Puma / Dorman 6LE / MacFarlane B46B / 110 kVA Generator Resurrection

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John Rudd:
But....
Is it looking for gen volts at cranking speed....
So if a start is initated, it would energise the fuel solenoid, and the starter motor, it would then expect the starter to turn the engine over and as its directly coupled, be looking for an increase in speed or a rise in alternator volts?

The eStop is a puzzler unless there's an issue with the input circuitry.... But then I wouldnt expect it to use software to shut the unit down....
What heppens to the 'fuel solenoid' or lightbulb... When it is energised and you toggle the estop input?
Does it do anything? Like go off or remain on?

awemawson:
The point is JOHN that at the moment it is never energizing either output either in the machine or on the bench. So no cranking so no generated volts anyway !

So I reckon that it’s kaput . When the new one arrives and I’ve made a back up of its current state I will reflash the faulty one, but not until number two is in my hand!

John Rudd:
If the software is corrupt it wont help will it?

Are you flashing the new one with the same code?.... :zap:

If the code is ok, cant you just reflash the unit anyway? Got nothing to lose as its broke anyway..... :scratch:

awemawson:
There is a later version of the firmware that I would use. I'm not doing it yet just in case I'm missing something and it's finger trouble on my behalf!

awemawson:
In limbo mode at the moment waiting for the new controller, though I did manage a major tidy up (amazing how many tools you get out !)

First 'real' thing I did was to measure the coil current for the Fuel and Starter relays - max for the controller is 2 amps and I'm drawing 60 mA so no problems there!

Then although the controller specification says it has protection on these drivers, I added back emf diodes to both relays 'just in case' - after all both outputs have blown!

Then I pushed the boat out and ordered 12 metres of 35 mm CSA 'meter tails' to wire up the output socket, having eventually decided that the enormous tails that came with it were just TOO big to squeeze into the terminations even with paring down.

Then in anticipation of the new controller arriving I made up the new and hopefully correct length cable form to connect it to the Gathering DIN terminals.

At this point I decided that a bit or forensic investigation of what I previously connected up wrong would be a good idea - it turns out that I had connected the oil pressure and water temperature switches not to their intended destinations, but to the 'auto start' terminals. In this mode the controller tries to start up the engine as soon as it sees power. But I was reconnecting the negative battery terminal, so at the instant contact was made, the controller started the starter with attendant huge current flow, and I suspect that I probably pulled back when it arced, so power was probably going on and off a few times. Maybe this caused spikes killing the control :scratch:

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