EM-200-25-96_instructor-manual_V2024-2.indd Intructors manual for EM-200-25_052984 Speed and position sensors trainer EM-200-25_052984-96_V2024-2 © ConsuLab Educatech Inc, 2023. All rights reserved. EM-200-25_052984-96 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 © ConsuLab Educatech Inc, 2023. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 052984 and above. Table of contents Suggestions for teaching speed and position sensors 3 Theory 4 Introduction 5 Passive induction sensor (Magnetic induction sensor) 7 Hall effect sensor 11 Magneto-resistive sensors 13 Theory Exam 18 Student Answer Sheet 20 Answers 21 Student assignments Answers 22 SA-1 Student assignment — Answer 23 SA-2 Student assignment — Answers 24 SA-3 Student assignment — Answers 25 SA-4 Student assignment — Answers 26 SA-5 Student assignment — Answers 27 SA-6 Student assignment — Answers 28 SA-7 Student assignment — Answers 30 SA-8 Student assignment — Answers 31 SA-9 Student assignment — Answers 32 SA-10 Student assignment — Answers 34 SA-11 Student assignment — Answers 35 SA-12 Student assignment — Answers 36 SA-13 Student assignment — Resistance connection options 38 SA-13 Student assignment — DSO Sreen Shots 39 Assignments Exam 45 Student Answer Sheet 47 Answers 48 EM-200-25 Electric Wiring Diagram 49 consulab.com info@consulab.com 3 EM-200-25_052984-96 Suggestions for teaching speed and position sensors Suggestions for teaching speed and position sensors The EM-200-25 trainer is designed to be used in a classroom environment as either a demonstration tool or as a student lab activity. ConsuLab has built a sturdy, complete trainer that will give years of service. As an instructor, it is obviously your call as to how you will use it in your classes. However, some suggestions are : 1. Start with the basics of one sensor at a time. 2. Use a DMM initially to show students the information available. Continue the discussion talking about the limitations of the DMM in diagnostics. 3. Move the students into the use of the DSO. This is a natural progression from DMM to DSO. 4. Once students have grasped how the first sensor functions, have them, in very small groups, and accomplish the labs that apply to the sensor. 5. Do not go into the second sensor (Hall Effect) until the first is understood. 6. The Hall Effect sensor is probably one of the more difficult sensor to understand and yet it is found in many applica- tions on a vehicle. If you have a trainer that has a transistor wire it up in a simple on off circuit and demonstrate how fast the voltage changes when it is turned on and off. This will help to “bridge” the change from an analog sensor to a digital one. 7. Use a DMM after showing the transistor effect with a DSO. This may appear backwards, but the transistor demon- stration was just used to show the speed of a digital device. Now take a step backwards to show that the average voltage of a Hall Effect Sensor will not give enough information. Students need to recognize that the vast majority of digital sensors generate the on off signal that is the output. DMM’s will average the voltage and tell the students that the sensor is doing “something”, but will not whether the signal is accurate enough to be read. 8. Once the Hall Effect sensor theory is understood, have the students accomplish the labs that are applicable. The labs will identify the fact that a Hall Effect sensor require a power and ground to function. 9. Have a discussion about how the signal is used to give speed and position. Show them patterns off of other Hall Effect sensors : perhaps like an old 3X 18X CKP off of a GM product. 10. Dual trace the Hall Effect sensor with the magnetic sensor and make sure they recognize the impact of the notch. Note : This is a tremendous lab activity that if done correctly show that the student has a working knowledge of a DSO, by setting voltage, time and using trigger. Using the speed control increase and decrease the speed with a dual trace pattern on the screen. Identify that the relationship between the two sensor outputs is unchanged with speed. Only the amplitude and the frequency of patterns change. 11. The remaining 2 sensors on the EM-200-25 are magneto resistive with their only difference being where the magnet is placed. Make sure the students recognize that the signal looks like a Hall Effect, only at a lower voltage. 