GDI Soft start clutch controller??

[Hal]

Title says it. My firewood processor uses an electric clutch to control the chainsaw. The GDI controller is used to give a smooth start, and not shock the clutch or drive components. It is a control only, not a relay, full clutch current goes through the switch. As far as I can find out, GDI is the only manufacturer, and there are no similar items available.

So, the problem is this: the original unit lasted eight years and 700 hours of operation. It failed last year, and I replaced it, $100 , no big deal for that length of service. But, the new one quit Thursday, less than a year, less than 100 hours. I will call for the part Monday, but I am wondering, did I just get a poor part, or is there something else going on that caused the failure? It is protected by a ten amp fuse in line, and the specifications show a minimum of 47 amps over current.

I’m going to talk to a tech at the machine manufacturer when I order the part.

I am also wondering how badly it would tear up the works if I just bypass it

 

[wyliesdiesels]

have a pic of the controller? is there a circuit board? any burnt components? have a schematic?

 

[Hal]

Looks like any little plastic encapsulated relay. Manufacturer website gives specs and pinout, that’s all.

I did some more messing around with the machine yesterday. Bypassed the controller and got a click from the clutch. Started the engine and switched the saw on, nothing. After a little more head scratching, I noticed that my test light was very dim. Hooked a boost pack to the battery and the display read 11.2 volts. Turned the boost pack on and tried the switch, bypass still hooked up, and got a healthy clunk out of the clutch. Engine on, triggered the saw, and it ran.
Hooked the controller back up and away it went.

So what I have is a low voltage problem. It didn’t occur to me to check that, even though it had happened in the past. What flagged it that time was that the starter wasn’t working either. This time, the starter is definitely out, boosting doesn’t help, and I have been pull starting it. Looks like the engine has to come out to replace it.

So I have ether a bad alternator. A bad battery, or bad connections.

All my troubleshooting was fixated on the worst case scenario, didn’t check any of the other possibilities.

 

[Hal]

Ran the machine for an hour this morning on the boost pack, worked fine. I quit because I was overheating.

I’m going to finish this pile of logs withtheboost pack, then take it home a try to diagnose the low voltage problem.

 

[The Cobbler]

I would probably start with checking the battery voltage, c/w a load test, then a charge test . then move on if they show normal .

 

[PCustoms]

Ran the machine for an hour this morning on the boost pack, worked fine. I quit because I was overheating.

I’m going to finish this pile of logs withtheboost pack, then take it home a try to diagnose the low voltage problem.

Bring it over, I'll fix it for you and I've got a whole pile of logs we can test it on