battery charger is NOT in use, contact Independent Authorized Servicing Dealer. | |
| 1052 VSCF | DC Overvoltage RED Unit shuts down during operation. | Check the LEDs/Screen for alarms. Probable causes are: 1) The generator was temporarily overloaded. 2) The output was temporarily shorted. Try to restart the unit. | |
| 1053 VSCF | Gate Fault RED Unit shuts down during operation or starting. | Check the LEDs/Screen for alarms. AVR is damaged. Contact Independent Authorized Servicing Dealer. | |
| 1055 VSCF | Phase Error RED Unit shuts down during starting. | Check the LEDs/Screen for alarms. An incorrect voltage and frequency has been detected during starting. Probable causes are: 1) Alternator damage. Contact Independent Authorized Servicing Dealer. 2) Generator has started into a severe load. Manually operate generator breaker and try to restart unit. If problem persists, remove load and attempt to restart unit again. 3) The engine may not be reaching its prescribed speed. Proceed as follows: •Verify stepper motor is moving and linkage is free. •Verify stepper motor is plugged in. •Verify gas pressure is within specified limits. | |
| 1056 VSCF | Undervoltage RED Unit shuts down during operation or starting. | Check the LEDs/Screen for alarms. The generator output voltage is too low. Probable causes are: 1) The load is too large. Remove load and attempt to restart unit. 2) Alternator or AVR damage. Contact Independent Authorized Servicing Dealer. | |
| 1057 VSCF | Overvoltage RED Unit shuts down during operation or starting. | Check the LEDs/Screen for alarms. Probable causes are: 1) The generator has been overloaded. Remove load and attempt to restart unit. 2) Generator has started into a severe load. Manually operate generator breaker and try to restart unit. If problem persists, remove load and attempt to restart unit again. | |
| 1058 VSCF | DC Undervoltage RED Unit shuts down during operation or starting. | Check the LEDs/Screen for alarms. The DPE winding supplies this voltage. 1) Alternator damage. Contact Independent Authorized Servicing Dealer. | |
| 1059 VSCF | Field Loss RED Unit shuts down during starting. | Check the LEDs/Screen for alarms. Unit detects no output voltage while starting. 1) Alternator damage. Contact Independent Authorized Servicing Dealer. | |
| 1061 VSCF | Field Loss RED Unit shuts down during operation. | Check the LEDs/Screen for alarms. Unit detects loss of output voltage while running. 1) Alternator damage. Contact Independent Authorized Servicing Dealer. | |
| 1065 | Overfrequency RED Unit shuts down during operation. | Check the LEDs/Screen for alarms. Probable causes are: 1) Overload. Remove load and attempt to restart unit. 2) RPM sensor has failed. Contact Independent Authorized Servicing Dealer. 3) Stepper motor problem. Contact Independent Authorized Servicing Dealer. | |
| 1066 VSCF | Speed mismatch RED Unit shuts down during Operation or starting. | Check the LEDs/Screen for alarms. Probable causes are: 1) Fuel problem (pressure loss). Check fuel supply and attempt to restart unit. 2) Large overload. Remove load and attempt to restart unit. 3) Throttle or engine problem. Contact Independent Authorized Servicing Dealer. | |
| 2 | To Service | Fuel Maintenance | |
| 3 | To Service | Air Maintenance | |
| FXXX | Indicates a fault state. The DVR stops providing excitation. | ||
| HIGH TEMPERATURE | Unit shuts down during operation. | Check ventilation around the intake, exhaust and rear of generator. | Contact s Independent Authorized Servicing Dealer if no obstruction is found. |
| RPM SENSE LOSS | Unit was running and shuts down, attempts to restart. | Check the LEDs/Screen for alarms. | Clear alarm and remove household loads from the generator. Put back in AUTO and restart. If problem returns, contact Independent Authorized Servicing Dealer to investigate possible fuel issue. |
| Ubat | Battery voltage is out of limits given by Batt Undervolt setpoints. |
| Symptom | Cause | Remedy |
|---|---|---|
| AXXX indicates an alarm state. The DVR continues to provide excitation, if excitation is enabled. | [blank] Indicates normal operation in SLEEP mode. STBY Indicates normal operation in stand-by mode, waiting for the STRT state. STRT Indicates DVR is in a soft start state. RUN.V Indicates normal operation, with excitation in AVR mode. RUN.I Indicates normal operation, with excitation in FCR mode. RUN.P Indicates normal operation, with excitation in VAR or PF mode. FLSH Indicates DVR is in field flashing mode. IDLE Indicates normal operation in idle state, waiting for the speed to take off. | |
| Emergency Stop indicator LED illuminates when Emergency Stop switch is active (pushed in). | Resolve by deactivating (pulling out) Emergency Stop switch. | |
| Emergency Stop indicator LED is illuminated. | Resolve by deactivating (pulling out) Emergency Stop switch. | |
| Emergency Stop indicator LED. | Resolve by deactivating (pulling out) Emergency Stop switch. | |