12. Again, start with a DMM so everyone recognizes the limitations of meters. The future technicians that you are train- ing will use the DSO if they see its value. The remaining labs will show them this capability as they become proficient in the DSO’s use. 13. Make it educational and make it fun ! consulab.com info@consulab.com 4 EM-200-25_052984-96 Theory Theory consulab.com info@consulab.com 5 EM-200-25_052984-96 Introduction Introduction It seems that each year brings more and more information that is “required” to be taught in the modern automotive classroom. Each year it becomes increasingly difficult to pack it all in. Something has to go. With this in mind, you need to recognize that sensors should not fall off the curriculum band wagon. They are the building blocks of computer control and are virtually vin every automotive system. Whether it is engine control, CAN Bus, or brakes, sensors are basic and their operation and diagnosis procedures need to be instructed. Two areas of sensors are those that measure speed and/or position. We will look at 4 different types of speed and position sensors in this manual. 6 109 8 7 9 4 1 35 2 13 This sensors are arranged on a rotating shaft that can be rotated from 0 to 1200 RPM and is adjustable with a front pan- el control knob (7), which controls the 110V drive motor (5). In addition there is a switchable 5 volt power supply (8) and individual switches that can “unplug” the sensors (9) for multi-meter testing. There are test points for each sensor where a Digital Multi-meter (DMM) or a Digital Storage Oscilloscope (DSO) can be connected. Note : This trainer is a great stand alone demonstration unit or it can be used in a student lab situation for teaching either sensor operation or DSO testing. Normal patterns are included with this handout. 1. Passive inductive sensor 2. Hall Effect sensor 3. Magneto-resistive sensor with internal magnet 4. Magneto-resistive sensor with external magnet 5. Electric drive motor 6. Master power switch and trainer fuse 7. Drive motor speed control 8. 5V DC supply switch 9. Sensor connected/disconnected switches 10. Resistance jumper kit 11. Magneto-resistive sensor gap adjustment screw (Sensor #3) 12. Passive inductive sensor gap adjustment screw (Sensor #1) 13. Vibration adjustment screw consulab.com info@consulab.com 6 EM-200-25_052984-96 Introduction The four sensors used are : 1. Passive inductive sensor. This is a CKP (Crankshaft Position Sensor) from a 2008 Hyundai Accent. It is sometimes referred to as a magnetic inductive sensor. 2. Hall Effect sensor. This is a CMP (Camshaft Position Sensor) from the same 2008 Hyundai Accent. 3. Magneto-resistive sensor with an internal magnet. This is a front ABS (Antilock Brakes System) sensor from a 2008 GMC pickup. 4. Magneto-resistive sensor with an external magnetic strip. This is a front ABS sensor from a 2008 Honda Civic. Speed and position sensors are the building blocks to understanding common electronic devices. They also allow for the use and training on DMM and DSO. Additionally these sensors are frequently out in the weather catching road dirt, salt, water, snow and ice. These sensor are a source of frequent failures and function from -40 to over 200 ºF (-40 to over 90 ºC). Proper understanding of these sensors and how they operate in the many vehicle systems using them should be consid- ered to be a basic requirement. Let’s look at each one individually. consulab.com info@consulab.com 7 EM-200-25_052984-96 Passive induction sensor (Magnetic induction sensor) Passive induction sensor (Magnetic induction sensor) This sensor generates an AC (Alternating Current) signal. The sensor has a coil of wire wrapped around a permanent mag- net. The reluctor wheel is a ferromagnetic tooth reluctor which will absorb or concentrate the lines of force from the mag- net. The slots in the reluctor cause the lines of force to change from a concentrated to an un-concentrated state or move back and forth. When the lines of force move in one direction we get a positive signal. A negative signal is generated when the lines of force move in the opposite direction. The coil of wire “sees” this + then – pulse. The voltage generated by the sensor will be Alternating Current (AC) and will produce an analog (sine wave) signal. The output (voltage amplitude) and sensor frequency will vary with the speed of the reluctor. Typical values range from approximately 500 millivolts (500mV) at low speeds to as much as 30 volts at high speeds. Factors other than speed can affect the output voltage. These are : • Air gap of the sensor to reluctor wheel (adjustable on the EM-200-25) • Strength of the permanent magnet • Resistance of the sensor windings • Number of coil windings • Temperature of the sensor The EM-200-25 sensor #1 is from a Hyundai and should generate a signal like this one shown out of a Hyundai service manual : consulab.com info@consulab.com 8 EM-200-25_052984-96 Passive