HVAC Electronics Moduponent™ Kit 96-MD-4000-24_REVA © ConsuLab Educatech Inc, 2025. Tous droits réservés. Instructor guide for MD-4000-24_053345 Teacher Only 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 96-MD-4000-24 Trainer Use and Familiarization Trainer Use and Familiarization This manual is designed to provide instructors with all the fault descriptions and schematics. This manual is for the teacher eyes only as it reveals some answers and fault location. Be sure to read, understand and follow all content of the Operation Manual and the Instructors Manual before using the product, those will provide a safe working environ- ment for students and instructors. Those two manuals are also available in PDF format on our website. The product comes with two more manuals, Student Assignments manual and Answer keys and theory manual, which are available in PDF format on our website. The Student Assignments manual contain a theory section with student as- signments activitites and tests. The Answer keys and theory manual contain the same theory section, plus some note for the instructor, and the answer to the student assignments and tests. • Operation Manual • Instructors Manual • Student Assignments • Answers Keys and Theory • Operation Manual • Instructors Manual Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 96-MD-4000-24 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 3 Table of contents General description 6 SA-1 — MD-4001 Pulse Width Modulator (PWM) 8 SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 9 SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 2 SA-2 — MD-4002 5V Regulator 12 SA-2 — MD-4002 5V Regulator — Level 1 Answers 13 SA-2 — MD-4002 5V Regulator — Level 2 Answers 14 SA-2 — MD-4002 5V Regulator — Level 2 Answers 15 SA-3 — MD-4030 Potentiometer 16 SA-3 — MD-4030 Potentiometer — Level 1 Answers 17 SA-3 — MD-4030 Potentiometer — Level 1 Answers 18 SA-3 — MD-4030 Potentiometer — Level 2 Answers 19 SA-4 — MD-4040 12VDC 5-pin ISO Relay 20 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 22 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 23 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 Answers 24 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 25 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 Answers 26 96-MD-4000-24 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 4 SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) 27 SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 1 Answers 29 SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 30 SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 Answers 31 SA-6 — MD-4058 High Pressure Sensor 32 SA-6 — MD-4058 High Pressure Sensor — Level 1 33 SA-6 — MD-4058 High Pressure Sensor — Level 1 Answers 34 SA-7 — MD-4059 Sunload Sensor 35 SA-7 — MD-4059 Sunload Sensor — Level 1 36 SA-7 — MD-4059 Sunload Sensor — Level 1 Answers 37 SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor 38 SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 39 SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 Answers 40 SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor 41 SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 42 SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 Answers 43 SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) 44 SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) 45 SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) — Level 1 Answers 46 96-MD-4000-24 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 5 © ConsuLab Educatech Inc, 2025. 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 053345 and above. SA-11 — MD-4111 Fan 47 SA-11 — MD-4111 Fan — Level 1 49 SA-11 — MD-4111 Fan — Level 2 50 SA-11 — MD-4111 Fan — Level 2 51 SA-12 — MD-4115 Air Door Actuator 52 SA-12 — MD-4115 Air Door Actuator — Level 1 53 SA-12 — MD-4115 Air Door Actuator — Level 1 Answers 54 SA-13 — MD-4141 Optical Sensors 55 SA-13 — MD-4141Optical Sensors — Level 1 Answers 57 SA-13 — MD-4141Optical Sensors — Level 1 Answers 58 SA-13 — MD-4141Optical Sensors — Level 2 Answers 59 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) 60 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 62 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 Answers 63 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 64 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers 65 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers 66 consulab.com info@consulab.com 6 96-MD-4000-24 General Description General description The ConsuLab MD-4000-24_053345 is a versatile and adaptable electrical/electronic training system that allows stu- dents to build electronic circuits. Features • Protected with removable metal cover • Adjustable and protected power supply (2-14VDC) • Moduponent™ storage rails allow up to 16 individual Moduponents™ Educational Advantages • Can be used for teaching basic Ohm’s law or complex electronic circuits • Self-contained unit has a protected built-in adjustable power supply • Storage case holds up to 16 individual Moduponents™ • This set includes 15 different Moduponents™ from the entire MD-4000 series • Uses industry standard schematic symbols • Provides extreme flexibilty to allow instructors to create additional assignments and student activities • Assists instructors in the instruction of many tasks in area A6 and others of the ASE Education Foundation (NATEF) Liste of ModuponentsTM for ensemble MD-4000-24 52958 CL-1011A - Desktop Moduponent Case 52320 CL-1012-03 - Set of 26 jumper leads 53061 MD-4000 - DC Power Supply 53074 MD-4001 - Pulse Width Modulator 53095 MD-4002 - 5V Output (Regulator) 53070 MD-4030 - Potentiometer 53068 MD-4040 - 12VDC 5-pin ISO Relay 53067 MD-4052 - NCT Thermistor 53207 MD-4058 - High Pressure Sensor 53209 MD-4059 - Sunload Sensor 53210 MD-4060 - Windshield Temperature and Inside Moisture Sensor 53211 MD-4061 - In-vehicle Temperature and Humidity Sensor 53130 MD-4062 - PTC Thermistor 53073 MD-4111 - Fan 53208 MD-4115 - Air Door Actuator 53076 MD-4141 - Optical Sensors (3) 53077 MD-4142 - Transistors 96-MD-4000-24 Student assignements consulab.com info@consulab.com 7 Student Assignments Answers consulab.com info@consulab.com 8 96-MD-4000-24 SA-1-MD-4001 Pulse Width Modulator (PWM) SA-1 — MD-4001 Pulse Width Modulator (PWM) Electrical Symbol : MD-4000 Moduponent: MD-4001 Pulse Width Modulator (PWM) Electrical Symbol: Theory of operation: Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by electronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120VAC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4010 Resistors MD-4070 Light bulbs MD-4111 Fan MD-4120 Injector Additional equipment: Safety Glasses DVOM Oscilloscope (optional) Theory of operation: Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by elec- tronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4130 Fuses • MD-4010 Resistors • MD-4070 Light bulbs • MD-4111 Fan • MD-4120 Injector Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC consulab.com info@consulab.com 9 96-MD-4000-24 SA-1-MD-4001 Pulse Width Modulator (PWM) SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 Level 1 exercise: Practice measuring the resistance of 4 resistors with a DVOM. (1/2) LEVEL 1 SETTING UP TO MESURE PULSED VOLTAGE DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal ofthe MD-4001 PWM moduponent. Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent. Connect the DVOM red lead to the BLUE SIGNAL terminal of the MD-4001 PWM moduponent. Set the DVOM to V DC. Follow the instructions on next page for control dial settings and record measurements. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC MD-4000 MD-4001 SET METER V DC consulab.com info@consulab.com 10 96-MD-4000-24 SA-1-MD-4001 Pulse Width Modulator (PWM) Answers SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 Answers Level 1 exercise: Practice measuring the resistance of 4 resistors with a DVOM. (2/2) LEVEL 1 MEASURING PULSED VOLTAGE DONE DO THIS: 1 Set control dial to the second line marking. Record voltage at the signal terminal : 0 V. Set control dial to the fourth line marking. Record voltage at the signal terminal : 1,5 V. Set control dial to the sixth line marking. Record voltage at the signal terminal : 4.5 V. Set control dial to the eighth line marking. Record voltage at the signal terminal : 8,5 V. 2 With knowledge of PWM, what is happening here ? Voltage is being pulsed ON/OFF, not resistance added to the circuit. 3 What exactly is PWM ? ON versus OFF time. Proceed to SA-1 Level 2 to actually see this happen using an oscilloscope. consulab.com info@consulab.com 11 96-MD-4000-24 SA-1-MD-4001 Pulse Width Modulator (PWM) Answers SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 2 Answers Level 2 exercise: Observe PWM signal using an oscilloscope to capture a pattern. NOTE : *Prior oscilloscope knowledge is required for this Student Assignement. LEVEL 2 SETTING UP AN OSCILLOSCOPE TO OBSERVE A PWM SIGNAL DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4001 PWM moduponent. Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. Connect a black wire from the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply Connect one lead from an oscilloscope to the BLUE SIG terminal of the MD-4001 PWM moduponent. Connect the oscilloscope black lead to the BLACK – of the power supply. Adjust the PWM control knob to the sixth line. Adjust the oscilloscope settings until a pattern can be observed * 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time: 10 us per div Trigger: 12.0 V 2 On a separate sheet of paper, draw the pattern observed. See capture : Now adjust the PWM control knob right and left and observe the changes in the oscil- loscope pattern. 3 How fast is pulse width being modulated? 21 kHz 4 Describe the pattern changes observed and why the pattern changes: The time base stretches the pattern as the knob is turned right (ON time increased) and shortens the pattern as the knob is turned left (OFF time increased). consulab.com info@consulab.com 12 96-MD-4000-24 SA-2-MD-4002 5V Regulator SA-2 — MD-4002 5V Regulator Electrical Symbol : Theory of operation: Reference voltage has been used in electronics for years and is called Vref. The reason why modern automobiles use a 5-volt reference is to provide a consistent voltage to the engine control computer circuits, instead of fluctuating with battery/charging/cranking voltages. Also, as electricity flows through a sensor containing a resistance, any resistance introduced into this circuit will be a larger proportion of a 5 volt circuit than a 12 volt circuit, providing better accuracy. Due to this variable resistance, the signal return voltage to the ECM is always less than the reference voltage and used to compute changes in temperature, pressure or position. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4130 Fuses • MD-4053 MAP Sensor • MD-4054 TPS • MD-4057 MR Sensor • MD-4051 Hall Effect Sensor Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT consulab.com info@consulab.com 13 96-MD-4000-24 SA-2-MD-4002 5V Regulator Answers SA-2 — MD-4002 5V Regulator — Level 1 Answers Level 1 exercise: Set up a 5V reference voltage to illustrate modern vehicle sensor reference voltage LEVEL 1 SETTING UP A REFERENCE VOLTAGE OF 5V DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal ofthe MD-4002 PWM moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to VDC. LEVEL 1 MEASURING PULSED VOLTAGE DONE 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 12 V DC 2 Connect the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 5 V DC 3 Why is this voltage regulation needed? To control sensor reference voltage at a 5V level. 4 How is this 5V reference voltage used in an automobile today? The on-board computer sends a reference voltage to the sensors and actuators, usually 5 volts. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 MD-4002 SET METER V DC consulab.com info@consulab.com 14 96-MD-4000-24 SA-2-MD-4002 5V Regulator Answers SA-2 — MD-4002 5V Regulator — Level 2 Answers Level 2 exercise: Observe a 5V reference measured on a DVOM compared to an Oscilloscope pattern. (1/2) NOTE : *Prior oscilloscope knowledge is required for this Student Assignement. Additionnal Moduponents required : MD4002, MD-4051, MD-4053 and MD-4057 LEVEL 2 SETTING UP A REFERENCE VOLTAGE OF 5V DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5V Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to VDC. LEVEL 2 PROVIDE A 5V REFERENCE TO A SENSOR DONE 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 12 V. 2 Move the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 5 V. Remove the red DVOM lead from the 5V terminal. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the +5V terminal of the MD-4051 Hall Effect Sensor moduponent. 3 Without a ground wire connected to the MD-4051 Hall Effect Sensor, connect the DVOM red lead to the sensor BLACK GND terminal and record voltage: 5 V 4 Without a ground wire connected to the MD-4051 Hall Effect Sensor, move the DVOM red lead to the WHITE SIG terminal and record voltage: 5 V 5 With the DVOM red lead still connected to the WHITE SIG terminal, complete the 5V circuit by providing a black wire from the GND terminal back to BLACK – of the power supply. Record SIG voltage reading now with the 5V circuit completed: + or - 5 V 6 Using a DVOM to measure the voltage, were you able to see an accurate “signal”? No Connect an oscilloscope and obtain a waveform pattern. 7 Using an oscilloscope to measure voltage, were you able to see an accurate “signal”? Yes consulab.com info@consulab.com 15 96-MD-4000-24 SA-2-MD-4002 5V Regulator Answers SA-2 — MD-4002 5V Regulator — Level 2 Answers Level 2 exercise: Observe a 5V reference measured on a DVOM compared to an Oscilloscope pattern. (2/2) NOTE : *Prior oscilloscope knowledge is required for this Student Assignement. Additionnal Moduponents required : MD4002, MD-4051, MD-4053 and MD-4057 LEVEL 2 PROVIDE A 5V REFERENCE TO A SENSOR DONE REPEAT steps 3 – 9 for the following MD-4000-23 moduponents: 8 MD-4053 MAP sensor GND 5 SIG w/o GND 5 SIG w/GND 3.8 9 MD-4057 MR sensor GND 4.5 SIG w/o GND 4.5 SIG w/GND Varies with sensor speed consulab.com info@consulab.com 16 96-MD-4000-24 SA-3-MD-4030 Potentiometer SA-3 — MD-4030 Potentiometer Electrical Symbol : Theory of operation: A potentiometer is a three-terminal resistor with a sliding or wiping contact that creates an adjustable voltage divider. Two of the terminals are each end of a fixed resistance while the third terminal can be moved to different positions across the fixed resistance. In a potentiometer, the entire input voltage is applied across the length of this resistance and the output voltage is the voltage drop between the fixed and sliding contact. When moving the slider, the resistance between the sliding contact and one end of the resistance decreases while the resistance between the sliding contact and the other side of the resistance increases A voltage divider is a simple circuit which turns a large input voltage into a smaller output voltage. Voltage division is the result of distributing the input voltage among the components of the divider or in the case of a potentiometer, distributing input voltage across the length of the resistor coil. Voltage dividers are one of the most fundamental circuits in electronics. If only two terminals of the potentiometer are used, one end and the wiper, it controls amperage and acts as a variable resistor or rheostat. Pulse Width Modulation (PWM) is another way to control voltage and will be covered later in the assignment for the MD-4001 ModuponentTM. Potentiometers are commonly used to volume controls on audio equipment, lighting brightness control and fan speed control. Safety and Safeguards • ONLY use the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • The resistor coil will get warm to hot with higher voltage applied. Companion Moduponents™ • MD-4130 Fuses Protection • MD-4090 SPST Switch Circuit control • MD-4091 DPDT Switch Circuit control • MD-4071 LED’s Load operation • MD-4070 Light Bulbs Load operation • MD-4111 Motor Load operation MODUPONENT REVC MD-4030 50Ω - 25W POTENTIOMÈTRE POTENTIOMETER Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) 0.281'' PLEXI 1/4" LAMER 7/16'' PROF 0.08'' MD-4030 MODUPONENT POTENTIOMETER POTENTIOMÈTRE 50Ω - 25W consulab.com info@consulab.com 17 96-MD-4000-24 SA-3-MD-4030 Potentiometer Answers SA-3 — MD-4030 Potentiometer — Level 1 Answers Level 1A exercise: Demonstrate voltage dividing and how a potentiometer achieves this. LEVEL 1A SETTING UP A REFERENCE VOLTAGE OF 5V DONE Use a visual illustration to introduce voltage division, then follow up with an application demonstration using the potentiometer (1B). DO THIS: On a piece of paper, use a pencil to draw a 4” line. Make it a heavy, thick line. Using a DVOM set to Ω (resistance) touch the red lead on one end of the drawn line. See above photos Touch the black lead on the other end of the drawn line. 1 Record the resistance reading: Ω Now, without lifting the leads from the pencil line, move the leads slowly closer together. 2 Observe and record the resistance readings when the leads are 3” apart: Ω 3 Observe and record the resistance readings when the leads are 2” apart: Ω 4 Observe and record the resistance readings when the leads are 1” apart: Ω 5 Discuss the path that the ohm meters test voltage travels for each reading. Voltage divide 1 Voltage divide 2 consulab.com info@consulab.com 18 96-MD-4000-24 SA-3-MD-4030 Potentiometer Answers SA-3 — MD-4030 Potentiometer — Level 1 Answers Level 1B exercise: Practice measuring the resistance of 4 resistors with a DVOM. LEVEL 1B MEASURING RESISTANCE DONE Using the resistance lesson learned from 1A, demonstrate this on the potentiometer. DO THIS: See wiring diagram Connect the black lead from a DVOM to the LEFT terminal of the MD-4030 Potentiometer. Connect the red lead from a DVOM to the CENTER terminal of the MD-4030 Potentiometer. Set the DVOM to Ohms (Ω) Observe the resistance reading while moving the potentiometer dial between 0 - 100. 1 Which reading (0-100) is represented by the leads being 4” apart in Exercise 1A? 100 Ω 2 Which reading (0-100) is represented by the leads being 1” apart in Exercise 1A? 25 Ω MODUPONENT REVC MD-4030 50Ω - 25W POTENTIOMÈTRE POTENTIOMETER MD-4030 consulab.com info@consulab.com 19 96-MD-4000-24 SA-3-MD-4030 Potentiometer Answers SA-3 — MD-4030 Potentiometer — Level 2 Answers Level 2 exercise: Using the resistance lesson learned from 1B, demonstrate potentiometer voltage dividing. LEVEL 2 BASIC POTENTIOMETER OPERATION DONE Observe voltage division with a DVOM and a potentiometer. DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See left wiring diagram Connect a red wire between the RED + of the power supply to the LEFT terminal of the MD-4030 Potentiometer (output from a circuit/ input to potentiometer). Connect a black wire from the RIGHT terminal of the MD-4030 Potentiometer back to the BLACK – of the power supply (potentiometer ground circuit) Set the DVOM on V DC Connect the DVOM black lead to the BLACK – terminal of the power supply. Connect the DVOM red lead to the CENTER terminal of the MD-4030 Potentiometer (out- put from potentiometer / input to a circuit) Turn MD-4030 Potentiometer knob and observe divided voltage. See right wiring diagram Reverse power and ground wires to the potentiometer (RIGHT / Power – LEFT / Ground). Turn MD-4030 Potentiometer knob and again observe divided voltage. 1 Discuss and explain differences in voltage division measurements: Reading depends on where measurement is made – before or after the resistor element. 2 Using industry standard symbols, on a piece of paper draw a wiring diagram of a circuit using a potentiometer to control a light bulb. Assess student drawn wiring diagram. MODUPONENT REVC MD-4030 50Ω - 25W POTENTIOMÈTRE POTENTIOMETER MODUPONENT REVC MD-4030 50Ω - 25W POTENTIOMÈTRE POTENTIOMETER MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4030 MD-4000 MD-4030 consulab.com info@consulab.com 20 96-MD-4000-24 SA-4-MD-4040 12 VDC 5 Pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay Electrical Symbol : Theory of operation: Simply put, an automotive relay is an electrically or electronically operated switch that is able to control high current loads with a low current control circuit. There are two circuits inside a relay that are independent of each other, and often there is no physical connection between the two. The low current side is called the control circuit and the high current side is called the load circuit. The only “connection” is from electromagnetism. This is achieved by a coil of wire in the control circuit which becomes an electromagnet when that circuit is closed. This amount of current in the coil becomes the only load of that control circuit. (See above schematic) Common relays can have two sets of contacts in the high current side. One set remain “closed” and the other remain “open” when the relay is off. Energizing the relay reverses the position of the contacts. The terms N.C. (normally closed) and N.O. (normally open) are used to describe the position of the contacts. The relay above is a five terminal relay. More basic relays can have four terminals and only a N.O. set of contacts that close when the relay is energized. The magnetic field created in the control circuit coil then causes an armature to move the contacts to either open or closedepending on the design. The high current is switched on through the durable set of contacts that provide longevity of the connection. Newer relays control the load with electronics and use transistors to switch control circuit. It is important to note that most relays use some sort of “volt- age spike” suppression to control the inductive “kick” that is created when a relay coil is energized and then turned off. This kick could damage sensitive electronics elsewhere in the circuit if not controlled. The MD-4040 Relay Moduponent uses an internal resistor in parallel to the coil for spike suppression. For more information regarding testing relays go to the ConsuLab website under “Available Training”. The International Organization of Standardization (ISO) has designated relay connections to be commonly labeled as follows: • 85 & 86 Control circuit coil power and ground *(low amp) • 30 Battery 12V to operate load (high amp) • 87A N.C. contact of load circuit switch (not used) • 87 N.O. contact of load circuit switch, connects to 30 when control circuit coil is energized NOTE: Remember that specific vehicle manufacturers can often change how terminals 85 & 86 are used to control and feed the relay coil. Terminal 85 or 86 can be the B+ and the other terminal would be the ground. It is imperative to always check the vehicle specific circuit schematic to properly identify the relay terminals and how they are used in the circuit. Relays are found in all types of transportation vehicles (cars, trucks, vans, off-road equipment, agriculture, trailers, motorcycles, airplanes and boats) and are used to control any high amperage draw component. Examples are lighting control, electric motors like fuel pumps, wipers, windows, seat motors, or horns and solenoids. 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 LAMER 7/16'' PROF 0.080'' PLEXI 1/4" 0.281'' MODUPONENT MD-4040 12 VDC RELAY RELAIS 12 VCC 85 86 87 3087a consulab.com info@consulab.com 21 96-MD-4000-24 SA-4-MD-4040 12 VDC 5 Pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay Safety and Safeguards : • ONLY use the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4130 Fuses protection • MD-4141 Optical Sensor circuit control • MD-4142 Transistors circuit control • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4111 Fan load operation • MD-4070 Light Bulbs load operation • MD-4114 Solenoid load operation • MD-4071 LED’s load operation (resistance required) Additional Equipment: • Safety Glasses • DVOM consulab.com info@consulab.com 22 96-MD-4000-24 SA-4-MD-4040 12 VDC 5 Pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 Level 1A exercise: Build a relay control circuit to energize the relay control coil. LEVEL 1A BASIC RELAY CONTROL OPERATION DONE Build a relay control circuit using the built-in variable power supply as source voltage. DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram Connect a red wire between the RED + of the power supply to terminal 86 of the MD-4040 Relay Moduponent™. Connect a black wire from terminal 85 of the MD-4040 Relay back to the BLACK – of the power supply. Control circuit is now ready to test. Turn power supply ON and listen for an audible “click” as the contacts close. Unplug any wire to listen for contacts to open, then plug the wire back in to hear a “click” as the contacts close again. 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4040 consulab.com info@consulab.com 23 96-MD-4000-24 SA-4-MD-4040 12 VDC 5 Pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 Level 1B exercise: Build a relay load circuit that is controlled by the relay. Additional Moduponent required: MD-4114. LEVEL 1B BASIC RELAY OPERATED CIRCUIT DONE Building on Level 1A assignment, proceed with connecting a load circuit (Solenoid). DO THIS: Turn power supply OFF. See wiring diagram Connect another red wire between the RED + of the power supply to terminal 30 of the MD-4040 Relay (piggy backing wires is allowed). Connect another red wire between terminal 87 of the MD-4040 Relay to the RED termi- nal of MD-4114 Solenoid Moduponent™. Connect a black wire from the BLACK terminal of the MD-4114 Solenoid back to the BLACK (–) of the power supply (piggy backing wires is allowed). Based on lesson learned in the Level 1A assignment, discuss expected operation of MD-4114 Solenoid when power supply is switched from OFF to ON. Turn power supply OFF/ON to confirm relay operation. 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOIDMD-4000MD-4040 MD-4114 consulab.com info@consulab.com 24 96-MD-4000-24 SA-4-MD-4040 12 VDC 5 Pin ISO Relay Answers SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 Answers Level 1C exercise: Build a relay load circuit that is controlled by the relay. ) Additional Moduponent required: MD-4114. LEVEL 1C BASIC RELAY OPERATED CIRCUIT DONE DO THIS: See wiring diagram Based on lesson learned in the Level 1A&B exercise, discuss expected voltage readings at indicated circuit terminals (1-7) of both the control and load circuit, power supply ON, and w/85 ground connected or disconnected (CLOSED or OPEN) MD-4040 Relay Circuit terminal Closed Open 1. (87) 12 V 0 V 2. (87A) 0 V 12 V 3. (30) 12 V 12 V 4. (85) 0 V 0 V 5. (86) 12 V 12 V 6. (Solenoid RED) 12 V 0 V 7. (Solenoid BLACK) 0 V 0 V MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID 1 2 3 4 5 6 7 MD-4000 MD-4040 MD-4114 consulab.com info@consulab.com 25 96-MD-4000-24 SA-4-MD-4040 12VDC 5 pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 Level 2A exercise: Practice measuring voltage drops over the various circuits of a relay-controlled device. (1/2) *Remember: Voltage drop (Vd) is the loss of voltage by passing current through a resistance. Additional Moduponent required: MD-4070, MD-4130 and MD-4090. (optional) LEVEL 2A VOLTAGE DROP LESSONS (Vd) DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Using the MD-4000 electrical trainer with the MD-4070 Bulbs and MD-4040 12 VDC Relay moduponents, build the electrical circuit represented by the provided wiring diagram 1 (MD-4130 Fuses & MD-4090 SPST switches moduponents are optional). Set the DVOM to VDC ONLY check Vd with power supply ON (and optional MD-4090 SPST switches CLOSED) 1 Practice Vd on power side of CONTROL circuit (+): Red lead on power supply RED +, Black lead on terminal 86 of the MD-4040 12 V DC Relay 2 Practice Vd on ground side of CONTROL circuit (-): Red lead on terminal 85 of the MD-4040 12 VDC Relay, Black lead on power supply BLACK (-). 3 Practice Vd of the CONTROL circuit LOAD: Red lead on terminal 86 of MD-4040 12 VDC Relay, Black lead on terminal 85 of MD-4040 12 VDC Relay. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 MD-4000 MD-4040 MD-4070 consulab.com info@consulab.com 26 96-MD-4000-24 SA-4-MD-4040 12VDC 5 pin ISO Relay Answers SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 Answers Level 2A exercise: Practice measuring voltage drops over the various circuits of a relay-controlled device. (2/2) LEVEL 2A VOLTAGE DROP LESSONS (Vd) DONE DO THIS: 4 Practice Vd on power side of LOAD circuit (+): Red lead on power supply RED +, Black lead on terminal 30 of the MD-4040 12 VDC Relay. 5 Practice Vd on ground side of LOAD circuit (-): Red lead on BLACK – terminal of the L1 MD-4070 Bulb, Black lead on power supply (-). 6 Practice Vd over the LOAD: Red lead on RED H terminal of the MD-4070 Bulb, Black lead on BLACK - of the MD-4070 Bulb. 7 Where is most of the voltage dropped in each circuit? Over that circuits LOAD 8 Using industry standard symbols, on a piece of paper draw a wiring diagram of this circuit using a relay to control a light bulb. Assess student wiring diagram. 9 Are there any parts of this working circuit that have NOT had Vd measured? Yes - 30 to 87 & 87 to L1 (H) NOTE: 30 to 87A to L1 (L) is not a Vd due to no current passing with relay ON. LEVEL 2B CURRENT DRAW LESSON Level 2B exercise: Practice measuring circuit amperage of the various circuits in a relay-controlled device. DO THIS: Set the DVOM to AMPs and switch meter leads to correctly measure current. 11 Open the relay CONTROL circuit and measure amperage: 0.1 A 12 Open the relay LOAD circuit and measure amperage: 2.0 A (light on high) NOTE: The part of the circuit NOT asked to check amperage = 0 or 0,5 A (bulb OFF or LOW) MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 MD-4000 MD-4040 MD-4130 MD-4090 MD-4070 consulab.com info@consulab.com 27 96-MD-4000-24 SA-5-MD-4052 Negative Temperature Coefficient Thermistor (NTC) SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) Electrical Symbol : Theory of operation: A Thermistor is a type of resistor that changes its resistance based on its temperature. Unlike a resistor, an NTC thermis- tor has the property where the electrical resistance (Ω) DECREASES as temperature INCREASES and can be measured with an ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) or provide an ECM with a temperature val- ue. The operating range is non-linear (not a straight line) meaning that is achieves high precision within a limited tempera- ture range and is used in climate control applications (HVAC) as well as engine and transmission temperature monitoring. Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do NOT heat thermistor with an open flame or a heat gun! • Carefully use body temperature or ice. • Not polarity sensitive. • Normally receives a 5V reference value. • NOT a switch of a load but can control the BASE of a transistor. • Do not leave this trainer unattended with the power ON. NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T LAMER 7/16'' PROF 0.08'' PLEXI 1/4" 0.281'' MD-4052 MODUPONENT THERMISTOR THERMISTANCE T NTC 10KΩ @ 25 °C 5.215 3.222 -T MD-4000 MD-4062: redraw this for copyright purposes W MD-4058 * redraw this for copyright purposes consulab.com info@consulab.com 28 96-MD-4000-24 SA-5-MD-4052 Negative Temperature Coefficient Thermistor (NTC) Companion Moduponents™ • MD-4002 5V Regulator Circuit control • MD-4011 Resistors Circuit control • MD-4040 Relay Circuit control • MD-4142 Transistors Circuit control • MD-4111 Cooling Fan Load operation Additional Equipment: • Safety Glasses • DVOM • Ice • Thermometer SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) consulab.com info@consulab.com 29 96-MD-4000-24 SA-5-MD-4052 Negative Temperature Coefficient Thermistor (NTC) Answers SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 1 Answers Level 1 exercise: Observe the operation of an NTC thermistor by measuring electrical resistance at different temperatures. LEVEL 1 VOLTAGE DROP LESSONS (Vd) DONE Measure thermistor resistances at different temperatures. DO THIS: See wiring diagram Connect the DVOM red lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Connect the DVOM black lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Set the DVOM to Ohms (Ω). 1 Measure resistance at room temperature: 100kΩ@75ºF (25 ºC) 2 Using ice, cool the MD-4052 NTC Thermistor and measure the resistance at a lower temperature – how high can resistance be increased? 20 kΩ w/ICE 3 Using just body heat, warm up the MD-4052 NTC Thermistor and measure resistance ata higher temperature – how low can resistance be decreased? 8 kΩ @ body temp. NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T MD-4052 consulab.com info@consulab.com 30 96-MD-4000-24 SA-5-MD-4052 Negative Temperature Coefficient Thermistor (NTC) SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 Level 2 exercise: Simulate a typical automotive engine coolant temperature (ECT) circuit using the MD-4002 5 Volt Regulator and MD-4052 NTC Thermistor to teach the understanding of reference voltage for diagnostics, while also introducing hidden resistance circuit characteristics. (1/2) *NOTE this exercise requires a 10kΩ resistor not included in the MD-4010 but available on the optional MD-4011 Resistors moduponent (or a single 10kΩ / 1W resistor will also work if available). Additional Moduponent required but not included in kit: MD-4011 Resistors (10) LEVEL 2 BUILD A 5 VOLT REFERENCE ECT STYLE CIRCUIT DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to either YELLOW terminal of the MD-4052 NTC Thermistor. Connect a black wire from the other YELLOW terminal of the MD-4052 NTC Thermistor back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead piggy-back to the 5V red wire connected the MD-4052 NTC Thermistor, simulating back-probing an engine harness connector. Set the DVOM to VDC. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T MD-4052 MD-4002 SET METER V DC consulab.com info@consulab.com 31 96-MD-4000-24 SA-5-MD-4052 Negative Temperature Coefficient Thermistor (NTC) Answers SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 Answers Level 2 exercise: Simulate a typical automotive engine coolant temperature (ECT) circuit using the MD-4002 5 Volt Regulator and MD-4052 NTC Thermistor to teach the understanding of reference voltage for diagnostics, while also introducing hidden resistance circuit characteristics. (2/2) LEVEL 2 BUILD A 5 VOLT REFERENCE ECT STYLE CIRCUIT DONE DO THIS: 1 What is the voltage measured? 0.5 V DC (Plugged IN) 2 On an actual automobile, if any 5V referenced sensor is “back-probed” while the harness is still connected, what should the voltage measure? 2.4V-2.8V (plugged in @ 68 ºF / 20 ºC) (see sensor specification chart provided below). 3 Now, with the DVOM still connected to the 5V reference wire, unplug it from the MD-4052 NTC Thermistor. What is the voltage measured? 5.0 V DC (Unplugged) 4 In an actual automobile, if any 5V referenced sensor harness is “unplugged”, what will the voltage at the sensor harness measure? 5.0 V DC V. 5 Why does this circuit not work like it does on an automobile? This circuit does not have the extra circuit protection resistance built into the ECU which divides voltage. 6 Ask for wiring diagram 3 from MD-4000-22-96 Look at wiring diagram #3 provided and correct the circuit built to make it work like anactual automobile and explain below what had to be done and why? To simulate the built in ECU resistance, Insert 10K resistor (MD-4011 Resistors) in se- ries to simulate the hidden ECU resistor. See wiring diagram #3. *NOTE: wiring diagram # 3 is only provided to the instructor – assess student circuit build to this wiring diagram #3. 7 What does Negative Temperature Coefficient mean? Low Temperature = Higher Ω & Vd High Temperature = Low Ω & Vd Ignition Switch ON SENSOR SPECIFICATION CHART TEMPERATURE (Cº / Fº) OUTPUT VOLTAGE (V) 0º / 32º 3.3 − 3.7 V 20º / 68º 2.4 − 2.8 V 40º /104º 1.6 − 2.0 V 80º /176º 0.5 − -.9 V consulab.com info@consulab.com 32 96-MD-4000-24 SA-6-MD-4058 High Pressure Sensor SA-6 — MD-4058 High Pressure Sensor Electrical Symbol : Theory of operation: The A/C refrigerant pressure sensor is a 3-wire piezoelectric transducer (see MD-4055 Piezo Sensor). Applying a 5V ref- erence voltage, a low reference (ground) and a signal circuit enables the sensor to operate. This sensor is a safety device that is inserted into the high-pressure side of a refrigeration system and is directly exposed to the refrigerant pressures in order to monitor these pressures. This sensor pressure signal can be between 0.2V – 4.8V. When the refrigerant pressure is LOW, the signal value is near 0V. When the refrigerant pressure is HIGH, the signal value is near 5.0V. If the engine control module (ECM) receives either a too LOW or too HIGH signal voltage it will turn off the compressor clutch to prevent further system over/under pressure damage. The ECM also uses information from this sensor to determine the A/C system load on the engine as well as the heat load on the condenser and can be monitored on a scan tool. Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • Use CAUTION if applying unregulated compressed shop air. Companion Moduponents™ • MD-4130 Fuses • MD-4002 5 VDC Output • MD-4040 12VDC 5-pin relay • MD-4142 Transistors • MD-4111 Fan (pressure sensor controlled load) Additional Equipment: • Safety Glasses • DVOM • Bicycle air pump (or equivalent) GNDSIG5V HIGH PRESS. SENSOR CAPTEUR HP MODUPONENT MD-4058 REVD MD-4000 MD-4062: redraw this for copyright purposes W MD-4058 * redraw this for copyright purposes consulab.com info@consulab.com 33 96-MD-4000-24 SA-6-MD-4058 High Pressure Sensor SA-6 — MD-4058 High Pressure Sensor — Level 1 Level 1 exercise: Observe and measure a pressure sensor signal voltage at different pressure levels. (1/2) Additional Moduponents required: MD-4002. LEVEL 1 SETTING UP TO MEASURE DONE DO THIS: Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the red 5V terminal of the MD-4058 A/C Pressure Sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4058 A/C Pressure Sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4058 A/C Pressure Sensor moduponent. Set the DVOM to VDC Follow the instructions on next page to record measurements. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GNDSIG5V HIGH PRESS. SENSOR CAPTEUR HP MODUPONENT MD-4058 REVD MD-4058 consulab.com info@consulab.com 34 96-MD-4000-24 SA-6-MD-4058 High Pressure Sensor Answers SA-6 — MD-4058 High Pressure Sensor — Level 1 Answers Level 1 exercise: Observe and measure a pressure sensor signal voltage at different pressure levels. (2/2) Additional Moduponents required: MD-4002 5V Output. LEVEL 1 MEASURING SENSOR SIGNAL VOLTAGE DONE DO THIS: 1 Turn on power supply and verify a 5V reference at the 5V terminal of the MD-4058 A/C Pressure Sensor 2 Record the voltage at the blue SIG terminal without any pressure applied to the sensor 0,27V @ 5V V 3 Connect regulated compressed shop air or connect a bicycle air pump to the MD-4058 A/C Pressure Sensor service valve and add pressure in increments while observing the DVOM voltage reading. What is happening to the voltage as pressure is applied? It increases: 2 V @ 130 psi − 2.4 V @ 150 psi 4 In your own words, explain how this sensor works and how it is incorporated into a typi- cal automotive HVAC system. See Moduponent content page consulab.com info@consulab.com 35 96-MD-4000-24 SA-7-MD-4059 Sunload Sensor SA-7 — MD-4059 Sunload Sensor Electrical Symbol : Theory of operation: The heat produced by the sun on the closed cabin of an automobile can drastically affect the comfort of the passen- gers. Sunlight entering the windows alone can account for 60% of the interior heat load which must be overcome by the vehicles HVAC system. A sunload sensor is a photodiode sensor that monitors the intensity of exposed sunlight and sends a signal to the HVAC control to improve the comfort level of the driver and passengers. These sensors are usually located on the top of the dash for maximum sun exposure, in a removable panel (defroster vent or speaker grill). A photodiode increases resistance as the light intensity increases which then lowers the voltage signal sent to a control module. The operating voltage range is between 0V to 5V so as sun load increases, the voltage decreases. See MD-4141 Optical Sensors. Safety and Safeguards : *NOTE: Sunload sensors do not respond to fluorescent light, which is read as darkness. • When the sunload sensor is checked indoors or in the shade, an open circuit might be indicated. • Always check the sunload sensor at a place where sun shines directly on it. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4002 5V Moduponent • MD-4130 Fuses Additional Equipment: • Safety Glasses • DVOM • Flashlight or equivalent light source GNDSIG5V MODUPONENT MD-4059 SUNLOAD SENSOR CAPTEUR D'ENSOLEILLEMENT REVD consulab.com info@consulab.com 36 96-MD-4000-24 SA-7-MD-4059 Sunload Sensor SA-7 — MD-4059 Sunload Sensor — Level 1 Level 1 exercise: Observe and measure the sensor signal voltage as it changes with a light source applied. (1/2) Additional Moduponents required: MD-4002. LEVEL 1 MEASURING SENSOR SIGNAL VOLTAGE DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the red 5V terminal of the MD-4059 Sunload sensor moduponent Connect a black wire from the BLACK GND terminal of the MD-4059 Sunload sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4059 Sunload sensor moduponent. Set the DVOM to VDC Follow the instructions on next page to record measurements. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GNDSIG5V MODUPONENT MD-4059 SUNLOAD SENSOR CAPTEUR D'ENSOLEILLEMENT REVD MD-4059 consulab.com info@consulab.com 37 96-MD-4000-24 SA-7-MD-4059 Sunload Sensor Answers SA-7 — MD-4059 Sunload Sensor — Level 1 Answers Level 1 exercise: Observe and measure the sensor signal voltage as it changes with a light source applied. (2/2) Additional Moduponents required: MD-4002. LEVEL 1 MEASURING SENSOR SIGNAL VOLTAGE DONE DO THIS: 1 Turn on power supply and verify a 5V reference at the 5V terminal of the MD-4059 Sunload sensor 2 Using a DVOM, measure and record the voltage at the blue SIG terminal without any light source being applied to the sensor. 3,7 V 3 Apply a light source (see NOTE below) then measure and record the voltage 4 In your own words, explain how this sensor works and how it is incorporated into a typical automotive HVAC system. See Moduponent content page NOTE: Sunload sensors do not respond to fluorescent light, which is read as darkness. When the sunload sensor is checked indoors or in the shade, an open circuit might be indicated. Always check the sunload sensor at a place where sun shines directly on it. consulab.com info@consulab.com 38 96-MD-4000-24 SA-8-MD-4060 Windshield Temparature & Inside Moisture Sensor MD-4060 Windshield humidity and temperature sensor - * do we have an electrical symbol on file for this one? Je ne crois pas qu’il y est un symbole électrique existant. Si jamais nous trouvions quelques choses je te reviens sur cela. Je vous est fait une icone en espérant que ça vous convienne I do not believe that there is an existing electrical symbol. If we ever find anything I'll get back to you on that. I made an icon for you and I hope it suits you MD-4061 In-vehicle humidity and temperature sensor – * do we have an electrical symbol on file for this one? Je ne crois pas qu’il y est un symbole électrique existant. Si jamais nous trouvions quelques choses je te reviens sur cela. Je vous est fait une icone en espérant que ça vous convienne I do not believe that there is an existing electrical symbol. If we ever find anything I'll get back to you on that. I made an icon for you and I hope it suits you SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor Electrical Symbol : Theory of operation: The MD-4060 Moduponent is a windshield temperature and inside moisture sensor that provides information about relative humidity at the inside of the windshield, temperature at the inside of the windshield and temperature of the humidity sensor element. The MD-4115 has 3 terminals to measure sensor signal voltage: One measures sensor signal voltage for the inside windshield temperature, a second terminal measures signal voltage for relative humidity (%) at the sensor, and the third terminal measures signal voltage representing the temperature of the relative humidity sensor el- ement. Humidity sensors operate by detecting changes that alter electrical conductivity in the air. Two thermal sensors conduct electricity based on the humidity of the surrounding air. One sensor is encased in dry nitrogen while the other is exposed to ambient air and the difference between the two is used to calculate humidity. An infrared sensor remotely measures the radiated heat on the windshield and calculates the window temperature. Using these signal inputs, the HVAC control module will regulate the cabin humidity to prevent the windows from fogging up. This is a GM sensor that is normally located on the back side of the rear-view mirror. Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4002 5V Moduponent • MD-4130 Fuses Additional Equipment: • Safety Glasses • DVOM • Heat source – blow dryer (Do NOT use a heat gun due to high temperature) • Access to current weather information; room temperature and humidity GND5V RH% RH CAPT. D'HUM. HABI. & TEMP. PARE-BRISE MODUPONENT MD-4060 WIND. TEMP. & INSIDE MOIS. SENS. REVE consulab.com info@consulab.com 39 96-MD-4000-24 SA-8-MD-4060 Windshield Temparature & Inside Moisture Sensor SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 Level 1 exercise: Observe and measure the sensors three signal voltages while applying different levels of heat and humidity. (1/2) Additional Moduponents required: MD-4002. LEVEL 1 SETTING UP TO MESURE DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagrams Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the red 5V terminal of the MD-4060 Windshield Temp/Humidity sensor. Connect a black wire from the BLACK GND terminal of the MD-4060 Windshield Temp/ Humidity sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the correct BLUE SIG terminal of the MD-4060 Wind- shield Temp/Humidity sensor moduponent as requested in the instructions below. Set the DVOM to VDC Follow the instructions on next page to record measurements. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GND5V RH% RH CAPT. D'HUM. HABI. & TEMP. PARE-BRISE MODUPONENT MD-4060 WIND. TEMP. & INSIDE MOIS. SENS. REVE MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GND5V RH% RH CAPT. D'HUM. HABI. & TEMP. PARE-BRISE MODUPONENT MD-4060 WIND. TEMP. & INSIDE MOIS. SENS. REVE MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GND5V RH% RH CAPT. D'HUM. HABI. & TEMP. PARE-BRISE MODUPONENT MD-4060 WIND. TEMP. & INSIDE MOIS. SENS. REVE MD-4060 MD-4060 MD-4060 consulab.com info@consulab.com 40 96-MD-4000-24 SA-8-MD-4060 Windshield Temparature & Inside Moisture Sensor Answers SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 Answers Level 1 exercise: Observe and measure the sensors three signal voltages while applying different levels of heat and humidity. (2/2) Additional Moduponents required: MD-4002. LEVEL 1 MEASURING SENSOR SIGNAL VOLTAGE DONE DO THIS: 1 Turn on power supply and verify a 5V reference at the 5V terminal of the MD-4060 Windshield Temperature and Humidity sensor. 2 Before applying any temperature or humidity to the sensor, measure and record the voltage at all three signal terminals: Windshield temperature: 1.8 - 2.0 V Relative humidity %: 1.8 - 2.0 V Relative humidity temperature: 1.8 - 2.0 V 3 See left wiring diagram With the DVOM red lead inserted into the RH % (center) terminal, using ONLY the heat and moisture from your breath the same way you would breathe on a mirror to “fog” it up, breathe onto the sensor observing the change in voltage. 2.0 V UP to 3.2V after exposed to humid/hot breath 4 See middle wiring diagram With the DVOM red lead inserted into the windshield temperature (left) terminal, using a blow dryer as a heat source, observe the change in voltage. 2.0 V DOWN to 1.0 V after exposed to direct heat 5 See right wiring diagram With the DVOM red lead inserted into the relative humidity temperature (right) terminal, using a blow dryer as a heat source, observe the change in voltage. 2.0 V DOWN to 1.0 V after exposed to direct heat consulab.com info@consulab.com 41 96-MD-4000-24 SA-9-MD-4061 In-vehicle Temperature & Humidity Sensor MD-4060 Windshield humidity and temperature sensor - * do we have an electrical symbol on file for this one? Je ne crois pas qu’il y est un symbole électrique existant. Si jamais nous trouvions quelques choses je te reviens sur cela. Je vous est fait une icone en espérant que ça vous convienne I do not believe that there is an existing electrical symbol. If we ever find anything I'll get back to you on that. I made an icon for you and I hope it suits you MD-4061 In-vehicle humidity and temperature sensor – * do we have an electrical symbol on file for this one? Je ne crois pas qu’il y est un symbole électrique existant. Si jamais nous trouvions quelques choses je te reviens sur cela. Je vous est fait une icone en espérant que ça vous convienne I do not believe that there is an existing electrical symbol. If we ever find anything I'll get back to you on that. I made an icon for you and I hope it suits you SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor Electrical Symbol : Theory of operation: The MD-4061 Moduponent is an in-vehicle temperature and humidity sensor that provides the HVAC control module information about the relative humidity level and ambient air temperature inside the cabin of a vehicle. Humidity is the measurement of the concentration of water vapor present in the air. Temperature can change humidity because the maximum amount of water vapor that can be held in a given volume of air varies greatly by temperature; cold air can hold less mass of water per unit volume than hot air. The temperature sensor is a negative coefficient sensor (See MD- 4052 Thermistor) usually installed near the lower part of the dash and is equipped with a small aspirator fan to draw air over the sensor. Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4002 5V Moduponent • MD-4130 Fuses • MD-4052 Thermistor Additional Equipment: • Safety Glasses • DVOM • Heat source – blow dryer (Do NOT use a heat gun due to high temperature) • Access to current weather information; room temperature and humidity GND 12V 5V RH TEMP MODUPONENT MD-4061 CAPTEUR D'HUM. / TEMP. HABI. INSIDE HUM. / TEMP. SENSOR REVD consulab.com info@consulab.com 42 96-MD-4000-24 SA-9-MD-4061 In-vehicle Temperature & Humidity Sensor SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 Level 1 exercise: Observe and measure the sensors two signal voltages while applying different levels of heat. (1/2) Additional Moduponents required: MD-4002. LEVEL 1 SETTING UP TO MESURE DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagrams Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4061 In Vehicle Temp/Humidity sensor moduponent Connect a black wire from the BLACK GND terminal of the MD-4061 In Vehicle Temp/ Humidity sensor moduponent back to the BLACK – of the power supply. Connect another red wire between the RED + of the power supply to the RED BAT termi- nal of the MD-4002 5 Volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the red 5V terminal of the MD-4061 In Vehicle Temp/Humidity sensor. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to VDC Follow the instructions on next page to record measurements. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GND 12V 5V RH TEMP MODUPONENT MD-4061 CAPTEUR D'HUM. / TEMP. HABI. INSIDE HUM. / TEMP. SENSOR REVD MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 GND 12V 5V RH TEMP MODUPONENT MD-4061 CAPTEUR D'HUM. / TEMP. HABI. INSIDE HUM. / TEMP. SENSOR REVD consulab.com info@consulab.com 43 96-MD-4000-24 SA-9-MD-4061 In-vehicle Temperature & Humidity Sensor Answers SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 Answers Level 1 exercise: Observe and measure the sensors two signal voltages while applying different levels of heat. (2/2) Additional Moduponents required: MD-4002. LEVEL 1 SETTING UP TO MESURE DONE DO THIS: 1 Turn on power supply and verify a 5V reference at the 5V terminal of the MD-4061 In-vehicle Temperature and Humidity sensor. 2 Connect the DVOM red lead to the BLUE RH terminal of the MD-4061 In-vehicle Temp/ Humidity sensor moduponent and record the voltage here: 2.7 V 3 Connect the DVOM red lead to the BLUE TEMP terminal of the MD-4061 In-vehicle Temp/Humidity sensor moduponent and record the voltage here: 4.9 V 4 While still connected to the BLUE TEMP terminal, apply heat to the aspirator fan intake and record voltage: Decreases from 4.9V to below 2.0V 5 What type of thermistor is this temperature sensor? MD-4052 Negative coefficient / Temp. UP = Ω DOWN 6 Why does circuit voltage decrease with a temperature increase if resistance goes down? Due to fixed resistance in series that shares the 5V reference. If the thermistor resis- tance decreases with temperature, then the fixed resistor voltage drop will increase in a series circuit leaving a lesser voltage applied to the thermistor 2 voltage at SIG terminal w/o light applied 3.7V 3 voltage as light is applied? Voltage lowers to .3V w/light due to increase in W 4 how this sensor works and how used See moduponent content page MD-4060 Windshield Temp/Moisture 1 verify the 5V reference 5V 2 Ambient voltage measurements: Windshield temperature: 1.8-2.0V Relative humidity %: 1.8-2.0V Relative humidity temperature: 1.8-2.0V 3 RH% Observing change in voltage 2.0V UP to 3.2V after exposed to humid/hot breath 4 Windshield temp Observing change in voltage 2.0V DOWN to 1.0V after exposed to direct heat 5 RH temp Observing change in voltage 2.0V DOWN to 1.0V after exposed to direct heat MD-4061 In-Vehicle Temp/Humidity 1 verify the 5V reference 5V 2 (Relative Humidity) RH SIG voltage 2.7V 3 TEMP SIG voltage 4.9V 4 Voltage while heat is applied Decreases from 4.9V to below 2.0V 5 Type of thermistor (MD-4052) Negative coefficient / Temp UP = W DOWN 6 Why does voltage decrease with temperature increased if resistance goes down? Due to fixed resistance in series that shares the 5V reference. If the thermistor resistance decreases with temperature, then the fixed resistor voltage drop will increase in a series circuit leaving a lesser voltage applied to the thermistor MD-4062 (PTC) thermistor resistance at room temperature 980W @ 75°F (25°C) resistance at colder temperature Less than 980 W w/ice resistance at hotter temperature 1.02K W @ body temp MD-4115 Air Door Actuator 1 verify the 5V reference 5V 3 Full counterclockwise 0V 5 Full clockwise 5V 6 how this actuator works & how used See moduponent content page MD-4141 Optical Sensors Photoresistor Normal Light resistance 45K W ok Blocked light resistance 100K-150K W Flashlight resistance 100 W ok Photodiode consulab.com info@consulab.com 44 96-MD-4000-24 SA-10-MD-4062 Positive Temperature Coefficient Thermistor (PTC) SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) Electrical Symbol : Theory of operation: Like any resistor, an PTC thermistor has the property where the electrical resistance (Ω) INCREASES as temperature INCREASES and can be measured with an ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) The op- erating range is non-linear (not a straight line) meaning that is achieves high precision within a limited temperature range and is used in climate control applications as well as engine and transmission temperature monitoring Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do NOT heat thermistor with an open flame or a heat gun! • Carefully use body temperature or ice • Not polarity sensitive. • Normally receives a 5V reference value • NOT a switch of a load but can control the BASE of a transistor • Do not leave this trainer unattended with the power ON T 1KΩ @ 25 °C PTC MODUPONENT MD-4062 PTC THERMISTOR THERMISTANCE PTC REVC MD-4000 Moduponent: MD-4062 (PTC) Positive Temperature Coefficient Thermistor Electrical Symbol: Theory of operation: A Thermistor is a type of resistor that changes its resistance with temperature Like any resistor, an PTC thermistor has the property where the electrical resistance (W) INCREASES as temperature INCREASES and can be measured with an Ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) The operating range is non-linear (not a straight line) meaning that is achieves high precision within a limited temperature range and is used in climate control applications as well as engine and transmission temperature monitoring. INSERT REDRAWN GRAPH (* Replace this chart in the NTC as well) Safety and Safeguards: Use ONLY the protected built-in power supply Operates on a single 120VAC 15A outlet Do NOT heat thermistor with an open flame or a heat gun! Carefully use body temperature or ice Not polarity sensitive. Normally receives a 5V reference value NOT a switch of a load but can control the BASE of a transistor Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4002 5V regulator circuit control MD-4011 resistors circuit control Additional equipment: Safety Glasses DVOM Ice thermometer MD-4000 Moduponent: MD-4062 (PTC) Positive Temperature Coefficient Thermistor Electrical Symbol: Theory of operation: A Thermistor is a type of resistor that changes its resistance with temperature Like any resistor, an PTC thermistor has the property where the electrical resistance (W) INCREASES as temperature INCREASES and can be measured with an Ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) The operating range is non-linear (not a straight line) meaning that is achieves high precision within a limited temperature range and is used in climate control applications as well as engine and transmission temperature monitoring. INSERT REDRAWN GRAPH (* Replace this chart in the NTC as well) Safety and Safeguards: Use ONLY the protected built-in power supply Operates on a single 120VAC 15A outlet Do NOT heat thermistor with an open flame or a heat gun! Carefully use body temperature or ice Not polarity sensitive. Normally receives a 5V reference value NOT a switch of a load but can control the BASE of a transistor Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4002 5V regulator circuit control MD-4011 resistors circuit control Additional equipment: Safety Glasses DVOM Ice thermometer MD-4000 MD-4062: redraw this for copyright purposes W MD-4058 * redraw this for copyright purposes consulab.com info@consulab.com 45 96-MD-4000-24 SA-10-MD-4062 Positive Temperature Coefficient Thermistor (PTC) SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) Companion Moduponents™ • MD-4002 5V regulator Circuit control • MD-4011 Resistors Circuit control Additional Equipment: • Safety Glasses • DVOM • Ice • Thermometer consulab.com info@consulab.com 46 96-MD-4000-24 SA-10-MD-4062 Positive Temperature Coefficient Thermistor (PTC) Answers SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) — Level 1 Answers Level 1 exercise: Observe the operation of an PTC thermistor by measuring electrical resistance at different temperatures Additional Material required: Ice. LEVEL 1 BASIC THERMISTOR CONTROL OPERATION DONE Measure thermistor resistances at different temperatures. DO THIS: See wiring diagram Connect the DVOM red lead to one of the yellow terminals of the MD-4062 PTC Therm- istor Moduponent . Connect the DVOM black lead to the other yellow terminal of the MD-4062 PTC Therm- istor Moduponent. Set the DVOM to Ohms (Ω). 1 Measure resistance at room temperature : 980 kΩ @ 75 ºF (25 ºC) 2 Using ice, cool the MD-4062 PTC Thermistor and measure the resistance at a lower temperature – how low can resistance be decreased? Less than 980 w/ice 3 Using just body heat, warm up the MD-4062 PTC Thermistor and measure resistance at a higher temperature - how high can resistance be increased? 1.02 kΩ @ body temp. MD-4062 T 1KΩ @ 25 °C PTC MODUPONENT MD-4062 PTC THERMISTOR THERMISTANCE PTC REVC consulab.com info@consulab.com 47 96-MD-4000-24 SA-11-MD-4111 Fan SA-11 — MD-4111 Fan Electrical Symbol : Theory of operation: Brushless DC motors are just as the name states – direct current electric motors that don’t use any type of contact brushes to complete an electrical circuit in order to move the rotor. Instead, these motors have permanent magnets on the rotor while the electromagnets are in the stator. A computer controls the electromagnets in the stator to induce the rotation of the rotor up to full 360-degrees. They can be used for precise motion control, positioning or actuation, as well as for a fan motor due to good speed-torque characteristics, high efficiency, wide speed ranges and low mainte- nance. Brushless DC motors are commonly used to: • Cool radiators (thermostatically controlled) • Interior ventilation fans • Aspirator fans • Hybrid battery coolers Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • Turning blades will not cause injury. • Polarity to be observed due to electronic controls (cannot be damaged). MODUPONENT MD-4111 REVC 12VCC FAN VENTILATEUR 12 VCC PLEXI 1/4" LAMER 7/16'' PROF 0.080''0.281'' MD-4111 MODUPONENT FAN VENTILATEUR 5.215 3.222 M consulab.com info@consulab.com 48 96-MD-4000-24 SA-11-MD-4111 Fan SA-11 — MD-4111 Fan Companion Moduponents™ • MD-4130 Fuses Protection • MD-4040 Relay Circuit control • MD-4090 SPST Switch Circuit control • MD-4091 DPDT Switch Circuit control • MD-4052 Thermistor Circuit control • MD-4142 Transistors Circuit control • MD-4001 PWM Circuit control • MD-4141 Optical sensor Circuit control Additional Equipment: • Safety Glasses • DVOM consulab.com info@consulab.com 49 96-MD-4000-24 SA-11-MD-4111 Fan SA-11 — MD-4111 Fan — Level 1 Level 1 exercise: Understand DC brushless motor electrical polarity by building a simple circuit to operate the motor. LEVEL 1 BASIC DC BRUSHLESS MOTOR POLARITY AND OPERATION DONE Build a brushless motor circuit using the built-in variable power supply as source voltage DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4111 Fan Moduponent™. Connect a black wire from the BLACK terminal of the MD-4111 Fan back to the BLACK – of the power supply. Fan circuit is now ready to test. Turn power supply ON and observe fan operation. ** NOTE fan will not operate if polarity is reversed due to internal solid-state circuitry MODUPONENT MD-4111 REVC 12VCC FAN VENTILATEUR 12 VCC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4111 consulab.com info@consulab.com 50 96-MD-4000-24 SA-11-MD-4111 Fan SA-11 — MD-4111 Fan — Level 2 Level 2 exercise: Measure a brushless DC fan motor current draw under normal operation and with mechanical resistance to compare. Additional Moduponent required: MD-4090. LEVEL 2A DC BRUSHLESS MOTOR CURRENT DRAW LESSON DONE Build a brushless motor circuit using the built-in variable power supply as source voltage DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram Connect a red wire between the RED + of the power supply to the any terminal of the MD-4090 SPST Switch moduponent . Connect a red wire between the remaining terminal of the MD-4090 SPST Switch to the red terminal of the MD-4111 Fan moduponent. Connect a black wire from the BLACK terminal of the MD-4111 Fan back to the BLACK – of the power supply. Fan circuit is now ready to test. Turn MD-4090 SPST Switch ON and verify fan operation. Turn MD-4090 SPST Switch OFF MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 MODUPONENT MD-4111 REVC 12VCC FAN VENTILATEUR 12 VCC MD-4111 MD-4090 consulab.com info@consulab.com 51 96-MD-4000-24 SA-11-MD-4111 Fan SA-11 — MD-4111 Fan — Level 2 Level 2B exercise: Measure a brushless DC fan motor current draw under normal operation and with mechanical resistance to compare. Additional Moduponent required: MD-4090. LEVEL 2B DC BRUSHLESS MOTORCURRENT DRAW LESSON DONE Switch de DVOM leads to mesure amperage. DO THIS: See wiring diagram Open circuit and place DVOM in series with the fan motor. Turn MD-4090 SPST Switch ON. 1 Observe and record circuit amperage here: 0.09 A DC . 2 According to Ohm’s Law, does amperage go up or down when electrical resistance is added to a circuit? Down . See wiring diagram With a finger, slow down the fan, (adding resistance) while observing amperage. 3 Did amperage follow the previous answer? No 4 What is the cause of this amperage reading? *remember, Ohm’s Law is a Law Slowing down the motor physically is “mechanical” resistance, not “electrical” re- sistance. Mechanically slowing down a motor almost creates a short circuit since no work is being done. This illustrates a wiper blade frozen to a windshield, or hanging on an electric window glass while the motor tries to raise it consulab.com info@consulab.com 52 96-MD-4000-24 SA-12-MD-4115 Air Door Actuator SA-12 — MD-4115 Air Door Actuator Electrical Symbol : Theory of operation: To control the movement of cabin air in an automotive heating and air conditioning system, blend doors are used to divert the air being created by the blower fan through the HVAC ducting to the proper vent discharge or through the correct heat exchanger. These doors are connected to small electrically controlled motors/actuators that move and blend hot and cold air as commanded by a control module depending on system temperature needs or driver requests. In a vehicle, when an HVAC control module sets a command or a targeted value, the actuator control signal is changed to either 0 or 5 volts depending on the direction that the actuator needs to rotate to reach that commanded value. The MD-4115 moduponent toggle switch acts as a “controller” and uses voltage reversal to drive the actuator in either di- rection. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. Safety and Safeguards : • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion Moduponents™ • MD-4002 5V Moduponent • MD-4130 Fuses Additional Equipment: • Safety Glasses • DVOM 5V GNDSIG12V STOP AIR DOOR ACTUATOR ACTIONNEUR D'ENTRÉE D'AIR MODUPONENT MD-4115 REVC MD-4059 * redraw this for copyright purposes Voici deux dessins de ma conception. Here are two drawings of my design. MD-4115 * redraw this for copyright purposes Please redraw this drawing in this style but one that reflects our actual moduponent connections (For use as the “symbol”) consulab.com info@consulab.com 53 96-MD-4000-24 SA-12-MD-4115 Air Door Actuator SA-12 — MD-4115 Air Door Actuator — Level 1 Level 1 exercise: Observe and measure the actuators signal voltage as it changes with direction of rotation. (1/2) Additional Moduponent required: MD-4090. LEVEL 1 SETTING UP TO MEASURE DONE DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4115 Air Door Actuator moduponent Connect another red wire between the RED + of the power supply to the RED BAT termi- nal of the MD-4002 5 Volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator modupo- nent to the red 5V terminal of the MD-4115 Air Door Actuator. Connect a black wire from the BLACK GND terminal of the MD-4115 Air Door Actuator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4115 Air Door Actuator moduponent Set the DVOM to V DC. Follow the instructions on next page to record measurements. 5V GNDSIG12V STOP AIR DOOR ACTUATOR ACTIONNEUR D'ENTRÉE D'AIR MODUPONENT MD-4115 REVC SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4002 MD-4115 consulab.com info@consulab.com 54 96-MD-4000-24 SA-12-MD-4115 Air Door Actuator Answers SA-12 — MD-4115 Air Door Actuator — Level 1 Answers Level 1 exercise: Observe and measure the actuators signal voltage as it changes with direction of rotation. (2/2) Additional Moduponent required: MD-4090. LEVEL 1 MEASURING ACTUATOR SIGNAL VOLTAGE DONE DO THIS: 1 Turn on power supply and verify a 5V reference at the 5V terminal of the MD-4115 Air Door Actuator. 2 Move toggle switch to the left and hold it until the actuator can’t rotate anymore in the counterclockwise direction 3 Using the DVOM, measure and record the signal voltage at that position of rotation: 0 V 4 Move toggle switch to the right and hold it until the actuator can’t rotate anymore in the clockwise direction 5 Using the DVOM, measure and record the signal voltage at that position of rotation: 5 V 6 In your own words, explain how this actuator works and how it is incorporated into a typical automotive HVAC system? See Moduponent content page consulab.com info@consulab.com 55 96-MD-4000-24 SA-13-MD-4141 Optical Sensors SA-13 — MD-4141 Optical Sensors Electrical Symbol : Theory of operation: The MD-4141 Moduponent includes three (3) optical sensors: one photoresistor, one photodiode and one phototransis- tor. Each of these optical sensors incorporate a different electronic component that is sensitive to incoming light, using either a resistor, a diode or a transistor. Each of these sensors receive light to activate them, using unique characteris- tics to control a circuit or component. Prior knowledge of semiconductors like resistors, diodes and transistors are recommended prior to completing these assignments. PHOTORESISTOR A photoresistor’s resistance decreases with an increase in light intensity and can be used in light sensitive circuits. When there is low to no light, the resistance increases and this characteristic is used to control a transistor that in turn switch- es a circuit on. A common example would be security lighting that comes on at dusk. In an automobile, this could be also be used to control the automatic day/night rearview mirror element. PHOTODIODE A photodiode is a type of semiconductor diode which actually generates an electric current when light is applied to its surface. It converts the light’s energy into an electrical current. This actual response time is slower as their surface area increases, such as in a solar panel, but is still faster than the phototransistor. Photodiodes are designed to operate in both forward or reverse bias and used to switch circuits in electronic devices like a smoke detector or CD player. In an automobile, this could be used to sense sunload or twilight in climate control applications. PHOTOTRANSISTOR The phototransistor is a two or three terminal semiconductor that converts light energy into electric current. It is a spe- cial design transistor which has a light sensitive base, not a regular transistor base. When the base of this NPN transistor is exposed to light, the phototransistor converts it to electrical current proportional to the amount of light applied. The phototransistor amplifies the input light and the output current can be measured at the collector of the transistor. This component is used to detect light. MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PHOTORESISTOR PHOTODIODE PHOTOTRANSITOR consulab.com info@consulab.com 56 96-MD-4000-24 SA-13-MD-4141 Optical Sensors SA-13 — MD-4141 Optical Sensors Safety and Safeguards : • ONLY use the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • Observe polarity as component could be damaged.Companion Moduponents™ Companion Moduponents™ • MD-4130 Fuses Protection • MD-4142 Transistors Theory • MD-4010 Resistors Theory • MD-4140 Diodes Theory • MD-4090 SPST Switch Circuit control • MD-4091 DPDT Switch Circuit control • MD-4111 Fan Load operation • MD-4070 Light Bulbs Load operation • MD-4114 Solenoid Load operation • MD-4071 LED’s Load operation (resistance required) Additional Equipment: • Safety Glasses • DVOM • Flashlight consulab.com info@consulab.com 57 96-MD-4000-24 SA-13-MD-4141 Optical Sensors Answers SA-13 — MD-4141Optical Sensors — Level 1 Answers Level 1A exercise: observe the characteristics of three optical sensors. This Moduponent has three (3) Optical Sensors – the photoresistor, the photodiode, and the phototransistor that we will test for light sensitivity by measuring with a DVOM.) **Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). LEVEL 1A PHOTORESISTOR OPERATION DONE Measure the photoresistor resistance and how light affects it. DO THIS: See left wiring diagram Connect the DVOM red lead to either yellow terminal of the MD-4141 Photoresistor. Connect the DVOM black lead to either yellow terminal of the MD-4141 Photoresistor. Set the DVOM to Ohms (Ω). 1 In normal room light, measure and record the resistance measurement: 10 kΩ * de- pending on source lighting 2 Now, cover the photoresistor sensor to block light, observe and record the resistance measurement: 75-100 kΩ 3 Now, expose the photoresistor sensor to the light from a flashlight, observe and record the resistance measurement: 200-300 Ω 4 Did the resistance go up or down when exposed to light? UP MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF MD-4141 PHOTORESISTOR MD-4141 PHOTODIODE consulab.com info@consulab.com 58 96-MD-4000-24 SA-13-MD-4141 Optical Sensors Answers SA-13 — MD-4141Optical Sensors — Level 1 Answers Level 1B and 1C exercises: observe the characteristics of three optical sensors. This Moduponent has three (3) Optical Sensors – the photoresistor, the photodiode, and the phototransistor that we will test for light sensitivity by measuring with a DVOM. **Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). LEVEL 1B PHOTODIODE OPERATION DONE Measure the photoresistor resistance and how light affects it. DO THIS: See right wiring diagram Connect the DVOM red lead to either yellow terminal of the MD-4141 Photodiode. Connect the DVOM black lead to either yellow terminal of the MD-4141 Photodiode. Set the DVOM to mV. 1 In normal room light, measure and record the resistance measurement: 2.2 m Ω (4.5 m Ω w/light source applied) 2 Measure and record the mV reading: 200-300 mV Cover the sensor with your hand. 3 Measure and record the mV reading: 200 mV Now, shine a light on the sensor. 4 Measure and record the mV reading: 380 mV NOTE: measurements will vary with lighting applied, but the basic principle is; more light exposed to the photodiode, higher mV generated. LEVEL 1C PHOTOTRANSITOR OPERATION DONE Measure the voltage produced by a phototransistor as light affects it. DO THIS: Connect the DVOM red lead to either yellow terminal of the MD-4041 Phototransistor. Connect the DVOM black lead to either yellow terminal of the MD-4041 Phototransistor. Set the DVOM to mV. 1 Measure and record the mV reading: 380 mV Cover the sensor with your hand. 2 Measure and record the mV reading: 200 mV Now, shine a light on the sensor. 3 Measure and record the mV reading: 550 mV consulab.com info@consulab.com 59 96-MD-4000-24 SA-13-MD-4141 Optical Sensors Answers SA-13 — MD-4141Optical Sensors — Level 2 Answers Level 2 exercise: Build a working electrical circuit using 3 different optical sensors to turn on an LED. **Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). Additional Moduponents required: MD-4002 5 and MD-4071. LEVEL 2 PHOTORESISTOR OPERATION DONE Build a circuit using a photoresistor to operate an LED. DO THIS: Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed *if MD-4002 5V regulator is not available, adjust power supply to 5V before proceeding. See left wiring diagram Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to one of the YELLOW terminals of the MD-4141 photoresistor. Connect another red wire from the other YELLOW terminal of the MD-4141 photoresis- tor to the RED terminal of any MD-4071 LED. Connect a black wire from the BLACK terminal of the MD-4071 LED back to the BLACK – of the power supply. Shine a bright light onto the photoresistor and observe LED operation. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to various test points of the circuit and observe voltage changing with light application. 1 Explain why the LED illuminates when the photoresistor is exposed to light. A photoresistor’s resistance decreases with an increase in light intensity, causing less voltage dropped and allowing more current to flow, activating the diode to emit light. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF MD-4141MD-4071 MD-4000 MD-4002 consulab.com info@consulab.com 60 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) Electrical Symbol : Theory of operation: Transistors are created by combining several types of semiconductor materials into a component assembly. Like diodes, transistors control current flow and are used in many automotive applications such as solid-state switches. The type of transistor in this exercise is a Bipolar Transistors. Bipolar transistors vary current levels to control current. A transistor is a single semiconductor crystal that contains two junctions, one positive and one negative (PN). It is con- structed so that a P-type section is «sandwiched» between two N-type sections or an N-type section is «sandwiched» between two P-type sections. The transistor is similar to a diode. However, transistors contain three sections instead of two. The three materials are arranged so that N-type and P-type materials alternate either as an NPN or a PNP group. Unlike a Diode having two leads, transistors have three . In both NPN and PNP transistors, the three sections are called the emitter, the base, and the collector. In the schematic symbol, the emitter is identified by an arrowhead. Just as in the diode, the arrowhead points in the direction of conven- tional current flow and opposite to electron flow. It also points toward the N-type material. This will help you distinguish between an NPN and PNP schematic symbol. To provide conduction through the transistor, current must be supplied to the emitter-base circuit. A transistor works by using the base to control the current flow between the emitter and the collector. When the transistor is “turned on,” current can flow in the direction of the arrow only. When the transistor is “off,” current can’t flow in either direction. EMITTER CIRCUIT: PNP transistors: The emitter is connected to the most positive voltage usually through a stabilizing resistor. NPN transistors: The emitter ties to the negative terminal through a resistor. Collector Circuit: The collector is connected to the opposite battery terminal, usually through a load. TRANSISTORS MODUPONENT MD-4142 NPN T4 T2T1 PNP TRANSISTORS T3 REVD PLEXI 1/4" 0.281'' x 2 LAMER 7/16'' PROF 0.080'' MD-4142 TRANSISTORS T3 NPN T4 T2T1 PNP MODUPONENT 5.215 6.500 NPN PNP consulab.com info@consulab.com 61 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN): Base Circuit: The base voltage is established by a voltage divider that keeps a forward bias (difference voltage) between base and emitter. Current Flow: The forward bias turns the transistor on and lets it draw a steady current It’s important to realize that the base leg of a bipolar transistor controls the flow of current. Although it accounts for only a small amount of the total current flow (typically around 2% of the total), it is current flow through the base that allows current to flow from emitter to collector. Changing the base current a little results in a big change in the collector current. The emitter to base voltage is referred to as the bias voltage. The polarity of the bias voltage is determined by the type of transistor being used, NPN or PNP. To determine the polarity of the bias in a transistor, follow this simple rule. The arrow in the transistor always points to the negative. The current through the emitter circuit is always the largest of all. In fact, the emitter current must be equal to the base current added to the collector current. Put another way, the current in the emitter circuit is split between the base circuit and the collector circuit. Some compare transistors to relays – a high current circuit controlled by a low current switch. Transistor common uses: • Electronic circuit control • Switches for circuit boards and relays Safety and Safeguards : • ONLY use the protected built-in power supply • Operates on a single 120VAC 15A outlet • Do not leave this trainer unattended with the power ON Companion Moduponents™ • MD-4130 Fuses Protection • MD-4090 SPST Switch Circuit control • MD-4091 DPDT Switch Circuit control • MD-4040 Relay Circuit control • MD-4010 Resistors Load operation • MD-4071 LED’s Load operation • MD-4114 Solenoid Load operation • MD-4111 Fan Load operation Additional Equipment: • Safety Glasses • DVOM • ModuponentTM MD-4010 Resistors. • ModuponentTM MD-4071 LED’s. • ModuponentTM MD-4091 DPDT Switch. consulab.com info@consulab.com 62 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 Level 1 exercise: Practice identifying transistor types and terminals. (1/2) LEVEL 1 BASIC TRANSISTOR OPERATION DONE Identify transistor types (PNP or NPN). DO THIS: T1 On T1 transistor, note the terminal colors: BLUE RED BLACK. See table 1 Following the table on next page, connect your DVOM red lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #1, column +. Following the table on next page, connect your DVOM black lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #1, column −. Set the DVOM to Ohms (Ω) / Diode Test. Measure voltage drop at room temperature and record in table #1, column Meter Reading. Once all the tables are complete, we will analyze the results. T2 On T2 transistor, note the terminal colors: BLUE RED BLACK. See table 2 Following the table on next page, connect your DVOM red lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #2, column +. Following the table on next page, connect your DVOM black lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #2, column −. Set the DVOM to Ohms (Ω) / Diode Test. Measure voltage drop at room temperature and record in table #2, column Meter Reading Once all the tables are complete, we will analyze the results. T3 On T3 transistor, note the terminal colors: BLUE RED BLACK. Following the table on next page, connect your DVOM red lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #3, column +. Following the table on next page, connect your DVOM black lead to the terminal of the MD- 4142 Transistors Moduponent™ listed in table #3, column −. Set the DVOM to Ohms (Ω) / Diode Test. Measure voltage drop at room temperature and record in table #3, column Meter Reading Once all the tables are complete, we will analyze the results consulab.com info@consulab.com 63 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 Answers Level 1 exercise: Practice identifying transistor types and terminals. (2/2) LEVEL 1 BASIC TRANSISTOR OPERATION DONE DO THIS: T4 On T4 transistor, note the terminal colors: BLUE RED BLACK. See table 4 Following the table on next page, connect your DVOM red lead to the terminal of the MD-4142 Transistors Moduponent™ listed in table #4, column +. Following the table on next page, connect your DVOM black lead to the terminal of the MD-4142 Transistors Moduponent™ listed in table #4, column −. Set the DVOM to Ohms (Ω) / Diode Test. Measure voltage drop at room temperature and record in table #4, column Meter Reading. Once all the tables are complete, we will analyze the results. TABLE 1 - T1 TRANSITOR TABLE 2- T2 TRANSITOR + - Meter reading + - Meter reading BLUE RED OL BLUE RED 0.587 V BLUE BLACK OL BLUE BLACK 0.588 V RED BLUE 0.615 V RED BLUE OL RED BLACK OL RED BLACK OL BLACK BLUE 0.613 V BLACK BLUE OL BLACK RED Ol BLACK RED OL TABLE 3 - T3 TRANSITOR TABLE 4 - T4 TRANSITOR + - Meter reading + -- Meter reading BLUE RED OL BLUE RED 0.587 V BLUE BLACK OL BLUE BLACK 0.588 V RED BLUE 0.617 V RED BLUE OL RED BLACK OL RED BLACK OL BLACK BLUE 0.615 V BLACK BLUE OL BLACK RED OL BLACK RED OL NOTES: You should have 4 readings of OL and 2 voltage readings. The common terminal COLOR that you get a reading other than OL in the rows establish which terminal is the base. The column that the common terminal is in establishes whether the base is P or N. The higher of the 2 readings will identify which terminal is the emitter. consulab.com info@consulab.com 64 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Level 2 exercise: In each part of this exercise, three circuits will be created: 1. A relay control circuit 2. A relay load circuit 3. A photoresistor and transistor circuit used as the relay control switch (1/3). Additional Moduponents required: MD-4141 Optical Sensors, MD-4040 Relay, MD-4010 Resistors, and MD-4071 LED’s. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF TRANSISTORS MODUPONENT MD-4142 NPN T4 T2T1 PNP TRANSISTORS T3 REVD 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 220Ω - 1W 470Ω - 0.5W 47Ω - 5W MODUPONENT 100Ω - 2W REVC RÉSISTANCES RESISTORS MD-4010 MD-4000 MD-4141 MD-4142 MD-4040 MD-4010 MD-4071 AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S consulab.com info@consulab.com 65 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers Level 2A exercise: Practice identifying transistor types and terminals. LEVEL 2A CREATE AN LED CIRCUIT CONTROLLED BY A PHOTORESISTOR, RELAY AND A NPN TRANSISTOR DONE NPN DO THIS: Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram on previous page Connect a red wire between the RED + of the power supply to terminal 30 of the MD-4040 Relay. Connect another red wire between the RED + of the power supply to terminal 86 of the MD-4040 Relay. Connect a red wire between the 87A of the MD-4040 Relay and one of the terminals to the 470 Ω / 0.6 W resistor on the MD-4010 Resistors. Connect a red wire between the other terminal of the 470 Ω / 0.6 W resistor on the MD-4010 Resistors to any RED terminal of any LED on the MD-4071 LED. Connect a black wire from the BLACK terminal of that LED on the MD-4071 LED’s back to the BLACK – of the power supply. Using the “photoresistor” component of the MD-4141 Optical Sensors and either of the NPN transistors on the MD-4042 Transistors, complete the circuit using the photoresistor to switch the transistor on, allowing ground to the relay coil. 1 Upon completion, describe what happens when the photoresistor is exposed to light & dark: When the photoresistor sensor is covered, LED illuminates. When the photoresistor is exposed to light, LED is NOT illuminated. 2 When circuit is complete, functioning correctly and observed by an instructor, draw a wiring diagram of this circuit. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF TRANSISTORS MODUPONENT MD-4142 NPN T4 T2T1 PNP TRANSISTORS T3 REVD 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 220Ω - 1W 470Ω - 0.5W 47Ω - 5W MODUPONENT 100Ω - 2W REVC RÉSISTANCES RESISTORS MD-4010 AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S consulab.com info@consulab.com 66 96-MD-4000-24 SA-14-MD-4142 Transitors (2 x PNP, 2 x NPN) Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers Level 2B exercise: Practice identifying transistor types and terminals. LEVEL 2B CREATE AN LED CIRCUIT CONTROLLED BY A PHOTORESISTOR, RELAY AND A PNP TRANSISTOR DONE PNP DO THIS: Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram on previous page Connect a red wire between the RED + of the power supply to terminal 30 of the MD-4040 Relay. Connect another red wire between the RED + of the power supply to terminal 86 of the MD-4040 Relay. Connect a red wire between the 87A of the MD-4040 Relay and one of the terminals to the 470 Ω / 0.6 W resistor on the MD-4010 Resistors. Connect a red wire between the other terminal of the 470 Ω / 0.6 W resistor on the MD- 4010 Resistors to any RED terminal of any LED on the MD-4071 LED. Connect a black wire from the BLACK terminal of that LED on the MD-4071 LED’s back to the BLACK – of the power supply. Using the “photoresistor” component of the MD-4141 Optical Sensors and either of the PNP transistors on the MD-4042 Transistors, complete the circuit using the photoresistor to switch the transistor on, allowing ground to the relay coil. 1 Upon completion, describe what happens when the photoresistor is exposed to light & dark: When the photoresistor sensor is covered, LED illuminates. When the photoresistor is exposed to light, LED is NOT illuminated. 2 When circuit is complete, functioning correctly and observed by an instructor, draw a wiring diagram of this circuit. MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF TRANSISTORS MODUPONENT MD-4142 NPN T4 T2T1 PNP TRANSISTORS T3 REVD 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 220Ω - 1W 470Ω - 0.5W 47Ω - 5W MODUPONENT 100Ω - 2W REVC RÉSISTANCES RESISTORS MD-4010 AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S 96-MD-4000-24 Student assignements consulab.com info@consulab.com 67 Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. General description SA-1 — MD-4001 Pulse Width Modulator (PWM) SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 1 Answers SA-1 — MD-4001 Pulse Width Modulator (PWM) — Level 2 Answers SA-2 — MD-4002 5V Regulator SA-2 — MD-4002 5V Regulator — Level 1 Answers SA-2 — MD-4002 5V Regulator — Level 2 Answers SA-2 — MD-4002 5V Regulator — Level 2 Answers SA-3 — MD-4030 Potentiometer SA-3 — MD-4030 Potentiometer — Level 1 Answers SA-3 — MD-4030 Potentiometer — Level 1 Answers SA-3 — MD-4030 Potentiometer — Level 2 Answers SA-4 — MD-4040 12VDC 5-pin ISO Relay SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 1 Answers SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 SA-4 — MD-4040 12VDC 5-pin ISO Relay— Level 2 Answers SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 1 Answers SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 SA-5 — MD-4052 Negative Temperature Coefficient Thermistor (NTC)— Level 2 Answers SA-6 — MD-4058 High Pressure Sensor SA-6 — MD-4058 High Pressure Sensor — Level 1 SA-6 — MD-4058 High Pressure Sensor — Level 1 Answers SA-7 — MD-4059 Sunload Sensor SA-7 — MD-4059 Sunload Sensor — Level 1 SA-7 — MD-4059 Sunload Sensor — Level 1 Answers SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 SA-8 — MD-4060 Windshield Temperature & Inside Moisture Sensor — Level 1 Answers SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 SA-9 — MD-4061 In-vehicle Temperature & Humidity Sensor — Level 1 Answers SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) SA-10 — MD-4062 Positive Temperature Coefficient Thermistor (PTC) — Level 1 Answers SA-11 — MD-4111 Fan SA-11 — MD-4111 Fan — Level 1 SA-11 — MD-4111 Fan — Level 2 SA-11 — MD-4111 Fan — Level 2 SA-12 — MD-4115 Air Door Actuator SA-12 — MD-4115 Air Door Actuator — Level 1 SA-12 — MD-4115 Air Door Actuator — Level 1 Answers SA-13 — MD-4141 Optical Sensors SA-13 — MD-4141Optical Sensors — Level 1 Answers SA-13 — MD-4141Optical Sensors — Level 1 Answers SA-13 — MD-4141Optical Sensors — Level 2 Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 1 Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers SA-14 — MD-4142 Transitors (2 x PNP, 2 x NPN) — Level 2 Answers

