Overvoltage
Honeywell
AC output voltage above controller limit
Controller displays 'Overvoltage' and may shut down the generator; measured output voltage is above nominal (e.g., above 130V L-N on a 120V system).
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Faulty voltage regulator (AVR), Incorrect controller calibration, Loose or corroded sensing leads to controller, Defective alternator stator or rotor
How to Fix / Troubleshooting
Safety first: Open the main line circuit breaker to isolate the generator from the home. Turn the generator OFF and disconnect battery negative before opening panels.
Steps:
- Inspect voltage regulator wiring: Locate the automatic voltage regulator (AVR) inside the generator. Check all connectors for tightness and corrosion. Reseat plugs.
- Check sensing leads: Follow the small gauge wires from the alternator output to the controller/AVR. Repair any damaged insulation or loose terminals.
- Visual inspection of alternator: Look for burnt windings, discoloration, or a burnt smell from the alternator assembly.
- Test with meter: With a qualified person and proper PPE, run the generator isolated from the home and measure output voltage. If it remains high, the AVR is the most common failure and should be replaced with the correct Honeywell-specified part.
- Re-test: After AVR replacement, verify voltage and clear the Overvoltage alarm.
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Repair Difficulty
Hard
4/5
Required Part
Voltage Regulator (AVR)
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