induction sensor (Magnetic induction sensor) Zero volts is just about in the middle of the screen. The voltages go from zero up to a high of about 5 volts and then switch to below zero at about -4.5V. The gap in the pattern to the right of the middle is caused by a slightly wider notch in the reluctor. Manufactures use the notch and the different signal it produces to indicate position. For example TDC (Top Dead Center) might be the position of the notch. Large Notch The large notch is a different width and only shows up once each rotation of the reluctor. The spread out pattern is caused by this wider notch spinning past the sensor. So the module that is using this information can count the number of puls- es to determine speed and look for the wider notch to determine position. The pattern change that this notch causes is sometimes called the synch pulse. These sensors are frequently used as distributor pick-up coils, CKP (Crankshaft Position Sensors), CMP (Camshaft Posi- tion Sensors), or ABS (Anti-lock) wheel sensors. They can be initially tested using an ohmmeter assuming a specification is known. The specification for our sensor is 500-1000 Ω. When we connect an ohmmeter to the two terminals of the disconnected sensor we get : 0.870 kΩ is 870 Ω, so the resistive value of the sensor appears correct. Two notes here : First, do not use an ohmmeter on a live circuit as your value will not be correct and you may damage the meter. Second the sensor needs to be discon- nected and not functioning before resistance testing with an ohmmeter. consulab.com info@consulab.com 9 EM-200-25_052984-96 Passive induction sensor (Magnetic induction sensor) Shown below is a DSO (Digital Storage Oscilloscope) waveform taken from sensor #1 of the EM-200-25. If the air gap is not correct the generation of the AC will not be the same. We can demonstrate a varying air gap on the EM-200-25. If the air gap is larger than it should be, the pattern will not show as much AC generated voltage. The adjust- ment knob will move the sensor closer or farther away from the reluctor to demonstrate that improper air gaps will have an impact on generated voltages. Notice that the amplitude or amount of generated voltage has been greatly reduced from 3.5 volts average to 2.5 volts average. If the air gap on a magnetic induction sensor is too great, the signal might not be strong enough for whatever module is looking for it. consulab.com info@consulab.com 10 EM-200-25_052984-96 Passive induction sensor (Magnetic induction sensor) One additional consideration that a magnetic induction sensor has is that its output is proportional to its speed. When we increase the speed of the reluctor, the sensor output voltage and frequency will also increase as this figure shows. Notice that the output has increased as the speed increased. A voltmeter can be used to measure the generated output voltage of the sensor. In the figure below, a voltmeter is measuring sensor output voltage, but there is little information for the technician to compare against. Here is the output average at low speeds using the EM-200-25. To review, a magnetic induction sensor will produce AC voltage. The voltage will be proportional to the speed of the sensor and the air gap. A DMM’s ohmmeter can be used to measure the resistive value and a voltmeter can measure the sensors output, however the greatest amount of information is in using a DSO. Pattern analysis can tell the whole story. consulab.com info@consulab.com 11 EM-200-25_052984-96 Hall effect sensor Hall effect sensor The second sensor that we will look at is the Hall Effect sensor from the 2008 Hyundai CMP (Camshaft Position Sensor). NOTE- All active sensors require power from an external source for operation. Most are fed with 5 volts and the EM-200- 25 has an internal switchable power supply. Without the 5 V and a good ground, the sensor does nothing. The Hall Effect is described as when a current is passed through a semiconductor, a voltage is generated proportional to the strength of the permanent magnet. An integrated circuit, inside the body of the sensor will create a DC (direct current) square wave signal. The hall sensor and magnet are positioned so that as the notches and teeth of the wheel pass by, they will influ- ence the magnetic field. The output amplitude of the sensor will remain the same. The sensor is considered Active since it generates a signal at virtually any speed or even stopped, as opposed to the magnetic sensor that requires reluctor speed to produce a signal. The Hall-Effect sensor can be used for the same applications as the inductive sensor. The output will not vary as the speed