Student Assignments for CL-1919-06_053327 Part 2 — Basic Electricity Ohm’s Law and DC Circuits Trainer CL-1919-06-95_part2-Basic-electricity_V2023-2 © ConsuLab Educatech Inc, 2023. Tous droits réservés. CL-1919-06-95 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 Table of Contents Trainer Layout and Familiarization 3 Front Panel Component Identification 4 Electrical Component Identification 5 Electrical Accessories 6 Main Fuse 6 Storage Bag 6 Jumper Leads 6 Trainer Use and Operation 7 Warnings and Cautions 8 Student Learning Modules 9 MODULE 2 Basic Electricity Theory and Understanding 11 3 CL-1919-06-95 Introduction consulab.com info@consulab.com Trainer Layout and Familiarization The CL-1919-06_053052 Ohm’s Law and DC Circuits Trainer contains electrical and electronic components mounted on a panel containing electrical connection receptacles where students complete the wiring of circuits. The trainer is designed to provide learning assistance in the understanding of basic Ohm’s Law concepts and also provides learning activities for student learning of basic circuit components and operation. A built-in 120VAC to 14VDC (4 A max) power supply is internally protected and is adjustable from 2-14 VDC. The front panel contains a digital display indicating the DC voltage supply available to the trainer. The CL-1919-06_053052 trainer meets CSA/UL safety requirements. The CL-1919-06 also contains a surface mounted digital multi-meter (DMM) that is powered with two AAA replaceable batteries. NOTE : Because the trainer’s power supply output is limited to 4 A, the meter’s internal 10A ammeter fuse should never need replacement. The meter is used throughout the student activities and circuit construction for electrical measure- ments and diagnostic training. CL-1919-06 Ohm’s Law and DC Circuits Trainer CL-1919-06-95 Introduction consulab.com info@consulab.com 4 Front Panel Component Identification Front View 1. Trainer power cord receptacle, master ON/OFF switch and main fuse holder. 2. Positive (red) receptacles for circuit construction. These receptacles are only to be used with the trainer and not to be connected to any external devices as damage could result. 3. Negative (black) receptacles for circuit construction. These receptacles are only to be used with the trainer and not to be connected to any external devices as damage could result. 4. Digital Display for available trainer voltage (Displays the DC voltage that has been set by the voltage adjustment knob). 5. Power supply voltage adjustment knob (Adjusts the available DC voltage from 2-14 ± VDC). 6. Power supply safety reset button (Resets the internal protection cut-out. Push and hold until the O.L. light flashes, then release. The voltage display will read 0.000 when the O.L. lamp is on.). 7. Power supply “OVERLIMIT” indicator light (If a short circuit is created between the Positive & Negative sides of the trainer, the internal protection cut-out will trip and turn on the O.L. indicator light. It will remain on until the problem has been corrected and the RESET button is pushed). 8. PWM (Pulse Width Modulation) generator positive and negative receptacles. 9. PWM Adjustment knob (0-100% duty cycle). 10. Digital Multi-meter. Side View 1 3 2 47 6 5 9 8 10 CL-1919-06-95 Introduction consulab.com info@consulab.com 5 Electrical Component Identification 11. L1 – # 194 Bulb. 12. L2 – # 194 Bulb. 13. D1 – LED Bulb. 14. B1 – BUZZER. 15. T1 – NPN Transistor. 16. T2 – PNP Transistor. 17. D2 – Diode. 18. L3 – # 3157 LED Bulb. 19. M1 – DC Motor. 20. RL1 – ISO 5-pin Relay. 21. Electronic Flasher. 22. POT – 75Ω Potentiometer. 23. R1 – 100Ω Resistor. 24. R2 – 40Ω Resistor. 25. R3 – 20Ω Resistor. 26. R4 – 20Ω Resistor. 27. R5 – 2Ω Resistor. 28. F1 – Optional Circuit Fuse (ATC 2-3A). 29. SW1 – SPST Toggle Switch. 30. PB1 – N.O. Push Button Switch. Front View 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CL-1919-06-95 Introduction consulab.com info@consulab.com 6 Electrical Accessories Storage Bag Main Fuse Main Fuse Specifications: Model 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (5 mm x 20 mm). Storage Bag Jumper Leads CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT Your product may be equipped with either of the below jumper wire styles. They are identical in specifications and performance. All CL-1919-06’s will be shipped with banana plug jumper leads including: • 10 Red Jumper Leads — 23” (60cm) long • 10 Black Jumper Leads — 23” (60cm) long CL-1919-06-95 Introduction consulab.com info@consulab.com 7 Trainer Use and Operation The CL-1919-06-93 manual is designed to provide instructors and students with the necessary information for the prop- er and safe operation of the trainer. Note that the CL-1919-06 trainer includes student assignments (CL-1919-06-95 ) and an instructors manual (CL-1919-06-96). Be sure to read, understand and follow the instructions for each section. The CL-1919-06 is designed to be used as a “stand alone” resource to aid the instructor and students in the learning of basic electricity, Ohm’s Law, DMM meter use, basic electrical and electronic component operation, basic operational circuit construction and diagnosis and troubleshooting of circuit problems. NOTE: Before proceeding with this manual, the following tasks should have already been successfully performed and understood: 1. Familiarization with the CL-1919-06 component layout and identification (pages 5-8). 2. The CL-1919-06 should be set up on a bench/tabletop with the cover removed, the power cord plugged into the trainer and a 120VAC outlet and the master ON/OFF switch turned “on”. NOTE- The cover lid of the trainer can be placed on a table, then move the trainer on top of the cover. This po- sitions the trainer with a slight tilt providing an easier access for users. If properly completed, the digital display should be indicating the available DC voltage. For normal operation, and unless otherwise directed, the display should be adjusted to a reading of 14.0 - 14.6 ± volts. Rating Specifications: • Voltage: 100-240 VAC, single phase • Frequency: 50/60 Hz • Input Current: 2.2 A @120 VAC, 1.2 A @ 230VAC • Output current : 2-14 VDC, 4 A max. • Indoor use only • Temperature: 10 ºC – 30 ºC (50 ºF – 86 ºF) • Humidity (non-condensing): 90 % max. • Altitude : 2,000 m (6,562 ft) • Pollution Degree 2 • Overvoltage Category II Students conducting the circuit learning assignments should have completed the following Learning Modules which contain the prerequiste skills and knowledges: • Understanding basic digital multi-meter setup, use & interpretation (Student Learning Module #1). • Basic electricity (Student Learning Module #2). • Ohm’s Law (Student Learning Module #3). • Component explanation (Student Learning Module #4) • Ability to read and follow written instructions. • Ability to read and interpret basic electrical wiring schematics. CL-1919-06-95 Introduction consulab.com info@consulab.com 8 Warnings and Cautions Even though the power supply is internally protected against short-circuits and wiring errors, students should carefully read, understand and follow all activity instructions to avoid errors. NOTE- If the digital display shows “0.000” volts and the O.L. lamp is “on”, an overcurrent situation has been detected. To re-set the system, find and correct the wiring error, then push and hold the RESET button until the O.L. lamp flashes, then release. If the reset procedure was successfully completed, the display should read available voltage: 1. The 2-3A ATC blade type fuse on the trainer is for optional use by instructors and students as needed. Circuits can be connected with the fuse if desired. Remember that the trainer is internally protected to trip the over-current protection if current exceeds 4 A. 2. Access to fuse compartment and any other components inside of unit to be performed only by trained skilled per- sonnel. 3. L1 and L2 bulbs are made of glass and could break if impacted hard enough, therefore potentially creating a cutting hazard. 4. Do not connect any external device to be powered by the trainer as they may exceed the designed limits of the power supply and components. 5. Be sure to read, understand and follow each set of instructions. Be sure to ask your instructor if you have any ques- tions about any instruction or component. 6. Never “guess” about the results of a circuit. Always follow written instructions to avoid “guesswork”. 7. This product is intended for use in educational establishments by STUDENT OPERATORS at least 14 years of age and under the supervision of theRESPONSIBLE PERSON. 9 CL-1919-06-95 Introduction consulab.com info@consulab.com Student Learning Modules The CL-1919-06 manuals contain Student Learning Modules designed to provide information and resources to assist stu- dents in mastering various skills and knowledges covered with this trainer. Each module comes with educational support information, student activity assignments, student answer sheets, instructor keys and assessment tests. Instructors can use them as they see fit for their programs. Student answer sheets, schematics and assignments can be duplicated and distributed within the schools programs only. PDF fillable answer sheets are also available. Duplication of documents used for outside sources is prohibited. Assignment and test answer sheets can be filed in student files for record keeping of progress. It is recommended that instructors follow the chronological order of the assignments. However, each mod- ule can be presented on its own if desired. The CL-1919-06 Learning Modules 1. UNDERSTANDING THE DIGITAL MULTIMETER — SETUP, USE & INTERPRETATION 2. BASIC ELECTRICITY 3. OHM’S LAW 4. COMPONENT EXPLANATION 5. STUDENT EXPERIMENTS 6. ADVANCED STUDENT CIRCUIT ASSIGNMENTS 10 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com MODULE 2 Basic Electricity PREREQUISITES : At this point, it is necessary for all students to have successfully completed the instructional unit on digital multimeter setup and use to be able to correctly obtain accurate readings of voltage, resistance and amperage. If this is not true, STOP and complete the digital multimeter unit first. Obtain instructors permission to proceed to the next section. Understanding how to properly setup and read digital multimeters is required for student activities covered in the following unit of BASIC ELECTRICITY. 11 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com Theory and Understanding What is electricity ? Electricity has always been somewhat of a complicated subject to understand. Electricity wasn’t really “discovered” be- cause it occurs naturally. The early Greeks, Phoenicians, Mesopotamians and others were long aware of the presence of electrical properties in some materials. It was known that static electricity occurred in nature. Alessandro Volta (1745- 1827) was the first to create a “battery” which was called a “voltaic pile”. The modern term of VOLTS is taken from his name. Andre-Marie Ampère (1775-1836) was a French physicist who is credited with a basic understanding of electro- magnetism and electrodynamics. The term AMPERES or AMPS was taken from his name. The atom In order to understand electricity, it is necessary to have a very basic understanding of the composition of matter. Mat- ter is anything that takes up volume and space on earth and even in space. Matter is made up of molecules made from just over 100 individual components called “elements”. The very smallest part that an element can be broken down into is called an atom. The atom is made up of two basic parts : 1. The NUCLEUS (center of the atom) which is made up of two parts, neutrons and protons. Neutrons have a neutral electrical charge while protons have a positive charge. 2. Spinning around the nucleus in various orbits are electrons which have a negative charge. In a stable atom, there are an equal number of electrons and protons. The conductors & insulators All elements are electrically classified as either an electrical CONDUCTOR or an INSULATOR. The difference between the two is how many electrons there are in the outer most orbit ring (called the VALENCE RING). Conductors have four or less electrons in the valence ring, while insulators have four or more electrons. This means that the outer most electrons in conductors are held in orbit with less force than in an insulators outer orbit. It is easier to cause electrons to flow from atom to atom in a conductor than in an insulator. Copper is the most common conductor because of its cost and availability. Other conductors are gold, silver, aluminum and most metals. Common insulator materials are wood, glass, most plastics, rubber, nylon and fiberglass. Based on the results of many years of study and experimentation by many dedicated scientists, it is understood that “electricity” is the flow of electrons (an element of the atom) through a conductor from atom to atom whenever there is an imbalance of electrons established between two different points in a circuit. Imbalance means that at one point in a circuit there is an excess of electrons and at another point, there is a deficiency of electrons. Certain laws of physics indicate that nature wishes to exist in a “stabilized” state and if a conductive path is connected between the excess and deficiency locations of electrons, the electrons will flow between atoms until they are equal or stabilized. There remains today some disagreement on what direction electrons actually move. The CONVENTIONAL ELECTRON THEORY states that they flow from positive to negative in a circuit. 12 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com The ELECTRON THEORY states that they flow from negative to positive. There are very technical and complex argu- ments to substantiate each side and we will not get into those issues here. For purposes of this level of understanding, if you carefully follow the proper hookup of both the positive and negative (ground) wires in different circuit design applications, the actual direction of electron flow won’t really matter. For the purposes of this manual, any reference to electron or current flow will use the CONVENTIONAL THEORY (positive to negative). The semiconductors Materials with exactly four electrons in their outer orbit are neither conductors nor insulators, but are called semicon- ductors. Semiconductors can be either an insulator or a conductor in different circuit design applications. Examples of semiconductor materials include : Silicon, Germanium and Carbon. Semiconductors are used mostly in transistors, diodes, integrated circuit chips, computers, and other electronic devices. Magnetism Magnetism is an invisible force of nature present in either natural or man-made magnets. A magnet has a north pole and a south pole. If two magnets are brought together with both north poles facing each other, the magnets will repel or push each other away. If a north pole of one magnet and a south pole of another magnet are brought together, the mag- nets will “snap” together. Therefore, it is understood that like poles of magnets repel each other and unlike poles attract each other. The electrical charges of both electrons (−) and protons (+) are like poles of a magnet. Like charges (both − or +) will repel each other. The electron is held and pushed away from the proton which allows it to keep spinning around the nucleus. The electrons keep moving in their orbits because being like charges, they repel each other. Types of electricity There are generally three types of electricity : 1. Static Electricity 2. Alternating Current (AC) 3. Direct Current (DC) Static Electricity Static electricity occurs naturally in nature. Lightning during a storm is an extreme example of static electricity. Walking across some rugs and touching metal can result in small electrical shock caused from static. Sometimes, it can cause damage to automotive circuits and components. For the most part, static electricity performs no useful purpose. In the automobile, static electricity can be generated by sliding across the upholstery and touching a metal object resulting in a small spark. Often automotive technicians are required to wear special anti-static safety equipment which is designed to prevent damage to electrical circuits and components. 12 13 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com Alternating Current (AC) Alternating Current (AC) electricity is used in our homes and industry to power all the electrical devices we depend on for our lives. AC electricity is generated by power plants using coal, water, natural gas, solar, geo-thermal or nucle- ar power sources. The electricity is sent to homes and factories using overhead and underground wires ending up in electrical panels that branch off into individual circuits. Alternating Current can be very dangerous and even lethal, and only qualified and experienced technicians should work on this type of electricity. There are a few places in the automo- bile where AC electricity may be used with the alternator and many engine sensors being the most common examples. Newer hybrid and electric vehicles can use both AC and DC electricity. Most electric and hybrid cars operate on very dangerous levels of both AC and DC electricity and all appropriate safety precautions must be followed when working on these vehicles. EV (Electric Vehicles) are becoming more common with the world embracing cleaner fuels and trying to reduce the carbon footprint of which fossil fuels (gasoline and diesel) are huge contributors. Most EV vehicles can have both AC and DC voltages approaching 500 volts. New service and safety procedures have been developed to allow trained, certified and qualified repair technicians to safely work on these vehicles. NEVER attempt to work on or even touch high voltage EV systems without the proper training and supervision. Direct Current (DC) Direct Current (DC) electricity is commonly used in the automobile. True or “pure” DC electricity can be generated by a battery using a chemical reaction to create an electron imbalance. However, there are many different electronic circuits and devices that can change AC electricity to DC electricity and be very close to “pure” DC electricity generated from a battery. Also, there are devices that can change DC to AC electricity. Again, the electric and hybrid vehicles use these devices for the operation of the hybrid power train. EV and some hybrid vehicles use components called “inverters” to change AC to DC or DC to AC. Most automotive electrical circuits in today’s vehicles operate in the 12-14 volts DC range. As vehicle technology evolves, many vehicle manufacturers are now using systems with 48 V or higher system voltages. As stated earlier, many EV and hybrids use voltages from 300-500 volts. Direct Current circuits consist of a “positive” side (from the battery to a resistance) and a “negative” or ground side (from the resistance back to the bat- tery). The term “resistance” is any component in the circuit that does “work” for us. Examples could be motors, sole- noids, coils, light bulbs, heaters, relays or more. The most common term used today for “resistance” is the circuit “load” Dangerous electrical shock hazards from 12 volt DC circuits are extremely rare. However, with electric and hybrid vehicles, high voltage batteries generating voltages in excess of 500 volts can be used. These voltages represent a very dangerous shock hazard and there are many safety precautions and safety procedures which must be carefully followed to prevent injuries. There are also specially designed multimeters and test equipment designed to high voltage batteries. Technicians must receive very specialized training and certifications before working on high voltage hybrid electrical systems. NEVER work on or gain access to any high voltage EV or hybrid electrical system without proper safety training and certification. consulab.com info@consulab.com 14 CL-1919-06-95 Module 2 — Basic Electricity Sources of electricity There are several available sources to generate electricity. Let’s look at the most common ones : Chemical Reaction – Having two dissimilar metals coming in contact with an acid will generate electricity. This is how batteries operate whether they are either wet cell or dry cell. The only difference between the two is whether the acid is in liquid or paste form. The voltage generated by a battery is dependent on the materials used in the battery construc- tion and design. Batteries consist of “cells” each of which must contain “plates” of dissimilar metals and an acid. For example, an automotive lead-acid battery contains Lead (−) and Lead Oxide (+) and diluted sulfuric acid. Each cell of an automotive lead-acid battery generates about 2.1 volts. Cells can be inter-connected in parallel or series. Parallel con- nections give the battery long operational life without increasing the cell voltage totals and series connections cause the cell voltages to add together to higher voltage. Therefore, a 12V car battery has six cells connected in series resulting in an output voltage of 12.6 when fully charged. Magnetism – Physicists discovered years ago that if a conductor such as a copper wire is moved through an established magnetic field, a voltage is generated. This law of physics was used to develop generators and alternators which are used throughout countless applications. Additionally, either the magnetic field or the electrical conductor can be moved to generate electricity. Pressure – In the late 1800’s, it was discovered that when pressure was applied to some crystals (quartz, topaz and some salts), a small voltage is generated. This process is called “piezoelectricity” and is used by some microphones, underwater hydrophones, gas charcoal grill ignitors, some fuel injectors and detonation knock sensors. Light – Also, in the 1800’s, experiments consisting of shining light over both liquids and metals found that electrons (elec- tricity) were released from the surface of some materials. The electrons can be collected and caused to flow in conduc- tors. The process is called “photoelectricity” and components such as photocells have been developed. Applications of this process are camera exposure meters, automatic headlight dimming systems used in vehicles and in a larger applica- tion, solar arrays for the generation of electricity. Heat – Again in the 1800’s, it was discovered that when two dissimilar metals are joined together and then heated, a very small amount of electricity is generated. Components called “thermocouples” were developed using this process and are used for the measurement of temperature. Another process discovered during experiments is called the Peltier Effect and causes the transfer of heat in materials in one direction as electricity is passed through it. It also can cause cooling if the electron flow is reversed. Applications of this concept are portable beverage coolers and heated and cooled seats used in vehicles. Common electrical terms What is Voltage ? Voltage or Volts — Voltage is the electrical “pressure” pushing electrons through the circuit. Voltage is the difference in pressure between any two points in a circuit. Some sources will use the acronym “E” for electromotive force as a sym- bol for voltage. Others use “V” for simplicity. Voltage can also be called the “electromotive force” pushing electrons in circuit. 15 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com Compare voltage to the pressure in a water hose. If you open the nozzle, water will flow out of the hose as long as there is pressure pushing it. If two different water tanks were connected by a pipe and one was higher than the other, water would flow between them until the water was at the same height. Many instructors use the water pipe system analogy to help teach electricity. Voltage is more or less equal to the water pressure (psi) in the pipes. As long as there is pressure, water flow is possible if a valve is opened. In the automobile, the battery develops the initial electrical pressure and the alternator also creates “pressure” to cause electrons to flow. The DC battery represents a difference in the number of electrons at one battery post compared to the other. This electron imbalance is “waiting” to stabilize whenever a conductive path is connected between the positive and negative posts of the battery. A “dead” battery has no electron imbalance and thus, no electrons will flow. What is Amperage ? Amperage or Current — Amperage or current is a term used to measure the amount of electricity flowing in a circuit. There CANNOT be any current unless the circuit is operating. Technically, there is an actual measurement of current that states that one ampere is equal to 6.25 X 1018 electrons flowing past a given point in one second. This actual mathemat- ical expression is called a “coulomb”. It would be written as 625,100,000,000,000,000 electrons and is called a “quintil- lion”. This is a very difficult number to comprehend. Again, using the water analogy, current is the amount of water flowing inside the hose or the amount of water flowing out of the nozzle in a given amount of time. Water uses the “gallons per minute” specification and electricity uses “amperes” or current. Most sources use the acronym “A” for amperage. Others can use “I” for intensity. There are two factors in electricity that affect how many amperes flow in a circuit. They are the amount of voltage (pres- sure) and the amount of resistance (ohms). If we increase the pressure and/or lower the resistance, more amperes will flow. If the source pressure (battery voltage) stays the same and we increase the resistance, less amperes will flow in the circuit. It is common for technicians to abbreviate the term amperes into just “amps”. In conclusion, amps or current does the “work” in the circuit. The more amps that are flowing, the more electrical “work” is being done. The largest consumer of amps in the vehicle is the electrical starter. What is Electrical Resistance ? Resistance or Ohms — Resistance is the opposition to the flow of electrons and is the means by which useful things are performed by circuits. Most sources use the acronym “R” for resistance. The Greek symbol of Omega or “Ω” is normally associated with resistance. The term “ohm” was named after Georg Ohm (1759-1854) in his honor. Just like in a water system, the diameter of the hose or pipes dramatically affects how much water can flow, the diam- eter of the wires also affects how many amps that can safely flow in a circuit. Anything that is in the path of water can also reduce the flow and consequently, anything in the circuit that causes resistance will reduce the flow of current. All electrical circuits require some amount of resistance in order to perform useful work. 16 CL-1919-06-95 Module 2 — Basic Electricity consulab.com info@consulab.com For example, a light bulb has a calculated amount of resistance that determines how many amps flows in the circuit when the light bulb is turned on. In the water system example, a sprinkler will cause a certain amount of water to flow. If we increase the size of the holes of the sprinkler (less resistance), then more water will flow. If we keep lowering the resistance, the pressure will also be reduced. In electrical circuits, anything that adds resistance to a circuit results in a reduction in the flow of current. Desired resistance can come from light bulbs, coils, resistors, and motors and are designed into circuits. Unwanted resistances can be in the circuit which can cause unwanted circuit performance. Unwanted resistance results in reduced circuit amperage and voltage drops. Among the most common sources of unwanted resistances are : corrosion, heat, loose or dirty contacts, and rust. If resistance increases in a circuit, the amount of amperage flowing will decrease. All circuits MUST have some amount of designed resistance in order to function properly. Therefore, any device that per- forms any function in the vehicle represents a certain amount of resistance in the circuit. Technicians are often required to find and repair the source of unwanted circuit resistance. What are Watts ? Watts or Wattage : The term watts is used to describe an amount of electrical power consumed. The term “watt” was named after James Watt (1736-1819), a Scottish mechanical engineer and inventor who worked with steam engines. We can use the water comparison again to describe watts. In the case of a water wheel turning grinding stones that is pow- ered by water, we could increase the power developed by the system two different ways : • Increase the amount of water (flow rate) hitting the water wheel, or • Increase the pressure (voltage) hitting the water wheel. Wattage is a term used to describe the “amount of work”. Watts are calculated by multiplying the volts times the amperage or current. If a common #3157 dual filament automotive light bulb used for tail and stop lights is turned on and operated with the tail light filament, it will consume 8.26 watts of power and will draw 0.59 amps of current with an operating voltage of 14 VDC. However, the same bulb operating with the stop light filament on will draw 2.10 amps and consume 29.42 watts of power. This means that the stop light filament will be brighter than the tail light filament and uses more “power” or watts. A thousand watts is called a “kilo-watt” and is expressed as “kW”. Many vehicles use kilo-watts to express the developed horsepower of the engine. There are approximately 746 watts in one horsepower (1 hp). It is important for technicians to understand these basic electrical principles, but it is much more critical that the techni- cian understand the operational relationships between the three operating factors of electricity. After completion of BASIC ELECTRICITY module, ask your instructor TEST 5. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. Trainer Layout and Familiarization Front Panel Component Identification Electrical Component Identification Electrical Accessories Main Fuse Storage Bag Jumper Leads Trainer Use and Operation Warnings and Cautions Student Learning Modules MODULE 2 Basic Electricity Theory and Understanding

Student Assignments for CL-1919-06_053327 Part 4 — Component Explanation Ohm’s Law and DC Circuits Trainer CL-1919-06-95_Part4_component-explanation_V2023- © ConsuLab Educatech Inc, 2023. Tous droits réservés. CL-1919-06-95 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 Table of Contents Trainer Layout and Familiarization 3 Front Panel Component Identification 4 Electrical Component Identification 5 Electrical Accessories 6 Trainer Use and Operation 7 Warnings and Cautions 8 Student Learning Modules 9 MODULE 4 Component Explanation Light bulbs (incandescent) 11 Led (light emitting diode) 12 Buzzer 13 Diode 13 Transistors 15 Motor 17 Relay 17 Electronic flasher 19 Potentiometer 20 Resistors 21 Fuses 21 Circuit breakers 22 Fusible links 23 Switches 23 Pulse width modulation (PWM) 25 3 CL-1919-06-95 Introduction consulab.com info@consulab.com Trainer Layout and Familiarization The CL-1919-06_053052 Ohm’s Law and DC Circuits Trainer contains electrical and electronic components mounted on a panel containing electrical connection receptacles where students complete the wiring of circuits. The trainer is designed to provide learning assistance in the understanding of basic Ohm’s Law concepts and also provides learning activities for student learning of basic circuit components and operation. A built-in 120VAC to 14VDC (4 A max) power supply is internally protected and is adjustable from 2-14 VDC. The front panel contains a digital display indicating the DC voltage supply available to the trainer. The CL-1919-06_053052 trainer meets CSA/UL safety requirements. The CL-1919-06 also contains a surface mounted digital multi-meter (DMM) that is powered with two AAA replaceable batteries. NOTE : Because the trainer’s power supply output is limited to 4 A, the meter’s internal 10A ammeter fuse should never need replacement. The meter is used throughout the student activities and circuit construction for electrical measure- ments and diagnostic training. CL-1919-06 Ohm’s Law and DC Circuits Trainer CL-1919-06-95 Introduction consulab.com info@consulab.com 4 Front Panel Component Identification Front View 1. Trainer power cord receptacle, master ON/OFF switch and main fuse holder. 2. Positive (red) receptacles for circuit construction. These receptacles are only to be used with the trainer and not to be connected to any external devices as damage could result. 3. Negative (black) receptacles for circuit construction. These receptacles are only to be used with the trainer and not to be connected to any external devices as damage could result. 4. Digital Display for available trainer voltage (Displays the DC voltage that has been set by the voltage adjustment knob). 5. Power supply voltage adjustment knob (Adjusts the available DC voltage from 2-14 ± VDC). 6. Power supply safety reset button (Resets the internal protection cut-out. Push and hold until the O.L. light flashes, then release. The voltage display will read 0.000 when the O.L. lamp is on.). 7. Power supply “OVERLIMIT” indicator light (If a short circuit is created between the Positive & Negative sides of the trainer, the internal protection cut-out will trip and turn on the O.L. indicator light. It will remain on until the problem has been corrected and the RESET button is pushed). 8. PWM (Pulse Width Modulation) generator positive and negative receptacles. 9. PWM Adjustment knob (0-100% duty cycle). 10. Digital Multi-meter. Side View 1 3 2 47 6 5 9 8 10 CL-1919-06-95 Introduction consulab.com info@consulab.com 5 Electrical Component Identification 11. L1 – # 194 Bulb. 12. L2 – # 194 Bulb. 13. D1 – LED Bulb. 14. B1 – BUZZER. 15. T1 – NPN Transistor. 16. T2 – PNP Transistor. 17. D2 – Diode. 18. L3 – # 3157 LED Bulb. 19. M1 – DC Motor. 20. RL1 – ISO 5-pin Relay. 21. Electronic Flasher. 22. POT – 75Ω Potentiometer. 23. R1 – 100Ω Resistor. 24. R2 – 40Ω Resistor. 25. R3 – 20Ω Resistor. 26. R4 – 20Ω Resistor. 27. R5 – 2Ω Resistor. 28. F1 – Optional Circuit Fuse (ATC 2-3A). 29. SW1 – SPST Toggle Switch. 30. PB1 – N.O. Push Button Switch. Front View 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 CL-1919-06-95 Introduction consulab.com info@consulab.com 6 Electrical Accessories Storage Bag Main Fuse Main Fuse Specifications: Model 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (5 mm x 20 mm). Storage Bag Jumper Leads CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT CL-1919-05 POWER SUPPLY FUSE SPECIFICATIONS – 239002P 2A, 250V, 239 Series, Slo-Blow Fuse (8mm x 20mm) TRAINERS MAIN FUSE LOCATION PULL TAB AWAY UNTIL FUSE HOLDER POPS OUT CLOSE UP OF MAIN FUSE HOLDER CLOSE UP OF MAIN FUSE HOLDER SPARE FUSE FUSE IN CIRCUIT Your product may be equipped with either of the below jumper wire styles. They are identical in specifications and performance. All CL-1919-06’s will be shipped with banana plug jumper leads including: • 10 Red Jumper Leads — 23” (60cm) long • 10 Black Jumper Leads — 23” (60cm) long CL-1919-06-95 Introduction consulab.com info@consulab.com 7 Trainer Use and Operation The CL-1919-06-93 manual is designed to provide instructors and students with the necessary information for the prop- er and safe operation of the trainer. Note that the CL-1919-06 trainer includes student assignments (CL-1919-06-95 ) and an instructors manual (CL-1919-06-96). Be sure to read, understand and follow the instructions for each section. The CL-1919-06 is designed to be used as a “stand alone” resource to aid the instructor and students in the learning of basic electricity, Ohm’s Law, DMM meter use, basic electrical and electronic component operation, basic operational circuit construction and diagnosis and troubleshooting of circuit problems. NOTE: Before proceeding with this manual, the following tasks should have already been successfully performed and understood: 1. Familiarization with the CL-1919-06 component layout and identification (pages 5-8). 2. The CL-1919-06 should be set up on a bench/tabletop with the cover removed, the power cord plugged into the trainer and a 120VAC outlet and the master ON/OFF switch turned “on”. NOTE- The cover lid of the trainer can be placed on a table, then move the trainer on top of the cover. This po- sitions the trainer with a slight tilt providing an easier access for users. If properly completed, the digital display should be indicating the available DC voltage. For normal operation, and unless otherwise directed, the display should be adjusted to a reading of 14.0 - 14.6 ± volts. Rating Specifications: • Voltage: 100-240 VAC, single phase • Frequency: 50/60 Hz • Input Current: 2.2 A @120 VAC, 1.2 A @ 230VAC • Output current : 2-14 VDC, 4 A max. • Indoor use only • Temperature: 10 ºC – 30 ºC (50 ºF – 86 ºF) • Humidity (non-condensing): 90 % max. • Altitude : 2,000 m (6,562 ft) • Pollution Degree 2 • Overvoltage Category II Students conducting the circuit learning assignments should have completed the following Learning Modules which contain the prerequiste skills and knowledges: • Understanding basic digital multi-meter setup, use & interpretation (Student Learning Module #1). • Basic electricity (Student Learning Module #2). • Ohm’s Law (Student Learning Module #3). • Component explanation (Student Learning Module #4) • Ability to read and follow written instructions. • Ability to read and interpret basic electrical wiring schematics. CL-1919-06-95 Introduction consulab.com info@consulab.com 8 Warnings and Cautions Even though the power supply is internally protected against short-circuits and wiring errors, students should carefully read, understand and follow all activity instructions to avoid errors. NOTE- If the digital display shows “0.000” volts and the O.L. lamp is “on”, an overcurrent situation has been detected. To re-set the system, find and correct the wiring error, then push and hold the RESET button until the O.L. lamp flashes, then release. If the reset procedure was successfully completed, the display should read available voltage: 1. The 2-3A ATC blade type fuse on the trainer is for optional use by instructors and students as needed. Circuits can be connected with the fuse if desired. Remember that the trainer is internally protected to trip the over-current protection if current exceeds 4 A. 2. Access to fuse compartment and any other components inside of unit to be performed only by trained skilled per- sonnel. 3. L1 and L2 bulbs are made of glass and could break if impacted hard enough, therefore potentially creating a cutting hazard. 4. Do not connect any external device to be powered by the trainer as they may exceed the designed limits of the power supply and components. 5. Be sure to read, understand and follow each set of instructions. Be sure to ask your instructor if you have any ques- tions about any instruction or component. 6. Never “guess” about the results of a circuit. Always follow written instructions to avoid “guesswork”. 7. This product is intended for use in educational establishments by STUDENT OPERATORS at least 14 years of age and under the supervision of theRESPONSIBLE PERSON. 9 CL-1919-06-95 Introduction consulab.com info@consulab.com Student Learning Modules The CL-1919-06 manuals contain Student Learning Modules designed to provide information and resources to assist stu- dents in mastering various skills and knowledges covered with this trainer. Each module comes with educational support information, student activity assignments, student answer sheets, instructor keys and assessment tests. Instructors can use them as they see fit for their programs. Student answer sheets, schematics and assignments can be duplicated and distributed within the schools programs only. PDF fillable answer sheets are also available. Duplication of documents used for outside sources is prohibited. Assignment and test answer sheets can be filed in student files for record keeping of progress. It is recommended that instructors follow the chronological order of the assignments. However, each mod- ule can be presented on its own if desired. The CL-1919-06 Learning Modules 1. UNDERSTANDING THE DIGITAL MULTIMETER — SETUP, USE & INTERPRETATION 2. BASIC ELECTRICITY 3. OHM’S LAW 4. COMPONENT EXPLANATION 5. STUDENT EXPERIMENTS 6. ADVANCED STUDENT CIRCUIT ASSIGNMENTS 10 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com MODULE 4 Component Explanation 11 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Component Explanation The CL-1919-06 utilizes common electrical and electronic components for student use in constructing and understand- ing circuits. This unit is designed to explain each one individually, then in the next unit, students will connect the compo- nents into useful circuits. The component explanations follow the chronological order that the components are orga- nized on the trainer. Light bulbs (incandescent) SINGLE FILAMENT INCANDESCENT BULB SCHEMATIC SYMBOL DUAL FILAMENT INCANDESCENT BULB SCHEMATIC SYMBOL The CL-1919-06 trainer uses two incandescent light bulbs (L1 and L2). The term incandescent refers to any light bulb that operates by passing electrical current through a small wire (filament) which in turn causes the wire to heat up and glow giving off light (incandescence). Incandescent light bulbs at one time were very popular and were used for countless applications. Although incandescent light bulbs are very reliable, they have a few disadvantages in that they generate considerable amounts of heat and require relatively large amounts of electrical current compared to newer technology light bulbs. Some incandescent light bulbs contain two separate filaments inside a single glass enclosure. These bulbs are called “dual-filament” bulbs and are commonly used in vehicle applications such as a combination tail/stop light bulb. The filaments have different amounts of resistance which in turn causes the bulb to operate at a different brightness. The tail light filament will have a higher resistance than the stop light. This results in the tail light being “dimmer” than the stop light. With a filament having less resistance, more current will pass through it and the brighter the bulb will be. Incandescent light bulbs can be tested using an ohmmeter (if the bulb is removed from the circuit) or common testers such as continuity testers, 12V test lights and voltmeters. Testing also can involve measuring available voltage and volt- age drop testing of both positive and ground circuits. The common electrical schematic for an incandescent single and dual-filament light bulb is shown above. Ohmmeter testing of incandescent bulbs should be used only for determining if the bulb filament has continuity or is open. Ohmmeter testing should not be used in calculating the bulbs resistance. Incandescent bulbs need to have “dynamic resistance” determined by measuring the bulbs current flow and using Ohm’s Law with available voltage to determine actual “live” resistance. Dynamic resistance testing was covered earlier in this manual. 