The PowerZone–DLA is a generator-set controller. It is used on generator sets from Generac, including the MLT4060MVD, MLT4200IV and MLT6.
| Code | Meaning | Remedy |
|---|---|---|
| Fail to Start | Fail to Start — engine does not start and run within three starting cycles; LCD screen displays the "Fail to Start" alarm | The starting sequence can be repeated after the starter cools for at least two minutes. Pressing the Stop (O) button will clear the alarm and reset the controller. |
| Symptom | Cause | Remedy |
|---|---|---|
| CAN Data Fail | Indicates failure of the CAN data link to the engine ECU. | Check all wiring and termination resistors (if required). |
| CAN ECU Warning / CAN ECU Shutdown | This indicates a fault condition detected by the engine ECU and transmitted to the controller. | |
| Continuous starting of generator when in AUTO mode | Check that there is no signal present on the Remote Start input. Check configured polarity is correct; Check the mains supply is available and within configured limits | |
| Controller seems to revert to an earlier configuration | When editing a configuration using the PC software it is vital that the configuration is first read from the controller before editing it. This edited configuration must then be written back to the controller for the changes to take effect; When editing a configuration using the fascia editor, be sure to press the AUTO Mode button to save the change before moving to another item or exiting the fascia editor | |
| Electrical Trip fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input. | |
| Engine runs but the lights do not turn on | Check Warm up timer has timed out; Ensure Inhibit Light Input 1, 2, 3 or 4 are not active on the module inputs; Check connections to the lights; The genset may not take load in MANUAL/START Mode unless there is an active load signal. | |
| Fail to Start is activated after pre-set number of attempts to start | Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed-sensing signal is present on the controller inputs. See engine manual. | |
| Generator fails to start on receipt of Remote Start signal. | Check Start Delay timer has timed out; Check signal is on Remote Start input. Confirm correct configuration of input is configured to be used as Remote Start; Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending on configuration, then set does not start if oil pressure is not low. | |
| High Coolant Temperature operates after engine has fired. | Check engine temperature; Check switch/sensor and wiring; Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the controller. | |
| High coolant temperature shutdown | Low coolant level | Allow engine to cool, then check coolant level in radiator. Add coolant if needed |
| Incorrect reading on engine gauges — Fail To Stop when engine is at rest | Check engine is operating correctly; Check that sensor is compatible with the controller and that the controller configuration is suited to the sensor. | |
| Low Oil Pressure operates after engine has fired | Check engine oil pressure; Check oil pressure switch/sensor and wiring; Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the controller and is correctly configured. | |
| Low oil pressure shutdown | Low oil level | Check oil level. Add oil if necessary |
| Mast lights off, checking inside control box | Loose lighting connections | Inspect the connections inside the control box. |
| Mast lights off, checking inside the control box | Loose lighting connections | Inspect the connections inside the control box. |
| Mast lights off, checking outside the control box | Light fixture is too hot | Allow light to cool 10–15 minutes before restarting. |
| One or more lights do not turn on | Light breaker tripped | Inspect light breakers |
| Pre-heat inoperative | Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct. | |
| Shutdown fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input. | |
| Starter motor inoperative | Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure oil pressure switch or sensor is indicating the low oil pressure state to the controller. | |
| The lights are flashing | Dusk-to-dawn sensor adjustment needed | Adjust the dusk-to-dawn sensor according to Dusk to Dawn Sensor |
| Unit cranks but does not start | Low fuel level | Check fuel level in tank. Verify fuel pump operation. |
| Unit cranks, but will not start | Low fuel level | Verify fuel level in tank |
| Unit is inoperative — Read/Write configuration does not operate | Check the battery and wiring to the unit; Check the DC supply; Check the DC fuse. | |
| Unit shuts down | Check DC supply voltage is not above 35 V or below 9 V; Check the operating temperature is not above 70 °C. Check the DC fuse. | |
| Unit stalls when export power is used | Load exceeds unit rating | Turn outlet breaker ON and load sense switch OFF, confirm generator output is 60 Hz ± 2 Hz. Reapply load |
| Unit starts but stumbles and dies | Low ambient temperature | Verify if ambient temperature is within unit limits. |
| Unit starts, but stumbles and dies | Low ambient temperature | Verify if ambient temperature is within unit limits |
| Warning fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input. |
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.