changes. There are other designs of Hall Effect Sensors that use external magnets and ferromagnetic shutter wheels that pass between the sensor and magnet. These types are more typically used in distributors. Changes in speed and position can be measured using this sensor. Some of these sensors have adjustment procedures that properly position the sensor. This adjustment must be set correctly or the sensor might not function correctly. Once power is applied to the Hall Effect and the trigger wheel/reluctor is spinning, the sensor will generate a square wave DC signal that is different from the magnetic inductive sensor AC signal. Most Hall Effect sensor have 3 wires : Power (5 volts) ground and the signal. consulab.com info@consulab.com 12 EM-200-25_052984-96 Hall effect sensor Notice in the above waveform, the signal starts at zero volts indicated by the red horizontal line on the left middle edge. The signal rises to just about 5 volts and then sharply falls back to zero. This is a digital signal whereas the magnetic in- duction sensor was considered an analog signal. If we speed up the EM-200-25, more patterns (frequency) will appear on the screen but the amplitude will not change. Changing the air gap does not change the voltage, unless the air gap is too great, causing the sensor to not produce any output. Frequently, vehicles will have both a magnetic induction sensor and a Hall Effect sensor. The 2008 Hyundai Accent in the EM-200-25 uses the magnetic induction sensor as the CKP and the Hall Effect for its CMP. If we use a DSO and dual trace these two sensors over the same period of time, you will see what the module sees. Two patterns : one DC digital signal (top pattern) and one AC analog signal (bottom pattern). Channel A is blue and is the analog AC signal. Channel B is red and is the digital DC signal. consulab.com info@consulab.com 13 EM-200-25_052984-96 Magneto-resistive sensors Magneto-resistive sensors We will look at the last two sensors together since they are very similar. Their outputs will look the same on a DSO. The magneto-resistive sensor can have its magnet internal or external in a strip formed like a reluctor. The principle behind this sensor is the fact that magnetic field can be used to vary the resistance of a current carrying conductor. Varying the resistance changes the current flow which is amplified in an IC (integrated circuit) and produces a square wave DC signal that looks like a Hall Effect signal. This is called the anisotropic magnetoresistance (AMR) effect. The current output of the sensor is generally very low (between 7 mA and 14 mA). It is not practical to measure this current, so generally voltage that is pushing the current is measured using a DSO. One of the major difference in these sensors is that they can be used to determine direction of rotation. The sensor may have an internal magnet and use a toothed wheel like other sensors or it may use an external magnetic encoder with multiple magnetic segments and alternating polarity. The magneto-resistive sensor is most often a two-wire sensor, however, a three-wire configuration is found on some appli- cations and like the Hall Effect it requires power generally in the 5-volt range. The sensor is less affected by increasing air gaps and can provide a signal at near zero rpm. Since the sensor can detect the slightest beginning motion, it is sometimes used in steering angle position and Hill-Assist” sensors with varying spaced triggers. consulab.com info@consulab.com 14 EM-200-25_052984-96 Magneto-resistive sensors Typical MR sensor output waveform The MR sensor output voltage is greatly reduced from the typical Hall Effect. Hall voltage is usually around supply voltage and in the case of the Hyundai was 5 volts. On the magneto resistive the output voltage runs from a low of about 0.5 V to a high of 1.5 V. Sensor #3 is from a front ABS unit of a 2008 GMC Pickup while sensor #4 is from a 2008 Honda Civic ABS system. Re- member that the only difference in these two sensors is : where does the magnet sit. Is it internal or in a strip external to the sensor ? An ohmmeter is generally not used on these sensors since their output is only present when a supply voltage is present. A voltmeter or a meter set up to read pulse width can be used and will be used in the student activity portion of this man- ual. A DSO is considered to be the tool of choice for many technicians. The mounting of these ABS wheel speed sensors may be on the front strut. consulab.com info@consulab.com 15 EM-200-25_052984-96 Magneto-resistive sensors Again the main difference is in where is the magnet. This picture shows the reluctor of an