CONNECTION GP-WATER 1378222 - Caterpillar

Engine:
3054 (S/N: CHN1-UP; TCN1-UP)
3056 (S/N: SNX1-UP)
Description of Change: The improved 206-9503 Controller for the marine auxiliary gensets is available. The improved controller has been used in production since the middle of 2004. The improved units can be identified by a manufacturer's serial number that is greater than 2099409. The improved controller is not susceptible to overfrequency shutdowns from noise or spikes on the AC circuit, that are caused by thyristor controlled motors etc.Adaptable To: The improved 206-9503 Controller is effective with the above listed serial numbers.Troubleshooting
The following troubleshooting guides can assist in finding faults. This troubleshooting guide may also help to avoid unnecessary replacement of a good controller.
With the default programming on the controller, no LED indicators are activated when the controller is powered up. No LED indicators are activated when the switch on the controller is set to auto mode or manual mode.The controller does not activate any LED indicators unless the programmed outputs such as alarms or shutdowns that are triggered are activated.The absence of activated LED indicators does not necessarily indicate that the controller is faulty.
The genset will not reach full speed.
Remove the magnetic pickup and remove debris.
Field refit the magnetic pickup and adjust the pickup to the correct setting.
The starter relay output of the controller is prematurely disconnected, or the starter relay output of the controller is not activated at all.
Illustration 1 g01233624
Check the "Crank Disconnect Settings" in the software interface kit service tool 217-7202 Service Kit. Refer to Illustration 1.
Illustration 2 g01233647
If "Alternator Input Frequency Present" is selected, Refer to Illustration 2, ensure that the "Crank Disconnect on Alternator Frequency" setting is at least 20 Hz. Refer to Illustration 1.
Ensure that the "Crank Disconnect on Magnetic Pickup" is at least 500 rpm. Refer to Illustration 1.
Ensure that the "Crank Disconnect Charge Alternator Voltage" is at least 0.8 times the rated battery voltage, for example 20 DCV for a 24 DCV genset. Refer to Illustration 1.
Ensure that the charging alternator excitation output from the controller is connected correctly to the excitation input at the charging alternator. If not, the controller will sense full battery voltage at the battery charging alternator excitation output. When starting, if the threshold is lower than the battery voltage, this low threshold will activate the "Crank Disconnect Charge Alternator Voltage", disabling the starter relay before the starter relay is activated by the start circuitry.