12 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Led (light emitting diode) LED SCHEMATIC SYMBOL DUAL LED BULB SCHEMATIC SYMBOL The LED (light emitting diode) is fast becoming one of the most popular lighting sources used today. LEDs are found around the home, in industry and in most all vehicles today. They are used in appliances, digital readout devices, signs and countless other applications. It has some very useful advantages over incandescent bulbs in that they use extreme- ly small amounts of electricity, are extremely bright, operate with relatively cool temperatures, have a long life span and are easily adaptable to many colors and sizes. LEDs used in vehicles are often grouped together to form different shapes that match styling differences in the vehicle. LEDs can also be “sequenced” to come on in different patterns for specific design effects. LEDs create light by passing electrical current though a special semiconductor material. Although the exact definition of how a LED works is a very complex technology, for the purposes of this section, we will state that a LED creates light from the movement of photons which are part of an atom when electrons are passed through a semiconductor. Photons are a source of energy which is this case, is used for light. LEDs have definite polarity concerns when being installed in a circuit. They must be installed properly in the positive and negative sides of a DC circuit. LEDs can have normal operating voltages of about 2.1 volts but are also available in 12VDC designs. LEDs with voltage ranges of 2.1 V must be installed with a voltage dropping resistor in series with the LED. Some LED packages have built in dropping resistances and can be safely connected to 12 volts. If a non-protected 2.1V LED is connected to a 12V circuit, it will be instantly ruined. The LEDs used in the CL-1919-06 is designed to oper- ate properly on full source voltage (14.6 volts) and is internally protected from reverse polarity hookup. If the trainer’s L3 LED is installed backwards, nothing will happen and the LED bulb will operation normally. This is because the 3157 LED bulb does have specific polarity. Like all 3157 bulbs, it can be correctly installed two different ways. Other LED bulbs require proper polarity hookup (See drawing below). CATHODE (NEGATIVE SIDE - shorter wire) ANODE (POSITIVE SIDE - longer wire) FLAT EDGE LONG WIRE SHORT WIRE LEDs are most commonly tested in the circuit. Checks for proper supply voltage and a good ground circuits are made and if present, the most common method is to replace the LED with another one. 13 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Buzzer BUZZER SCHEMATIC SYMBOL The CL-1919-06 buzzer is an audible device that primarily is used for constructing vehicle horn circuits. Electrical audi- ble devices are available in countless styles, shapes and can generate numerous tones, sounds and volume levels. The most common audible devices operate from 12 VDC but there are variations. Audible devices are also often polarity sensitive requiring the proper connections of positive and negative circuits. The CL-1919-06 12VDC buzzer is protected from reversed polarity and if connected improperly, no damage will occur. A common example of an audible warning device used in an automobile is the horn, seat belt and lights left on indica- tors. Audible devices are often tested by performing an available voltage and ground circuit test at the device, and if present, the device is usually replaced. Diode DIODE SCHEMATIC SYMBOL ANODE (+) CATHODE (−) CURRENT FLOW Diodes are used in electrical circuits for numerous purposes and applications. A diode acts like an electrical one-way check valve in that it allows electron flow in one direction, but blocks it in the opposite direction. Most simple diodes have two leads or terminals. One is called the ANODE and is a positive (+) polarity. The other is called the CATHODE and is a negative (-) polarity. Diodes conduct current flow from the ANODE to the CATHODE. If a diode is connected in a circuit with the positive side of the circuit connected to the ANODE, the diode with conduct current. If the negative side of the circuit is connected to the ANODE, the diode will block current. Typical diodes have very low internal resistances causing a voltage drop in the circuit of about 750 mV or 0.750 V. 14 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Testing of Diodes NOTE : Diodes must be electrically disconnected from the circuit prior to testing to obtain accurate results. A. Diodes can be tested with an ohmmeter : 1. Using an ohmmeter, set the ohmmeter to read “AUTO RANGING”. 2. Connect the positive test lead to the diode CATHODE and the negative test lead to the diode ANODE. 3. With this hookup, the ohmmeter should show a reading of approximately 5.5 MΩ. 4. Reverse the ohmmeter test leads to the diode. The ohmmeter should read “infinity” or “OL” or “1.” depending on the DMM style. 5. If the ohmmeter shows continuity in both directions ,or infinity in both directions, the diode is either “shorted” (shows continuity) or “open” (shows infinity). NOTE- Ohmmeters can often have different internal circuit polarities and thus the readings of steps 3 & 4 may be re- versed. B. Diodes can also be tested with the DIODE TEST function of a DMM if equipped with this feature : 1. Set the DMM to the DIODE TEST function. 2. Hookup of the meter test leads to the diode as when using the ohmmeter. 3. With the RED test lead on the ANODE (+) terminal of the diode, the meter should show a voltage drop of approxi- mately 500 mV or 0.500 V (±). 4. With the BLACK test lead on the ANODE (+), the meter should show “infinity”, “OL” or “1.” depending on meter style. C. Diodes can also be tested with a 12 volt test light : 1. Install a small BLACK jumper wire to the CATHODE (-) terminal of the diode. 2. Connect the other end of this BLACK jumper to the negative terminal of a 12 volt battery. 3. Connect a 12 volt test light to the positive terminal of a 12 volt battery. 4. Connect the probe of the test light to the ANODE (+) terminal of the diode. 5. The test light should illuminate. If the test light does not come on, the diode is open. 6. Reverse the connections of the BLACK jumper wire and the 12 volt test light to the battery. (BLACK jumper con- nects to the diode ANODE (+) terminal and the test light probe connects to the diode CATHODE (-) terminal). 7. The test light should remain OFF. If the test light comes on, the diode is shorted. 15 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Transistors NPN TRANSISTOR SCHEMATIC SYMBOL PNP TRANSISTOR SCHEMATIC SYMBOL COLLECTOR BASE EMITTER COLLECTOR BASE EMITTER The electronic transistor has literally changed the world and electrical and electronic devices we use every day. Before transistors, all electrical devices including TV’s and radios operated with a device called a “vacuum tube”. Vacuum tubes were bulky and generated high amounts of heat. There were also more expensive and difficult to manufacture than transistors. The invention of the transistor is considered by many to be one of the biggest events in the history of mankind. Transistors allowed the development of “portable” electronic devices. The high majority of circuits used in devices today utilize many different types of transistors and other semi-conductor devices. A transistor is a semi-conductor device that is used to amplify and/or switch electronic circuits. It consists of semi-con- ductor material with at least three electrical terminals consisting of BASE, COLLECTOR and EMITTER. It can both ampli- fy power and switch circuits. There are two basic types of simple transistors. One is called N-P-N and the other is P-N-P. For switching circuits, a transistor can be thought of as a type of relay. A relay has both a LOAD circuit and a CONTROL circuit. Transistors have the same. For both transistors, current flows into the transistor at the BASE and COLLECTOR and out of the EMITTER. The COLLECTOR TO EMITTER is the LOAD circuit (higher current) and the BASE to EMITTER is the CONTROL circuit (lower current). For a NPN transistor, the BASE circuit is positively switched to turn the transistor on. For a PNP transistor, the BASE circuit is negatively switched to turn the transistor on. The LOAD is on the positive side of an NPN and on the ground side of a PNP transistor. NPN Transistor Circuit Hookup : 1. Connect NPN Collector to one side of the load. 2. Connect other side of the load to supply voltage positive. 3. Connect NPN Base to one side of the switch. 4. Connect other side of switch to supply voltage. 5. Connect NPN Emitter to ground. The LOAD would be connected from source voltage through the load to the COLLECTOR of the transistor. The CONTROL circuit would be connected from source voltage through a switch to the BASE of the transistor. The EMITTER circuit is grounded. 16 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com PNP Transistor Circuit Hookup : 1. Connect PNP Base to the switch and the other side of the switch to ground 2. Connect PNP Emitter to positive power supply 3. Connect PNP Collector to positive side of controlled device 4. Connect the ground side of the controlled device to ground Supply voltage is connected to the EMITTER and the LOAD would be connected from COLLECTOR to ground. The CONTROL voltage would be connected from the BASE through a switch to ground. Transistors can be tested in many ways, but for the purposes of this manual, an ohmmeter will be used. Some technicians use a mental “trick” when identifying whether a transistor is a PNP or NPN. They look at the schematic symbol for the transistor in the circuit and observe the EMITTER arrow. If the arrow is pointing away from the center they say : “Not Pointing In” or NPN. If the arrow is pointing to center they say : “Pointing In” or PNP. Because a transistor is made up of basically two-diode type circuits, the DIODE TEST function of a DMM can also be used. Follow the below chart to test transistors using an ohmmeter : Testing Transistors with a DMM Ohmmeter NOTE : Transistors can be tested with an ohmmeter and/or the “DIODE TEST” function of a DMM if equipped. Some technicians prefer the DIODE CHECK method over the ohmmeter because it “loads” the two solid state connections inside the transistor which can give more accurate testing of the transistor under a load. N P N P N P − + → TEST LEAD POLARITY + − ← E B C E B C M A O M A O I S L I S L T E L T E L T E T E E C E C R T R T O O R R SHOULD CONDUCT WITH OHMMETER LEADS CONNECTED BETWEEN POINTS. SHOULD NOT IF LEADS ARE REVERSED. SHOULD CONDUCT WITH OHMMETER LEADS CONNECTED BETWEEN POINTS. SHOULD NOT IF LEADS ARE REVERSED. COLLECTOR TO EMITTER testing should ALWAYS show “open circuit” or infinity. If it doesn’t, the transistor is shorted. 17 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Motor MOTOR SCHEMATIC SYMBOL Motors are used in many different applications in electrical circuits. There are DC motors of many different designs and styles. The CL-1919-06 trainer uses a simple DC motor that is designed to draw between 10 mA or 40 mA of current at 14.00 volts depending on the motor installed on your specific trainer. Some DC motors rotational direction can be reversed by reversing the electrical polarity of the positive and ground circuits feeding the motors. Motors are designed to perform useful work such as moving a window, operate a door lock, raise/lower an antenna, operate windshield wipers, move a seat or rotate a blower cage to move air. Each motor will have a design amperage for the motor to operate within. Motors can have single or multiple speeds. They are mechanically coupled to device they are designed to move or rotate. DC motors can be use brushes or can be brushless types. Brushless DC motors are becoming very common on today’s vehicles especially on EV and hybrids. Testing Motors Motors are tested by measuring the available voltage, the motor current draw and the voltage drops of both the positive and ground portions of the circuit. Some motors also mechanically fail due to defective or worn bearings. Relay RELAY SCHEMATIC SYMBOL CL-1919-06 WIRING BLANK TEMPLATE CIRCUIT __________________________________________ NAME _________________________ DATE __________ INSTRUCTOR’S CHECK: _____________________ CREDIT/GRADE: ____________________________ COMMENTS:___________________________________________________________________________ Relays are commonly used throughout the electrical industry. A relay performs the function of controlling a high amper- age circuit with a very small amperage control circuit. Prior to the use of relays, very large wires had to be connected to switches that were capable of handling the high current of the devices being controlled. A relay has two “parts” or is divided into two distinct portions. One is called the “CONTROLLED LOAD” (HIGH CURRENT) side and often controls the turning on or off devices such as motors. The other is called “CONTROL” (LOW CURRENT) side and usually contains some type of switch or switching circuit to turn the relay on and off. 18 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com The CONTROL side (COIL CIRCUIT) contains a coil of wire which, when supplied with a positive and negative source, creates a magnetic field that in turn moves a mechanical switch inside the relay which either connects or disconnects high current contacts. Either the positive or negative (ground) side of the coil can be switched to control the relay. A very common relay used in automotive circuits is the ISO 5-pin relay. ISO stands for International Standards Organization and indicates that the terminal placement, configuration and identification of this relay will be identical regardless of manu- facturer. The CL-1919-06 uses a standard 5-pin ISO mini relay. 5-PIN RELAY PIN DESCRIPTION 85 NORMALLY COIL GROUND 86 NORMALLY COIL 12V FEED 30 12V FEED IN FOR CONTROLLED CIRCUIT or 12V OUT TO CONTROLLED COMPONENT 87A NORMALLY CLOSED CONTACT — CAN BE 12V FEED IN or 12V OUT TO CONTROLLED COMPONENT 87 NORMALLY OPEN CONTACT — CAN BE 12V FEED IN or 12V OUT TO CONTROLLED COMPONENT 30 to 87A NORMALLY CLOSED WHEN REALY IS OFF 30 to 87 NORMALLY OPEN WHEN RELAY IS OFF Control Side (coil circuit) Relay terminals #85 and #86 are the two ends of the relay coil. Terminal #85 normally is connected to a ground circuit. As previously stated, when a positive voltage is connected to terminal #86 and a ground circuit is supplied to terminal #85, the coil is energized and a magnetic field will be established with the coil. This will cause a movement of a switch lever inside the relay which also results in an audible “click” sound when the coil is energized. The coil current of this ISO relay will be approximately 160 mA @ 14.00 volts. The resistance of the relay coil will be about 80 Ω. Relay circuits can switch either the positive side of the coil or the ground side. Check with the circuit wiring schematic to determine which is used. NOTE : Some newer relays can have a higher coil resistance than 80 ohms. Always check service information to confirm. NOTE : Relay coils generate an induced voltage when they are de-energized which can exceed 200-400 volts. If this induced voltage is allowed to escape the relay, it can damage sensitive electronic components like PCM’s and modules. The induced voltage is controlled by two methods. One uses a “shunt” resistor connected in parallel to the relay coil. The other method uses a diode connected across the relay coil. If the coil is protected by a resistor, it doesn’t matter which coil terminal (85 or 86) is ground and which is B+. However, if the coil is protected by a diode, the hookup of the 85 & 86 terminals MUST be properly connected based on how the diode is installed in the coil. Hooking up the relay coil circuit “backwards” will instantly destroy the protection diode, but the relay will still operate although without spike protection. ALWAYS follow specific circuit schematics when hooking up and testing relays. NOTE : The CL-1919-06 relay is shunt resistor protected and therefore, terminals 85 & 86 can be either ground or B+. 19 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Controlled Side (load circuit) The three remaining terminals of the ISO relay are labeled #30, #87 and #87a. The relay has two sets of contacts. One set are normally closed (NC) when the relay is off. These are labeled #30 and #87a. The other set of contacts are normally open (NO) when the relay is off. These are labeled #30 and #87. When the relay is turned off, there is a connec- tion between #30 and #87a. When the relay is turned on, the connection between #30 and #87a is broken (open) and terminals #30 and #87 are connected. Most relay coils are protected from induced voltage spikes when the coil circuit is interrupted. The most common meth- od uses a “shunt resistor” connected in parallel with both ends of the coil. Another option is to use a diode in parallel with the coil. If either 85 or 86 can be either positive or ground, the relay is resistor protected. If a diode is used, then 86 must be used as the positive coil feed. The relay in the CL-1919-06 is resistor protected. ISO Relay Testing ISO relays can be tested using several different techniques. Testing the relay in the circuit can involve checking for the presence of a voltage supply (usually to terminal # 30) and also testing for a voltage connection (#30 & #87) when the relay is turned on. Checking for a power source and a ground source to the relay coil is also a valuable test. Relay coil resistance can be measured with an ohmmeter and coil current flow can be measured with an ammeter. Always check a relay while it is under load to check for voltage drop across the load terminals. Some technicians mistakenly believe that if the relay “clicks”, it is OK. This is not true. Always check for voltage drop across relay terminals 30 to 87 and 30 to 87a with the relay under the same load as in the circuit. Electronic flasher ELECTRONIC FLASHER SCHEMATIC SYMBOL BAT SIG GND Electronic flashers are most commonly used in vehicles to operate the turning signals and hazard warning lights. There are also other specific uses for them in specialized circuits. The electronic flasher differs from the older style “thermal” flasher in that electronic flashers can handle larger amounts of current. Most vehicles today use electronic flashers. Flasher Testing Electronic flashers are commonly tested by confirming the presence of a positive and ground circuits available to the flasher and that the load or signal side of the flasher is connected to a known good bulb (or other load) and ground. Checking for available voltage and voltage drop testing of both positive and ground circuits is also done. 20 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Potentiometer POTENTIOMETER SCHEMATIC SYMBOL A potentiometer is best described as a “variable resistance” that can be controlled by turning a knob or by sliding a control knob back and forth. Common applications of a potentiometer are the volume, tone and balance controls on a typical audio system. A potentiometer usually has three terminals. Looking at the above schematic symbol of a poten- tiometer, notice that there is a resistance with two ends each having a terminal. The third terminal is represented by an arrow and as the potentiometer is adjusted, the arrow moves back and forth along the resistance. This results in a vary- ing resistance between terminals #I and #H as well as between terminals #G and #H. As the resistance between #I and #H decreases, the resistance between #G and #H will increase. This will be reversed as the potentiometer is adjusted in the opposite direction. Potentiometers are used in many circuits in industry as well as in vehicles. A common application of a potentiometer in a vehicle is a TP (Throttle Position Sensor). In a typical TP circuit, terminals #G and #I would be connected to a positive power supply (usually 5 volts) and a ground. Terminal #H would be connected to a movable arm that would move as the driver steps on the accelerator pedal. This results in a varying voltage between terminal #H and ground which is used to “inform” the computer of the position of the accelerator pedal. As stated previously, potentiometers are also used as volume, bass, treble, fade and balance controls in audio systems. Testing Potentiometers Accurate testing of a potentiometer can be performed using an oscilloscope or graphing multi-meter. As a potentiom- eter is used over time, it can develop a “bad spot” on the sliding resistance which will affect the signal when the mov- able arm slides across this area. This condition can cause unwanted circuit performance. Testing a potentiometer with ohmmeter will not reveal these “glitches”. Ohmmeter testing will measure the resistance of the potentiometer and show changes in resistance as the potentiometer is moved. Voltage testing of the supply voltage and ground circuits as well as the varying signal voltage can also be done. Oscilloscope or some type of signal display method is the only way to accurately test potentiometers. 21 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Resistors RESISTOR SCHEMATIC SYMBOL Resistors are commonly used in electrical circuits for many purposes. Among the most common examples are to reduce voltage in specific parts of a circuit or to serve as current limiting devices. Most common resistors are manufactured from carbon and can be designed to contain resistance values from less than one ohm to over millions of ohms depend- ing on the intended application. In expressing the amount of resistance in a resistor, terms of “kilo” for 1,000 and “mega” for 1,000,000 ohms are used. Abbreviations are used for these terms : “kilo = kΩ = Kilohm” and “mega = MΩ = Megohm”. Some resistors have a color-coded system using colored rings around the resistor that are used to identify the resistors ohm value and ± accuracy tolerance range. Resistors are also classified by “wattage” which is how much current the re- sistor can safely conduct without overheating and burning up. Variable resistors are also used in electrical and electron- ic circuits and are called potentiometers (3-wire) or rheostats (2-wire). Resistors introduce a specific and desired amount of resistance in a circuit to provide intended results, whereas unwanted resistance caused from corrosion, loose or dirty connections is undesirable and needs to be identified and repaired. Voltage drop testing is the most accurate method of determining the location of unwanted resistance in a circuit (See voltage drop testing section). Testing Resistors Resistors can be tested using an ohmmeter (out of the circuit) or conducting a voltage drop test across the resistor using a voltmeter. Variable resistors can be testing using an oscilloscope or graphing multimeter. Unwanted resistances in a circuit are tested by conducting voltage drop tests from one point in a circuit to another while the circuit is operating. Common voltage drop specifications for low current circuits range from 0.1-0.2 volts (100-200 mV). Exceptions can be mechanical switches, solenoids and relays. Fuses FUSE SCHEMATIC SYMBOL Circuits are commonly protected from excessive current by “over-current” devices. Among the most common are fuses, circuit breakers and fusible links. The CL-1919-06 uses a common replaceable ATC type plastic fuse rated at 2 or 3 amps. Other types of fuses include ATC, MAXI ATC, MINI ATC, MICRO ATC, glass, cartridge and ceramic fuses. The purpose of a fuse is to protect the circuit from excessive current which could cause damage and/or fires. Most fuses are designed for a “one-time” protection event and will “open” if current exceeds it’s designed value. 22 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Fuses are designed with amperage values of less than one amp to many hundreds of amps depending on the circuit it protects. Automotive fuses commonly range from 2-100 amps. A fuse contains a particular size and diameter of wire that is designed to melt and break the circuit if the current flowing through the fuse exceeds its amperage value. NEVER replace a blown fuse with a larger amperage fuse ! This can cause wiring to overheat and cause fires and circuit damage. Testing Fuses Most fuses have two terminals and are identified as “feed” and “load”. Fuses are tested using a 12-volt test light, volt- meter or ohmmeter (out of circuit). A good fuse should have zero resistance, should have no voltage drop across it and should have full circuit voltage on both sides of the fuse. If it is “blown” or open, one terminal will have circuit voltage and one will measure zero. NOTE : If a fuse is installed in a circuit, anytime current is flowing in that circuit, there will be a voltage drop across the two terminals of the fuse. This fact allows technicians to determine how much current is flowing through the circuit by using specific charts that convert the voltage drop to current. Circuit breakers CIRCUIT BREAKER SCHEMATIC SYMBOL A circuit breaker is also an over-current protection device but often can be either automatically or manually reset after it protects the circuit by opening. Circuit breakers are used in homes, industry and the automobile. They are rated by the maximum current they can conduct without “tripping” or opening the circuit. The CL-1919-06 uses a manually reset circuit breaker (located near the voltage adjustment knob). If wiring errors are made on the trainer that result in excessive current flow, the circuit breaker will open and the O.L. indicator light will illuminate. After the circuit error is identified and corrected, the circuit breaker can be reset by pushing and holding in on the RESET button until the O.L indicator flashes, then release the RESET button. Testing Circuit Breakers Automotive circuit breakers can be testing using 12-volt test lights, voltmeters, voltage drop testing across the circuit breaker or ohmmeter (out of the circuit). Most circuit breakers have two electrical terminals and operate similar to fuse with the exception that circuit breakers can be reset after the protection event. The CL-1919-06 uses a circuit breaker device in the overload circuit protection circuit. When an overload occurs, the cir- cuit breaker trips, thus interrupting the circuit until the error is corrected. Circuit breakers are commonly used in some vehicle circuits. 23 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Fusible links FUSIBLE LINK SCHEMATIC SYMBOL A fusible link is also a type of over-current protection device commonly used on vehicles. A fusible link is a short length of special designed wire and insulation that is smaller in diameter than the other circuit wiring. If a short-circuit condition occurs or the circuit has more current flowing in it than it was designed to handle, the fusible link will melt and open the circuit providing protection. The insulation covering the fusible link is designed to swell up during the melting and can be inspected and identified as the source of the problem. Fusible links are often used at the battery, power distribution center and starter solenoid on many vehicles. Fusible links are serviced by replacing the melted section with a replacement of the same size. Some repair sources offer specific amperage bulk fusible link wire for repair purposes. Although the CL-1919-06 doesn’t use fusible links, it is important that students understand the operation of them. Switches SPST SWITCH SCHEMATIC SYMBOL Switches are control devices designed to turn a circuit on or off. There are many different switch designs ranging from simple to very complex. Switches can operate mechanically or electronically. The CL-1919-06 uses a SPST switch. The term SPST means that it can control 1 “pole” or “single pole”. Therefore the switch would have two electrical terminals and would be installed in a single wire of a circuit. The acronym of “ST” means “single throw”. Single throw means the switch has only two positions, open (N.O.) or closed (N.C.). So in the case of a SPST switch it would have two terminals and can be switched either on or off. “ON” electrically connects the two terminals together and “OFF” disconnects them. SPST TOGGLE SWITCH ON OFF LOAD L1 BAT + N.O. SPST SWITCH N.C. SPST SWITCH 24 Other types of switches SPDT- (Single Pole Double Throw) (not used on the CL-1919-06) – A SPDT switch has three terminals and three positions. The toggle switch has a center off position during which there is no connection to the other terminals. Moving the toggle to one side connects the center terminal with one of the end terminals. Moving the toggle from center to the opposite side connects the center terminal to the other end terminal. SPDT TOGGLE SWITCH ON OFF LOAD L1 BAT + LOAD L2 ON SPDT SWITCH SCHEMATIC SYMBOL DPST – (Double Pole Single Throw) (not used on the CL-1919-06) – A DPST switch is really two single pole switches con- nected together. The switch will have four terminals and has either an “on” or “off” position. The two sets of terminals are not internally connected and the switch can be used to control two separate circuits. DPST SWITCH SCHEMATIC SYMBOL DPST TOGGLE SWITCH ONOFF LOAD L1 BAT + BAT + LOAD L2 DPDT- (Double Pole Double Throw) (not used on the CL-1919-06) – A DPDT switch is also two switches connected to- gether. It can be configured either as a “center off” with two “on” positions (either side) (ON-OFF-ON) or a two position switch which controls two circuits (ON-ON). DPDT SWITCH SCHEMATIC SYMBOL DPDT TOGGLE SWITCH ON OFF LOAD L1 BAT + LOAD L3 ON BAT + LOAD L4LOAD L2 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com 25 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Pulse width modulation (PWM) PULSE WIDTH MODULATION SCHEMATIC SYMBOL Pulse Width Modulation is an electrical term that describes the control of DC voltage in a circuit by changing the amount of time (pulse) that the circuit is on compared to the time it is off. The term “modulation” means that the circuit is con- stantly modulating or switching on and off. PWM is commonly used in many electrical components including washers, stoves, dishwashers, most electronic devices. In the automobile, PWM control of circuits, such as fuel pumps, HVAC blower motors, wiper motors and others, is used. PWM control of circuits allows the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency and current draw due to the faster switching speeds of the circuit. Fuel injection supply pumps are commonly controlled with PWM to provide a more efficient response to pressure and volume requirements. Computers or microprocessors are typically responsible for control of PWM circuits. It is important to understand the terms below when working with PWM. Pulse Width The term PULSE WIDTH is the amount of time that the circuit is turned on and is usually measured in milliseconds. Duty Cycle The term DUTY CYCLE which is often used when discussing PWM, refers to the amount of time the circuit is ON and is expressed as a percentage. A 10% duty cycle means that the circuit is turned on 10% of the time and off 90% of the time. For example, a 50% duty cycle means that the circuit is on as much as it is off. As the ON time increases, the OFF time decreases. Just to be clear, the device is NOT operating on 6V, but the multimeter “averages” the voltages seen and thus displays 6V. In reality, the device is operating on 12V for only for 50% of the total time. A graphing voltmeter or oscilloscope are the only tools where PWM signals can be accurately displayed. For example, on a 12-volt circuit oper- ating on and off with a 50% duty cycle, the “output” voltage would be measured at 6 volts. Many digital multimeters are equipped to measure DUTY CYCLE. PWM (Pulse Width Modulation) Duty Cycle ON OFF ON OFF ON OFF ON OFF ON OFF 100% 75% 50% 10% 0% Pulse Width Frequency 1 Hz 1 Cycle Example - 1 sec (Positive switched) 26 CL-1919-06-95 Module 4 — Component Explanation consulab.com info@consulab.com Ground or Positive Switched PWM PWM circuits can be either POSITIVE or GROUND switched. This is important to know because the pattern displayed could be easily misunderstood. For example, a pattern showing a short duration at the top of the pattern could be a short duty cycle for a positive switched circuit or a long duty cycle for a ground switched circuit. Properly reading and understanding a wiring schematic is required to fully understand PWM circuits. Frequency FREQUENCY is a term used to define how many “on/off” cycles there are in a given amount of time. Frequency is mea- sured in hertz (Hz). A very simple example of frequency is a circuit that is on for 2 seconds during a total time of 4 seconds. The entire “cycle” includes the time that the circuit is on and also the time it is off. If the circuit is on once for 2 seconds during a total time of 4 seconds, the frequency will be 1 Hz. If the circuit was turned on twice for 1 second each and off for 1 second each during the same time, the frequency would now be 2 Hz, but the time base of 4 seconds remains the same. Actual circuits operate much faster than this example. Another example of frequency would be the engine RPM’s. The frequency of the RPM’s would be lower at idle speeds than it would be a cruising speeds. The CL-1919-06 contains a PWM generator circuit that is adjustable throughout a 0-100% range. The voltage available at the positive (RED) and negative (BLACK) terminals will be close to zero at 0% Duty Cycle and about 13.00 volts at 100% duty cycle. The BLACK terminal is connected to a ground source and the RED terminal output is controlled by the adjustment knob. Some digital multimeters and scan tools are able to display and measure frequency. 75%50%25% Voltage Time Avg voltage 3V 6V 9V 0V 12V PWM TYPICAL WAVEFORM (Positive switched) After completion of COMPONENT EXPLANATION module, ask your instructor TEST 11. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. Trainer Layout and Familiarization Front Panel Component Identification Electrical Component Identification Electrical Accessories Trainer Use and Operation Warnings and Cautions Student Learning Modules MODULE 4 Component Explanation Pulse width modulation (PWM) Switches Fusible links Fuses Resistors Potentiometer Electronic flasher Relay Motor Transistors Diode Buzzer Led (light emitting diode) Light bulbs (incandescent) Circuit breakers

Answer Keys for MD-4000-23_053344 Driveability Electronics Moduponent™ Kit Teacher only MD-4000-23_053344-91 © ConsuLab Educatech Inc, 2025. All rights reserved. 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, 2025. 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 053344 and above. MD-4000-23_053344-91 Table of contents Table of contents General description 3 Student Assignments Answers SA-1 MD-4001 Pulse Width Modulator (PWM) 5 SA-2 MD-4002 5V Regulator 9 SA-3 MD-4040 12VDC 5-pin ISO Relay 13 SA-4 MD-4050 Variable Reluctance Sensor 20 SA-5 MD-4051 Hall Effect Sensor 25 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) 30 SA-7 MD-4053 MAP Sensor 35 SA-8 MD-4054 TP Sensor 40 SA-9 MD-4055 Piezo Knock Sensor 44 SA-10 MD-4057 Magnetic Resistive Sensor 47 SA-11 MD-4112 Stepper Motor 52 SA-12 MD-4114 Solenoid 55 SA-13 MD-4120 Injector 59 SA-14 MD-4141 Optical Sensors 65 consulab.com info@consulab.com 3 MD-4000-23_053344-91 General description General description The ConsuLab MD-4000-23_053344 is a versatile and adaptable electrical/electronic training system that allows students to build electronic circuits. Features • Protected with removable metal cover • Adjustable and protected power supply (2-14VDC) • Moduponent™ storage rails allow up to 16 individual Moduponents™ Educational Advantages • Can be used for teaching basic Ohm’s law or complex electronic circuits • Self-contained unit has a protected built-in adjustable power supply • Storage case holds up to 16 individual Moduponents™ • This set includes 14 different Modupon ents™ from the entire MD-4000 series • Uses industry standard schematic symbols • Provides extreme flexibilty to allow instructors to create additional as nd student activities • Can assist instructors in the instruction of many tasks in area A6 and others of the ASE Education Foundation (NATEF) List of MD-4000-23 ModuponentsTM • 52958 CL-1011A Desktop Moduponent Case • 52320 CL-1012-03 Set of 26 Jumper Leads • 53061 MD-4000 DC Power Supply • 53074 MD-4001 Pulse Width Modulator (PWM) • 53095 MD-4002 5V Output (Regulator) • 53068 MD-4040 12VDC 5-pin ISO Relay • 53072 MD-4050 Variable Reluctance Sensor • 53071 MD-4051 Hall Effect Sensor • 53067 MD-4052 NTC Thermistor • 53085 MD-4053 MAP Sensor • 53082 MD-4054 TP Sensor • 53079 MD-4055 Piezo Knock Sensor • 53132 MD-4057 Magnetic Resistive (2-wire ABS) Sensor • 53083 MD-4112 Stepper Motor • 53134 MD-4114 Solenoid • 53133 MD-4120 Injector • 53076 MD-4141 Optical Sensors consulab.com info@consulab.com 4 MD-4000-23_053344-91 Student assignments Answers Student Assignments Answers consulab.com info@consulab.com 5 MD-4000-23_053344-91 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC Electrical Symbol Theory of operation Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by electronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4010 Resistors • MD-4070 Light bulbs • MD-4111 Fan • MD-4120 Injector Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) MD-4000 Moduponent: MD-4001 Pulse Width Modulator (PWM) Electrical Symbol: Theory of operation: Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by electronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120VAC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4010 Resistors MD-4070 Light bulbs MD-4111 Fan MD-4120 Injector Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 6 MD-4000-23_053344-91 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) - Level 1 ( Page 1 of 2 ) Level 1 exercise: Perform a voltage measurement of PW Modulation in response to a 12V source. WIRING DIAGRAM #1 MD-4000 MD-4001 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC Level 1 Setting up to measure pulsed voltage Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4001 PWM moduponent. See wiring diagram #1 Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent. Connect the DVOM red lead to the BLUE SIGNAL terminal of the MD-4001 PWM moduponent. Set the DVOM to V DC. Follow the instructions on next page for control dial settings and record measurements. consulab.com info@consulab.com 7 MD-4000-23_053344-91 Student assignments SA-1 Answers SA-1 MD-4001 Pulse Width Modulator (PWM) — Level 1 Answers ( Page 2 of 2 ) Level 1 Measuring pulsed voltage Done Do this : Set control dial to the second line marking. Record voltage at the signal terminal: 0 V. Set control dial to the fourth line marking. Record voltage at the signal terminal: 1,5 V. 1 Set control dial to the sixth line marking. Record voltage at the signal terminal: 4,5 V. Set control dial to the eighth line marking. Record voltage at the signal terminal: 8,5 V. 2 With knowledge of PWM, what is happening here? Voltage is being pulsed ON/OFF, not resistance added to the circuit. 3 What exactly is PWM? ON versus OFF time. 4 Proceed to SA1 Level 2 to actually see this happen using an oscilloscope. consulab.com info@consulab.com 8 MD-4000-23_053344-91 Student assignments SA-1 Answers SA-1 MD-4001 Pulse Width Modulator (PWM) — Level 2 Answers NOTE : *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a PWM signal using an oscilloscope to capture a pattern. Level 1 Setting up an oscilloscope to observe a PWM signal Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4001 PWM moduponent. Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. See diagram #1 Connect a black wire from the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply Connect one lead from an oscilloscope to the BLUE SIG terminal of the MD-4001 PWM moduponent. Connect the oscilloscope black lead to the BLACK – of the power supply. Adjust the PWM control knob to the sixth line. Adjust the oscilloscope settings until a pattern can be observed * 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time: 10 μs per div Trigger: 12.0 V 2 On a separate sheet of paper, draw the pattern observed. See capture : Now adjust the PWM control knob right and left and observe the changes in the oscilloscope pattern. 3 How fast is pulse width being modulated? 21 kHz 4 Describe the pattern changes observed and why the pattern changes: The time base stretches the pattern as the knob is turned right (ON time increased) and shortens the pattern as the knob is turned left (OFF time increased). consulab.com info@consulab.com 9 MD-4000-23_053344-91 Student assignments SA-2 SA-2 MD-4002 5V Regulator Electrical Symbol Theory of operation Reference voltage has been used in electronics for years and is called Vref. The reason why modern automobiles use a 5-volt reference is to provide a consistent voltage to the engine control computer circuits, instead of fluctuating with battery/charging/cranking voltages. Also, as electricity flows through a sensor containing a resistance, any resistance introduced into this circuit will be a larger proportion of a 5 volt circuit than a 12 volt circuit, providing better accuracy. Due to this variable resistance, the signal return voltage to the ECM is always less than the reference voltage and used to compute changes in temperature, pressure or position. Safety and Safeguards • 1 Amp circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4053 MAP Sensor • MD-4054 TPS • MD-4057 MR Sensor • MD-4051 Hall Effect Sensor Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT consulab.com info@consulab.com 10 MD-4000-23_053344-91 Student assignments SA-2 Answers SA-2 MD-4002 5V Regulator — Level 1 Answers Level 1 exercise: Set up a 5V reference voltage to illustrate modern vehicle sensor reference voltage. MD-4000 MD-4002 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT WIRING DIAGRAM #1 Level 1 Setting up a reference voltage of 5V Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5V Regulator moduponent. See wiring diagram #1 Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. Level 1 Measuring pulsed voltage Done 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 12 V DC 2 Connect the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 5 V DC 3 Why is this voltage regulation needed? To control sensor reference voltage at a 5V level. 4 How is this 5V reference voltage used in an automobile today? The on-board computer sends a reference voltage to the sensors and actuators, usually 5 volts. consulab.com info@consulab.com 11 MD-4000-23_053344-91 Student assignments SA-2 SA-2 MD-4002 5V Regulator — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a 5V reference measured on a DVOM compared to an Oscilloscope pattern. Additional Moduponents required: MD4002, MD-4051, MD-4053 and MD-4057. ( Page 1 of 2 ) Level 2 Setting up a reference voltage of 5V Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5V Regulator moduponent. See wiring diagram #1 Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. consulab.com info@consulab.com 12 MD-4000-23_053344-91 Student assignments SA-2 Answers Level 2 Provide a 5V reference to a sensor Done 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 12 V 2 Connect the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: 5 V Remove the red DVOM lead from the 5V terminal. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator moduponent to the +5V terminal of the MD-4051 Hall Effect Sensor moduponent. 3 Without a ground wire connected to the MD-4051 Hall Effect Sensor, connect the DVOM red lead to the sensor BLACK GND terminal and record voltage: 5 V 4 Without a ground wire connected to the MD-4051 Hall Effect Sensor, move the DVOM red lead to the WHITE SIG terminal and record voltage: 5 V 5 With the DVOM red lead still connected to the WHITE SIG terminal, complete the 5V circuit by providing a black wire from the GND terminal back to BLACK – of the power supply. Record SIG voltage reading now with the 5V circuit completed: 5 V ± little change 6 Using a DVOM to measure the voltage, were you able to see an accurate “signal”? No Connect an oscilloscope and obtain a waveform pattern. 7 Using an oscilloscope to measure voltage, were you able to see an accurate “signal”? Yes REPEAT steps 3 – 9 for the following MD-4000-23 moduponents : 8 MD-4053 MAP sensor GND 5 V SIG w/o GND 5 V SIG w/GND 3,8 V 9 MD-4057 MR sensor GND 4,5 V SIG w/o GND 4,5 V SIG w/GND Varies with sensor speed SA-2 MD-4002 5V Regulator — Level 2 Answers ( Page 2 of 2 ) consulab.com info@consulab.com 13 MD-4000-23_053344-91 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay Electrical Symbol Theory of operation Simply put, an automotive relay is an electrically or electronically operated switch that is able to control high current loads with a low current control circuit. There are two circuits inside a relay that are independent of each other, and often there is no physical connection between the two. The low current side is called the control circuit and the high current side is called the load circuit. The only “connection” is from electromagnetism. This is achieved by a coil of wire in the control circuit which becomes an electromagnet when that circuit is closed. This amount of current in the coil becomes the only load of that control circuit. (See above schematic) Common relays can have two sets of contacts in the high current side. One set remain “closed” and the other remain “open” when the relay is off. Energizing the relay reverses the position of the contacts. The terms N.C. (normally closed) and N.O. (normally open) are used to describe the position of the contacts. The relay above is a five terminal relay. More basic relays can have four terminals and only a N.O. set of contacts that close when the relay is energized. The magnetic field created in the control circuit coil then causes an armature to move the contacts to either open or close depending on the design. The high current is switched on through the durable set of contacts that provide longevity of the connection. Newer relays control the load with electronics and use transistors to switch control circuit. It is important to note that most relays use some sort of “voltage spike” suppression to control the inductive “kick” that is created when a relay coil is energized and then turned off. This kick could damage sensitive electronics elsewhere in the circuit if not controlled. The MD-4040 Relay Moduponent uses an internal resistor in parallel to the coil for spike suppression. For more information regarding testing relays go to the ConsuLab website under “Available Training”. The International Organization of Standardization (ISO) has designated relay connections to be commonly labeled as follows: • 85 & 86 Control circuit coil power and ground *(low amp) • 30 Battery 12V to operate load (high amp) • 87A N.C. contact of load circuit switch (not used) • 87 N.O. contact of load circuit switch, connects to 30 when control circuit coilis energized 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 LAMER 7/16'' PROF 0.080'' PLEXI 1/4" 0.281'' MODUPONENT MD-4040 12 VDC RELAY RELAIS 12 VCC 85 86 87 3087a consulab.com info@consulab.com 14 MD-4000-23_053344-91 Student assignments SA-3 NOTE: Remember that specific vehicle manufacturers can often change how terminals 85 & 86 are used to control and feed the relay coil. Terminal 85 or 86 can be the B+ and the other terminal would be the ground. It is imperative to always check the vehicle specific circuit schematic to properly identify the relay terminals and how they are used in the circuit. Relays are found in all types of transportation vehicles (cars, trucks, vans, off-road equipment, agriculture, trailers, motorcycles, airplanes and boats) and are used to control any high amperage draw component. Examples are lighting control, electric motors like fuel pumps, wipers, windows, seat motors, or horns and solenoids. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses protection • MD-4141 Optical Sensor circuit control • MD-4142 Transistors circuit control • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4111 Fan load operation • MD-4070 Light Bulbs load operation • MD-4114 Solenoid load operation • MD-4071 LED’s load operation (resistance required) Additional Equipment • Safety Glasses • DVOM consulab.com info@consulab.com 15 MD-4000-23_053344-91 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 Level 1A exercise: Build a relay control circuit to energize the relay control coil. ( Page 1 of 3 ) MD-4000 MD-4040 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 WIRING DIAGRAM #1 Level 1 A Basic Relay Control Operation Done Build a relay control circuit using the built-in variable power supply as source voltage. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram #1 Connect a red wire between the RED + of the power supply to terminal 86 of the MD-4040 Relay Moduponent™. Connect a black wire from terminal 85 of the MD-4040 Relay back to the BLACK – of the power supply. Control circuit is now ready to test. Turn power supply ON and listen for an audible “click” as the contacts close. Unplug any wire to listen for contacts to open, then plug the wire back in to hear a “click” as the contacts close again. consulab.com info@consulab.com 16 MD-4000-23_053344-91 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 Level 1B exercise: Build a relay load circuit that is controlled by the relay. Additional Moduponent required: MD-4114 ( Page 2 of 3 ) MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID MD-4000 MD-4040 MD-4114 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 WIRING DIAGRAM #2 Level 1 B Basic Relay Operated Circuit Done Building on Level 1A assignment, proceed with connecting a load circuit (Solenoid). DO THIS : Turn OFF the power supply. See wiring diagram #2 Connect another red wire between the RED + of the power supply to terminal 30 of the MD-4040 Relay (piggy backing wires is allowed). Connect another red wire between terminal 87 of the MD-4040 Relay to the RED terminal of MD-4114 Solenoid Moduponent™. Connect a black wire from the BLACK terminal of the MD-4114 Solenoid back to the BLACK (–) of the power supply (piggy backing wires is allowed). Based on lesson learned in the Level 1A assignment, discuss expected operation of MD-4114 Solenoid when power supply is switched from OFF to ON. Turn power supply OFF/ON to confirm relay operation. consulab.com info@consulab.com 17 MD-4000-23_053344-91 Student assignments SA-3 Answers SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 Answers ( Page 3 of 3 ) WIRING DIAGRAM #3 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4000 MD-4040 1 2 3 4 5 MD-4114 6 7 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 B Basic Relay Operated Circuit Done DO THIS : See wiring diagram #3 Based on lesson learned in the Level 1A&B exercise, discuss expected voltage readings at indicated circuit terminals (1-7) of both the control and load circuit, power supply ON, and w/85 ground connected or disconnected (CLOSED or OPEN) MD-4040 Relay Circuit terminal Closed Open 1. (87) 12 V 0 V 2. (87A) 0 V 12 V 3. (30) 12 V 12 V 4. (85) 0 V 12 V 5. (86) 12 V 12 V 6. (Solenoid RED) 12 V 0 V 7. (Solenoid BLACK) 0 V 0 V consulab.com info@consulab.com 18 MD-4000-23_053344-91 Student assignments SA-3 Answers SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 2 Answers Level 2A exercise: Practice measuring voltage drops over the various circuits of a relay-controlled device. Remember: Voltage drop (Vd) is the loss of voltage by passing current through a resistance. Additional Moduponents required: MD-4070 (optional), MD-4130 and MD-4090. ( Page 1 of 2 ) WIRING DIAGRAM #4 Level 2 A Voltage Drop Lessons (Vd) Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #4 Using the MD-4000 electrical trainer with the MD-4070 Bulbs and MD-4040 12 V DC Relay moduponents, build the electrical circuit represented by the provided wiring diagram 1 (MD-4130 Fuses & MD-4090 SPST switches moduponents are optional). Set the DVOM to V DC ONLY check Vd with power supply ON (and optional MD-4090 SPST switches CLOSED) 1 Practice Vd on power side of CONTROL circuit (+): Red lead on power supply RED +, Black lead on terminal 86 of the MD-4040 12 V DC Relay 1.0 mV 2 Practice Vd on ground side of CONTROL circuit (-): Red lead on terminal 85 of the MD-4040 12 V DC Relay, Black lead on power supply BLACK (-). 1.0 mV 3 Practice Vd of the CONTROL circuit LOAD: Red lead on terminal 86 of MD-4040 12 V DC Relay, Black lead on terminal 85 of MD-4040 12 V DC Relay. 12.0 mV 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4000 MD-4070 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 consulab.com info@consulab.com 19 MD-4000-23_053344-91 Student assignments SA-3 Answers SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 2 Answers ( Page 2 of 2 ) WIRING DIAGRAM #5 Level 2 A Voltage Drop Lessons (Vd) Done 4 Practice Vd on power side of LOAD circuit (+): Red lead on power supply RED +, Black lead on terminal 30 of the MD-4040 12 V DC Relay. 19.0 mV 5 Practice Vd on ground side of LOAD circuit (-): Red lead on BLACK – terminal of the L1 MD-4070 Bulb, Black lead on power supply (-). 19.0 mV 6 Practice Vd over the LOAD: Red lead on RED H terminal of the MD-4070 Bulb, Black lead on BLACK - of the MD-4070 Bulb. 11.9 mV 7 Where is most of the voltage dropped in each circuit? Over that circuits LOAD 8 Using industry standard symbols, on a piece of paper draw a wiring diagram of this circuit using a relay to control a light bulb. ( Assess student wiring diagram ) 9 Are there any parts of this working circuit that have NOT had Vd measured? Yes - 30 to 87 & 87 to L1 (H) 10 If so, use a color highlighter to mark the wiring diagram NOTE: 30 to 87A to L1 (L) is not a Vd due to no current passing with relay ON. Level 2 B Current Draw Lesson Done Level 2B exercise: Practice measuring circuit amperage of the various circuits in a relay-controlled device. DO THIS: Set the DVOM to AMPs and switch meter leads to correctly measure current. 11 Open the relay CONTROL circuit and measure amperage: 0.1 A 12 Open the relay LOAD circuit and measure amperage: 2.0 A (light on HIGH) NOTE: The part of the circuit NOT asked to check amperage. 0 or 0.5 A (bulb OFF or LOW) See wiring diagram #5 Practice this entire exercise with different moduponent loads (fuses, switches, fan, solenoid, etc). SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES MD-4130MD-4000 MD-4090 MD-4040 MD-4070 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 consulab.com info@consulab.com 20 MD-4000-23_053344-91 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor Electrical Symbol Theory of operation A VR sensor is a passive analog sensor that can be used to convert mechanical motion to electrical energy without any direct contact when positioned near a turning rotor, gear, shaft or other moving device. Passive sensors have an internal magnet and coil of wire located within the sensor that becomes a transducer used to measure changes in magnetic reluctance. Located near the sensor is a “trigger wheel” or often called “tone wheel” which when rotated, the teeth on the wheel concentrate the magnetic field in the sensor which results in the generation of a high and low amplitude signal output as the tone wheel rotates. Both the frequency and amplitude of the sensor signal changes with speed of the reluctor wheel. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) VARIABLE RELUCTANCE SENSOR CAPTEUR À RÉLUCTANCE VARIABLE SIGNAL RPM MODUPONENT MD-4050 REVD MD-4000 Moduponent: MD-4050 Variable Reluctance Sensor Electrical Symbol: Theory of operation: A VR sensor is a passive analog sensor that can be used to convert mechanical motion to electrical energy without any direct contact when positioned near a turning rotor, gear, shaft or other moving device. Passive sensors have an internal magnet and coil of wire located within the sensor that becomes a transducer used to measure changes in magnetic reluctance. Located near the sensor is a “trigger wheel” or often called “tone wheel” which when rotated, the teeth on the wheel concentrate the magnetic field in the sensor which results in the generation of a high and low amplitude signal output as the tone wheel rotates. Both the frequency and amplitude of the sensor signal changes with speed of the reluctor wheel. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) MAGNET COIL SIG. SIG. PASSIVE SENSOR consulab.com info@consulab.com 21 MD-4000-23_053344-91 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor — Level 1 Level 1 exercise: Generate and measure the AC signal voltage generated by a variable reluctance sensor. ( Page 1 of 2 ) VARIABLE RELUCTANCE SENSOR CAPTEUR À RÉLUCTANCE VARIABLE SIGNAL RPM MODUPONENT MD-4050 REVD MD-4000 MD-4050 SET METER: V AC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + WIRING DIAGRAM #1 Level 1 Setting Up To Measure A VR Sensor Signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4050 VR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4050 VR Sensor moduponent motor control back to the BLACK – of the power supply. Connect the DVOM black lead to either YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent. Connect the DVOM red lead to the remaining YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent. Set the DVOM to V AC *NOTE: this sensor generates an AC Voltage signal. Follow the instructions on next page for motor control dial settings and record measurements. consulab.com info@consulab.com 22 MD-4000-23_053344-91 Student assignments SA-4 Answers SA-4 MD-4050 Variable Reluctance Sensor — Level 1 Answers ( Page 2 of 2 ) Level 1 Measuring a VR sensor generated signal voltage Done DO THIS : 1 Set motor control dial to the fifth line marking. Record voltage at the signal terminals here: 0.8 V AC Set motor control dial to the sixth line marking. Record voltage at the signal terminals here: 1.3 V AC Set motor control dial to the seventh line marking. Record voltage at the signal terminals here: 1.8 V AC Set motor control dial to the eighth line marking. Record voltage at the signal terminals here: 2,5 V AC Set control dial to FULL ON. Record voltage at the signal terminals here: 3.5 V AC 2 With knowledge of Variable Reluctance, what is happening here? Analog, passive sensor that converts mechanical motion to electrical energy without any direct contact. 3 How is this technology used in an automobile today? CKP and CMP sensors, transmission shaft speed sensors. 4 Proceed to SA4 Level 2 to actually see this happen using an oscilloscope. consulab.com info@consulab.com 23 MD-4000-23_053344-91 Student assignments SA-4 Answers SA-4 MD-4050 Variable Reluctance Sensor — Level 2 Answers NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a variable reluctance sensor signal using an oscilloscope to capture a pattern. Level 2 Setting up to measure a VR sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4050 VR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4050 VR Sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to either YELLOW terminal of the MD-4050 VR Sensor moduponent Connect the BLACK lead from the oscilloscope* to the remaining YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent Level 2 Observing a VR sensor generated oscilloscope signal Done DO THIS : 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time: 5 μs per div Trigger: Trigger: 3.0 V 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. See capture : consulab.com info@consulab.com 24 MD-4000-23_053344-91 Student assignments SA-4 Answers Level 2 Observing a VR sensor generated oscilloscope signal Done 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. See capture : 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. See capture : consulab.com info@consulab.com 25 MD-4000-23_053344-91 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor Electrical Symbol Theory of operation A Hall Effect sensor is an active 3 wire sensor that requires a 5-volt reference voltage to operate and consists basically of a thin piece of a rectangular p-type semiconductor material passing a continuous current through itself. This sensor also requires some type of trigger or tone wheel to operate. Depending on the sensor design, the presence of a tone wheel rotating by a Hall Effect sensor causes either a high or a low signal voltage depending on whether the peak or valley is passing by the sensor. Wheel speed sensors, crankshaft and camshaft position sensors are just a few automotive applications. Safety and Safeguards • Requires a 5-volt protected reference voltage supplied. • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) +5V GNDSIG RPM HALL EFFECT SENSOR CAPTEUR À EFFET HALL MODUPONENT MD-4051 REVC PERMANENT MAGNET HALL EFFECT SENSOR consulab.com info@consulab.com 26 MD-4000-23_053344-91 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor — Level 1 Level 1 exercise: Test a Hall Effect sensor with a DVOM. Additional Moduponent required: MD-4002. ( Page 1 of 2 ) +5V GNDSIG RPM HALL EFFECT SENSOR CAPTEUR À EFFET HALL MODUPONENT MD-4051 REVC MD-4000 53071 MD-4051 HALL EFFECT SENSOR LEVEL 1 MD-4002 MD-4051 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT WIRING DIAGRAM #1 Level 1 Setting Up To Measure Hall Effect Sensor Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4051 Hall Effect sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4051 Hall Effect sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. consulab.com info@consulab.com 27 MD-4000-23_053344-91 Student assignments SA-5 Answers Level 1 Measuring a Hall Effect sensor signal voltage Done Verify 5V reference is at the 5V terminal of the MD-4051 Hall Effect sensor moduponent. With your hand, slowly rotate the reluctor wheel past the sensor from PEAK to valley, holding at each position in order to observe voltage signal. 1 At the WHITE SIG terminal, record the voltage measured when the tone wheel passes: PEAK: 5 V DC VALLEY: 0 V DC 2 How is a Hall Effect Sensor used in an automobile today? IGN system speed and position. SA-5 MD-4051 Hall Effect Sensor — Level 1 Answers ( Page 2 of 2 ) consulab.com info@consulab.com 28 MD-4000-23_053344-91 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a Hall Effect Signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) Level 2 Setting up to measure a Hall sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4051 Hall Effect sensor moduponent Connect a black wire from the BLACK GND terminal of the MD-4051 Hall Effect sensor moduponent back to the BLACK – of the power supply Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4051 Hall Effect sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4051 Hall Effect sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope to the White SIG terminal of the MD-4051 Hall Effect sensor moduponent. Connect the BLACK lead from the oscilloscope to the BLACK – of the power supply. Follow the instructions below for motor control dial settings and record measurements. consulab.com info@consulab.com 29 MD-4000-23_053344-91 Student assignments SA-5 Answers Level 2 Observing a HALL EFFECT sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time: 10 μs per div Trigger: 5.0 V 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. See capture : 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. See capture : SA-5 MD-4051 Hall Effect Sensor — Level 2 Answers ( Page 2 of 2 ) consulab.com info@consulab.com 30 MD-4000-23_053344-91 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) Electrical Symbol Theory of operation A Thermistor is a type of resistor that changes its resistance based on its temperature. Unlike a resistor, an NTC thermistor has the property where the electrical resistance (Ω) DECREASES as temperature INCREASES and can be measured with an ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) or provide an ECM with a temperature value. The operating range is non-linear (not a straight line) meaning that is achieves high precision within a limited temperature range and is used in climate control applications (HVAC) as well as engine and transmission temperature monitoring. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do NOT heat thermistor with an open flame or a heat gun! • Carefully use body temperature or ice. • Not polarity sensitive. • Normally receives a 5V reference value. • NOT a switch of a load but can control the BASE of a transistor. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4002 5V Regulator circuit control • MD-4011 Resistors circuit control • MD-4040 Relay circuit control • MD-4142 Transistors circuit control • MD-4111 Cooling Fan load operation NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T LAMER 7/16'' PROF 0.08'' PLEXI 1/4" 0.281'' MD-4052 MODUPONENT THERMISTOR THERMISTANCE T NTC 10KΩ @ 25 °C 5.215 3.222 -T Additional Equipment • Safety Glasses • DVOM • Ice • Thermometer MD-4000 MD-4062: redraw this for copyright purposes W MD-4058 * redraw this for copyright purposes consulab.com info@consulab.com 31 MD-4000-23_053344-91 Student assignments SA-6 Answers SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 1 Answers Level 1 exercise: Observe the operation of an NTC thermistor by measuring electrical resistance at different temperatures. WIRING DIAGRAM #1 NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T MD-4052 SET METER: Ohms Level 1 Basic Thermistor Control Operation Done Measure thermistor resistances at different temperatures. DO THIS : See wiring diagram #1 Connect the DVOM red lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Connect the DVOM black lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Set the DVOM to Ohms (Ω). 1 Measure resistance at room temperature: 10 kΩ @ 75 ºF (25 ºC) 2 Using ice, cool the MD-4052 NTC Thermistor and measure the resistance at a lower temperature – how high can resistance be increased? 20 kΩ with ice 3 Using just body heat, warm up the MD-4052 NTC Thermistor and measure resistance at a higher temperature – how low can resistance be decreased? 8 kΩ @ body temperature consulab.com info@consulab.com 32 MD-4000-23_053344-91 Student assignments SA-6 Answers SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) Answers WIRING DIAGRAM #3 ECT 5V 10KΩ SENSOR GROUND SIGNAL RESISTORS RÉSISTANCES 150Ω - 1W 220Ω - 1W 470Ω - 1W 100Ω - 1W 330Ω - 1W 4.7kΩ - 1W 10kΩ - 1W 100kΩ - 1W 1kΩ - 1W 47kΩ - 1W MODUPONENT MD-4011 REVB NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 MD-4052 MD-4002 SET METER: V DC MD-4011 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + consulab.com info@consulab.com 33 MD-4000-23_053344-91 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 2 Level 2 exercise : Simulate a typical automotive engine coolant temperature (ECT) circuit using the MD-4002 5 Volt Regulator and MD-4052 NTC Thermistor to teach the understanding of reference voltage for diagnostics, while also introducing hidden resistance circuit characteristics. Additional Moduponent required but not included in kit: MD-4011 Resistors (10) NOTE: this exercise requires a 10kΩ resistor not included in the MD-4010 but available on the optional MD-4011 Resistors moduponent (or a single 10kΩ / 1W resistor will also work if available). ( Page 1 of 2 ) WIRING DIAGRAM #2 NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT SET METER: V DC MD-4052 MD-4002MD-4000 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 2 Build a 5 Volt reference ECT style circuit Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram #2 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to either YELLOW terminal of the MD-4052 NTC Thermistor. Connect a black wire from the other YELLOW terminal of the MD-4052 NTC Thermistor back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead piggy-back to the 5V red wire connected the MD-4052 NTC Thermistor, simulating back-probing an engine harness connector. Set the DVOM to V DC. consulab.com info@consulab.com 34 MD-4000-23_053344-91 Student assignments SA-6 Answers SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 2 Answers ( Page 2 of 2 ) Level 2 Build a 5 Volt reference ECT style circuit Done 1 What is the voltage measured? 0.5 V DC (Plugged IN) 2 On an actual automobile, if any 5V referenced sensor is “back-probed” while the harness is still connected, what should the voltage measure? 2.4V-2.8V (plugged in @ 68 ºF / 20 ºC) (see sensor specification chart provided below). 3 Now, with the DVOM still connected to the 5V reference wire, unplug it from the MD-4052 NTC Thermistor. What is the voltage measured? 5.0 V DC (Unplugged) 4 In an actual automobile, if any 5V referenced sensor harness is “unplugged”, what will the voltage at the sensor harness measure? 5.0 V DC 5 Why does this circuit not work like it does on an automobile? This circuit does not have the extra circuit protection resistance built into the ECU which divides voltage. 6 Ask for wiring diagram #3 from MD- 4000-22-96 Look at wiring diagram #3 provided and correct the circuit built to make it work like an actual automobile and explain below what had to be done and why? Simulate the built in ECU resistance *NOTE: wiring diagram # 3 is only provided to the instructor – assess student circuit build to this wiring diagram #3. 7 What does Negative Temperature Coefficient mean? Low Temperature = Higher Ω & Vd High Temperature = Low Ω & Vd Ignition Switch ON Sensor Specification Chart TEMPERATURE (Cº / Fº) OUTPUT VOLTAGE (V) 0º / 32º 3.3 − 3.7 V 20º / 68º 2.4 − 2.8 V 40º /104º 1.6 − 2.0 V 80º /176º 0.5 − -.9 V INSTRUCTOR NOTE: ECU internal resistor and resistance is “hidden” when circuit is open! Resistance in a circuit will not drop voltage if there is no current flow. This exercise will help students remember how to test reference voltage at any 5 V sensor. consulab.com info@consulab.com 35 MD-4000-23_053344-91 Student assignments SA-7 SA-7 MD-4053 MAP Sensor Electrical Symbol Theory of operation A MAP sensor is a piezoelectric type sensor where electrical resistance changes when pressure is applied to a silicone crystal, also known as a semiconductor. As internal intake manifold pressure/vacuum changes with throttle position, the MAP sensor is exposed to those changes. The electrical resistance of the sensor reacts to those changes. A 5-volt electrical reference value is applied to the sensor and this value then passes through the changing resistance of the sensor only allowing a “signal” voltage to return to the ECU. Basically, a variable voltage drop occurs over the MAP sensor dependent on manifold pressures. A MAP sensor that reads 1 or 2 volts at idle may read 4.5 volts to 5 volts at wide open throttle. Discuss the concept of throttle position in relation to manifold vacuum / pressure: • Engine OFF, the absolute pressure in the manifold equals atmospheric pressure, or 14.7 psi. • Engine ON, the vacuum in the manifold reflects throttle position. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4002 5-volt reference • MD-4054 TPS Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) MAP SENSOR CAPTEUR MAP 5V SIG GND MODUPONENT MD-4053 REVC MD-4000 Moduponent: MD-4053 MAP sensor Electrical Symbol: Theory of operation: A MAP sensor is a Piezoelectric type sensor where electrical resistance changes when pressure is applied to a silicone crystal, also known as a semiconductor. As internal intake manifold pressure/vacuum changes with throttle position, the MAP sensor is exposed to those changes. The electrical resistance of the sensor reacts to those changes. A 5-volt electrical reference value is applied to the sensor and this value then passes through the changing resistance of the sensor only allowing a “signal” voltage to return to the ECU. Basically, a variable voltage drop occurs over the MAP sensor dependent on manifold pressures. A MAP sensor that reads 1 or 2 volts at idle may read 4.5 volts to 5 volts at wide open throttle Discuss the concept of throttle position in relation to manifold vacuum / pressure Engine OFF, the absolute pressure in the manifold equals atmospheric pressure, or 14.7 psi. Engine ON, the vacuum in the manifold reflects throttle position Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4002 5 volt reference MD-4054 TPS Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 36 MD-4000-23_053344-91 Student assignments SA-7 SA-7 MD-4053 MAP Sensor — Level 1 Level 1 exercise: Measure a MAP sensor signal voltage under different pressure/vacuum conditions. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) MAP SENSOR CAPTEUR MAP 5V SIG GND MODUPONENT MD-4053 REVC SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 SET METER: V DC MD-4002 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4053 WIRING DIAGRAM #1 Level 1 Setting Up To Measure Map Sensor Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4053 MAP sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4053 MAP sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4053 MAP sensor moduponent Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 37 MD-4000-23_053344-91 Student assignments SA-7 Answers SA-7 MD-4053 MAP Sensor — Level 1 Answers ( Page 2 of 2 ) Level 1 Measuring MAP sensor signal voltage Done DO THIS : 1 Push the provided syringe plunger all the way in prior to attaching it to the MD-4053 MAP sensor moduponent port. Verify the plunger to sensor seal is good with no leaks. Record voltage measured at the BLUE SIG terminal here: 4.0 V DC 2 Pull on the plunger to about ½ stroke of its travel. While holding the plunger, record voltage measured at the BLUE SIG terminal here: 2.3 V DC 3 Pull on the plunger to FULL stroke of its travel, being careful not to pull the plunger out. While holding the plunger, record voltage measured at the BLUE SIG terminal here: 1.5 V DC 4 How is a MAP sensor used in an automobile today? MAP provides instantaneous intake manifold pressure/vacuum information to the ECU. 1-1.5 V @ idle (high suction using syringe), 4.5 V @ WOT (low to no suction using syringe). consulab.com info@consulab.com 38 MD-4000-23_053344-91 Student assignments SA-7 Answers SA-7 MD-4053 MAP Sensor — Level 2 Answers NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a MAP sensor signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 Level 2 Setting up an oscilloscope to observe a MAP sensor signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5VDC Output moduponent . Connect a black wire from the BLACK GND terminal of the MD-4002 5VDC Output moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4053 MAP sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4053 MAP sensor moduponent back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to the BLUE SIG terminal of the moduponent . Connect the oscilloscope* black lead to the BLACK – of the power supply. Adjust the oscilloscope* settings until a pattern can be observed * Level 2 Observing a MAP sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: 2 V per div Time: 5 μs per div Trigger: 5.0 V 2 Push the provided syringe plunger all the way in prior to attaching it to the MD-4053 MAP sensor moduponent port. Verify the plunger to sensor seal is good with no leaks. On a separate sheet of paper, draw and label the pattern observed. See capture : consulab.com info@consulab.com 39 MD-4000-23_053344-91 Student assignments SA-7 Answers Level 2 Observing a MAP sensor generated oscilloscope signal Done 3 Pull on the plunger to about ½ stroke of its travel. On a sheet of paper, draw and label the pattern observed. See capture : 4 Pull on the plunger to about FULL stroke of its travel. On the same sheet of paper, draw and label the pattern observed. See capture : consulab.com info@consulab.com 40 MD-4000-23_053344-91 Student assignments SA-8 SA-8 MD-4054 TP Sensor Electrical Symbol Theory of operation A throttle position sensor (TPS) is used to monitor the throttle plate position in an internal combustion engine. TPS is usually located on the throttle shaft so that it can directly monitor its position. The sensor signal is used by the ECU as an input to its control system, usually comparing this signal to the signals from the MAP sensor, MAF sensor, CKP & CMP sensors along with other sensors to communicate engine load. A constant voltage output of around 0.18 V with the throttle at its idle position. As the throttle moves from its idle position, the output progressively increases with increasing throttle opening. When the throttle is fully open position, the output is around 4.86 V. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4002 5-volt reference • MD-4053 MAP sensor Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) TP SENSOR CAPTEUR TP MD-4054 MODUPONENT REVD MD-4000 Moduponent: MD-4054 Mechanical TPS Electrical Symbol: Theory of operation: A throttle position sensor (TPS) is used to monitor the throttle plate position in an internal combustion engine. TPS is usually located on the throttle shaft so that it can directly monitor its position. The sensor signal is used by the ECU as an input to its control system, usually comparing this signal to the signals from the MAP sensor, MAF sensor, CKP & CMP sensors along with other sensors to communicate engine load. A constant voltage output of around 0.18 V with the throttle at its idle position. As the throttle moves from its idle position, the output progressively increases with increasing throttle opening. When the throttle is fully open position, the output is around 4.86 V. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4002 5 volt reference MD-4053 MAP Sensor Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 41 MD-4000-23_053344-91 Student assignments SA-8 SA-8 MD-4054 TP Sensor — Level 1 Level 1 exercise: Measure the voltage signal from a mechanical throttle position sensor under different throttle positions. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) WIRING DIAGRAM #1 TP SENSOR CAPTEUR TP MD-4054 MODUPONENT REVD SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 MD-4002 SET METER: V DC MD-4054 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Measure TPS Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4054 TP Sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4054 TP Sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4054 TP sensor. Set the DVOM to V DC. consulab.com info@consulab.com 42 MD-4000-23_053344-91 Student assignments SA-8 Answers SA-8 MD-4054 TP Sensor — Level 1 Answers ( Page 2 of 2 ) Level 1 Measuring TPS voltage at different positions Done DO THIS : 1 Without moving the TPS at all, or “at rest”. Record voltage measured at the BLUE SIG terminal here: 0.2 VDC @ 75 ºF (25 ºC) 2 Moving the sensor to FULL sweep, or “wide open throttle” (WOT). Record voltage measured at the BLUE SIG terminal here: 4.7 VDC with ice 3 How does the voltage change in between at rest and WOT? Smooth transition. 4 What is this signal telling the ECU? Informs the ECU the amount of throttle you are requesting from the engine and is used to calculate fuel air ratios. consulab.com info@consulab.com 43 MD-4000-23_053344-91 Student assignments SA-8 Answers SA-8 MD-4054 TP Sensor — Level 2 Answers NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a TPS sweep signal using an oscilloscope to capture a pattern. Level 2 Setting up an oscilloscope to observe a TPS signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4054 TPS moduponent. Connect a black wire from the BLACK terminal of the MD-4054 TPS moduponent back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to the BLUE SIG terminal of the MD-4054 TPS moduponent. Connect the oscilloscope* black lead to the BLACK – of the power supply. Adjust the oscilloscope* settings until a pattern can be observed * Level 2 Observing a TPs generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: 2 V per div Time: 1 s per div Trigger: Not used 2 On a separate sheet of paper, draw the pattern observed. See capture : Now move the TPS control clockwise and then release it slowly (sweeping) while observing the changes in the oscilloscope pattern 3 Describe the pattern changes observed and why the pattern changes: Voltage slopes up and down over time, reflecting throttle movement, illustrating a smooth transition of throttle operation (or not, if there was a “glitch” in the sweep). 4 How can this pattern be more helpful than a DVOM in diagnosing a TPS issue? The fast “refresh” rate of an oscilloscope pattern can allow minor “glitches” in the TPS sweeping action to be virtually seen. consulab.com info@consulab.com 44 MD-4000-23_053344-91 Student assignments SA-9 SA-9 MD-4055 Piezo Knock Sensor Electrical Symbol Theory of operation A knock sensor is a type of a Piezoelectric sensor, used to sense any unusual vibration frequencies caused by engine detonation. The internal sensor is constructed out of either a ceramic or crystal material that generates an electric “signal” when subjected to pressure or vibration. It’s like an engine microphone! The prefix piezo- is Greek for ‘press’ or ‘squeeze’. Safety and Safeguards • Do NOT damage by tapping too hard while observing the signal created. • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) PIEZO SENSOR CAPTEUR PIEZO MD-4055 MODUPONENT REVC MD-4000 Moduponent: MD-4055 Piezoelectric Sensor (KNOCK sensor) Electrical Symbol: Theory of operation: A knock sensor is a type of a Piezoelectric sensor, used to sense any unusual vibration frequencies caused by engine detonation. The internal sensor is constructed out of either a ceramic or crystal material that generates an electric “signal” when subjected to pressure or vibration. It’s like an engine microphone! The prefix piezo- is Greek for 'press' or 'squeeze'. Safety and Safeguards: Do NOT damage by tapping too hard while observing the signal created. 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Additional equipment: Safety Glasses DVOM Oscilloscope consulab.com info@consulab.com 45 MD-4000-23_053344-91 Student assignments SA-9 Answers SA-9 MD-4055 Piezo Sensor — Level 1 Answers Level 1 exercise: Demonstrate and measure the electrical signal produced by a Piezo electric sensor with signal processing. WIRING DIAGRAM #1 PIEZO SENSOR CAPTEUR PIEZO MD-4055 MODUPONENT REVC MD-4055 SET METER: V AC Level 1 Setting Up To Measure PIEZO Signal Done DO THIS : See wiring diagram #1 Connect the DVOM black lead to one of the YELLOW terminals at the bottom of the MD-4055 Piezo Sensor moduponent. Connect the DVOM red lead to the remaining YELLOW terminal of the MD-4055 Piezo Sensor moduponent. Set the DVOM to V AC * NOTE: this sensor generates an AC voltage. Follow the instructions below and record measurements. Level 1 Measuring Piezo generated voltage Done 1 With the DVOM connected as instructed above, LIGHTLY tap on the bolt head securing the MD-4055 Piezo Sensor to the moduponent panel. Record voltage on the DVOM here: 0.03 V AC 2 For comparison, with the DVOM connected as instructed above, switch the DVOM to V DC and again, LIGHTLY tap on the bolt head securing the MD-4055 Piezo Sensor to the moduponent panel. Record voltage on the DVOM here: 0 V DC 3 What exactly is happening when the sensor is tapped on? Piezoelectric effect changes pressure, acceleration, strain or force by converting them into an electrical charge. Piezo crystals are used to detect engine pre-ignition and adjust timing to prevent damage. 4 Proceed to SA9 Level 2 to actually see this happen using an oscilloscope. consulab.com info@consulab.com 46 MD-4000-23_053344-91 Student assignments SA-9 Answers SA-9 MD-4055 Piezo Sensor — Level 2 Answers NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a vibration induced signal using an oscilloscope to capture a pattern. Level 2 Setting Up To Measure PIEZO Signal Done DO THIS : Connect one lead from an oscilloscope to one of the YELLOW terminals of the MD-4055 Piezo Sensor moduponent. Connect the oscilloscope* black lead to the remaining YELLOW terminals of the MD-4055 Piezo Sensor moduponent. Adjust the oscilloscope* settings* Level 2 Observing a PIEZO generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: 1 V per div Time: 200 ms per div Trigger: Not used Gently “TAP” on the bolt of the sensor until a pattern is observed. 2 On a separate sheet of paper, draw the pattern observed. See capture : consulab.com info@consulab.com 47 MD-4000-23_053344-91 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor Electrical Symbol Theory of operation An MR sensor is an active 2 wire sensor with a redundant ground terminal for testing. This sensor requires a 5 volt reference voltage to operate and has an internal magnet. Active sensors also require some type of trigger or tone wheel to operate. The tone wheel can be of two types based on the specific design of the sensor. The advantage of this type sensor is that it is less affected by increasing air gaps and can provide a signal at near 0 RPM. Since the sensor can detect the slightest beginning motion, it is used in steering angle position sensors with varying spaced triggers as well as hill assist detection. MR sensors today usually have two wires connected to them, but a few may have three with a GND wire sometimes used. Technicians today often look at an MR sensor with two wires and mistakenly think it is a passive inductive AC generator. If testing procedures for a passive sensor are used by technicians, they will get what they may think are improper results and may condemn a perfectly good active MR sensor. The important difference is that the MR sensor will have a supply voltage and a ground circuit, where a passive sensor usually does not have any voltage on the two wires, with the exception being those passive sensors that use a small bias voltage for diagnostics. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) RPM MAGNETIC RESISTIVE ABS SENSOR CAPTEUR ABS MAGNÉTORÉSISTIF 5V GNDSIG MODUPONENT MD-4057 REVC MD-4000 Moduponent: MD-4057 Magneto-Resistive Sensor Electrical Symbol: Theory of operation: An MR sensor is an active 2 wire sensor with a redundant ground terminal for testing. This sensor requires a 5 volt reference voltage to operate and has an internal magnet. Active sensors also require some type of trigger or tone wheel to operate. The tone wheel can be of two types based on the specific design of the sensor. The advantage of this type sensor is that it is less affected by increasing air gaps and can provide a signal at near 0 RPM. Since the sensor can detect the slightest beginning motion, it is used in steering angle position sensors with varying spaced triggers as well as hill assist detection. MR sensors today usually have two wires connected to them, but a few may have three with a GND wire sometimes used. Technicians today often look at an MR sensor with two wires and mistakenly think it is a passive inductive AC generator. If testing procedures for a passive sensor are used by technicians, they will get what they may think are improper results and may condemn a perfectly good active MR sensor. The important difference is that the MR sensor will have a supply voltage and a ground circuit, where a passive sensor usually does not have any voltage on the two wires, with the exception being those passive sensors that use a small bias voltage for diagnostics. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) MAGNET MR SENSOR POWER IN SIG. OUT GND (OPT.) CIRCUIT BOARD MR CIRCUITRY consulab.com info@consulab.com 48 MD-4000-23_053344-91 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor — Level 1 Level 1 exercise: Test an MR sensor with a DVOM. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) WIRING DIAGRAM #1 RPM MAGNETIC RESISTIVE ABS SENSOR CAPTEUR ABS MAGNÉTORÉSISTIF 5V GNDSIG MODUPONENT MD-4057 REVC SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 MD-4057 SET METER: V DC MD-4000 MD-4057 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Measure MR Sensor Signal Voltage Done NOTE: A thorough understanding of MR sensors is needed to accurately test one. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4057 MR Sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4057 MR Sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4057 MR Sensor moduponent Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 49 MD-4000-23_053344-91 Student assignments SA-10 Answers SA-10 MD-4057 Magnetic Resistive Sensor — Level 1 Answers ( Page 2 of 2 ) Level 1 Measuring a MR sensor signal voltage Done DO THIS : 1 Verify 5V reference is at the 5V terminal of the MD-4057 MR Sensor moduponent. With your hand, slowly rotate the reluctor wheel from “peak” to “valley”, holding at each position in order to observe voltage signal. At the BLUE SIG ter minal, record the voltage measured when the tone wheel passes: PEAK: 1.3 V DC VALLEY: 0.6 V DC 2 How is an MR Sensor used in an automobile today? Any place a very accurate speed or position signal is required, including detecting both directions of rotation. consulab.com info@consulab.com 50 MD-4000-23_053344-91 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a magneto-resistive sensor signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) Level 2 Setting up to measure a MR sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5VDC Output moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5VDC Output moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4057 MR sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4057 MR sensor moduponent back to the BLACK – of the power supply. Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4057 MR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4057 MR Sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope to the BLUE SIG terminal of the MD-4057 MR Sensor moduponent. Connect the BLACK lead from the oscilloscope to the BLACK – of the power supply. Follow the instructions below for motor control dial settings and record measurements consulab.com info@consulab.com 51 MD-4000-23_053344-91 Student assignments SA-10 Answers Level 2 Observing a MR sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time:10 μs per div Trigger: 1.4 V 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. See capture : 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. See capture : SA-10 MD-4057 Magnetic Resistive Sensor — Level 2 Answers ( Page 2 of 2 ) consulab.com info@consulab.com 52 MD-4000-23_053344-91 Student assignments SA-11 SA-11 MD-4112 Stepper Motor Electrical Symbol Theory of operation A stepper motor is a brushless DC motor that rotates in steps. This is very useful because it can be precisely positioned. A stepper motor consists of a rotor that is generally a permanent magnet surrounded by windings of a stator. By energizing one or more of the stator phases, a magnetic field is generated by the current flowing in the coil causing the rotor to align with this field. As we activate the windings step by step in a particular order and let a current flow through them, they will magnetize the stator which create electromagnetic poles respectively causing the rotor (motor) to turn in increments. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) IN A IN B IN C IN D BAT GND MD-4112 MODUPONENT STEPPER MOTOR MOTEUR PAS À PAS REVD MD-4000 Moduponent: MD-4112 Stepper Motor Electrical Symbol: Theory of operation: A stepper motor is a brushless DC motor that rotates in steps. This is very useful because it can be precisely positioned. A stepper motor consists of a rotor that is generally a permanent magnet surrounded by windings of a stator. By energizing one or more of the stator phases, a magnetic field is generated by the current flowing in the coil causing the rotor to align with this field. As we activate the windings step by step in a particular order and let a current flow through them, they will magnetize the stator which create electromagnetic poles respectively causing the rotor (motor) to turn in increments. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) STATOR WINDING N S N S S N ROTOR STATOR consulab.com info@consulab.com 53 MD-4000-23_053344-91 Student assignments SA-11 SA-11 MD-4112 Stepper Motor — Level 1 Level 1 exercise: Demonstrate the various drive modes of a 4 coil / 6 pole stepper motor. ( Page 1 of 2 ) WIRING DIAGRAM #1 IN A IN B IN C IN D BAT GND MD-4112 MODUPONENT STEPPER MOTOR MOTEUR PAS À PAS REVD MD-4000 MD-4112 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Operate A Stepper Motor Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4112 Stepper Motor moduponent. Connect a black wire from the BLACK GND terminal at the bottom of the MD-4112 Stepper Motor moduponent back to the BLACK – of the power supply. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 54 MD-4000-23_053344-91 Student assignments SA-11 Answers Level 1 Demonstrating Stepper Motor Operation Done DO THIS: 1 to 1 phase operation (low power needed, low torque output) Press the moduponent YELLOW highlighted buttons in order by the steps listed. 