Panel Tester Operation - Lofa Technologies

1 PanelTesterOperation463-3000-10 Initial- 21-Jul-20081EP250, EL240 and the LOFA logo are trademarks ofLOFAI ndustries, Testerallows quick diagnoses of theproper Operation of engine control panels . Theavailable testharnesses provide simple plug and playconnections to standardLOFA mechanicalenginecontrol panels as well as EP250 , EL240 andMC536 controllers. LEDs and a buzzer indicate the stateof the Panel outputs. Circuitry and pushbuttonsstimulate all Panel inputs to verify correct Operation ofthe attached Panel . The Tester can also be used tocalibrate tachometers for use withEP250 and EM500control compact rugged design allows benchtop or field Operation . Power options include a AC power supplyas well as battery leads with aligator test harnesses can be developed to allow testing theengine harness in addition to the control PowerAdditional equipment can be powered from the binder posts with Alligator Battery the post thumb screws from the red and black binder binder post with the black base and red thumbscrew is used to test harnesses with aseparate starter wire.

2 No connection is normally made to this the ring terminal of the red wire to the red post and the ring terminal of the black wire to theblack binder thethumb screws to their respective binder the red alligator clip to positive (+) terminal of the the black alligator clip to negative (-) terminal of the batteryUsing AC Power power supply plug into black AC line cord into AC Panel Tester does not have a power down the Tester requires disconnecting the power Tester Operation2463-3000-10 Initial- 21-Jul-2008 TestingPanelsPreheat ModesVarious LOFA control panels support different preheat modes. These can categorized asPreheat IndicationandAutomatic Preheat Controlwhich can either beGroundorPositive. Ground signals provide a groundwhen active while positive signals provide battery power when active. When inactive neither provides groundor battery properly test the Panel requires knowing the preheat mode the Panel IndicationPreheat indication modes are used when an external preheat timercontrols the Operation and duration ofpreheator the Panel is wired to use the keyswitch preheat position (the indent position between Run andStart).

3 To test these modes, the Tester needs to be set toOUTPOSorOUTGNDby pressing thePREHEATMODE button until the appropriate LED is indicated PREHEAT MODE is the Tester Preheat ControlWith automatic preheat control modes; the control Panel controls the Operation and duration of preheat. Totest these modes, the Tester needs to be set toINPOSorINGNDby pressing thePREHEAT MODE buttonuntil the appropriate LED is TestsThePOWER OKLED indicates that the Panel test has connecting thepanel to the Tester with the appropriate cables, turn the Panel key switch to therun position. The Panel LEDs should flash to test their function. TheSOL+ / RUNLED should illuminate indicating the Panel s solenoid output is enabled. If15 FFUSED should illuminate if the pink/black harness wire is (ALM)is an optional shutdown indication for a buzzer, flasher light orother controller. Typically the alarm output is energized briefly when the keyswitch is turned on as a self test.

4 If the engine shuts down for any reason thisalarm output will Tester Operation463-3000-10 Initial- 21-Jul-20083 NoteALARM (ARM)is optional and will not illuminate unless connected tothe ALM terminal on thecircuit board. The alarm output is only available on the EP and MC series a short delay (typically 10 to 30 seconds) the solenoid output turns off unless the Panel key switch isturned to the start solenoid power will turn back on when the Panel s keyswitch is turned to startas indicated by theSTARTER 50 LEDand the Tester buzzer starting, the solenoid output will remain on as indicatedby theSOL+ / RUNLED until the key switch is turned to the off position or the Panel senses an input switchbeing grounded. If theSOL+ / RUNLED extinguishing without a shutdown input indicates a wiring fault orcircuit board 3 INLED is an optional input. This LED is typically not TestPreheat IndicationTo test preheat indication, press thePREHEAT pushbutton on the right side of the Tester .

5 When using thepanel key switch preheat position, thePREHEAT (PRH)LED will illuminate when the key switch is in thepreheat !When using the key switch preheat position, pressing thePREHEAT pushbutton when thetester is inOUT GNDand the key switch is in the preheat position may damage the Tester !When the key switch preheat position is used the Tester shouldbe set toOUT Preheat ControlWhen the Panel enables preheat control thePREHEAT (PRH)LED will illuminate. Automatic preheat controlbegins as soon as the Panel key switch is turned to the run position. The preheat time can be verified bychecking the time from the key switch being turn to run and the LED TestsThe gauge pushbuttons are usedto testpropergauge function the correct gauge moves when the pushbutton is pressed to verify nowires have been crossed in the Panel or open circuited, the temperature gauge needle is theTEMP GAUGE button grounds thetemperaturegauge signalcausingtheneedle to open circuited, the oil pressure gauge needle is pegged.

