Controller module repairs
Generator Controller Module Repairs & Reprogramming
We diagnose, reprogram and replace generator controller modules on site across Gauteng, including Deep Sea, ComAp, SmartGen and Datakom units. Control panel repair or reprogramming typically costs R3,500 to R14,000, and you get a written quote before we start.
Callout fee waived when you accept our written quote. 1-year workmanship guarantee. See prices
- Deep Sea, ComAp, SmartGen, Datakom
- Reprogramming on site
- Written quote first
- Onsite across Gauteng
The module
What is wrong with my generator controller?
The controller is the module on the panel door that reads the engine sensors, shows alarms, and decides whether the generator may start. When it fails, a healthy engine can refuse to start, stop for no clear reason, or ignore a mains failure.
We start by reading the alarm and the event log. Then we test the module’s power supply, its inputs from the sensors and its outputs to the starter and the fuel solenoid. That tells us whether the module itself has failed or whether it is reporting a real fault elsewhere on the set.
If the module is sound but its settings are wrong or lost, we reprogram it with the maker’s configuration software. If it is damaged, obsolete or will not hold a configuration, we fit a compatible replacement and set it up for your engine and your changeover.
What we do
Diagnosis, reprogramming and replacement
Module diagnosis
We read the alarm, check the event log and test power, inputs and outputs to find out whether the module or a sensor has failed.
Reprogramming
We restore or correct the start delay, cooldown, alarm, sensor and automatic mains-failure settings with the maker’s software.
Replacement
When the module is burnt, obsolete or will not hold its settings, we fit a compatible unit and configure it for your set.
Upgrades from older modules
An older panel can often take a current module. We check the wiring, the sensors and the engine signals first.
Auto-start and AMF setup
We set the module to start on a mains failure and work with your ATS, then prove it by simulating a mains failure.
Commissioning
After any repair, we run the start, stop, alarms and transfer and watch each one work.
Controller makes
Controller modules we repair and reprogram
Deep Sea Electronics (DSE)
DSE4520, DSE6120, DSE7320 and DSE8610 families, among others, common on standby diesels.
ComAp
InteliNano, InteliLite and InteliGen modules.
SmartGen
HGM6120 and HGM7220 families and other HGM series modules.
Datakom
D-series and DKG modules, including the D-500 and DKG-307.
Related Pages
Panels, controller guides and starting faults
- Control Panel Repairs Relays, breakers, fuses and panel wiring
- Controller Brands, Alarms & Codes What controller alarms and error codes mean
- Deep Sea (DSE) Controllers Auto start, AMF set-up and replacement
- ATS Repairs Transfer switch and start request
- Not Auto Starting The set stays still when the mains fails
- Generator Fault Finding How we find the failed system
- Generator Repair Costs Typical prices for controller and panel work
Common Questions
Questions about generator controller repairs
How much does a generator controller repair cost?
Control panel repair or reprogramming typically costs R3,500 to R14,000, depending on whether the module needs new settings, a repair or a replacement. You get a free written quote before we start.
Can you reprogram my controller?
Yes. We reprogram Deep Sea, ComAp, SmartGen and Datakom modules, and others where the maker’s software allows it, restoring the start, stop, alarm, sensor and auto-start settings for your engine.
Should I repair or replace the controller?
Repair or reprogram it when the module powers up and responds. Replace it when it is burnt, obsolete or will not hold its settings. We test before we recommend either.
Is a controller repair the same as a control panel repair?
No. A controller repair deals with the module itself. A control panel repair covers the relays, breakers, fuses and wiring around it. We do both, often on the same visit.
The screen shows a shutdown. Should I disconnect the sensor?
No. A shutdown usually reports a real problem such as low oil pressure or high temperature. We test the sensor and the engine before we touch the alarm.
Why does my generator only start manually?
The engine is fine, but the automatic start chain is not. We check the controller mode, the mains sensing and the start signal from the ATS.
What should I photograph before you come?
The controller screen with the alarm showing, the brand and model label on the module, and the generator data plate.
Still unsure what the fault is? Call or WhatsApp 082 057 4605 for onsite diagnosis.
Service Areas
Onsite visits across Gauteng
We come to your generator anywhere in Gauteng, 24/7. Choose your region for local suburbs, call-out details and the faults we see most there.
What to send before we attend
These details help us plan the visit and bring the right parts. Send what you can on WhatsApp; if you can’t find the model number, we still book the visit.
- Location
- The suburb or site, so the visit can be booked in the right area.
- Make and model
- The generator brand and model, if they are known.
- kVA
- The size printed on the data plate.
- Fuel type
- Diesel, petrol, LPG, natural gas, or dual-fuel.
- Controller model
- The module name on the panel, when it is visible.
- Fault or alarm
- What the set does, and any text on the screen.
- Photos
- The generator, the data plate, and the controller or alarm. Send these on WhatsApp.
Book a Visit
Send the alarm text
A photo of the controller screen is the most useful thing you can send, with your suburb and the fuel type.
- Call
- 082 057 4605
- Message us on WhatsApp
What happens next
- We reply with questions about the generator, or to book a visit.
- A technician comes to you. For a breakdown we arrive within 1 hour.
- The fault is diagnosed on site and you get a written quote. No work starts until you accept it.
Charlie, lead technician: Degree in Mechanical Engineering, Degree in Electrical Engineering, Diesel Plant Fitter. Generator specialists since 2000.