| Engine cranks but will not start. | 1) Out of fuel. 2) Defective fuel solenoid (FS). 3) Defective spark plug(s). 4) Valve clearance needs adjustment. | 1) Replenish fuel / Turn on fuel valve. 2) * 3) Clean, check gap, or replace plug(s). 4) Adjust valve clearance. |
| Engine shutdown | Fuel tank running dry, oil pressure less than 20 psi, coolant level low, high coolant temperature | Check fuel level and add if necessary; check for leaks; inspect engine for damage; check oil level and add if necessary; visually inspect engine for leaks; check coolant level and add if necessary; check radiator hoses, engine block, water pump for leaks; check oil to ensure no coolant mixed in; allow engine to cool before checking |
| Engine starts hard and runs rough. | 1) Air cleaner plugged or damaged. 2) Defective spark plug(s). 3) Fuel regulator not set. 4) Fuel pressure incorrect. 5) Fuel selector in wrong position. | 1) Check / replace air cleaner. 2) Clean, check gap, or replace plug(s). 3) Set fuel regulator. 4) Confirm fuel pressure to regulator is 10–12 in. water column (19–22 mm mercury) for LP, and 3.5–7 in. water column (7–13 mm mercury) for natural gas. 5) Move selector to correct position. |
| Engine will not crank. | 1) Fuse blown. 2) Loose, corroded or defective battery cables. 3) Defective starter contact. 4) Defective starter motor. 5) Dead battery. | 1) Correct short circuit condition by replacing 7.5 Amp fuse. 2) Tighten, clean or replace as necessary.* 3) Tighten, clean or replace as necessary.* 4) Tighten, clean or replace as necessary.* 5) Charge or replace battery. |
| Generator does not pull full power. | Current calibration incorrect. Contact Independent Authorized Servicing Dealer. | |
| Generator is set to OFF, but the engine continues to run. | 1) Control board wired incorrectly. 2) Defective control board. | 1) Repair wiring or replace control board.* 2) Replace control board. |
| Generator stalls when large load is supplied. | Total load is too big for the generator. Loads must be less than 10 kW or 2 hp when operating under 3600 rpm.Contact installing dealer to correct installation. | |
| HIGH COOLANT TEMPERATURE SHUTDOWN | Coolant temperature is 230°F or more. | Check coolant level in overflow jug. Add coolant if low. Stop engine immediately. |
| High Coolant Temperature Shutdown | Low coolant level, Blockage in radiator, Leakage in coolant hoses, engine block, or water pump | Add coolant if needed. Allow engine to cool, then check coolant level in radiator. Restart engine and check coolant temperature (on controller). Stop engine immediately if coolant temperature is 210°F (99°C) or more. Check radiator shroud and ducting for blockage and remove any foreign matter. Inspect for visible leaks. Check tension of water pump serpentine drive belt. Remove load on generator and restart engine. Check coolant temperature and shut engine down immediately if it starts to overheat. See the OEM engine operator’s manual for additional information on engine overheating. |
| High Coolant Temperature shut down | 1. Check the coolant level in the overflow jug. 2. Restart the engine and read the coolant temperature to verify High Coolant Temperature shut down. Stop the engine immediately if the coolant temperature is 230°F (110°C) or more. 3. Allow the engine to cool. Add coolant to the overflow jug if it is low and then check the level of coolant in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4 in (2 cm) below the filler neck. Secure the radiator cap back into its original position. 4. Check the radiator shroud and ducting for blockage and remove any foreign matter. 5. Inspect coolant hoses, engine block and water pump for visible leaks. 6. Check the tension of the serpentine drive belt for the water pump. 7. If no other problems are found, remove the load on the generator and restart the engine. Check the coolant temperature and shut the engine down immediately if it starts to overheat. | |
| LOW COOLANT LEVEL SHUT DOWN | Allow engine to cool. Check coolant level in the radiator. Access the radiator cap by removing the access panel. | |
| LOW COOLANT LEVEL SHUTDOWN | Coolant level in the radiator is low, coolant hoses, engine block or water pump have visible leaks. | Check and add coolant. Inspect for leaks. Check engine oil for mixed coolant. |
| LOW FUEL LEVEL SHUT DOWN | Fuel level is low or fuel tank has leaks. | Check the fuel level on the LCD window. Ensure no leaks in the fuel tank. Check the fuel level sender and connecting wiring for damage. |
| LOW FUEL LEVEL SHUTDOWN | Fuel level on the LCD window is low, fuel tank has leaks, fuel level sender or wiring damaged. | Check and refill fuel. Inspect for leaks. Check fuel level sender and wiring. |
| LOW OIL PRESSURE SHUTDOWN | Oil pressure is less than 20 psi, engine has oil leaks. | Check oil level with dipstick. Visually inspect for leaks. Restart and verify oil pressure. Check oil pressure sender. |