1 IN AIN A IN B IN C IN D 2 IN A IN B IN CIN C IN D 3 IN A IN BIN B IN C IN D 4 IN A IN B IN C IN DIN D 5 IN AIN A IN B IN C IN D 6 Which direction did the stepper motor turn? Clockwise 7 Will the reverse pattern turn the motor in the opposite direction? YES DO THIS: 2 to 2 phase operation (higher power needed, higher torque output) Press the moduponent YELLOW highlighted buttons in order by the steps listed. 1 IN AIN A IN B IN C IN DIN D 2 IN AIN A IN B IN CIN C IN D 3 IN A IN BIN B IN CIN C IN D 4 IN A IN BIN B IN C IN DIN D 5 IN AIN A IN B IN C IN DIN D 6 Which direction did the stepper motor turn? Clockwise 7 Will the reverse pattern turn the motor in the opposite direction? YES SA-11 MD-4112 Stepper Motor — Level 1 Answers ( Page 2 of 2 ) consulab.com info@consulab.com 55 MD-4000-23_053344-91 Student assignments SA-12 SA-12 MD-4114 Solenoid Electrical Symbol Theory of operation Solenoid is the generic term for a coil of wire used as an electromagnet that converts electrical energy to mechanical energy or motion. In other words, an electromagnet is used to cause something else to physically move. A solenoid creates a magnetic field from electric current and uses that magnetic field to create linear motion – to physically move an object (pintle, armature, plunger, linkage, etc). Solenoids are commonly used as: • Fuel injectors • Starter motor drive gear control • Emission control – purge solenoids • Automatic Transmissions – shift solenoids • Electric door and trunk locks. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Polarity should be observed but cannot damage a solenoid if reversed. • This Moduponent™ will not work correctly without a switch, the power supply current ramp is not instant enough to operate solenoid (Level 3 lesson). • Do not leave this trainer unattended with the power ON Companion ModuponentsTM • MD-4130 Fuses protection • MD-4040 Relay circuit control • MD-4142 Transistors circuit control • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4141 Optical Sensor circuit control • MD-4071 LED’s circuit operation confirmation MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID Additional Equipment • Safety Glasses • DVOM PLEX 1/4" 5.215 3.222 LAMER 7/16'' PROF 0.080''0.281'' X2 SOLENOÏDE MD-4114 SOLENOID MODUPONENT consulab.com info@consulab.com 56 MD-4000-23_053344-91 Student assignments SA-12 SA-12 MD-4114 Solenoid — Level 1 Level 1 exercise: Build a simple circuit to energize and observe solenoid operation. Additional Moduponent required: MD-4090 WIRING DIAGRAM #1 SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID MD-4000 MD-4090MD-4114 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Basic Solenoid Operation Done Build a solenoid circuit using the built-in variable power supply as source voltage. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply, Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the any terminal of the MD-4090 SPST Switch Moduponent™. Connect a red wire between the remaining terminal of the MD-4090 SPST Switch to the RED terminal of the MD-4114 Solenoid Moduponent™. Connect a black wire from the black terminal of the MD-4114 Solenoid back to the BLACK – of the power supply. Circuit is now ready to test. Turn MD-4090 SPST Switch ON/OFF and watch for motion of the solenoid plunger. consulab.com info@consulab.com 57 MD-4000-23_053344-91 Student assignments SA-12 Answers SA-12 MD-4114 Solenoid — Level 2 Answers Level 2 exercise: Build a complete working electric solenoid circuit including switches, relays and circuit protection. Additional Moduponents required: MD-4040 12 V DC Relay, MD-4091 DPDT switches. Optional Moduponents suggested: MD-4130 Fuses and MD-4090 SPST switches. ( Page 1 of 2 ) Level 2 Build a complete working electric solenoid circuit Done Build a complete working electric solenoid circuit. DO THIS : Plug in the power supply to a 110 VAC outlet. Turn ON the power supply, Test for 12 V DC at the power supply, adjust as needed. Turn OFF the power supply. 1 Use the printed diagram showing components ONLY on next page. Using the provided component ONLY diagram, complete drawing the electrical circuit that would operate the solenoid incorporating the MD-4000 power supply, MD-4114 Solenoid, MD-4040 12 V DC Relay, and MD-4091 DPDT switches moduponents. * Optional moduponents: MD-4130 Fuses and MD-4090 SPST switches Hint CONTROL SIDE: Source voltage, protection, switch, relay coil and ground circuit. Hint LOAD SIDE: Source voltage, protection, relay contacts, solenoid and ground circuit. On the MD-4000 trainer, actually build the circuit from that drawing. Wiring diagram answer : Compare student diagrams to answer sheet provided. MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4130 MD-4090 MD-4040 MD-4114 MD-4000 Circuit is now ready to test. 2 Turn the MD-4090 SPST switch ON/OFF and verify circuit operation using a visual observation of solenoid plunger motion Assess circuit operation. 3 Using industry standard symbols, on a piece of paper redraw a wiring diagram of this circuit using a power source, fuses, switches, and a relay to control an electric solenoid. Assess student created wiring diagram. consulab.com info@consulab.com 58 MD-4000-23_053344-91 Student assignments SA-12 Answer SA-12 MD-4114 Solenoid — Level 2 Answer ( Page 2 of 2 ) COMPLETED WIRING DIAGRAM MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4130 MD-4090 MD-4040 MD-4114 MD-4000 consulab.com info@consulab.com 59 MD-4000-23_053344-91 Student assignments SA-13 SA-13 MD-4120 Injector Electrical Symbol Theory of operation An internal combustion engine requires compression, fuel and air to function. The method that fuels are introduced into an engine have changed a lot over time, but today’s modern engines use an electric solenoid valve called a fuel injector to spray fuel into an engine. These electronically controlled valves are capable of opening and closing many times a second which allows for atomizing of the fuel evenly in order to optimize combustion and efficiency. Fuel pressure is applied to the closed injector and when it is pulsed to open/close, it simply acts as a spray nozzle to break up the fuel into a fine spray. It doesn’t actually control the fuel flow because the amount of fuel sprayed is increased or decreased by an electrical control unit - in other words, it is just like turning a water hose nozzle on and off very fast. The longer the injector nozzle is open, the more fuel flows past it into the engine and this ratio of ON/OFF is called Pulse Width Modulation (PWM). The duration that an injector remains open versus closed (PWM) is determined by many input sensor information and this injector moduponent will allow for engine RPM (more/less openings per second) and PWM (longer/shorter open time) to be adjusted for demonstration and learning purposes. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4001 PWM Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) GNDSIG12V INJ PW MODULATION RPM MODUPONENT MD-4120 INJECTOR INJECTEUR REVD 21 INJECTOR consulab.com info@consulab.com 60 MD-4000-23_053344-91 Student assignments SA-13 SA-13 MD-4120 Injector — Level 1 Level 1 exercise: Perform a signal voltage measurement of a typical automotive fuel injector at different RPM’s and Pulse Width Modulations. ( Page 1 of 3 ) WIRING DIAGRAM #1 GNDSIG12V INJ PW MODULATION RPM MODUPONENT MD-4120 INJECTOR INJECTEUR REVD MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4120 SET METER: V DC Level 1 Setting Up To Measure Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4120 Injector moduponent . Connect a black wire from the BLACK GND terminal of the MD-4120 Injector moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIGNAL terminal of the MD-4120 Injector moduponent. Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 61 MD-4000-23_053344-91 Student assignments SA-13 Answers SA-13 MD-4120 Injector — Level 1 Answers ( Page 2 of 3 ) Level 1 Measuring signal voltage Done DO THIS : 1 Set the RPM dial to the fourth line marking. Set the PWM dial to the fourth line marking . Record voltage at the signal terminal here: 0.5 V DC Set the RPM dial to the fourth line marking. Set the PWM dial to the sixth line marking . Record voltage at the signal terminal here: 0.8 V DC Set the RPM dial to the fourth line marking. Set the PWM dial to the eightth line marking . Record voltage at the signal terminal here: 1.2 - 1.5 V DC Set the RPM dial to the sixth line marking. Set the PWM dial to the fourth line marking . Record voltage at the signal terminal here: 1.25 V DC Set the RPM dial to the sixth line marking. Set the PWM dial to the eightth line marking . Record voltage at the signal terminal here: 3 V DC consulab.com info@consulab.com 62 MD-4000-23_053344-91 Student assignments SA-13 Answers SA-13 MD-4120 Injector — Level 1 Answers ( Page 3 of 3 ) Level 1 Measuring signal voltage Done DO THIS : 2 Discuss these observations: How did the injector “sound” change? Tone and frequency. 3 What affected voltage readings more – RPM or PWM? PWM Why? 4 What is happening to the actual injector spray time in these different scenarios? Longer PWM = longer injector ON time (spray time). 5 Explain “pulse width”: Electrical circuit ON versus OFF time. consulab.com info@consulab.com 63 MD-4000-23_053344-91 Student assignments SA-13 Answers SA-13 MD-4120 Injector — Level 2 Answers NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Obtain an oscilloscope pattern for a fuel injectors PWM and compare it to frequency/RPM. Level 2 Setting up to measure Injector PWM Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4120 Injector moduponent. Connect a black wire from the BLACK GND terminal of the MD-4120 Injector moduponent back to the BLACK – of the power supply. Connect one lead of an oscilloscope to the BLUE SIGNAL terminal of the MD-4120 Injector moduponent. Connect the black lead of an oscilloscope to the back to the BLACK – of the power supply. Follow the instructions below for PWM control dial settings and record measurements. Level 2 Measuring pulsed voltage with an oscilloscope Done Set the MOTOR control dial (RPM) to the fifth line. 1 Record the oscilloscope settings used to obtain a signal: Voltage: 5 V per div Time: 5 ms per div Trigger: 12.0 V 2 Set PWM control dial to the third line marking. On a sheet of paper, draw and label the pattern observed. See capture : 3 Set PWM control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. See capture : consulab.com info@consulab.com 64 MD-4000-23_053344-91 Student assignments SA-13 Answers Level 2 Measuring pulsed voltage with an oscilloscope Done 4 Set PWM control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. See capture : 5 Set PWM control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. See capture : 6 Set PWM control dial to FULL ON. On a sheet of paper, draw and label the pattern observed. See capture : 7 Move the MOTOR control dial up to FULL SPEED and turn back down, observe the PWM and report your observations with explanation within: The pulse width remains the same while frequency of PWM increases. This means more injector events within the same time frame. consulab.com info@consulab.com 65 MD-4000-23_053344-91 Student assignments SA-14 SA-14 MD-4141 Optical Sensors Electrical Symbols Theory of operation The MD-4141 Moduponent includes three (3) optical sensors: one photoresistor, one photodiode and one phototransistor. Each of these optical sensors incorporate a different electronic component that is sensitive to incoming light, using either a resistor, a diode or a transistor. Each of these sensors receive light to activate them, using unique characteristics to control a circuit or component. Prior knowledge of semiconductors like resistors, diodes and transistors are recommended prior to completing these assignments. PHOTORESISTOR A photoresistor’s resistance decreases with an increase in light intensity and can be used in light sensitive circuits. When there is low to no light, the resistance increases and this characteristic is used to control a transistor that in turn switches a circuit on. A common example would be security lighting that comes on at dusk. In an automobile, this could be also be used to control the automatic day/night rearview mirror element. PHOTODIODE A photodiode is a type of semiconductor diode which actually generates an electric current when light is applied to its surface. It converts the light’s energy into an electrical current. This actual response time is slower as their surface area increases, such as in a solar panel, but is still faster than the phototransistor. Photodiodes are designed to operate in both forward or reverse bias and used to switch circuits in electronic devices like a smoke detector or CD player. In an automobile, this could be used to sense sunload or twilight in climate control applications. PHOTOTRANSISTOR The phototransistor is a two or three terminal semiconductor that converts light energy into electric current. It is a special design transistor which has a light sensitive base, not a regular transistor base. When the base of this NPN transistor is exposed to light, the phototransistor converts it to electrical current proportional to the amount of light applied. The phototransistor amplifies the input light and the output current can be measured at the collector of the transistor. This component is used to detect light. MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 Photoresistor PhototransistorPhotodiode consulab.com info@consulab.com 66 MD-4000-23_053344-91 Student assignments SA-14 Safety and Safeguards • ONLY use the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • Observe polarity as component could be damaged. Companion ModuponentsTM • MD-4130 Fuses protection • MD-4142 Transistors theory • MD-4010 Resistors theory • MD-4140 Diodes theory • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4111 Fan load operation • MD-4070 Light Bulbs load operation • MD-4114 Solenoid load operation • MD-4071 LED’s load operation (resistance req’d) Additional Equipment • Safety Glasses • DVOM • Flashlight consulab.com info@consulab.com 67 MD-4000-23_053344-91 Student assignments SA-14 Answers SA-14 MD-4141 Optical Sensors — Level 1 Answers Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). Level 1 exercise : Observe the characteristics of three optical sensors. This Moduponent has three ( 3 ) Optical Sensors – the photoresistor, the photodiode, and the phototransistor that we will test for light sensitivity by measuringv with a DVOM. ( Page 1 of 2 ) WIRING DIAGRAM #1 WIRING DIAGRAM #2 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF SET METER: Ohms PHOTORESISTOR MD-4141 SET METER: mV PHOTODIODE MD-4141 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF Level 1A Photoresistor operation Done Measure the photoresistor resistance and how light affects it. DO THIS : See wiring diagram #1 Connect the DVOM red lead to either yellow terminal of the MD-4041 Photoresistor. Connect the DVOM black lead to either yellow terminal of the MD-4041 Photoresistor. Set the DVOM to Ohms (Ω). 1 In normal room light, measure and record the resistance measurement: 10 kΩ * depending on source lighting 2 Now, cover the photoresistor sensor to block light, observe and record the resistance measurement: 75-100 kΩ 3 Now, expose the photoresistor sensor to the light from a flashlight, observe and record the resistance measurement: 200-300 Ω 4 Did the resistance go up or down when exposed to light? Up consulab.com info@consulab.com 68 MD-4000-23_053344-91 Student assignments SA-14 Answers SA-14 MD-4141 Optical Sensors — Level 1 Answers ( Page 2 of 2 ) Level 1B Photodiode operation Done Measure the voltage produced by a photodiode as light affects it. DO THIS : See wiring diagram #2 Connect the DVOM red lead to either yellow terminal of the MD-4041 Photodiode. Connect the DVOM black lead to either yellow terminal of the MD-4041 Photodiode. Set the DVOM to mV. 1 In normal room light, measure and record the resistance measurement: 2.2 m Ω (4.5 m Ω w/light source applied) 2 Measure and record the mV reading: 200-300 mV Cover the sensor with your hand. 3 Measure and record the mV reading: 200 mV Now, shine a light on the sensor. 4 Measure and record the mV reading: 380 mV NOTE: measurements will vary with lighting applied, but the basic principle is; more light exposed to the photodiode, higher mV generated. Level 1C PhotoTransistor operation Done Measure the voltage produced by a phototransistor as light affects it. DO THIS : Connect the DVOM red lead to either yellow terminal of the MD-4041 Phototransistor. Connect the DVOM black lead to either yellow terminal of the MD-4041 Phototransistor. Set the DVOM to mV. 1 Measure and record the mV reading: 380 mV Cover the sensor with your hand. 2 Measure and record the mV reading: 200 mV Now, shine a light on the sensor. 3 Measure and record the mV reading: 550 mV consulab.com info@consulab.com 69 MD-4000-23_053344-91 Student assignments SA-14 Answers SA-14 MD-4141 Optical Sensors — Level 2 Answers Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). Level 2 exercise: Build a working electrical circuit using 3 different optical sensors to turn on an LED. Additional Moduponents required: MD-4002 5 and MD-4071. WIRING DIAGRAM #3 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S MD-4000 MD-4002 MD-4071 MD-4141 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF Level 2 Photoresistor operation Done Build a circuit using a photoresistor to operate an LED. DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed * if MD-4002 5V regulator is not available, adjust power supply to 5V before proceeding. See wiring diagram #3 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to one of the YELLOW terminals of the MD-4141 photoresistor. Connect another red wire from the other YELLOW terminal of the MD-4141 photoresistor to the RED terminal of any MD-4071 LED. Connect a black wire from the BLACK terminal of the MD-4071 LED back to the BLACK – of the power supply. Shine a bright light onto the photoresistor and observe LED operation. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to various test points of the circuit and observe voltage changing with light application. 1 Explain why the LED illuminates when the photoresistor is exposed to light. A photoresistor’s resistance decreases with an increase in light intensity, causing less voltage dropped and allowing more current to flow, activating the diode to emit light. consulab.com info@consulab.com 70 MD-4000-23_053344-91 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. Tous droits réservés. General description Student Assignments Answers SA-1 MD-4001 Pulse Width Modulator (PWM) SA-2 MD-4002 5V Regulator SA-3 MD-4040 12VDC 5-pin ISO Relay SA-4 MD-4050 Variable Reluctance Sensor SA-5 MD-4051 Hall Effect Sensor SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) SA-7 MD-4053 MAP Sensor SA-8 MD-4054 TP Sensor SA-9 MD-4055 Piezo Knock Sensor SA-10 MD-4057 Magnetic Resistive Sensor SA-11 MD-4112 Stepper Motor SA-12 MD-4114 Solenoid SA-13 MD-4120 Injector SA-14 MD-4141 Optical Sensors

Student assignments for MD-4000-23_053344 Driveability Electronics Moduponent™ Kit MD-4000-23_053344-95 © ConsuLab Educatech Inc, 2025. All rights reserved. 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, 2025. 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 053344 and above. MD-4000-23_053344-95 Table of contents Table of contents General description 3 Student Assignments SA-1 MD-4001 Pulse Width Modulator (PWM) 5 SA-2 MD-4002 5V Regulator 9 SA-3 MD-4040 12VDC 5-pin ISO Relay 13 SA-4 MD-4050 Variable Reluctance Sensor 20 SA-5 MD-4051 Hall Effect Sensor 24 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) 29 SA-7 MD-4053 MAP Sensor 33 SA-8 MD-4054 TP Sensor 37 SA-9 MD-4055 Piezo Knock Sensor 41 SA-10 MD-4057 Magnetic Resistive Sensor 44 SA-11 MD-4112 Stepper Motor 49 SA-12 MD-4114 Solenoid 52 SA-13 MD-4120 Injector 56 SA-14 MD-4141 Optical Sensors 61 consulab.com info@consulab.com 3 MD-4000-23_053344-95 General description General description The ConsuLab MD-4000-23_053344 is a versatile and adaptable electrical/electronic training system that allows students to build electronic circuits. Features • Protected with removable metal cover • Adjustable and protected power supply (2-14VDC) • Moduponent™ storage rails allow up to 16 individual Moduponents™ Educational Advantages • Can be used for teaching basic Ohm’s law or complex electronic circuits • Self-contained unit has a protected built-in adjustable power supply • Storage case holds up to 16 individual Moduponents™ • This set includes 14 different Modupon ents™ from the entire MD-4000 series • Uses industry standard schematic symbols • Provides extreme flexibilty to allow instructors to create additional as nd student activities • Can assist instructors in the instruction of many tasks in area A6 and others of the ASE Education Foundation (NATEF) List of MD-4000-23 ModuponentsTM • 52958 CL-1011A Desktop Moduponent Case • 52320 CL-1012-03 Set of 26 Jumper Leads • 53061 MD-4000 DC Power Supply • 53074 MD-4001 Pulse Width Modulator (PWM) • 53095 MD-4002 5V Output (Regulator) • 53068 MD-4040 12VDC 5-pin ISO Relay • 53072 MD-4050 Variable Reluctance Sensor • 53071 MD-4051 Hall Effect Sensor • 53067 MD-4052 NTC Thermistor • 53085 MD-4053 MAP Sensor • 53082 MD-4054 TP Sensor • 53079 MD-4055 Piezo Knock Sensor • 53132 MD-4057 Magnetic Resistive (2-wire ABS) Sensor • 53083 MD-4112 Stepper Motor • 53134 MD-4114 Solenoid • 53133 MD-4120 Injector • 53076 MD-4141 Optical Sensors consulab.com info@consulab.com 4 MD-4000-23_053344-95 Student assignments Student Assignments consulab.com info@consulab.com 5 MD-4000-23_053344-95 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC Electrical Symbol Theory of operation Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by electronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4010 Resistors • MD-4070 Light bulbs • MD-4111 Fan • MD-4120 Injector Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) MD-4000 Moduponent: MD-4001 Pulse Width Modulator (PWM) Electrical Symbol: Theory of operation: Pulse width modulation is used to allow the operation of a DC motor at various speeds without the requirement of voltage dropping resistors. It also allows a more precise control of motor efficiency due to the faster switching speeds of the circuit. A PWM controlled circuit basically means that the circuit operating voltage is controlled as needed by electronically switching the circuit ON/OFF quickly or slowly instead of adding resistors to permanently change the voltage. The longer the circuit stays switched ON (Closed), the higher the voltage and the longer the circuit remains OFF (Open), the lower the circuit voltage is. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120VAC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4010 Resistors MD-4070 Light bulbs MD-4111 Fan MD-4120 Injector Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 6 MD-4000-23_053344-95 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) - Level 1 ( Page 1 of 2 ) Level 1 exercise: Perform a voltage measurement of PW Modulation in response to a 12V source. WIRING DIAGRAM #1 MD-4000 MD-4001 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4001 BAT SIG 0 - 100 % PWM MLI GND GND MODUPONENT REVC Name : Group : Date : Level 1 Setting up to measure pulsed voltage Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4001 PWM moduponent. See wiring diagram #1 Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent. Connect the DVOM red lead to the BLUE SIGNAL terminal of the MD-4001 PWM moduponent. Set the DVOM to V DC. Follow the instructions on next page for control dial settings and record measurements. consulab.com info@consulab.com 7 MD-4000-23_053344-95 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) — Level 1 ( Page 2 of 2 ) Level 1 Measuring pulsed voltage Done Do this : Set control dial to the second line marking. Record voltage at the signal terminal: V. Set control dial to the fourth line marking. Record voltage at the signal terminal: V. 1 Set control dial to the sixth line marking. Record voltage at the signal terminal: V Set control dial to the eighth line marking. Record voltage at the signal terminal: V. 2 With knowledge of PWM, what is happening here? 3 What exactly is PWM? 4 Proceed to SA1 Level 2 to actually see this happen using an oscilloscope. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 8 MD-4000-23_053344-95 Student assignments SA-1 SA-1 MD-4001 Pulse Width Modulator (PWM) — Level 2 NOTE : *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a PWM signal using an oscilloscope to capture a pattern. Level 1 Setting up an oscilloscope to observe a PWM signal Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4001 PWM moduponent. Connect a black wire from the LEFT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply. See diagram #1 Connect a black wire from the RIGHT BLACK GND terminal at the bottom of the MD-4001 PWM moduponent back to the BLACK – of the power supply Connect one lead from an oscilloscope to the BLUE SIG terminal of the MD-4001 PWM moduponent. Connect the oscilloscope black lead to the BLACK – of the power supply. Adjust the PWM control knob to the sixth line. Adjust the oscilloscope settings until a pattern can be observed * 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V 2 On a separate sheet of paper, draw the pattern observed. Now adjust the PWM control knob right and left and observe the changes in the oscilloscope pattern. 3 How fast is pulse width being modulated? 4 Describe the pattern changes observed and why the pattern changes: Name : Group : Date : Instructor : Grade : Name : Group : Date : consulab.com info@consulab.com 9 MD-4000-23_053344-95 Student assignments SA-2 SA-2 MD-4002 5V Regulator Electrical Symbol Theory of operation Reference voltage has been used in electronics for years and is called Vref. The reason why modern automobiles use a 5-volt reference is to provide a consistent voltage to the engine control computer circuits, instead of fluctuating with battery/charging/cranking voltages. Also, as electricity flows through a sensor containing a resistance, any resistance introduced into this circuit will be a larger proportion of a 5 volt circuit than a 12 volt circuit, providing better accuracy. Due to this variable resistance, the signal return voltage to the ECM is always less than the reference voltage and used to compute changes in temperature, pressure or position. Safety and Safeguards • 1 Amp circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4053 MAP Sensor • MD-4054 TPS • MD-4057 MR Sensor • MD-4051 Hall Effect Sensor Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT consulab.com info@consulab.com 10 MD-4000-23_053344-95 Student assignments SA-2 SA-2 MD-4002 5V Regulator — Level 1 Level 1 exercise: Set up a 5V reference voltage to illustrate modern vehicle sensor reference voltage. MD-4000 MD-4002 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT WIRING DIAGRAM #1 Level 1 Setting up a reference voltage of 5V Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5V Regulator moduponent. See wiring diagram #1 Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. Level 1 Measuring pulsed voltage Done 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: V. 2 Connect the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: V. 3 Why is this voltage regulation needed? 4 How is this 5V reference voltage used in an automobile today? Name : Group : Date : Instructor : Grade : Name : Group : Date : consulab.com info@consulab.com 11 MD-4000-23_053344-95 Student assignments SA-2 SA-2 MD-4002 5V Regulator — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a 5V reference measured on a DVOM compared to an Oscilloscope pattern. Additional Moduponents required: MD4002, MD-4051, MD-4053 and MD-4057. ( Page 1 of 2 ) Level 2 Setting up a reference voltage of 5V Done Do this : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5V Regulator moduponent. See wiring diagram #1 Connect a black wire from the BLACK GND terminal of the MD-4002 5V Regulator moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. Name : Group : Date : consulab.com info@consulab.com 12 MD-4000-23_053344-95 Student assignments SA-2 Level 2 Provide a 5V reference to a sensor Done 1 Connect the DVOM red lead to the RED BAT terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: V. 2 Connect the DVOM red lead to the RED 5V terminal of the MD-4002 5 Volt Regulator moduponent. Record voltage here: V. Remove the red DVOM lead from the 5V terminal. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator moduponent to the +5V terminal of the MD-4051 Hall Effect Sensor moduponent. 3 Without a ground wire connected to the MD-4051 Hall Effect Sensor, connect the DVOM red lead to the sensor BLACK GND terminal and record voltage: V 4 Without a ground wire connected to the MD-4051 Hall Effect Sensor, move the DVOM red lead to the WHITE SIG terminal and record voltage: V 5 With the DVOM red lead still connected to the WHITE SIG terminal, complete the 5V circuit by providing a black wire from the GND terminal back to BLACK – of the power supply. Record SIG voltage reading now with the 5V circuit completed: V 6 Using a DVOM to measure the voltage, were you able to see an accurate “signal”? Connect an oscilloscope and obtain a waveform pattern. 7 Using an oscilloscope to measure voltage, were you able to see an accurate “signal”? REPEAT steps 3 – 9 for the following MD-4000-23 moduponents : 8 MD-4053 MAP sensor GND SIG w/o GND SIG w/GND 9 MD-4057 MR sensor GND SIG w/o GND SIG w/GND SA-2 MD-4002 5V Regulator — Level 2 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 13 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay Electrical Symbol Theory of operation Simply put, an automotive relay is an electrically or electronically operated switch that is able to control high current loads with a low current control circuit. There are two circuits inside a relay that are independent of each other, and often there is no physical connection between the two. The low current side is called the control circuit and the high current side is called the load circuit. The only “connection” is from electromagnetism. This is achieved by a coil of wire in the control circuit which becomes an electromagnet when that circuit is closed. This amount of current in the coil becomes the only load of that control circuit. (See above schematic) Common relays can have two sets of contacts in the high current side. One set remain “closed” and the other remain “open” when the relay is off. Energizing the relay reverses the position of the contacts. The terms N.C. (normally closed) and N.O. (normally open) are used to describe the position of the contacts. The relay above is a five terminal relay. More basic relays can have four terminals and only a N.O. set of contacts that close when the relay is energized. The magnetic field created in the control circuit coil then causes an armature to move the contacts to either open or close depending on the design. The high current is switched on through the durable set of contacts that provide longevity of the connection. Newer relays control the load with electronics and use transistors to switch control circuit. It is important to note that most relays use some sort of “voltage spike” suppression to control the inductive “kick” that is created when a relay coil is energized and then turned off. This kick could damage sensitive electronics elsewhere in the circuit if not controlled. The MD-4040 Relay Moduponent uses an internal resistor in parallel to the coil for spike suppression. For more information regarding testing relays go to the ConsuLab website under “Available Training”. The International Organization of Standardization (ISO) has designated relay connections to be commonly labeled as follows: • 85 & 86 Control circuit coil power and ground *(low amp) • 30 Battery 12V to operate load (high amp) • 87A N.C. contact of load circuit switch (not used) • 87 N.O. contact of load circuit switch, connects to 30 when control circuit coilis energized 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 LAMER 7/16'' PROF 0.080'' PLEXI 1/4" 0.281'' MODUPONENT MD-4040 12 VDC RELAY RELAIS 12 VCC 85 86 87 3087a consulab.com info@consulab.com 14 MD-4000-23_053344-95 Student assignments SA-3 NOTE: Remember that specific vehicle manufacturers can often change how terminals 85 & 86 are used to control and feed the relay coil. Terminal 85 or 86 can be the B+ and the other terminal would be the ground. It is imperative to always check the vehicle specific circuit schematic to properly identify the relay terminals and how they are used in the circuit. Relays are found in all types of transportation vehicles (cars, trucks, vans, off-road equipment, agriculture, trailers, motorcycles, airplanes and boats) and are used to control any high amperage draw component. Examples are lighting control, electric motors like fuel pumps, wipers, windows, seat motors, or horns and solenoids. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses protection • MD-4141 Optical Sensor circuit control • MD-4142 Transistors circuit control • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4111 Fan load operation • MD-4070 Light Bulbs load operation • MD-4114 Solenoid load operation • MD-4071 LED’s load operation (resistance required) Additional Equipment • Safety Glasses • DVOM consulab.com info@consulab.com 15 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 Level 1A exercise: Build a relay control circuit to energize the relay control coil. ( Page 1 of 3 ) MD-4000 MD-4040 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 WIRING DIAGRAM #1 Level 1 A Basic Relay Control Operation Done Build a relay control circuit using the built-in variable power supply as source voltage. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram #1 Connect a red wire between the RED + of the power supply to terminal 86 of the MD-4040 Relay Moduponent™. Connect a black wire from terminal 85 of the MD-4040 Relay back to the BLACK – of the power supply. Control circuit is now ready to test. Turn power supply ON and listen for an audible “click” as the contacts close. Unplug any wire to listen for contacts to open, then plug the wire back in to hear a “click” as the contacts close again. Name : Group : Date : consulab.com info@consulab.com 16 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 Level 1B exercise: Build a relay load circuit that is controlled by the relay. Additional Moduponent required: MD-4114 ( Page 2 of 3 ) MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID MD-4000 MD-4040 MD-4114 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 WIRING DIAGRAM #2 Level 1 B Basic Relay Operated Circuit Done Building on Level 1A assignment, proceed with connecting a load circuit (Solenoid). DO THIS : Turn OFF the power supply. See wiring diagram #2 Connect another red wire between the RED + of the power supply to terminal 30 of the MD-4040 Relay (piggy backing wires is allowed). Connect another red wire between terminal 87 of the MD-4040 Relay to the RED terminal of MD-4114 Solenoid Moduponent™. Connect a black wire from the BLACK terminal of the MD-4114 Solenoid back to the BLACK (–) of the power supply (piggy backing wires is allowed). Based on lesson learned in the Level 1A assignment, discuss expected operation of MD-4114 Solenoid when power supply is switched from OFF to ON. Turn power supply OFF/ON to confirm relay operation. consulab.com info@consulab.com 17 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 1 ( Page 3 of 3 ) WIRING DIAGRAM #3 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4000 MD-4040 1 2 3 4 5 MD-4114 6 7 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Name : Group : Date : Instructor : Grade : Level 1 B Basic Relay Operated Circuit Done DO THIS : See wiring diagram #3 Based on lesson learned in the Level 1A&B exercise, discuss expected voltage readings at indicated circuit terminals (1-7) of both the control and load circuit, power supply ON, and w/85 ground connected or disconnected (CLOSED or OPEN) MD-4040 Relay Circuit terminal Closed Open 1. (87) V V 2. (87A) V V 3. (30) V V 4. (85) V V 5. (86) V V 6. (Solenoid RED) V V 7. (Solenoid BLACK) V V consulab.com info@consulab.com 18 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 2 Level 2A exercise: Practice measuring voltage drops over the various circuits of a relay-controlled device. Remember: Voltage drop (Vd) is the loss of voltage by passing current through a resistance. Additional Moduponents required: MD-4070 (optional), MD-4130 and MD-4090. ( Page 1 of 2 ) Name : Group : Date : WIRING DIAGRAM #4 Level 2 A Voltage Drop Lessons (Vd) Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #4 Using the MD-4000 electrical trainer with the MD-4070 Bulbs and MD-4040 12 V DC Relay moduponents, build the electrical circuit represented by the provided wiring diagram 1 (MD-4130 Fuses & MD-4090 SPST switches moduponents are optional). Set the DVOM to V DC ONLY check Vd with power supply ON (and optional MD-4090 SPST switches CLOSED) 1 Practice Vd on power side of CONTROL circuit (+): Red lead on power supply RED +, Black lead on terminal 86 of the MD-4040 12 V DC Relay 2 Practice Vd on ground side of CONTROL circuit (-): Red lead on terminal 85 of the MD-4040 12 V DC Relay, Black lead on power supply BLACK (-). 3 Practice Vd of the CONTROL circuit LOAD: Red lead on terminal 86 of MD-4040 12 V DC Relay, Black lead on terminal 85 of MD-4040 12 V DC Relay. 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4000 MD-4070 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 consulab.com info@consulab.com 19 MD-4000-23_053344-95 Student assignments SA-3 SA-3 MD-4040 12VDC 5-pin ISO Relay — Level 2 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : WIRING DIAGRAM #5 Level 2 A Voltage Drop Lessons (Vd) Done 4 Practice Vd on power side of LOAD circuit (+): Red lead on power supply RED +, Black lead on terminal 30 of the MD-4040 12 V DC Relay. 5 Practice Vd on ground side of LOAD circuit (-): Red lead on BLACK – terminal of the L1 MD-4070 Bulb, Black lead on power supply (-). 6 Practice Vd over the LOAD: Red lead on RED H terminal of the MD-4070 Bulb, Black lead on BLACK - of the MD-4070 Bulb. 7 Where is most of the voltage dropped in each circuit? 8 Using industry standard symbols, on a piece of paper draw a wiring diagram of this circuit using a relay to control a light bulb. 9 Are there any parts of this working circuit that have NOT had Vd measured? 10 If so, use a color highlighter to mark the wiring diagram Level 2 B Current Draw Lesson Done Level 2B exercise: Practice measuring circuit amperage of the various circuits in a relay-controlled device. DO THIS: Set the DVOM to AMPs and switch meter leads to correctly measure current. 11 Open the relay CONTROL circuit and measure amperage: 12 Open the relay LOAD circuit and measure amperage: See wiring diagram #5 Practice this entire exercise with different moduponent loads (fuses, switches, fan, solenoid, etc). SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES MD-4130MD-4000 MD-4090 MD-4040 MD-4070 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 AMPOULES MODUPONENT MD-4070 REVD LIGHT BULBS HI B COM A L2 LO L1 consulab.com info@consulab.com 20 MD-4000-23_053344-95 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor Electrical Symbol Theory of operation A VR sensor is a passive analog sensor that can be used to convert mechanical motion to electrical energy without any direct contact when positioned near a turning rotor, gear, shaft or other moving device. Passive sensors have an internal magnet and coil of wire located within the sensor that becomes a transducer used to measure changes in magnetic reluctance. Located near the sensor is a “trigger wheel” or often called “tone wheel” which when rotated, the teeth on the wheel concentrate the magnetic field in the sensor which results in the generation of a high and low amplitude signal output as the tone wheel rotates. Both the frequency and amplitude of the sensor signal changes with speed of the reluctor wheel. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) VARIABLE RELUCTANCE SENSOR CAPTEUR À RÉLUCTANCE VARIABLE SIGNAL RPM MODUPONENT MD-4050 REVD MD-4000 Moduponent: MD-4050 Variable Reluctance Sensor Electrical Symbol: Theory of operation: A VR sensor is a passive analog sensor that can be used to convert mechanical motion to electrical energy without any direct contact when positioned near a turning rotor, gear, shaft or other moving device. Passive sensors have an internal magnet and coil of wire located within the sensor that becomes a transducer used to measure changes in magnetic reluctance. Located near the sensor is a “trigger wheel” or often called “tone wheel” which when rotated, the teeth on the wheel concentrate the magnetic field in the sensor which results in the generation of a high and low amplitude signal output as the tone wheel rotates. Both the frequency and amplitude of the sensor signal changes with speed of the reluctor wheel. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) MAGNET COIL SIG. SIG. PASSIVE SENSOR consulab.com info@consulab.com 21 MD-4000-23_053344-95 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor — Level 1 Level 1 exercise: Generate and measure the AC signal voltage generated by a variable reluctance sensor. ( Page 1 of 2 ) Name : Group : Date : VARIABLE RELUCTANCE SENSOR CAPTEUR À RÉLUCTANCE VARIABLE SIGNAL RPM MODUPONENT MD-4050 REVD MD-4000 MD-4050 SET METER: V AC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + WIRING DIAGRAM #1 Level 1 Setting Up To Measure A VR Sensor Signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4050 VR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4050 VR Sensor moduponent motor control back to the BLACK – of the power supply. Connect the DVOM black lead to either YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent. Connect the DVOM red lead to the remaining YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent. Set the DVOM to V AC *NOTE: this sensor generates an AC Voltage signal. Follow the instructions on next page for motor control dial settings and record measurements. consulab.com info@consulab.com 22 MD-4000-23_053344-95 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor — Level 1 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : Level 1 Measuring a VR sensor generated signal voltage Done DO THIS : 1 Set motor control dial to the fifth line marking. Record voltage at the signal terminals here: V. Set motor control dial to the sixth line marking. Record voltage at the signal terminals here: V. Set motor control dial to the seventh line marking. Record voltage at the signal terminals here: V. Set motor control dial to the eighth line marking. Record voltage at the signal terminals here: V. Set control dial to FULL ON. Record voltage at the signal terminals here: V. 2 With knowledge of Variable Reluctance, what is happening here? 3 How is this technology used in an automobile today? 4 Proceed to SA4 Level 2 to actually see this happen using an oscilloscope. consulab.com info@consulab.com 23 MD-4000-23_053344-95 Student assignments SA-4 SA-4 MD-4050 Variable Reluctance Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a variable reluctance sensor signal using an oscilloscope to capture a pattern. Level 2 Setting up to measure a VR sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4050 VR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4050 VR Sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to either YELLOW terminal of the MD-4050 VR Sensor moduponent Connect the BLACK lead from the oscilloscope* to the remaining YELLOW SIGNAL terminal of the MD-4050 VR Sensor moduponent Level 2 Observing a VR sensor generated oscilloscope signal Done DO THIS : 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. Name : Group : Date : Instructor : Grade : Name : Group : Date : consulab.com info@consulab.com 24 MD-4000-23_053344-95 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor Electrical Symbol Theory of operation A Hall Effect sensor is an active 3 wire sensor that requires a 5-volt reference voltage to operate and consists basically of a thin piece of a rectangular p-type semiconductor material passing a continuous current through itself. This sensor also requires some type of trigger or tone wheel to operate. Depending on the sensor design, the presence of a tone wheel rotating by a Hall Effect sensor causes either a high or a low signal voltage depending on whether the peak or valley is passing by the sensor. Wheel speed sensors, crankshaft and camshaft position sensors are just a few automotive applications. Safety and Safeguards • Requires a 5-volt protected reference voltage supplied. • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) +5V GNDSIG RPM HALL EFFECT SENSOR CAPTEUR À EFFET HALL MODUPONENT MD-4051 REVC PERMANENT MAGNET HALL EFFECT SENSOR consulab.com info@consulab.com 25 MD-4000-23_053344-95 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor — Level 1 Level 1 exercise: Test a Hall Effect sensor with a DVOM. Additional Moduponent required: MD-4002. ( Page 1 of 2 ) +5V GNDSIG RPM HALL EFFECT SENSOR CAPTEUR À EFFET HALL MODUPONENT MD-4051 REVC MD-4000 53071 MD-4051 HALL EFFECT SENSOR LEVEL 1 MD-4002 MD-4051 SET METER: V DC MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT WIRING DIAGRAM #1 Level 1 Setting Up To Measure Hall Effect Sensor Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4051 Hall Effect sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4051 Hall Effect sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Set the DVOM to V DC. Name : Group : Date : consulab.com info@consulab.com 26 MD-4000-23_053344-95 Student assignments SA-5 Level 1 Measuring a Hall Effect sensor signal voltage Done Verify 5V reference is at the 5V terminal of the MD-4051 Hall Effect sensor moduponent. With your hand, slowly rotate the reluctor wheel past the sensor from PEAK to valley, holding at each position in order to observe voltage signal. 