internal magneto resistive sensor labeled as the toothed ring. The toothed ring is virtually the same as for a Hall Effect reluctor. When we look at the external magnetic strip, you will notice that there are no slots or notches. There are a series of small magnets separated by non-magnetic material. The sensor rides alongside the strip as this photo shows. This strip contains the small pole magnets separated by non-magnetic material The sensor sits alongside the strip This photo shows the darker colored strip as part of the trigger or reluctor wheel. The MR sensor using the axial magnetic pole magnet strip provides a faster resolution signal and is used for applications requiring high accuracy. If you are a student, we hope these simplified explanations of how these sensors function will help you as you learn about speed and position sensors. consulab.com info@consulab.com 16 EM-200-25_052984-96 Magneto-resistive sensors If you are an instructor, teach pattern analysis in your classes. It is helpful to get the students/technicians to distinguish a good pattern from a bad. Use iATN as a source for patterns. You have to be a sponsoring member to use the available patterns. The free Pico Automotive 6 software and many Facebook technicial forums are other great learning resources for sensor waveform pattern analysis. Request permission from the posting technician and give him credit in your handout. For example here is a known good Ford Taurus CKP. Here is a known bad CKP sensor from a Toyota. consulab.com info@consulab.com 17 EM-200-25_052984-96 Magneto-resistive sensors After sensor replacement, the pattern changed to : Patterns taken off of iATN and other sources, will give you a wealth of information that would be impossible to collect on your own. Always request permission from the posting technician and keep his/her name on the pattern to give credit. We hope this simplified explanation of these 4 sensors will be of value to you in the future. Teaching some old sensors from a new perspective might just give the students what they need to function on today’s modern vehicle. Using the EM-200-25 with this manual can enhance the experience. The separate Student Activities Manual contains some easily understood lab activities for the student. Coupled with iATN patterns for known good and known bad, the student understanding will be greatly improved. consulab.com info@consulab.com 18 EM-200-25_052984-96 Theory Exam Theory Exam (2 pages) Use the answer sheet for your answers. Do not write on this test paper. 1. Two technicians are discussing a magnetic sensor. Technician A states that the sensor will generate an AC voltage when functioning correctly. Technician B states that the sensor does not need a power source. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 2. Technician A states that increasing the speed of the reluctor will increase the output of a magnetic sensor. Techni- cian B states that decreasing the air gap of a magnetic sensor will decrease its output. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 3. The larger notch on a spinning reluctor will cause a... A. lower voltage generation B. different spacing on the generated signal C. square wave DC signal D. change in the sensor’s resistance 4. A Hall Effect Sensor will generate a(n)... A. AC voltage B. resistance change while spinning C. pulse width modulated AC signal D. square wave DC signal consulab.com info@consulab.com 19 EM-200-25_052984-96 Theory Exam 5. A voltmeter is placed on a Hall Effect Sensor and reads 2.5 VDC. Technician A states that this indicates the sensor is bad. Technician B states that this indicates a bad power supply. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 6. The synch pulse can be used to indicate the... A. position of the reluctor B. speed of the reluctor C. validity of the signal D. ability of the sensor to function 7. Technician A states that a magneto-resistive Sensor can have an internal magnet. Technician B states that a magne- to-resistive Sensor can have an external magnet. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 8. A magneto-resistive sensor is being checked with an ohmmeter. Technician A states that this can be used to de- termine if the sensor is functional. Technician B states that this is not a correct test for a magneto-resistive sensor. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 9. Technician A states that a magneto-resistive sensor might be used as a wheel speed sensor. Technician B states that a Hall Effect sensor might be used as a CKP or a CMP. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 10. An external magnet magneto-resistive sensor will have the sensor position... A. in line with the reluctor B. touching the reluctor C. spinning with the reluctor D. alongside the reluctor consulab.com info@consulab.com 20 EM-200-25_052984-96 Theory Exam Theory Exam Student Answer Sheet Circle the correct answer. 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 21 EM-200-25_052984-96 Theory Exam Answers Circle the correct answer. 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D consulab.com info@consulab.com 22 EM-200-25_052984-96 Student assignments Answers Student assignments Answers The purpose of the following student assignments is to have you develop an under- standing how these four speed and position sensors function. We will use a DMM for ohmmeter, voltage, pulse width and frequency measurements. We will also use a two channel DSO to analyze the signal generated. During each assignment fill in the student answer sheet. If you can print the DSO patterns, you can attach them to the lab activity sheets. If you cannot print them, show your instructor the saved pattern so he can sign off on the lab activity sheet. consulab.com info@consulab.com 23 EM-200-25_052984-96 SA-1 Student assignment SA-1 Student assignment Answer 1. Specifications : 800-1000 Ω Output voltage @ RPM AC or DC ? Frequency @ RPM Pulse width 2. 872 Ω 3. Yes 4. 0.130 AC Volts 23 Hz Frequency 55% Pulse width 5. 0.5 AC Volts 100 Hz Frequency 55% Pulse width 6. Why does the sensor generate a signal ? Motion between the spinning reluctor and the permanent magnet generates AC signal. 7. What happened to the AC Volts generated with increased speed ? The AC voltage increased with increased speed. 8. What happened to the frequency generated with increased speed ? The frequency increased at higher speed. 9. What happened to the pulse width generated with increased speed ? The pulse width remained the same at all speeds. consulab.com info@consulab.com 24 EM-200-25_052984-96 SA-2 Student assignment SA-2 Student assignment Answers 1. 2. 3. Yes 4. Why did the results in #3 occur ? Increased speed between the reluctor and the permanent magnet caused increased voltage. 5. Yes 6. Why did the results in #5 occur ? More reluctor teeth pass during the same period of time with each tooth creating an AC signal. consulab.com info@consulab.com 25 EM-200-25_052984-96 SA-3 Student assignment SA-3 Student assignment Answers 3. 1 VAC 5. 0.5 VAC 6. 4 Turns 9. V peak 11. Instructor signature 12. 4 Turns. Note : It will vary slightly with each EM-200-25. 13. What general statement can you make about gap and output voltage ? As the gap is increased there is less interaction between the reluctor and the permanent magnet causing less volt- age production. consulab.com info@consulab.com 26 EM-200-25_052984-96 SA-4 Student assignment SA-4 Student assignment Answers 3. 5 V DC 5. No 8. V DC 10. No 11. What significance does the answer in numbers 5 and 10 have on the operation of the Hall Effect Sensor ? Under normal operating conditions, the 5 VDC power supply does not vary the voltage. It is a steady 5V. consulab.com info@consulab.com 27 EM-200-25_052984-96 SA-5 Student assignment SA-5 Student assignment Answers 4. 0 VDC 7. 0.2 VDC 8. 1.8 VDC 9. Frequency 111 Hz Pulse Width 66% PWM Min Volts 1.68 V Max Volts 1.96 V Avg Volts 1.8 V 10. Frequency 293 Hz Pulse Width 66% PWM Min Volts 1.72 V Max Volts 1.84 V Avg Volts 1.8 V 11. What reading(s) changed ? Frequency. 12. Why did the change occur ? Faster speed caused greater frequency of pattern. 13. What reading(s) did NOT change ? All the rest. 14. Why didn’t the reading(s) change ? Digital signal that rely on reluctor shape not speed. consulab.com info@consulab.com 28 EM-200-25_052984-96 SA-6 Student assignment SA-6 Student assignment Answers (2 pages) 4. VDC minimum VDC maximum 7. VDC minimum VDC maximum. Print or show your instructor the pattern. 8. VDC minimum VDC maximum. Print or show your instructor the pattern. 9. Instructor signature 10. Frequency Hz Pulse Width PWM Min Volts V Instructor signature Max Volts V Avg Volts V consulab.com info@consulab.com 29 EM-200-25_052984-96 SA-6 Student assignment 11. What reading(s) changed ? Only frequency. 12. Why did the change occur ? The faster spinning reluctor shaft caused more activity resulting in greater frequency. 13. What reading(s) did NOT change ? The voltage and pulse width did not change. 14. Why didn’t the reading(s) change ? The Voltage and Pulse Width are a factor of the reluctor shape and the 5 VDC supply. They are not affected by the speed of the reluctor. 