| Low Coolant Level | Shutdown, Low coolant level, Coolant hoses leaking, Engine block or water pump leaking | Allow engine to cool, then check coolant level in radiator. Add coolant, if needed. |
| Low Coolant Level Shutdown | Low coolant level, Coolant hoses leaking, Engine block or water pump leaking | Allow engine to cool, then check coolant level in radiator. Add coolant if needed. Inspect hoses for leaks. Repair or replace as necessary. Visually inspect for leaks. Verify no coolant has mixed with the engine oil (oil will appear milky). See the OEM engine operator’s manual for additional information. |
| Low Fuel Level | Shutdown, Low fuel level, Unit not level, Fuel tank leaking, Damaged fuel sender or wiring | Check fuel level in LCD window of controller. Confirm that unit is sitting level to ensure an accurate reading. Check tank for leaks. Check for continuity between sender and engine controller. |
| Low Fuel Level Shut-down | Low fuel level, Unit not level, Fuel tank leaking, Damaged fuel sender or wiring | Check fuel level in LCD window of controller. Verify unit is sitting level to ensure an accurate reading. Check tank for leaks. Check for continuity between sender and engine controller (see DC Wiring). |
| Low Fuel Level Shutdown | 1. Check fuel level on the Liquid Crystal Display (LCD) window. Verify the unit is sitting level to ensure an accurate reading. 2. Check for leaks in fuel tank. The fuel tank should not run dry under normal circumstances. The engine controller will shut the engine down when there is five percent of fuel remaining in the tank. 3. If fuel level is good and no leaks are found, check the fuel level sender and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the appropriate bolts from the control panel to access the inside of the control box. See the appropriate DC wiring diagram Wiring Diagrams for the proper path between the engine controller and the fuel level sender. | |
| Low Load indicator LED illuminates when genset has operated at less than 30% capacity for more than 15 minutes. | Resolve by increasing electrical load. If unable to operate genset at more than 30% load, use a smaller generator. | |
| Low Load indicator LED is illuminated. | Resolve by increasing electrical load. If unable to operate genset at more than 30% load, use a smaller generator. | |
| Low Load indicator LED. • Indicates genset has operated at less than 30% capacity for more than 15 minutes. | Resolve by increasing electrical load. If unable to operate genset at more than 30% load, use a smaller generator. | |
| Low Oil Pressure | Shutdown, Low oil level, Oil leaking from engine, Oil pressure sender | Check oil level on dipstick. Add oil, if needed. Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds. See engine operator’s manual to identify corrective action. |
| Low Oil Pressure Shut-down | Low oil level, Oil leaking from engine, Oil pressure sender | Check oil level on dipstick. Add oil, if needed. Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds. Refer to engine operator’s manual to identify corrective action. |
| Low Oil Pressure Shutdown | Low oil level, Oil leaking from engine, Oil pressure sender | Check oil level on dipstick. Add oil, if needed. Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds. See the OEM engine operator’s manual to identify corrective action. |
| Lug Door Open indicator LED illuminates when lug-box door is open. | Resolve by closing lug-box door. If condition remains unresolved, inspect lug-box door safety switch for proper operation. | |
| Lug Door Open indicator LED is illuminated. | Resolve by closing lug-box door. If condition remains unresolved, inspect lug-box door safety switch for proper operation. | |
| Lug Door Open indicator LED. | Resolve by closing lug-box door. If condition remains unresolved, inspect lug-box door safety switch for proper operation. | |
| No AC output from generator. | 1) Main line circuit breaker is in the OFF (or OPEN) position. 2) Generator internal failure. | 1) Reset circuit breaker to ON (or CLOSED). 2) * |
| OVERCRANK SHUTDOWN | Engine will not start. | Check fuel level, fuel pump operation, air filter for blockage. Refer to manual for additional troubleshooting. |
| OVERSPEED OR UNDERSPEED SHUTDOWN | Engine speed is above or below 60.0 Hz. | Disconnect loads and adjust engine speed as needed based on manual instructions. |
| Output voltage is low/high. | Voltage calibration incorrect. Contact Independent Authorized Servicing Dealer. | |
| Overcrank Shutdown | Fuel level low, Check fuel level in tank, Check fuel pump operation, Check air filter for blockage | See the OEM engine operator’s manual for additional information. |
| Overcrank shut down | 1. Check the fuel level in the tank. 2. Check for proper operation of the fuel pump. 3. Check air filter for blockage. 4. If the engine will not start, consult the engine operation and maintenance manual for additional information on troubleshooting starting problems. |
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.