1 At the WHITE SIG terminal, record the voltage measured when the tone wheel passes: PEAK: V VALLEY: V. 2 How is a Hall Effect Sensor used in an automobile today? Name : Group : Date : Instructor : Grade : SA-5 MD-4051 Hall Effect Sensor — Level 1 ( Page 2 of 2 ) consulab.com info@consulab.com 27 MD-4000-23_053344-95 Student assignments SA-5 SA-5 MD-4051 Hall Effect Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a Hall Effect Signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) Name : Group : Date : Level 2 Setting up to measure a Hall sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4051 Hall Effect sensor moduponent Connect a black wire from the BLACK GND terminal of the MD-4051 Hall Effect sensor moduponent back to the BLACK – of the power supply Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4051 Hall Effect sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4051 Hall Effect sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope to the White SIG terminal of the MD-4051 Hall Effect sensor moduponent. Connect the BLACK lead from the oscilloscope to the BLACK – of the power supply. Follow the instructions below for motor control dial settings and record measurements. consulab.com info@consulab.com 28 MD-4000-23_053344-95 Student assignments SA-5 Level 2 Observing a HALL EFFECT sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. SA-5 MD-4051 Hall Effect Sensor — Level 2 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 29 MD-4000-23_053344-95 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) Electrical Symbol Theory of operation A Thermistor is a type of resistor that changes its resistance based on its temperature. Unlike a resistor, an NTC thermistor has the property where the electrical resistance (Ω) DECREASES as temperature INCREASES and can be measured with an ohmmeter. A thermistor does not “read” anything but senses the temperature around it which then changes the electrical resistance of it. It can be used to control a switch (transistor base) or provide an ECM with a temperature value. The operating range is non-linear (not a straight line) meaning that is achieves high precision within a limited temperature range and is used in climate control applications (HVAC) as well as engine and transmission temperature monitoring. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do NOT heat thermistor with an open flame or a heat gun! • Carefully use body temperature or ice. • Not polarity sensitive. • Normally receives a 5V reference value. • NOT a switch of a load but can control the BASE of a transistor. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4002 5V Regulator circuit control • MD-4011 Resistors circuit control • MD-4040 Relay circuit control • MD-4142 Transistors circuit control • MD-4111 Cooling Fan load operation NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T LAMER 7/16'' PROF 0.08'' PLEXI 1/4" 0.281'' MD-4052 MODUPONENT THERMISTOR THERMISTANCE T NTC 10KΩ @ 25 °C 5.215 3.222 -T Additional Equipment • Safety Glasses • DVOM • Ice • Thermometer MD-4000 MD-4062: redraw this for copyright purposes W MD-4058 * redraw this for copyright purposes consulab.com info@consulab.com 30 MD-4000-23_053344-95 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 1 Level 1 exercise: Observe the operation of an NTC thermistor by measuring electrical resistance at different temperatures. Name : Group : Date : Instructor : Grade : WIRING DIAGRAM #1 NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T MD-4052 SET METER: Ohms Level 1 Basic Thermistor Control Operation Done Measure thermistor resistances at different temperatures. DO THIS : See wiring diagram #1 Connect the DVOM red lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Connect the DVOM black lead to one of the yellow terminals of the MD-4052 NTC Thermistor Moduponent™. Set the DVOM to Ohms (Ω). 1 Measure resistance at room temperature: Ω 2 Using ice, cool the MD-4052 NTC Thermistor and measure the resistance at a lower temperature – how high can resistance be increased? Ω 3 Using just body heat, warm up the MD-4052 NTC Thermistor and measure resistance at a higher temperature – how low can resistance be decreased? Ω Name : Group : Date : consulab.com info@consulab.com 31 MD-4000-23_053344-95 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 2 Level 2 exercise : Simulate a typical automotive engine coolant temperature (ECT) circuit using the MD-4002 5 Volt Regulator and MD-4052 NTC Thermistor to teach the understanding of reference voltage for diagnostics, while also introducing hidden resistance circuit characteristics. Additional Moduponent required but not included in kit: MD-4011 Resistors (10) NOTE: this exercise requires a 10kΩ resistor not included in the MD-4010 but available on the optional MD-4011 Resistors moduponent (or a single 10kΩ / 1W resistor will also work if available). ( Page 1 of 2 ) WIRING DIAGRAM #2 NTC 10KΩ @ 25 °C THERMISTANCE NTC REVC NTC THERMISTOR MODUPONENT MD-4052 T SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT SET METER: V DC MD-4052 MD-4002MD-4000 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Name : Group : Date : Level 2 Build a 5 Volt reference ECT style circuit Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram #2 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to either YELLOW terminal of the MD-4052 NTC Thermistor. Connect a black wire from the other YELLOW terminal of the MD-4052 NTC Thermistor back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead piggy-back to the 5V red wire connected the MD-4052 NTC Thermistor, simulating back-probing an engine harness connector. Set the DVOM to V DC. consulab.com info@consulab.com 32 MD-4000-23_053344-95 Student assignments SA-6 SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) — Level 2 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : Level 2 Build a 5 Volt reference ECT style circuit Done 1 What is the voltage measured? V. 2 On an actual automobile, if any 5V referenced sensor is “back-probed” while the harness is still connected, what should the voltage measure? V. (see sensor specification chart provided below). 3 Now, with the DVOM still connected to the 5V reference wire, unplug it from the MD-4052 NTC Thermistor. What is the voltage measured? V. 4 In an actual automobile, if any 5V referenced sensor harness is “unplugged”, what will the voltage at the sensor harness measure? V. 5 Why does this circuit not work like it does on an automobile? 6 Ask for wiring diagram #3 from MD- 4000-22-96 Look at wiring diagram #3 provided and correct the circuit built to make it work like an actual automobile and explain below what had to be done and why? 7 What does Negative Temperature Coefficient mean? Ignition Switch ON Sensor Specification Chart TEMPERATURE (Cº / Fº) OUTPUT VOLTAGE (V) 0º / 32º 3.3 − 3.7 V 20º / 68º 2.4 − 2.8 V 40º /104º 1.6 − 2.0 V 80º /176º 0.5 − -.9 V consulab.com info@consulab.com 33 MD-4000-23_053344-95 Student assignments SA-7 SA-7 MD-4053 MAP Sensor Electrical Symbol Theory of operation A MAP sensor is a piezoelectric type sensor where electrical resistance changes when pressure is applied to a silicone crystal, also known as a semiconductor. As internal intake manifold pressure/vacuum changes with throttle position, the MAP sensor is exposed to those changes. The electrical resistance of the sensor reacts to those changes. A 5-volt electrical reference value is applied to the sensor and this value then passes through the changing resistance of the sensor only allowing a “signal” voltage to return to the ECU. Basically, a variable voltage drop occurs over the MAP sensor dependent on manifold pressures. A MAP sensor that reads 1 or 2 volts at idle may read 4.5 volts to 5 volts at wide open throttle. Discuss the concept of throttle position in relation to manifold vacuum / pressure: • Engine OFF, the absolute pressure in the manifold equals atmospheric pressure, or 14.7 psi. • Engine ON, the vacuum in the manifold reflects throttle position. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4002 5-volt reference • MD-4054 TPS Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) MAP SENSOR CAPTEUR MAP 5V SIG GND MODUPONENT MD-4053 REVC MD-4000 Moduponent: MD-4053 MAP sensor Electrical Symbol: Theory of operation: A MAP sensor is a Piezoelectric type sensor where electrical resistance changes when pressure is applied to a silicone crystal, also known as a semiconductor. As internal intake manifold pressure/vacuum changes with throttle position, the MAP sensor is exposed to those changes. The electrical resistance of the sensor reacts to those changes. A 5-volt electrical reference value is applied to the sensor and this value then passes through the changing resistance of the sensor only allowing a “signal” voltage to return to the ECU. Basically, a variable voltage drop occurs over the MAP sensor dependent on manifold pressures. A MAP sensor that reads 1 or 2 volts at idle may read 4.5 volts to 5 volts at wide open throttle Discuss the concept of throttle position in relation to manifold vacuum / pressure Engine OFF, the absolute pressure in the manifold equals atmospheric pressure, or 14.7 psi. Engine ON, the vacuum in the manifold reflects throttle position Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4002 5 volt reference MD-4054 TPS Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 34 MD-4000-23_053344-95 Student assignments SA-7 SA-7 MD-4053 MAP Sensor — Level 1 Level 1 exercise: Measure a MAP sensor signal voltage under different pressure/vacuum conditions. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) MAP SENSOR CAPTEUR MAP 5V SIG GND MODUPONENT MD-4053 REVC SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 SET METER: V DC MD-4002 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4053 WIRING DIAGRAM #1 Name : Group : Date : Level 1 Setting Up To Measure Map Sensor Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4053 MAP sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4053 MAP sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4053 MAP sensor moduponent Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 35 MD-4000-23_053344-95 Student assignments SA-7 SA-7 MD-4053 MAP Sensor — Level 1 ( Page 2 of 2 ) Level 1 Measuring MAP sensor signal voltage Done DO THIS : 1 Push the provided syringe plunger all the way in prior to attaching it to the MD-4053 MAP sensor moduponent port. Verify the plunger to sensor seal is good with no leaks. Record voltage measured at the BLUE SIG terminal here: V. 2 Pull on the plunger to about ½ stroke of its travel. While holding the plunger, record voltage measured at the BLUE SIG terminal here: V. 3 Pull on the plunger to FULL stroke of its travel, being careful not to pull the plunger out. While holding the plunger, record voltage measured at the BLUE SIG terminal here: V. 4 How is a MAP sensor used in an automobile today? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 36 MD-4000-23_053344-95 Student assignments SA-7 SA-7 MD-4053 MAP Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a MAP sensor signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 Name : Group : Date : Instructor : Grade : Level 2 Setting up an oscilloscope to observe a MAP sensor signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5VDC Output moduponent . Connect a black wire from the BLACK GND terminal of the MD-4002 5VDC Output moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4053 MAP sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4053 MAP sensor moduponent back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to the BLUE SIG terminal of the moduponent . Connect the oscilloscope* black lead to the BLACK – of the power supply. Adjust the oscilloscope* settings until a pattern can be observed * Level 2 Observing a MAP sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 Push the provided syringe plunger all the way in prior to attaching it to the MD-4053 MAP sensor moduponent port. Verify the plunger to sensor seal is good with no leaks. On a separate sheet of paper, draw and label the pattern observed. 3 Pull on the plunger to about ½ stroke of its travel. On a sheet of paper, draw and label the pattern observed. 4 Pull on the plunger to about FULL stroke of its travel. On the same sheet of paper, draw and label the pattern observed. Name : Group : Date : consulab.com info@consulab.com 37 MD-4000-23_053344-95 Student assignments SA-8 SA-8 MD-4054 TP Sensor Electrical Symbol Theory of operation A throttle position sensor (TPS) is used to monitor the throttle plate position in an internal combustion engine. TPS is usually located on the throttle shaft so that it can directly monitor its position. The sensor signal is used by the ECU as an input to its control system, usually comparing this signal to the signals from the MAP sensor, MAF sensor, CKP & CMP sensors along with other sensors to communicate engine load. A constant voltage output of around 0.18 V with the throttle at its idle position. As the throttle moves from its idle position, the output progressively increases with increasing throttle opening. When the throttle is fully open position, the output is around 4.86 V. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4002 5-volt reference • MD-4053 MAP sensor Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) TP SENSOR CAPTEUR TP MD-4054 MODUPONENT REVD MD-4000 Moduponent: MD-4054 Mechanical TPS Electrical Symbol: Theory of operation: A throttle position sensor (TPS) is used to monitor the throttle plate position in an internal combustion engine. TPS is usually located on the throttle shaft so that it can directly monitor its position. The sensor signal is used by the ECU as an input to its control system, usually comparing this signal to the signals from the MAP sensor, MAF sensor, CKP & CMP sensors along with other sensors to communicate engine load. A constant voltage output of around 0.18 V with the throttle at its idle position. As the throttle moves from its idle position, the output progressively increases with increasing throttle opening. When the throttle is fully open position, the output is around 4.86 V. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses MD-4002 5 volt reference MD-4053 MAP Sensor Additional equipment: Safety Glasses DVOM Oscilloscope (optional) consulab.com info@consulab.com 38 MD-4000-23_053344-95 Student assignments SA-8 SA-8 MD-4054 TP Sensor — Level 1 Level 1 exercise: Measure the voltage signal from a mechanical throttle position sensor under different throttle positions. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) WIRING DIAGRAM #1 TP SENSOR CAPTEUR TP MD-4054 MODUPONENT REVD SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4000 MD-4002 SET METER: V DC MD-4054 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Measure TPS Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4054 TP Sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4054 TP Sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4054 TP sensor. Set the DVOM to V DC. Name : Group : Date : consulab.com info@consulab.com 39 MD-4000-23_053344-95 Student assignments SA-8 Name : Group : Date : Instructor : Grade : SA-8 MD-4054 TP Sensor — Level 1 ( Page 2 of 2 ) Level 1 Measuring TPS voltage at different positions Done DO THIS : 1 Without moving the TPS at all, or “at rest”. Record voltage measured at the BLUE SIG terminal here: V. 2 Moving the sensor to FULL sweep, or “wide open throttle” (WOT). Record voltage measured at the BLUE SIG terminal here: V. 3 How does the voltage change in between at rest and WOT? 4 What is this signal telling the ECU? consulab.com info@consulab.com 40 MD-4000-23_053344-95 Student assignments SA-8 SA-8 MD-4054 TP Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a TPS sweep signal using an oscilloscope to capture a pattern. Name : Group : Date : Instructor : Grade : Level 2 Setting up an oscilloscope to observe a TPS signal Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4054 TPS moduponent. Connect a black wire from the BLACK terminal of the MD-4054 TPS moduponent back to the BLACK – of the power supply. Connect one lead from an oscilloscope* to the BLUE SIG terminal of the MD-4054 TPS moduponent. Connect the oscilloscope* black lead to the BLACK – of the power supply. Adjust the oscilloscope* settings until a pattern can be observed * Level 2 Observing a TPs generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 On a separate sheet of paper, draw the pattern observed. Now move the TPS control clockwise and then release it slowly (sweeping) while observing the changes in the oscilloscope pattern 3 Describe the pattern changes observed and why the pattern changes: 4 How can this pattern be more helpful than a DVOM in diagnosing a TPS issue? Name : Group : Date : consulab.com info@consulab.com 41 MD-4000-23_053344-95 Student assignments SA-9 SA-9 MD-4055 Piezo Knock Sensor Electrical Symbol Theory of operation A knock sensor is a type of a Piezoelectric sensor, used to sense any unusual vibration frequencies caused by engine detonation. The internal sensor is constructed out of either a ceramic or crystal material that generates an electric “signal” when subjected to pressure or vibration. It’s like an engine microphone! The prefix piezo- is Greek for ‘press’ or ‘squeeze’. Safety and Safeguards • Do NOT damage by tapping too hard while observing the signal created. • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) PIEZO SENSOR CAPTEUR PIEZO MD-4055 MODUPONENT REVC MD-4000 Moduponent: MD-4055 Piezoelectric Sensor (KNOCK sensor) Electrical Symbol: Theory of operation: A knock sensor is a type of a Piezoelectric sensor, used to sense any unusual vibration frequencies caused by engine detonation. The internal sensor is constructed out of either a ceramic or crystal material that generates an electric “signal” when subjected to pressure or vibration. It’s like an engine microphone! The prefix piezo- is Greek for 'press' or 'squeeze'. Safety and Safeguards: Do NOT damage by tapping too hard while observing the signal created. 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Additional equipment: Safety Glasses DVOM Oscilloscope consulab.com info@consulab.com 42 MD-4000-23_053344-95 Student assignments SA-9 SA-9 MD-4055 Piezo Sensor — Level 1 Level 1 exercise: Demonstrate and measure the electrical signal produced by a Piezo electric sensor with signal processing. WIRING DIAGRAM #1 PIEZO SENSOR CAPTEUR PIEZO MD-4055 MODUPONENT REVC MD-4055 SET METER: V AC Name : Group : Date : Instructor : Grade : Level 1 Setting Up To Measure PIEZO Signal Done DO THIS : See wiring diagram #1 Connect the DVOM black lead to one of the YELLOW terminals at the bottom of the MD-4055 Piezo Sensor moduponent. Connect the DVOM red lead to the remaining YELLOW terminal of the MD-4055 Piezo Sensor moduponent. Set the DVOM to V AC * NOTE: this sensor generates an AC voltage. Follow the instructions below and record measurements. Level 1 Measuring Piezo generated voltage Done 1 With the DVOM connected as instructed above, LIGHTLY tap on the bolt head securing the MD-4055 Piezo Sensor to the moduponent panel. Record voltage on the DVOM here: V AC. 2 For comparison, with the DVOM connected as instructed above, switch the DVOM to V DC and again, LIGHTLY tap on the bolt head securing the MD-4055 Piezo Sensor to the moduponent panel. Record voltage on the DVOM here: V DC. 3 What exactly is happening when the sensor is tapped on? 4 Proceed to SA9 Level 2 to actually see this happen using an oscilloscope. Name : Group : Date : consulab.com info@consulab.com 43 MD-4000-23_053344-95 Student assignments SA-9 SA-9 MD-4055 Piezo Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a vibration induced signal using an oscilloscope to capture a pattern. Level 2 Setting Up To Measure PIEZO Signal Done DO THIS : Connect one lead from an oscilloscope to one of the YELLOW terminals of the MD-4055 Piezo Sensor moduponent. Connect the oscilloscope* black lead to the remaining YELLOW terminals of the MD-4055 Piezo Sensor moduponent. Adjust the oscilloscope* settings* Level 2 Observing a PIEZO generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V Gently “TAP” on the bolt of the sensor until a pattern is observed. 2 On a separate sheet of paper, draw the pattern observed. Name : Group : Date : Instructor : Grade : Name : Group : Date : consulab.com info@consulab.com 44 MD-4000-23_053344-95 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor Electrical Symbol Theory of operation An MR sensor is an active 2 wire sensor with a redundant ground terminal for testing. This sensor requires a 5 volt reference voltage to operate and has an internal magnet. Active sensors also require some type of trigger or tone wheel to operate. The tone wheel can be of two types based on the specific design of the sensor. The advantage of this type sensor is that it is less affected by increasing air gaps and can provide a signal at near 0 RPM. Since the sensor can detect the slightest beginning motion, it is used in steering angle position sensors with varying spaced triggers as well as hill assist detection. MR sensors today usually have two wires connected to them, but a few may have three with a GND wire sometimes used. Technicians today often look at an MR sensor with two wires and mistakenly think it is a passive inductive AC generator. If testing procedures for a passive sensor are used by technicians, they will get what they may think are improper results and may condemn a perfectly good active MR sensor. The important difference is that the MR sensor will have a supply voltage and a ground circuit, where a passive sensor usually does not have any voltage on the two wires, with the exception being those passive sensors that use a small bias voltage for diagnostics. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) RPM MAGNETIC RESISTIVE ABS SENSOR CAPTEUR ABS MAGNÉTORÉSISTIF 5V GNDSIG MODUPONENT MD-4057 REVC MD-4000 Moduponent: MD-4057 Magneto-Resistive Sensor Electrical Symbol: Theory of operation: An MR sensor is an active 2 wire sensor with a redundant ground terminal for testing. This sensor requires a 5 volt reference voltage to operate and has an internal magnet. Active sensors also require some type of trigger or tone wheel to operate. The tone wheel can be of two types based on the specific design of the sensor. The advantage of this type sensor is that it is less affected by increasing air gaps and can provide a signal at near 0 RPM. Since the sensor can detect the slightest beginning motion, it is used in steering angle position sensors with varying spaced triggers as well as hill assist detection. MR sensors today usually have two wires connected to them, but a few may have three with a GND wire sometimes used. Technicians today often look at an MR sensor with two wires and mistakenly think it is a passive inductive AC generator. If testing procedures for a passive sensor are used by technicians, they will get what they may think are improper results and may condemn a perfectly good active MR sensor. The important difference is that the MR sensor will have a supply voltage and a ground circuit, where a passive sensor usually does not have any voltage on the two wires, with the exception being those passive sensors that use a small bias voltage for diagnostics. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) MAGNET MR SENSOR POWER IN SIG. OUT GND (OPT.) CIRCUIT BOARD MR CIRCUITRY consulab.com info@consulab.com 45 MD-4000-23_053344-95 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor — Level 1 Level 1 exercise: Test an MR sensor with a DVOM. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) Name : Group : Date : WIRING DIAGRAM #1 RPM MAGNETIC RESISTIVE ABS SENSOR CAPTEUR ABS MAGNÉTORÉSISTIF 5V GNDSIG MODUPONENT MD-4057 REVC SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT MD-4002 MD-4057 SET METER: V DC MD-4000 MD-4057 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Measure MR Sensor Signal Voltage Done NOTE: A thorough understanding of MR sensors is needed to accurately test one. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5-volt Regulator moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5-volt Regulator moduponent back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5-volt Regulator moduponent to the red 5V terminal of the MD-4057 MR Sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4057 MR Sensor moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIG terminal of the MD-4057 MR Sensor moduponent Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 46 MD-4000-23_053344-95 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor — Level 1 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : Level 1 Measuring a MR sensor signal voltage Done DO THIS : 1 Verify 5V reference is at the 5V terminal of the MD-4057 MR Sensor moduponent. With your hand, slowly rotate the reluctor wheel from “peak” to “valley”, holding at each position in order to observe voltage signal. At the BLUE SIG ter minal, record the voltage measured when the tone wheel passes: PEAK: V VALLEY: V 2 How is an MR Sensor used in an automobile today? consulab.com info@consulab.com 47 MD-4000-23_053344-95 Student assignments SA-10 SA-10 MD-4057 Magnetic Resistive Sensor — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Observe a magneto-resistive sensor signal using an oscilloscope to capture a pattern. Additional Moduponent required: MD-4002 ( Page 1 of 2 ) Name : Group : Date : Level 2 Setting up to measure a MR sensor signal with an oscilloscope Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5VDC Output moduponent. Connect a black wire from the BLACK GND terminal of the MD-4002 5VDC Output moduponent back to the BLACK – of the power supply. Connect another RED wire from the 5V terminal of the MD-4002 5VDC Output to the 5V terminal of the MD-4057 MR sensor moduponent. Connect a black wire from the BLACK GND terminal of the MD-4057 MR sensor moduponent back to the BLACK – of the power supply. Connect a red wire between the RED + of the power supply to the RED terminal of the MD-4057 MR Sensor moduponent motor control. Connect a black wire from the BLACK terminal of the MD-4057 MR Sensor moduponent motor control back to the BLACK – of the power supply. Connect one lead from an oscilloscope to the BLUE SIG terminal of the MD-4057 MR Sensor moduponent. Connect the BLACK lead from the oscilloscope to the BLACK – of the power supply. Follow the instructions below for motor control dial settings and record measurements consulab.com info@consulab.com 48 MD-4000-23_053344-95 Student assignments SA-10 Level 2 Observing a MR sensor generated oscilloscope signal Done 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 Set motor control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. 3 Set motor control dial to the sixth line marking. On a sheet of paper, draw and label the pattern observed. 4 Set motor control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. 5 Set motor control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. 6 Set motor control dial to the FULL ON. On a sheet of paper, draw and label the pattern observed. SA-10 MD-4057 Magnetic Resistive Sensor — Level 2 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 49 MD-4000-23_053344-95 Student assignments SA-11 SA-11 MD-4112 Stepper Motor Electrical Symbol Theory of operation A stepper motor is a brushless DC motor that rotates in steps. This is very useful because it can be precisely positioned. A stepper motor consists of a rotor that is generally a permanent magnet surrounded by windings of a stator. By energizing one or more of the stator phases, a magnetic field is generated by the current flowing in the coil causing the rotor to align with this field. As we activate the windings step by step in a particular order and let a current flow through them, they will magnetize the stator which create electromagnetic poles respectively causing the rotor (motor) to turn in increments. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) IN A IN B IN C IN D BAT GND MD-4112 MODUPONENT STEPPER MOTOR MOTEUR PAS À PAS REVD MD-4000 Moduponent: MD-4112 Stepper Motor Electrical Symbol: Theory of operation: A stepper motor is a brushless DC motor that rotates in steps. This is very useful because it can be precisely positioned. A stepper motor consists of a rotor that is generally a permanent magnet surrounded by windings of a stator. By energizing one or more of the stator phases, a magnetic field is generated by the current flowing in the coil causing the rotor to align with this field. As we activate the windings step by step in a particular order and let a current flow through them, they will magnetize the stator which create electromagnetic poles respectively causing the rotor (motor) to turn in increments. Safety and Safeguards: 1 Amp circuit protection included in 5V output circuit Use ONLY the protected built-in power supply Operates on a single 120V AC 15A outlet Do not leave this trainer unattended with the power ON Companion Moduponents: MD-4130 Fuses Additional equipment: Safety Glasses DVOM Oscilloscope (optional) STATOR WINDING N S N S S N ROTOR STATOR consulab.com info@consulab.com 50 MD-4000-23_053344-95 Student assignments SA-11 SA-11 MD-4112 Stepper Motor — Level 1 Level 1 exercise: Demonstrate the various drive modes of a 4 coil / 6 pole stepper motor. ( Page 1 of 2 ) Name : Group : Date : WIRING DIAGRAM #1 IN A IN B IN C IN D BAT GND MD-4112 MODUPONENT STEPPER MOTOR MOTEUR PAS À PAS REVD MD-4000 MD-4112 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Setting Up To Operate A Stepper Motor Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4112 Stepper Motor moduponent. Connect a black wire from the BLACK GND terminal at the bottom of the MD-4112 Stepper Motor moduponent back to the BLACK – of the power supply. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 51 MD-4000-23_053344-95 Student assignments SA-11 Level 1 Demonstrating Stepper Motor Operation Done DO THIS: 1 to 1 phase operation (low power needed, low torque output) Press the moduponent YELLOW highlighted buttons in order by the steps listed. 1 IN AIN A IN B IN C IN D 2 IN A IN B IN CIN C IN D 3 IN A IN BIN B IN C IN D 4 IN A IN B IN C IN DIN D 5 IN AIN A IN B IN C IN D 6 Which direction did the stepper motor turn? 7 Will the reverse pattern turn the motor in the opposite direction? YES NO DO THIS: 2 to 2 phase operation (higher power needed, higher torque output) Press the moduponent YELLOW highlighted buttons in order by the steps listed. 1 IN AIN A IN B IN C IN DIN D 2 IN AIN A IN B IN CIN C IN D 3 IN A IN BIN B IN CIN C IN D 4 IN A IN BIN B IN C IN DIN D 5 IN AIN A IN B IN C IN DIN D 6 Which direction did the stepper motor turn? 7 Will the reverse pattern turn the motor in the opposite direction? YES NO SA-11 MD-4112 Stepper Motor — Level 1 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 52 MD-4000-23_053344-95 Student assignments SA-12 SA-12 MD-4114 Solenoid Electrical Symbol Theory of operation Solenoid is the generic term for a coil of wire used as an electromagnet that converts electrical energy to mechanical energy or motion. In other words, an electromagnet is used to cause something else to physically move. A solenoid creates a magnetic field from electric current and uses that magnetic field to create linear motion – to physically move an object (pintle, armature, plunger, linkage, etc). Solenoids are commonly used as: • Fuel injectors • Starter motor drive gear control • Emission control – purge solenoids • Automatic Transmissions – shift solenoids • Electric door and trunk locks. Safety and Safeguards • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Polarity should be observed but cannot damage a solenoid if reversed. • This Moduponent™ will not work correctly without a switch, the power supply current ramp is not instant enough to operate solenoid (Level 3 lesson). • Do not leave this trainer unattended with the power ON Companion ModuponentsTM • MD-4130 Fuses protection • MD-4040 Relay circuit control • MD-4142 Transistors circuit control • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4141 Optical Sensor circuit control • MD-4071 LED’s circuit operation confirmation MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID Additional Equipment • Safety Glasses • DVOM PLEX 1/4" 5.215 3.222 LAMER 7/16'' PROF 0.080''0.281'' X2 SOLENOÏDE MD-4114 SOLENOID MODUPONENT consulab.com info@consulab.com 53 MD-4000-23_053344-95 Student assignments SA-12 SA-12 MD-4114 Solenoid — Level 1 Level 1 exercise: Build a simple circuit to energize and observe solenoid operation. Additional Moduponent required: MD-4090 Name : Group : Date : Instructor : Grade : WIRING DIAGRAM #1 SPST SWITCHES MODUPONENT REVD MD-4090 INTÉRRUPTEURS SPST S2 S1 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID MD-4000 MD-4090MD-4114 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + Level 1 Basic Solenoid Operation Done Build a solenoid circuit using the built-in variable power supply as source voltage. DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply, Test for 12.0 VDC at the power supply, adjust as needed. Turn OFF the power supply. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the any terminal of the MD-4090 SPST Switch Moduponent™. Connect a red wire between the remaining terminal of the MD-4090 SPST Switch to the RED terminal of the MD-4114 Solenoid Moduponent™. Connect a black wire from the black terminal of the MD-4114 Solenoid back to the BLACK – of the power supply. Circuit is now ready to test. Turn MD-4090 SPST Switch ON/OFF and watch for motion of the solenoid plunger. Name : Group : Date : consulab.com info@consulab.com 54 MD-4000-23_053344-95 Student assignments SA-12 SA-12 MD-4114 Solenoid — Level 2 Level 2 exercise: Build a complete working electric solenoid circuit including switches, relays and circuit protection. Additional Moduponents required: MD-4040 12 V DC Relay, MD-4091 DPDT switches. Optional Moduponents suggested: MD-4130 Fuses and MD-4090 SPST switches. ( Page 1 of 2 ) Name : Group : Date : Level 2 Build a complete working electric solenoid circuit Done Build a complete working electric solenoid circuit. DO THIS : Plug in the power supply to a 110 VAC outlet. Turn ON the power supply, Test for 12 V DC at the power supply, adjust as needed. Turn OFF the power supply. 1 Use the printed diagram showing components ONLY on next page. Using the provided component ONLY diagram, complete drawing the electrical circuit that would operate the solenoid incorporating the MD-4000 power supply, MD-4114 Solenoid, MD-4040 12 V DC Relay, and MD-4091 DPDT switches moduponents. * Optional moduponents: MD-4130 Fuses and MD-4090 SPST switches Hint CONTROL SIDE: Source voltage, protection, switch, relay coil and ground circuit. Hint LOAD SIDE: Source voltage, protection, relay contacts, solenoid and ground circuit. On the MD-4000 trainer, actually build the circuit from that drawing. Circuit is now ready to test. 2 Turn the MD-4090 SPST switch ON/OFF and verify circuit operation using a visual observation of solenoid plunger motion 3 Using industry standard symbols, on a piece of paper redraw a wiring diagram of this circuit using a power source, fuses, switches, and a relay to control an electric solenoid. consulab.com info@consulab.com 55 MD-4000-23_053344-95 Student assignments SA-12 SA-12 MD-4114 Solenoid — Level 2 ( Page 2 of 2 ) INCOMPLETE WIRING DIAGRAM SHOWING COMPONENTS ONLY Name : Group : Date : Instructor : Grade : POWER SUPPLY ATC FUSES DPDT SWITCHES RELAY SOLENOID MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + F2 F 3 F4 MODUPONENT REVC MD-4130 F1 FUSIBLES ATC ATC FUSES S1 S2 COMMUTATEURS DPDT DPDT SWITCHES MODUPONENT MD-4091 REVC 86 87 3087a MODUPONENT RELAIS ISO 12 VCC REVD 12VDC ISO RELAY MD-4040 85 MD-4114 MODUPONENT REVC SOLÉNOÏDE SOLENOID consulab.com info@consulab.com 56 MD-4000-23_053344-95 Student assignments SA-13 SA-13 MD-4120 Injector Electrical Symbol Theory of operation An internal combustion engine requires compression, fuel and air to function. The method that fuels are introduced into an engine have changed a lot over time, but today’s modern engines use an electric solenoid valve called a fuel injector to spray fuel into an engine. These electronically controlled valves are capable of opening and closing many times a second which allows for atomizing of the fuel evenly in order to optimize combustion and efficiency. Fuel pressure is applied to the closed injector and when it is pulsed to open/close, it simply acts as a spray nozzle to break up the fuel into a fine spray. It doesn’t actually control the fuel flow because the amount of fuel sprayed is increased or decreased by an electrical control unit - in other words, it is just like turning a water hose nozzle on and off very fast. The longer the injector nozzle is open, the more fuel flows past it into the engine and this ratio of ON/OFF is called Pulse Width Modulation (PWM). The duration that an injector remains open versus closed (PWM) is determined by many input sensor information and this injector moduponent will allow for engine RPM (more/less openings per second) and PWM (longer/shorter open time) to be adjusted for demonstration and learning purposes. Safety and Safeguards • 1A circuit protection included in 5V output circuit. • Use ONLY the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. Companion ModuponentsTM • MD-4130 Fuses • MD-4001 PWM Additional Equipment • Safety Glasses • DVOM • Oscilloscope (optional) GNDSIG12V INJ PW MODULATION RPM MODUPONENT MD-4120 INJECTOR INJECTEUR REVD 21 INJECTOR consulab.com info@consulab.com 57 MD-4000-23_053344-95 Student assignments SA-13 SA-13 MD-4120 Injector — Level 1 Level 1 exercise: Perform a signal voltage measurement of a typical automotive fuel injector at different RPM’s and Pulse Width Modulations. ( Page 1 of 3 ) Name : Group : Date : WIRING DIAGRAM #1 GNDSIG12V INJ PW MODULATION RPM MODUPONENT MD-4120 INJECTOR INJECTEUR REVD MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + MD-4000 MD-4120 SET METER: V DC Level 1 Setting Up To Measure Signal Voltage Done DO THIS : Plug in the power supply to a 120VAC 15A outlet. Turn ON the power supply. Test for 12.0 VDC at the power supply, adjust as needed. See wiring diagram #1 Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4120 Injector moduponent . Connect a black wire from the BLACK GND terminal of the MD-4120 Injector moduponent back to the BLACK – of the power supply. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to the BLUE SIGNAL terminal of the MD-4120 Injector moduponent. Set the DVOM to V DC. Follow the instructions on next page to record measurements. consulab.com info@consulab.com 58 MD-4000-23_053344-95 Student assignments SA-13 SA-13 MD-4120 Injector — Level 1 ( Page 2 of 3 ) Level 1 Measuring signal voltage Done DO THIS : 1 Set the RPM dial to the fourth line marking. Set the PWM dial to the fourth line marking . Record voltage at the signal terminal here: V Set the RPM dial to the fourth line marking. Set the PWM dial to the sixth line marking . Record voltage at the signal terminal here: V Set the RPM dial to the fourth line marking. Set the PWM dial to the eightth line marking . Record voltage at the signal terminal here: V Set the RPM dial to the sixth line marking. Set the PWM dial to the fourth line marking . Record voltage at the signal terminal here: V Set the RPM dial to the sixth line marking. Set the PWM dial to the eightth line marking . Record voltage at the signal terminal here: V consulab.com info@consulab.com 59 MD-4000-23_053344-95 Student assignments SA-13 Name : Group : Date : Instructor : Grade : SA-13 MD-4120 Injector — Level 1 ( Page 3 of 3 ) Level 1 Measuring signal voltage Done DO THIS : 2 Discuss these observations: How did the injector “sound” change? 3 What affected voltage readings more – RPM or PWM? Why? 4 What is happening to the actual injector spray time in these different scenarios? 5 Explain “pulse width”: consulab.com info@consulab.com 60 MD-4000-23_053344-95 Student assignments SA-13 SA-13 MD-4120 Injector — Level 2 NOTE: *Prior oscilloscope knowledge is required for this Student Assignment. Level 2 exercise: Obtain an oscilloscope pattern for a fuel injectors PWM and compare it to frequency/RPM. Name : Group : Date : Instructor : Grade : Level 2 Setting up to measure Injector PWM Done DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed. Connect a red wire between the RED + of the power supply to the RED 12V terminal of the MD-4120 Injector moduponent. Connect a black wire from the BLACK GND terminal of the MD-4120 Injector moduponent back to the BLACK – of the power supply. Connect one lead of an oscilloscope to the BLUE SIGNAL terminal of the MD-4120 Injector moduponent. Connect the black lead of an oscilloscope to the back to the BLACK – of the power supply. Follow the instructions below for PWM control dial settings and record measurements. Level 2 Measuring pulsed voltage with an oscilloscope Done Set the MOTOR control dial (RPM) to the fifth line. 1 Record the oscilloscope settings used to obtain a signal: Voltage: V per div Time: s per div Trigger: V. 2 Set PWM control dial to the third line marking. On a sheet of paper, draw and label the pattern observed. 3 Set PWM control dial to the fifth line marking. On a sheet of paper, draw and label the pattern observed. 4 Set PWM control dial to the seventh line marking. On a sheet of paper, draw and label the pattern observed. 5 Set PWM control dial to the eighth line marking. On a sheet of paper, draw and label the pattern observed. 6 Set PWM control dial to FULL ON. On a sheet of paper, draw and label the pattern observed. 7 Move the MOTOR control dial up to FULL SPEED and turn back down, observe the PWM and report your observations with explanation within: Name : Group : Date : consulab.com info@consulab.com 61 MD-4000-23_053344-95 Student assignments SA-14 SA-14 MD-4141 Optical Sensors Electrical Symbols Theory of operation The MD-4141 Moduponent includes three (3) optical sensors: one photoresistor, one photodiode and one phototransistor. Each of these optical sensors incorporate a different electronic component that is sensitive to incoming light, using either a resistor, a diode or a transistor. Each of these sensors receive light to activate them, using unique characteristics to control a circuit or component. Prior knowledge of semiconductors like resistors, diodes and transistors are recommended prior to completing these assignments. PHOTORESISTOR A photoresistor’s resistance decreases with an increase in light intensity and can be used in light sensitive circuits. When there is low to no light, the resistance increases and this characteristic is used to control a transistor that in turn switches a circuit on. A common example would be security lighting that comes on at dusk. In an automobile, this could be also be used to control the automatic day/night rearview mirror element. PHOTODIODE A photodiode is a type of semiconductor diode which actually generates an electric current when light is applied to its surface. It converts the light’s energy into an electrical current. This actual response time is slower as their surface area increases, such as in a solar panel, but is still faster than the phototransistor. Photodiodes are designed to operate in both forward or reverse bias and used to switch circuits in electronic devices like a smoke detector or CD player. In an automobile, this could be used to sense sunload or twilight in climate control applications. PHOTOTRANSISTOR The phototransistor is a two or three terminal semiconductor that converts light energy into electric current. It is a special design transistor which has a light sensitive base, not a regular transistor base. When the base of this NPN transistor is exposed to light, the phototransistor converts it to electrical current proportional to the amount of light applied. The phototransistor amplifies the input light and the output current can be measured at the collector of the transistor. This component is used to detect light. MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 PLEXI 1/4" 0.281'' LAMER 7/16'' PROF 0.080'' MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES 5.215 3.222 Photoresistor PhototransistorPhotodiode consulab.com info@consulab.com 62 MD-4000-23_053344-95 Student assignments SA-14 Safety and Safeguards • ONLY use the protected built-in power supply. • Operates on a single 120VAC 15A outlet. • Do not leave this trainer unattended with the power ON. • Observe polarity as component could be damaged. Companion ModuponentsTM • MD-4130 Fuses protection • MD-4142 Transistors theory • MD-4010 Resistors theory • MD-4140 Diodes theory • MD-4090 SPST Switch circuit control • MD-4091 DPDT Switch circuit control • MD-4111 Fan load operation • MD-4070 Light Bulbs load operation • MD-4114 Solenoid load operation • MD-4071 LED’s load operation (resistance req’d) Additional Equipment • Safety Glasses • DVOM • Flashlight consulab.com info@consulab.com 63 MD-4000-23_053344-95 Student assignments SA-14 SA-14 MD-4141 Optical Sensors — Level 1 Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). Level 1 exercise : Observe the characteristics of three optical sensors. This Moduponent has three ( 3 ) Optical Sensors – the photoresistor, the photodiode, and the phototransistor that we will test for light sensitivity by measuringv with a DVOM. ( Page 1 of 2 ) Name : Group : Date : WIRING DIAGRAM #1 WIRING DIAGRAM #2 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF SET METER: Ohms PHOTORESISTOR MD-4141 SET METER: mV PHOTODIODE MD-4141 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF Level 1A Photoresistor operation Done Measure the photoresistor resistance and how light affects it. DO THIS : See wiring diagram #1 Connect the DVOM red lead to either yellow terminal of the MD-4041 Photoresistor. Connect the DVOM black lead to either yellow terminal of the MD-4041 Photoresistor. Set the DVOM to Ohms (Ω). 1 In normal room light, measure and record the resistance measurement: Ω 2 Now, cover the photoresistor sensor to block light, observe and record the resistance measurement: Ω 3 Now, expose the photoresistor sensor to the light from a flashlight, observe and record the resistance measurement: Ω 4 Did the resistance go up or down when exposed to light? consulab.com info@consulab.com 64 MD-4000-23_053344-95 Student assignments SA-14 SA-14 MD-4141 Optical Sensors — Level 1 ( Page 2 of 2 ) Name : Group : Date : Instructor : Grade : Level 1B Photodiode operation Done Measure the voltage produced by a photodiode as light affects it. DO THIS : See wiring diagram #2 Connect the DVOM red lead to either yellow terminal of the MD-4041 Photodiode. Connect the DVOM black lead to either yellow terminal of the MD-4041 Photodiode. Set the DVOM to mV. 1 In normal room light, measure and record the resistance measurement: Ω 2 Measure and record the mV reading: mV Cover the sensor with your hand. 3 Measure and record the mV reading: mV Now, shine a light on the sensor. 4 Measure and record the mV reading: mV Level 1C PhotoTransistor operation Done Measure the voltage produced by a phototransistor as light affects it. DO THIS : Connect the DVOM red lead to either yellow terminal of the MD-4041 Phototransistor. Connect the DVOM black lead to either yellow terminal of the MD-4041 Phototransistor. Set the DVOM to mV. 1 Measure and record the mV reading: mV Cover the sensor with your hand. 2 Measure and record the mV reading: mV Now, shine a light on the sensor. 3 Measure and record the mV reading: mV consulab.com info@consulab.com 65 MD-4000-23_053344-95 Student assignments SA-14 SA-14 MD-4141 Optical Sensors — Level 2 Prior knowledge of semiconductors like resistors, diodes and transistors are recommended before completing these assignments (see MD-4010, MD-4140 & MD-4142). Level 2 exercise: Build a working electrical circuit using 3 different optical sensors to turn on an LED. Additional Moduponents required: MD-4002 5 and MD-4071. Name : Group : Date : Instructor : Grade : WIRING DIAGRAM #3 MODUPONENT MD-4000 2-15 V SOURCE CC VARIABLE REVC DC POWER SUPPLY - ON/OFF RESET O.L. 3A. MAX. + SORTIE 5 VCC MODULE MAX 1A GND MODUPONENT REVD MD-4002 5 VDC OUTPUT 5VBAT AMPOULES À DEL MD-4071 MODUPONENT REVD LED'S MD-4000 MD-4002 MD-4071 MD-4141 MD-4141 MODUPONENT OPTICAL SENSORS CAPTEURS OPTIQUES REVF Level 2 Photoresistor operation Done Build a circuit using a photoresistor to operate an LED. DO THIS : Plug in the power supply to a 120V AC 15A outlet. Turn ON the power supply. Test for 12.0 V DC at the power supply, adjust as needed * if MD-4002 5V regulator is not available, adjust power supply to 5V before proceeding. See wiring diagram #3 Connect a red wire between the RED + of the power supply to the RED BAT terminal of the MD-4002 5 Volt Regulator. Connect a black wire from the BLACK GND terminal of the MD-4002 5 Volt Regulator back to the BLACK – of the power supply. Connect a red wire between the 5V terminal of the MD-4002 5 Volt Regulator to one of the YELLOW terminals of the MD-4141 photoresistor. Connect another red wire from the other YELLOW terminal of the MD-4141 photoresistor to the RED terminal of any MD-4071 LED. Connect a black wire from the BLACK terminal of the MD-4071 LED back to the BLACK – of the power supply. Shine a bright light onto the photoresistor and observe LED operation. Connect the DVOM black lead to BLACK – of the power supply. Connect the DVOM red lead to various test points of the circuit and observe voltage changing with light application. 1 Explain why the LED illuminates when the photoresistor is exposed to light. Name : Group : Date : consulab.com info@consulab.com 66 MD-4000-23_053344-95 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. Tous droits réservés. General description Student Assignments SA-1 MD-4001 Pulse Width Modulator (PWM) SA-2 MD-4002 5V Regulator SA-3 MD-4040 12VDC 5-pin ISO Relay SA-4 MD-4050 Variable Reluctance Sensor SA-5 MD-4051 Hall Effect Sensor SA-6 MD-4052 Negative Temperature Coefficient Thermistor (NTC) SA-7 MD-4053 MAP Sensor SA-8 MD-4054 TP Sensor SA-9 MD-4055 Piezo Knock Sensor SA-10 MD-4057 Magnetic Resistive Sensor SA-11 MD-4112 Stepper Motor SA-12 MD-4114 Solenoid SA-13 MD-4120 Injector SA-14 MD-4141 Optical Sensors

