Kohler MainpwroverL Shutdown

ere109
ere109 Registered Users Posts: 3 ✭
in Off Grid Solar & Battery Systems #1
Good morning; first post. I've got an off grid cabin with a 1.5kw solar setup, 48v battery Bank, Outback inverters, and a Kohler 14RESA generator. The generator just stopped running and started throwing a "MainpwroverL" error. I've been messing with it all weekend with no luck.
According to the manual, there's too much DC input, so I completely shut down and disconnected my solar inverter - same error. I've tried another battery, replaced the start relay, and still I get about four clicks, then the MainpwroverL message returns. I shorted the solenoid and it spins. My gut tells me the RDC2 board has gone bad, but that's a $1500 part, so I'd love to be proven wrong. I'm considering pulling the board and driving to a Kohler dealer to have it tested - about two hours on good roads.
Has anyone dealt with this error? Thoughts on next steps? Much appreciated.
More info: mine has the green RDC2 board, and is running firmware v6.12.

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  • BB.
    BB. Super Moderators, Administrators Posts: 33,653 admin
    #2
    Checking the generic Kohler error codes:

    https://thecampingadvisor.com/kohler-generator-fault-code-list/

    MainPwrOverLSDMain power overload. An over current fault on the 70 controller power output (short circuit)Contact an authorized distributor/dealer for service. Check for shorted run relay. Check wiring for short circuits

    From the Manual for the 142-
    https://manualsdump.com/en/manuals/kohler-14-20resa-14-20resal/95344/67

    6.3.1Controller Internal Circuit Protection

    The controller is equipped with internal circuit protection. A fault message, Accy PwrOver Warning or MainPwrOverL Shutdown, is displayed if this internal protection is activated. Press OFF to reset. Contact an authorized Kohler distributor/ dealer for service.

    It appears to be a main power (AC output short circuit or low voltage(?))?

    Disconnect the AC load(s) and try again?

    Good Luck!

    -Bill

    Near San Francisco California: 3.5kWatt Grid Tied Solar power system+small backup genset
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  • BB.
    BB. Super Moderators, Administrators Posts: 33,653 admin
    #3
    By the way, the Genset has a high and low AC output voltage (L1-L2) error... So it would seem that your error warning is a "true" over current output error vs "simple voltage error"...

    Also your error is "SD" shutdown (?) only... The over voltage error is "SD*" which includes an engine cool down before shutting down.

    https://forum.solar-electric.com/discussion/358474/kohler-mainpwroverl-shutdown#latest

    -Bill
    Near San Francisco California: 3.5kWatt Grid Tied Solar power system+small backup genset
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  • ere109
    ere109 Registered Users Posts: 3 ✭
    #4
    Thanks Bill. I'm at a loss. I opened all the breakers and completely separated the generator from the solar, and still got the message - it has to be something internal. After I disconnected the board and pulled it out of the way, I did find one ground terminal that was slightly loose. I haven't plugged it back in out of cold (-10F) and frustration.
    I'm new to off -grid, as I just bought this place in October and there's a LOT of learning.
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  • ere109
    ere109 Registered Users Posts: 3 ✭
    #5
    I'm circling back around to questioning the solenoid. I couldn't find a shop willing to test the control board without a fun service call (at $1.75 a mile, plus hourly), so I watched some more videos. A solenoid is a much cheaper next step, so I ordered one. I'll be back.
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