15. How would you describe the Hall Effect signal ? The Hall Effect signal is a square wave DC voltage starting near 0V and rising to near 5V. 16. What effect did changing speed have on the pattern ? Changing the speed only changed the number of pulses on the screen. consulab.com info@consulab.com 30 EM-200-25_052984-96 SA-7 Student assignment SA-7 Student assignment Answers 5. Yes 6. Why or why not ? Most DSO’s will display multiple patterns. Either 2 or 4 patterns. 9. Instructor signature 11. Instructor signature consulab.com info@consulab.com 31 EM-200-25_052984-96 SA-8 Student assignment SA-8 Student assignment Answers 4. 0 VDC 7. 1.36 VDC 8. 1.21 VDC 9. Frequency 0 Hz Pulse Width OL PWM Min Volts 1.2 V Max Volts 1.24 V Avg Volts 1.21 V 10. Frequency 0 Hz Pulse Width OL PWM Min Volts 1.2 V Max Volts 1.24 V Avg Volts 1.21 V 11. What reading(s) changed ? No reading changed. 12. Why did the change occur ? The meter was overloaded (OL). 13. What reading(s) did NOT change ? 14. Why didn’t the reading(s) change ? 15. What is different about these readings when compared to the Hall Effect sensor readings ? The readings of the magneto-resistive sensor are at a greatly reduced voltage level. consulab.com info@consulab.com 32 EM-200-25_052984-96 SA-9 Student assignment SA-9 Student assignment Answers (2 pages) 4. VDC minimum VDC maximum 7. VDC minimum VDC maximum 8. VDC minimum VDC maximum. 9. Frequency Hz Pulse Width PWM Min Volts V Max Volts V Instructor signature Avg Volts V consulab.com info@consulab.com 33 EM-200-25_052984-96 SA-9 Student assignment 10. Frequency Hz Pulse Width PWM Min Volts V Max Volts V Avg Volts V 11. What reading(s) changed ? The number of pulses increased. 12. Why did the change occur ? The reluctor shaft exposed more slots. 13. What reading(s) did NOT change ? The voltage levels. 14. Why didn’t the reading(s) change ? The voltage levels are determined by the power supply. 15. How would you describe the signal from a magneto-resistive sensor ? The signal from the Magneto Resistive sensor resembles a Hall Effect signal but at greatly reduced voltage levels. consulab.com info@consulab.com 34 EM-200-25_052984-96 SA-10 Student assignment SA-10 Student assignment Answers 5. 1.21 VDC 7. What does the voltage do ? Remains steady until it drops to zero. 8. Why does this occur ? 11. What does the pattern do ? 12. Why does this occur ? consulab.com info@consulab.com 35 EM-200-25_052984-96 SA-11 Student assignment SA-11 Student assignment Answers 4. 0 VDC 7. 0.6 VDC 8. 0.98 VDC 9. Frequency 0 Hz Pulse Width OL PWM Min Volts 0.96 V Max Volts 1 V Avg Volts 0.98 V 10. Frequency 0 Hz Pulse Width OL PWM Min Volts 0.96 V Max Volts 1 V Avg Volts 0.98 V 11. What reading(s) changed ? None of the readings changed. 12. Why did the change occur ? They are unaffected by speed changes. 13. What reading(s) did NOT change ? 14. Why didn’t the reading(s) change ? 15. What is different about these readings when compared to the Hall Effect sensor readings ? The Hall Effect sensor produced a greater voltage difference. The readings changed with speed changes. consulab.com info@consulab.com 36 EM-200-25_052984-96 SA-12 Student assignment SA-12 Student assignment Answers (2 pages) 4. VDC minimum VDC maximum 7. VDC minimum VDC maximum 8. VDC minimum VDC maximum. Print or show your instructor the pattern. 9. Frequency Hz Pulse Width PWM Instructor signature Min Volts V Max Volts V Avg Volts V consulab.com info@consulab.com 37 EM-200-25_052984-96 SA-12 Student assignment 10. Frequency Hz Pulse Width PWM Instructor signature Min Volts V Max Volts V Avg Volts V 11. What reading(s) changed ? Frequency. 12. Why did the change occur ? More pulses with increased speed of the reluctor. 13. What reading(s) did NOT change ? Voltage readings. 14. Why didn’t the reading(s) change ? Voltage is fixed by power supply. 15. How would you describe the signal from a magneto-resistive sensor ? The signal from the magneto-resistive sensor is similar to that from a Hall Effect but at greatly reduced voltages. consulab.com info@consulab.com 38 EM-200-25_052984-96 SA-13 Student assignment SA-13 Student assignment Resistance connection options Below are oscilloscope waveform screenshots of various resistance connection options using the jumper wires on the EM-200-25 sensors. They are intended to give you a guide to show the effect on sensor operation and to serve as an “ANSWER KEY” for student assignments you may wish to design. REMEMBER : NOTE : Many different variations of scope waveforms can be obtained when using the resistor package. Depending on where you insert the resistance and which side of the resistance you connect your scope signal probe as well as the position of the connecter CONNECTED/DISCONNECTED switch will result in many different types of