6 Pressing theOIL GAUGE button grounds theoil pressuregauge signalcausingthe needleto Tester Operation4463-3000-10 Initial- 21-Jul-2008 When open circuited, theoptionalfuellevelgauge needle is theFUEL GAUGE buttongrounds thefuel levelgauge signalcausingthe needle solenoid outputpowers the can only betestedwhile the Tester is simulating a running TestThe Tester is equipped with a frequency generatortosimulate engine RPM. The RPMoutputis activatedwhen the circuit senses a start signal from the UPincreases the simulated RPM whileSPEEDDOWN decreases the simulated RPM. The change isRPM should bereflectedbychanges on the Panel TestsPushbuttonson the right side of the Tester stimulate the Panel pressing these switches simulates a fault for ALTERNATOR(battery charge), OIL PSI (pressure), TEMPERATURE, AUX 1, AUX 2and corresponding LED on the Panel should illuminate asthepushbutton is is an additional shutdown input option for EP250 seriespanels.

7 When the SW terminal on the circuit board isconnected and grounded the AUX 1 LED TestsShutdown is overridden for the initial 10 seconds after the key switch isreleased from the start position. This delay allows the engine to buildoil pressure and the alternator to start charging the this delay, if an input pushbutton is pressed for 1 second or moreand the Panel is configured for shutdown for that input, the Panel willturn the solenoid output off. This is indicated on the Panel Tester by theSOL+ / RUNLED 50pushbuttonallowsrestartingthe panelwithoutusing the panelkeyswitch. Once a shutdown hasbeen testedpressingtheSTARTER 50resets time thepanelsstarteroutputis activatedthebuzzer on the Tester sounds and the starter time thepanelsenses the starter signal,shutdowns areoverriddenfor 10 Tester Operation463-3000-10 Initial- 21-Jul-20085 WARNING!DO NOTus e theSTARTER 50pushbutton with MC536 panels !

8 The MC536 starter output design may damage the Tester !Automatic Start Stop TestsAutomatic Start Stop is a variation of normal Panel testing. When the automatic start conditions of the panelare met, thepa nel s autostart will enable the Panel (as indicated by theSOL+ / RUNLED) and engage thestarter(as indicated by the STARTER 50 LED and buzzer). After a brief delay fro the starter signal, the paneltester will simulate the engine RPM. When the autostartdetects the RPM the starter output is turned the automatic conditions are met, the autostart will initiate as shutdown. Depending on the autostartprogramming this may includea cool downperiod. The shutdown is indicated by theSOL+ / RUNLED being CalibrationTheCAL TACH1800 RPMbutton allows calibrating a tachometer at1800 RPMforEP250F and EM500panels. Pressing theCAL TACH 1800 RPMbutton causes the LED to illuminate indicating the RPM is now at1800 RPM.

9 T he dipswitch diagrambelow the LED is the switch setting for VDO tachometers used in calibrating a tachometer forEP250F orEM500 panels ,the Tester can not be used to calibrate tachometers for a specific panels can be automatically calibrated to the engine spulses per revolution using a DPG , EP250F panels can be calibrated by setting thepulses per revolution using a DPG 5200 or theEP250 Configuration panels automatically synthesis thetachometerfrequencybased on the J1939 reported engine Tester Operation6463-3000-10 Initial- 21-Jul-2008 General TroubleshootingFor additional information, refer to engine manufacturer troubleshooting response from starter motorPossible CausePossible RemedyNo battery voltage to starterVerify wiring and battery connection (power and ground)Battery dischargedCharge or replace battery, verify alternator chargingTripped over currentprotectionCorrect fault, replace or reset over current protectionNo signal from control systemNo powerto control system (seeControl System Troubleshooting below)Defective starter solenoidReplace starter solenoidDefective starter motorReplace starter motorEngine will crank but not startPossible CausePossible RemedyEnginenot getting fuelCheckfuellevel,filter, fuel pump, verify no air in fuel linesFuel run/stop solenoid notengagedSee Fuel Solenoid Run/StopTroubleshooting(below)Tripped over currentprotectionCorrect fault, replace or reset over current protectionNo preheat (cold condition)

10 See Preheat TroubleshootingEngine runs for 10 seconds and shuts downPossible CausePossible RemedyShutdown switch input activeVerify shutdown source exists, correct condition or correct faulty circuitBatterynot chargingVerify alternatorcharging (see Alternator not charging battery below)Control board did not sensestart signalEngine started through alternate method ( , manual air start, push start,etc.)Defective controlsystemSee Control Panel Troubleshooting (below)Engineruns longer than 10 secondsand shuts downPossible CausePossible RemedyShutdown switch input activeCorrect engine fault,verifyshutdown switch wiringCircuit overload protectiontrippedCorrect overload, keepcontrol systemfromoverheating(over 185 F/85 C)Voltagetransients (spikes)Addsuppressor diodes,protect fromnearby lightening strikes,shieldinduced spikes from other equipment, add electric motor control relayDefective control systemSee ControlSystem Troubleshooting(below)