waveforms. The resistor package creates many “teachable moments” in allowing students to understand what unwanted resis- tance would have on different parts of the circuit and how best to test a vehicle for abnormal conditions. EM-200-25 Trainer Connected to a Pico EM-200-25 Trainer Used with a uScope consulab.com info@consulab.com 39 EM-200-25_052984-96 SA-13 Student assignment DSO Sreen Shots ANALOG MAGNETIC (VR) PASSIVE SENSOR Analog Magnetic (VR) sensor – (Normal operation – no resistance installed) Analog Magnetic (VR) sensor – (resistance inserted in the Signal circuit) consulab.com info@consulab.com 40 EM-200-25_052984-96 SA-13 Student assignment HALL EFFECT ACTIVE SENSOR Hall Effect sensor – Normal operation (no resistance installed) Hall Effect sensor – (Resistance installed in the Signal circuit) consulab.com info@consulab.com 41 EM-200-25_052984-96 SA-13 Student assignment Hall Effect sensor – (Resistance installed in the Ground circuit) MAGNETO-RESISTIVE RADIAL SENSOR Magneto-Resistive Radial sensor – Normal operation (no resistance inserted) consulab.com info@consulab.com 42 EM-200-25_052984-96 SA-13 Student assignment Magneto-Resistive Radial Sensor (resistance inserted in 5V circuit) Magneto-Resistive Radial Sensor (resistance inserted in Signal circuit) consulab.com info@consulab.com 43 EM-200-25_052984-96 SA-13 Student assignment MAGNETO-RESISTIVE AXIAL SENSOR Magneto-resistive Axial sensor – Normal operation (no resistance inserted) Magneto-resistive Axial sensor – Resistance inserted in SIG circuit consulab.com info@consulab.com 44 EM-200-25_052984-96 SA-13 Student assignment Magneto-resistive Axial sensor – probe on 5V power – normal operation Magneto-resistive Axial sensor – probe on 5V power – resistance inserted consulab.com info@consulab.com 45 EM-200-25_052984-96 Assignments Exam Assignments Exam (2 pages) The following questions should be attempted after the 12 labs for the EM-200-25 Speed and Position Sensors Trainer have been completed. Use the answer sheet for your answers. Do not write on this test paper. 1. A magnetic inductive sensor will generate a... A. pulsing DC signal B. pulse width modulated signal C. variable resistance signal D. pulsing AC signal 2. Technician A states that a magnetic sensor requires an applied power, like 5 VDC to function. Technician B states that a magnetic sensor requires 3 wires to function. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 3. Increasing the speed of the reluctor will cause a(n)... A. reduction in the DC output B. increase in the AC output C. increase in the DC output D. reduction in the AC output 4. Technician A states that a Hall Effect sensor can be used to determine the speed of something. Technician B states that a Hall Effect sensor must have an applied power to function. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B consulab.com info@consulab.com 46 EM-200-25_052984-96 Assignments Exam 5. A DMM can be used to look at... A. voltage B. resistance C. frequency D. All of the above 6. As the speed of a Hall Effect Sensor is increased the... A. number of pulses will increase B. number of pulses will decrease C. DC voltage will increase D. DC voltage will decrease 7. The signal from a magneto-resistive sensor looks similar to the signal from a... A. magnetic sensor B. synch pulse C. Hall Effect D. None of the above 8. As the magneto-resistive sensor is moved away from the reluctor, increasing the air gap, the signal will... A. increase B. decrease C. pulse width modulate D. not change until it disappears 9. Technician A states that the air gap on an adjustable magneto-resistive sensor is insignificant. Technician B states that too great of an air gap will prevent the sensor from generating any output. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A nor Technician B 10. A Hall Effect sensor loses its power. Technician A states that this will not allow the sensor to function. Technician B states that this might result in a no start if the sensor is a CKP or a CMP. Who is correct ? A. Technician A only B. Technician B only C. Both Technician A and Technician D. Neither Technician A nor Technician B consulab.com info@consulab.com 47 EM-200-25_052984-96 Assignments Exam Assignments Exam Student Answer Sheet Circle the correct answer. 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 48 EM-200-25_052984-96 Assignments Exam Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D consulab.com info@consulab.com 49 EM-200-25_052984-96 EM-200-25 Electric Wiring Diagram EM-200-25 Electric Wiring Diagram consulab.com info@consulab.com 50 EM-200-25_052984-96 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved.