HVAC electronics Moduponent™ kit MD-4000-24_053345 Rev. 2025/04 MD-4000-24_053345 HVAC electronics Moduponent™ kit consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL ADVANTAGES FEATURES LIST OF INCLUDED MODUPONENTS® OPTIONS TECHNICAL INFORMATIONS The ConsuLab MD-4000-24 is a versatile and adaptable electrical/electronic training series that allows students to build electronic circuits used in common HVAC systems. • Can be used for teaching basic Ohm’s law or circuits used in common HVAC systems • Self-contained unit has a protected built-in adjustable power supply and holds up to 16 different Moduponents® • Includes 15 different Moduponents® from the entire MD-4000 series • Uses industry standard schematic symbols • Can assist you in the instruction of many tasks in area A6 and others of the ASE Education Foundation (NATEF) • User manual included • Protected with removable metal cover • Adjustable and protected power supply (2-14VDC) • Moduponent® attachment rails allow up to 16 individual Moduponents® • Dimensions : 22 x 20 x 10 in (55.8 x 50.8 x 25.4 cm) • Weight : 33 lb (15 kg) • CL-1011A_52958 Desktop Moduponent® Case • CL-1012-03_52320 Set of 26 jumper leads • MD-4000_53061 DC Power Supply • MD-4001_53074 Pulse Width Modulator • MD-4002_53095 5V Output (Regulator) • MD-4030_53070 Potentiometer • MD-4040_53068 12VDC 5-pin ISO Relay • MD-4052_53067 NCT Thermistor • MD-4058_53207 High Pressure Switch • MD-4059_53209 Sunload Sensor • MD-4060_53210 Windshield Temperature and Inside Moisture Sensor • MD-4061_53211 In-vehicle Temperature and Humidity Sensor • MD-4062_53130 PTC Thermistor • MD-4111_53073 Fan • MD-4115_53208 Air Door Actuator • MD-4141_53076 Optical Sensors (3) • MD-4142_53077 Transistors • CL-1918-10B or CL-1918-10S 1918 upright stand or tabletop stand • MD-4000-4U_053359 Upgrade kit, convert a 1918 stand for use with MD-4000 Moduponents™

Student Assignments for EM-145S_053331 95-EM-145S-GM05_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. SONIC SWIVEL ENGINE STAND W/STARTING STATION 95-EM-145S-GM05 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, 2026. 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. Made in Canada. The content of this manual is applicable to models 053331 and above. Table of contents Product Description 3 Educational Advantages 3 Student Assignments: SA-1 Basic Component Identification 5 SA-2 Engine Specific Identification 7 SA-3 Sensor Identification 9 SA-4 Actuator Identification 10 SA-5 Charging System 11 SA-6 Cylinder Head Removal 12 SA-7 Cylinder Head Inspection 13 SA-8 Valve Train Inspection 14 SA-9 Cylinder Block Inspection 15 SA-10 Piston Removal, Inspection and Measurement 16 SA-11 Crankshaft Removal, Inspection and Measurement 17 Testing Engine Mechanical Condition 18 SA-12 Cylinder Balance Test 19 SA-13 Engine Running Vacuum Test 21 SA-14 Static Engine Compression Test 23 SA-15 Running Compression Test 25 SA-16 Cylinder Leak Down Test 27 SA-17 Relative Compression Test (Current Measuring Method) 29 SA-18 Relative Compression Test (Voltage Measuring Method) 31 SA-19 Cranking In-Cylinder Pressure Test Using Pressure Transducer 33 SA-20 Running In-Cylinder Pressure Test Using Pressure Transducer 36 Additional Learning Resources 39 Notes 40 95-145S-GM05 Product Desceiption and Advantages consulab.com info@consulab.com 3 Product Description The EM-145S-GM05_053331 GM Sonic engine on a swivel stand is designed for student instruction allowing students to practice engine mechanical inspection, disassembly, measurement and reassembly. The engine is securely mounted to a heavy duty rotating device equipped with an automatic lock to allow full 360 degree rotation. The steel mounting plate is used for engine mounting that allows full access for rear main seal and flywheel service. Each engine comes equipped with a manual transmission flywheel. The engine starting station contains all components and systems necessary for the starting and running of the GM Ecotec 1.8L engine. All necessary engine systems connections are provided to allow live operation of each swivel engine stand. Educational Advantages: • Accessibility of engine components is enhanced by removing the requirement of whole vehicles in the shop. • Ability to verify proper engine systems operation before and after engine repair. • Provides a single starting station that can be used with multiple engine stands. • All rotating components are covered with safety shields or guards to prevent injuries. • Continuity of subject matter is provided by students working on identical engines. • Multiple ASE tasks in the Engine Repair area can be performed on this product. 95-145S-GM05 Student Assignments consulab.com info@consulab.com 4 Student Assignments 95-145S-GM05 SA-1 — Basic Component Identification consulab.com info@consulab.com 5 SA-1 Basic Component Identification In preparation to diagnosing any engine mechanical issues, one has to know what they are working on first. This assignment is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Use this sheet to record all your answers. COMPONENT FUNCTION LOCATION ConsuLab Engine Trainer: EM-145 ___________________ Engine Mounts Transmission Transmission Fluid Level Inspection Coolant Hoses Coolant Reservoir & Cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain Plug Oil Dipstick Air Filter Fuel Filter(s) Throttle (body) 95-145S-GM05 SA-1 — Basic Component Identification consulab.com info@consulab.com 6 COMPONENT FUNCTION LOCATION Positive Crankcase Ventilation System Battery Starter Alternator Belt(s) Fuse Box – Power NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-2 — Engine Specific Identification consulab.com info@consulab.com 7 SA-2 Engine Specific Identification In preparation to diagnosing any engine mechanical issues, one has to know what they are working on first. This assignment is step two in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Use this sheet to record all your answers. ENGINE SYSTEM ENGINE SPECIFIC INFORMATION VIN & Decode Engine Type Gasoline □ Diesel □ Engine Model Engine Displacement Number of Cylinders Cylinder Numbering Firing Order Direction of Engine Rotation Compression Ratio Aspiration Turbo □ Supercharged □ N/A □ Camshaft Configuration OHV □ SOHC □ DOHC □ Turbo Type Charge Air Cooler Location & Function Fuel System Type 95-145S-GM05 SA-2 — Engine Specific Identification consulab.com info@consulab.com 8 ENGINE SYSTEM ENGINE SPECIFIC INFORMATION Other Technologies Questions: 1. Identify and record the engine displacement: _______________________________________________ 2. Is this an OHV or SOHC or DOHC engine? __________________________________________________ 3. What direction should this engine spin? ____________________________________________________ 4. Does engine spin 360° easily with ½” breaker bar? __________________________________________ 5. Take detailed digital photos of the engine, from numerous angles, to aid in your documentation and reassembly. NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-3 — Sensor Identification consulab.com info@consulab.com 9 SA-3 Sensor Identification In preparation to diagnosing any engine mechanical issues, one has to know what they are working on first. This assignment is step three in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Use this sheet to record all your answers. SENSOR FUNCTION LOCATION ECM/PCM CONNECTOR & PIN #’s Example: A/C Pressure switch Monitors the pressure level of the A/C loop Radiator Pin B-52 NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-4 — Actuator Identification consulab.com info@consulab.com 10 SA-4 Actuator Identification In preparation to diagnosing any engine mechanical issues, one has to know what they are working on first. This assignment is step four in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Use this sheet to record all your answers. ACTUATOR FUNCTION LOCATION ECM/PCM CONNECTOR & PIN #’s Example: Camshaft Position Actuator Solenoid Controls the position of the camshafts Cylinder Head Pin A-15 NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-5 — Charging System consulab.com info@consulab.com 11 SA-5 Charging System TASK RECORD RESULTS & INTERPRET Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = ____________ What can affect this vol- tage? _____________________________ Cranking Voltage Lowest voltage observed = ___________ Charging System Voltage Is this 2V over OCV? YES □ NO □ Is this system functioning properly? VOLTAGE DROPS TO VERIFY SYSTEM INTEGRITY NOTE: Current has to be flowing to perform an accurate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER □ UNDER □ Final Charging Voltage Are there any issues that would prevent proceeding with diagnosing engine performance issues? In preparation to diagnosing any engine mechanical issues, one has to know what they are working on first. This assignment is step five in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Use this sheet to record all your answers. NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-6 — Cylinder Head Removal consulab.com info@consulab.com 12 SA-6 Cylinder Head Removal Follow the procedure and use this sheet to record all your answers: 1. Locate the cylinder head removal procedure in service information. 2. The service information guidelines for the reuse of cylinder head bolts states that: _____________________________________________________________________________________________________ _____________________________________________________________________________________________________ 3. Loosen in sequence and remove the head bolts as directed by the service information. 4. Remove the cylinder head and place on a suitable stand, piece of wood, or non-marring surface, to pro- tect and maintain the surface finish of the sealing surfaces. NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-7 — Cylinder Head Inspection consulab.com info@consulab.com 13 SA-7 Cylinder Head Inspection Follow the procedure and use this sheet to record all your answers: 1. What is the RA specification for the cylinder head surface? _____________________________________________________________________________________________________ _____________________________________________________________________________________________________ 2. Inspect head for damage and record your observations. _____________________________________________________________________________________________________ _____________________________________________________________________________________________________ 3. Record the max spec for head warpage here:. _____________________________________________________________________________________________________ _____________________________________________________________________________________________________ 4. Use a straight edge to check the cylinder head for excessive warpage and record: _____________________________________________________________________________________________________ _____________________________________________________________________________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-8 — Valve Train Inspection consulab.com info@consulab.com 14 SA-8 Valve Train Inspection Follow the procedure and use this sheet to record all your answers: 1. Disassemble heads removing the valves and valve train. 2. Measure and record the inner diameter of the valve guides: ____________________________________________ 3. Are they within the guidelines published in the service information? ____________________________________ 4. Measure and record the valve stems: _________________________________________________________________ 5. Are they within the guidelines published in the service information?: ____________________________________ 6. Measure and record the specs for valve spring free lengths and pressures: _____________________________ 7. Are they within the guidelines published in the service information? ____________________________________ 8. Measure and record the valve margins, seat width and contact patterns: _______________________________ 9. Are they within the guidelines published in the service information? ____________________________________ 10. Measure and record cam lobe lift: ____________________________________________________________________ 11. Are they within the guidelines published in the service information? ____________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-9 — Cylinder Block Inspection consulab.com info@consulab.com 15 SA-9 Cylinder Block Inspection Follow the procedure and use this sheet to record all your answers: 1. Measure deck flatness with a straightedge: ___________________________________________________________ 2. Is it within the guidelines published in the service information? ________________________________________ 3. Measure and record the cylinder bore diameters, taper and out of roundness: ____________________________________________________________________________________________________ 4. Is it within the guidelines published in the service information? ________________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-10 — Piston Removal, Inspection and Measurement consulab.com info@consulab.com 16 SA-10 Piston Removal, Inspection and Measurement Follow the procedure and use this sheet to record all your answers: 1. Remove the pistons as directed by the service information. 2. Measure and record the cylinder bore diameters, taper and out of roundness: ____________________________________________________________________________________________________ 3. Are they within the guidelines published in the service information? ___________________________________ 4. Measure and record the specs for the piston diameter and ring land clearances: ____________________________________________________________________________________________________ 5. Are they within the guidelines published in the service information? ___________________________________ 6. Remove piston rings from one piston to inspect for carbon. Clean the grooves with proper tooling if direc- ted by your instructor. 7. Measure and record the piston ring end gaps: ________________________________________________________ 8. Are they within the guidelines published in the service information? ___________________________________ 9. Using proper tooling install rings and position them as directed by the service information on the piston. NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-11 — Crankshaft Removal, Inspection and Measurement consulab.com info@consulab.com 17 SA-11 Crankshaft Removal, Inspection and Measurement Follow the procedure and use this sheet to record all your answers: 1. Remove the crankshaft as directed by the service information. 2. Measure and record the crankshaft main bearing journal bearing surfaces, including the thrust bearings and fillet radius: _____________________________________________________________________________________________________ 3. Are they within the guidelines published in the service information? ____________________________________ 4. Measure and record the crankshaft rod bearing journal bearing diameters and fillet radius: ______________________________________________________________________________________________________ 5. Are they within the guidelines published in the service information?: ____________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 Testing Engine Mechanical Condition consulab.com info@consulab.com 18 Testing Engine Mechanical Condition In many diagnostic scenarios used to determine the cause of an abnormal engine operating condition, it may be necessary to perform one or more tests designed to more accurately pinpoint the location and cause of the problem. The tests commonly follow a “diagnostic path” which start out testing “general” or total engine condition testing, then can be followed with tests designed to more specifically pin-point the exact location of the problem. Some of these tests have been the industry standards for many years, while others have recently been in- troduced. Among the most recent additions have been those using a DSO (Digital Storage Oscilloscope) and pressure transducers. Although, there is somewhat of a learning curve required to become proficient with these tests, they are very accurate and can provide very detailed information about the mechanical health of an engine. Among the most commonly performed tests are: 1. Cylinder Balance Test (SA-12) 2. Engine Running Vacuum Test (SA-13) 3. Static or Cranking Compression Test (SA-14) 4. Running Compression Test (SA-15) 5. Cylinder Leakdown Test (SA-16) Advanced Level Tests: 6. Relative Cranking Compression Tests (Using an oscilloscope and current probe waveforms) (SA-17) 7. Relative Cranking Compression Tests (Using an oscilloscope and voltage waveforms) (SA-18) 8. In-cylinder (Cranking) Pressure Tests (Using an oscilloscope and a pressure transducer) (SA-19) 9. In-cylinder (Running) Pressure Tests (Using an oscilloscope and a pressure transducer) (SA-20) Summary: When diagnosing the mechanical condition of multi-cylinder engines, it must be remembered that although all cylinders usually share a common crankshaft, block and cylinder heads, each cylinder is actually an “individual engine”. An individual cylinder can have a problem that affects only that cylinder. Common examples are poor compression, leaking valves, worn camshaft lobe(s), oil consumption or head gasket issues and more. Other abnormal conditions can affect all cylinders at the same time causing poor performance. These can include variable valve timing, exhaust or intake restrictions, worn timing chains/gears, mechanical wear, fuel mixture or ignition timing problems and more. Below are suggested procedures for the most common mechanical dia- gnostic tests performed on today’s vehicles. The procedures are “generic” in design and may have to modified for specific engines or systems. Be sure to always follow OEM service information for the engine being tested. Typical Diagnostic Path: A. Evaluate the cranking and running condition of the engine. B. Determine if by the sounds or performance if a problem may exist. C. Look for any stored DTC’s using a scan tool. D. If abnormal conditions are observed, determine if the problem is single cylinder related or entire engine related. E. Based on your conclusions, determine the appropriate test required and begin to identify the specific cause. 95-145S-GM05 SA-12 — Cylinder Balance Test consulab.com info@consulab.com 19 ) The CYLINDER BALANCE TEST determines the individual power contribution of each cylinder to the whole en- gine. The test momentarily cancels either the ignition or the fuel to the cylinder being tested which technically “shuts if off” while the other cylinders are still operating. This drop in RPM will be more significant on 4-cylinder engines compared to 6 or 8 cylinder engines. If the cylinder being tested was contributing, and temporarily cancelled, the total engine RPM should drop. If the cylinder wasn’t contributing, there will be little if any change in total RPM. Some scan tools have the capability of performing a cylinder balance test. Check with the scan tool you have available for this feature and procedure details. The ConsuLab EM-145S-GM05 trainer is based on the Sonic platform and the GM engine management system will allow a scan tool to perform an injector cut-out test for each cylinder which can be used to perform an engine balance test. The procedure below explains how to perform this test with and without the scan tool option. NOTE: It is good practice to obtain the firing order of the engine and conduct the test in that or- der. Fill in the chart below with the firing order next to “1, 2, 3, 4, 5, 6, 7, 8” Example – 4-cyl engine firing order of 1432. Cylinder 1 = 1, 2 = 4, 3 = 3 and 4 = 2. This method makes the identification of a problem cylinder easier. Follow the procedure and use this sheet to record all your answers: WITH SCAN TOOL FUNCTION: 1. Connect a bi-directional scan tool to the DLC and select the active test for Select Cylinder Fuel Cut. (GM) 2. Connect the engine’s exhaust to an exhaust removal system and make sure it is turned on. NOTE: Most OEM’s recommend that the engine be at or close to operating temperature before conduc- ting this test. 3. Start the engine and begin the test. You may need to raise engine speed above idle (1,000 RPM’s) to prevent the engine management system from compensating. 4. Record the engine speed then disable the injector for cylinder number 1 and record the engine speed again. 5. Repeat the above procedure for the remaining cylinders and record your test results in the chart. Iden- tify the engines firing order and fill in the blanks here: FIRING ORDER CYLINDER # 1= 2= 3= 4= 5= 6= 7= 8= RPM Injector ON or CYLINDER RUN- NING RPM RPM RPM RPM RPM RPM RPM RPM RPM INJECTOR OFF or CYLINDER OFF RPM RPM RPM RPM RPM RPM RPM RPM SA-12 Cylinder Balance Test 95-145S-GM05 SA-12 — Cylinder Balance Test consulab.com info@consulab.com 20 WITHOUT SCAN TOOL FUNCTION: 6. Refer to OEM service information to determine the best method of cancelling out individual cylinders. On some engines, one can remove individual fuel injector connectors. On others, the COP coil connec- tor can be removed. On older engines, one can temporarily disconnect a spark plug wire and short the wire to ground. 7. Connect the engine’s exhaust to an exhaust removal system and make sure it is turned on and opera- ting. NOTE: Most OEM’s recommend that the engine be at or close to operating temperature before conducting this test. 8. Start the engine and begin the test. You may need to raise engine speed above idle (1,000 RPM’s) to prevent the engine management system from compensating. 9. Disable cylinder one in the firing order (using procedure determined above) and record RPM change. 10. Record the engine speed in the chart below. 11. Repeat the above procedure for the remaining cylinders and record your test results in the chart. Iden- tify the engines firing order and fill in the blanks here: 12. Analyze the results and determine the contribution of each cylinder to the engines total performance. If results were abnormal, list some possible failures below that could cause abnormal results. _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ FIRING ORDER CYLINDER # 1= 2= 3= 4= 5= 6= 7= 8= RPM Injector ON or CYLINDER RUNNING RPM RPM RPM RPM RPM RPM RPM RPM RPM INJECTOR OFF or CYLINDER OFF RPM RPM RPM RPM RPM RPM RPM RPM NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-13 — Engine Running Vacuum Test consulab.com info@consulab.com 21 SA-13 Engine Running Vacuum Test The ENGINE RUNNING VACUUM TEST is a very old but still reliable condition test for engines. It must be un- derstood that an engine is really only an “air pump” that brings in air, mixtures fuel with the air, burns it to create heat & pressure and then expels the spent exhaust gases. Anything that affects the “breathing” efficiency of the engine is important to understand. Even the term “vacuum” is often misunderstood by many. Technically, vacuum defined is the absence of any atmosphere. Therefore, an engine could not have “vacuum”. Instead, what is inside the engine is actually air pressure that is lower than outside atmospheric pressure (14.7psi @sea level). As the pistons move up and down and the intake and exhaust valves open and close, the engine draws air in through the throttle plates and expels the spent air through the exhaust valves. If the throttle plate diameter is less than the combined diameter of the cylinders, then a restriction is created which lowers the pressure of the incoming air. This lower pressure inside the engine is what is commonly called “vacuum”. Vacuum is often measured with a vacuum gauge which can give an accurate determination of the engine’s mechanical health. The normal mea- surement value of vacuum is given in “Inches of Mercury”. NOTE: It should be pointed out that the engine’s MAP (Manifold Absolute Pressure) sensor is often called the “vacuum” sensor, but in reality, it measures the reduced air pressure inside the engine (intake manifold) which changes constantly with many factors including engine load, temperature, timing, valve action, exhaust restric- tion, compression, and more. Follow the procedure and use this sheet to record all your answers: ENGINE RUNNING VACUUM TEST: 1. Inspect the intake manifold and identify an appropriate access point to attach the vacuum gauge hose. (examples are a vacuum fitting or threaded plug.) (Ideally, it should be in the center of the intake manifold). NOTE: Most OEM’s recommend that the engine be at or close to operating temperature before conduc- ting this test. 2. Ensure that the connection point does not interfere with the normal operation of any engine systems. 3. Connect the engine’s exhaust to an exhaust removal system and make sure it is turned on and operating. 4. Start the engine, let it idle and record the vacuum gauge reading: _______ (normal values = 17-19± inHg). Is the gauge reading steady or fluctuating? ________________ (normal value is steady). 5. Increase the engine RPM to 2000 RPM and record the vacuum gauge reading. ________ (normal = 21-22± inHg). Is the gauge reading steady or fluctuating? ________________ (normal value is steady). 6. Perform a snap throttle test by very quickly stepping on the accelerator pedal fully and quickly releasing again. 7. Note the vacuum readings while performing this test. Describe what the vacuum gauge did during the snap throttle test. ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ 95-145S-GM05 SA-13 — Engine Running Vacuum Test consulab.com info@consulab.com 22 8. Did the vacuum gauge respond quickly or slowly? _____________ (normal is a very rapid drop to almost zero and immediately returning to the reading before snap-test.) 9. There are common vacuum diagnostic charts available in textbooks or online that give specific causes and refers to engine components causing abnormal readings. Obtain a chart and analyze your results. List possible engine failures below that could affect vacuum readings. ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-14 — Static Engine Compression Test consulab.com info@consulab.com 23 SA-14 Static Engine Compression Test A STATIC ENGINE COMPRESSION TEST measures an individual cylinders’ ability to develop compression within the cylinder. This is a very common and valuable diagnostic tool in determining the mechanical condition of an engine. Normal compression values of most gasoline engines range from 125 psi to 150 psi. Diesel engines have substantially higher compression values. The most important factor is that all cylinders are within 20% of the highest to lowest value. Most OEM’s recommend that the engine be at operating temperature when performing a compression test, while a few others do not. The primary concern iis regarding spark plug removal and installa- tion and aluminum cylinder heads. Be sure to check OEM service information for the engine being tested. When performing a compression test, take note of the 1st, 2nd, 3rd and 4th gauge needle pulses. An engine in good condition should cause the gauge to jump on the 1st needle pulse to with 75% of the reading obtained on the 4th needle pulse. If it takes all four needle pulses to slowly build up the pressure, there may be mechani- cal problems in that cylinder. In addition, it is a good idea to remove all spark plugs. This increases the cranking speed and also allows diagnosis of an adjacent cylinder head gasket leak that might be “masked” if only one spark plug was removed. Follow the procedure and use this sheet to record all your answers: COMPRESSION TEST PROCEDURE: Prepare the engine as follows: 1. The engine should be warm for the best results. NOTE: There is considerable debate on this topic based on spark plugs installed in aluminum heads. Many OEM’s recommend having the engine at operating tem- perature. Follow your instructor’s policy.) 2. The battery must be fully charged. If not, correctly charge the battery until full charge is obtained. Some recommend that the battery charger be hooked up to the battery during the compression test. WARNING: Do not set battery charger on a maximum setting. 3. Disable the engine from running. This can typically be done two ways: Ignition or Fuel. As appropriate, disable the ignition system. WARNING: On older engines do not allow spark plug wires to operate with open circuit voltage while disconnected from spark plugs) It’s best to disable the ignition primary system) On newer engines, disconnect COP primary wires or the appropriate ignition fuse(s). Check with OEM service information for details. 4. Disable the fuel injection system. (Depending on specific engines, remove fuel injector connector or consult OEM service information for the best procedure to disable the fuel injectors from operating.) 5. Remove all the spark plugs. Keep the spark plugs in order of location for analysis. 6. Block the throttle plate wide open. (If ETC equipped, check with OEM service information for correct procedure) 7. Select the correct adaptor for the compression tester and thread it into cylinder number #1 spark plug hole. 8. Start with the compression gauge at zero and crank the engine through four compression strokes. (4 needle pulses) (Check OEM factory specs for recommended number of compression pulses) Note the pressure reading on the 1st and 4th compression stroke (needle pulse). 9. Record the readings below. Release pressure on gauge and move the compression tester to each cylinder and repeat the test and record the results. 95-145S-GM05 SA-14 — Static Engine Compression Test consulab.com info@consulab.com 24 10. If a cylinder has low compression, squirt approximately 15 ml (one tablespoon) of engine oil into the combustion chamber through the spark plug hole, then repeat test for that cylinder and record new reading on “WET TEST” line. 11. Analyze the results and determine if they are acceptable or if there is a problem indicated. NORMAL VALUES: Maximum variation between highest and lowest reading should not exceed 20%. Ge- nerally speaking, if a reading increases dramatically with oil, the rings are worn. If the reading does not increase, the valves are usually the problem 12. List possible failures creating low compression readings on a separate sheet of paper. ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ CYLINDER # 1 2 3 4 5 6 7 8 1ST STROKE PSI 4TH STROKE PSI WET TEST PSI NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-15 — Running Compression Test consulab.com info@consulab.com 25 SA-15 Running Compression Test The RUNNING COMPRESSION TEST is often performed to assist in isolating specific faults. The re- sults of this test are often misunderstood. One might think that the compression pressures of a running engine would be much higher than observed during a cranking compression test. The opposite is true. Normal values for running compression in a cylinder should be about ½ of the cranking compression values (60-75 psi ±). The reason for this has to do with the manifold vacuum reduces cylinder air mass as compared to the engine at cranking speed. A cranking compression test evaluates the “sealing” of the cylinder, whereas a running compression test evaluates the cylinders ability to “breathe”. Part of this test is to also do a “snap throttle” test. (see below). Follow the procedure and use this sheet to record all your answers: PROCEDURE: Following a static compression test and a cylinder balance test, a running compression test may be required to isolate identified faults. NOTE: Most agree that the engine should be at or near operating temperature before conducting test: 1. Install all spark plugs except one. (The cylinder to be tested). 2. If possible, ground the plug wire of the cylinder being tested to prevent module damage or leave COP module primary wire disconnected or the injector connecter. NOTE: Never run a cylinder without ignition and with the injector still operating! 3. The test can be done without a Schrader valve in the compression tester while some recommended leaving the valve in the gauge and releasing the gauge every 5-6 strokes. 4. Optionally, remove the Schrader valve from the base of the compression tester adaptor. 5. Insert the compression tester into the spark plug hole of the cylinder to be tested. 6. Start the engine and record your results. Normal values are roughly ½ of cranking compression pressures. 7. Now snap the throttle 2 or 3 times for a “snap acceleration” test reading. Reading should rise. Normal values are roughly 80% of idling compression values. 8. Repeat test on all desired cylinders and record results. 9. Analyze the results and determine if they are acceptable or if there is a problem indicated. CYLINDER # 1 2 3 4 5 6 7 8 RUNNING AT IDLE PSI SNAP THROTTLE PSI 95-145S-GM05 SA-15 — Running Compression Test consulab.com info@consulab.com 26 EVALUATING RESULTS: • A low snap test reading indicates problems in the engines induction system. (heavy carbon deposits, poor valve operation, multi-plane intake valve malfunction, worn intake cam lobes, valve timing, or air filter issues, etc.) • A high snap test reading indicates problems in the exhaust system. (restricted catalytic converters, pipes or mufflers, exhaust cam lobe issues, valve train lifters, buckets or valve timing) • A low reading on both idle and snap test indicates the cylinder is leaking compression pressures. (rings, worn ring lands, hole in piston, head gasket issues, worn valve seats or valves, etc.) 10. List your conclusions as to the cause of any abnormal results below: ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 SA-16 — Cylinder Leak Down Test consulab.com info@consulab.com 27 SA-16 Cylinder Leak Down Test The CYLINDER LEAK DOWN TEST is a very accurate and valuable diagnostic test often performed to isolate locations of compression problems. It consists of adding outside shop air into one cylinder at a time through the spark plug hole and listening for escaping air at common locations. This test is a “COMPARISON” test where results are compared to other cylinders. No cylinder will be totally “leak-free”. Normal leak down percentages range from 5% to 10% maximum, but anything above 20% is considered a problem. If only one cylinder exceeds 20%, then a cylinder specific problem exists, but if most all cylinders exceed 20%, the engine is considered “worn out”. Follow the procedure and use this sheet to record all your answers: PROCEDURE: 1. Remove the spark plugs and rotate the engine to put the cylinder being tested at TDC on the compression stroke. (There are various methods of doing this. Check with your instructor for additional details) 2. Be sure to read, understand and follow the instructions for the leak-down tester you are using. 3. Select the correct shop air adaptor from the tester and thread into the spark plug hole. 4. Adjust the tester according to tool instructions. 5. Connect the tool to the cylinder hose and record your readings. Caution: Introducing air into the cylinder may cause the engine to rotate if not at true TDC. Keep hands and tools away from potential moving parts like fan blades, belts and pulleys. NOTE: Each cylinder being tested must be placed at TDC on its compression stroke before testing. 6. Record the percentage of leakage in each of the cylinders in the chart. 7. Listen at various locations of the engine to determine where the air is leaking from. You may have to remove filler caps or other items to find the leak. Common causes for air heard leaking from are: - Throttle Body = Intake Valve - Tailpipe = Exhaust Valve - Radiator Cap bubbles = Head Gasket or Cracks - Oil Fill Cap or Dipstick = Piston Rings 8. Analyze the results and determine if they are acceptable or if there is a problem indicated. 9. List possible failures below to explain your test results: ____________________________________________________________________________________________ ____________________________________________________________________________________________ CYLINDER # 1 2 3 4 5 6 7 8 PERCENT LEAKAGE % % % % % % % % LOCATION % % % % % % % % NAME: _________________________________ GROUP: ________________ DATE: ________________ INSTRUCTOR: __________________________ COMMENTS: _____________________________________ 95-145S-GM05 Advanced Level Assignments consulab.com info@consulab.com 28 Advanced Level Assignments 95-145S-GM05 SA-17 — Relative Compression Test (Current) consulab.com info@consulab.com 29 SA-17 Relative Compression Test (Current Measuring Method) The RELATIVE COMPRESSION TEST can be quickly performed on an engine and if conducted properly, can give valuable diagnostic information without taking much time to perform. The term “relative” is used because the test compares the compression of each cylinder to each other. It does not measure actual compression. A smooth running engine in good condition should have close to equal compression in each cylinder. The test measures the electrical load on the starter as it cranks the engine. Individual cylinder compression factors affect the starter draw as the engine is cranked. Low compression does not require as much electrical load on the starter as normal compression would. There are two methods of measuring starter electrical load. One is using an amp clamp to measure starter cur- rent (SA-17 TEST) and the other is measuring the battery cranking voltage (SA-18 TEST). Both tests use an auto- motive oscilloscope. The oscilloscope is a voltmeter able to display voltage in a set amount of time. A scope can ONLY measure voltage. Whatever else we ask to scope to do must be converted to a voltage. The first is the current measuring method. The scope can “measure” current by using the amp clamp which detects changes in the magnetic field around the battery cable as current changes. As the engine is turned over the starter current will fluctuate as each cylinder comes up on the compression stroke providing greater resistance to rotation. The increases in current should be similar for each cylinder CURRENT MEASURING METHOD – PROCEDURE: This test will require a DSO (Digital Storage Oscilloscope) and a high amperage inductive clamp. The amp clamp will be connected around the positive or negative battery cable to the starter. As the engine is turned over the starter current will fluctuate as each cylinder comes up on the compression stroke providing greater resistance to rotation. The increases in current should be similar for each cylinder. 1. Disable the fuel injection system (usually the fuel pump relay is removed) and run the engine out of fuel. 2. It is preferable to use a 2-channel DSO which allows the use of a trigger. Using a trigger will allow you to identify specific cylinder locations if a problem is detected. A trigger is not absolutely required, but saves time. 3. If using a trigger, set up channel 1 to trigger or “sync” off of #1 injector or #1 ignition coil control circuit. Adjust DSO trigger settings for a “SINGLE TRIGGER”. 4. Connect the amp clamp to the DSO channel 2 and adjust it read 200-400 amps. Adjust DSO settings to match amp clamp. (Some DSO’s make these adjustments automatically by recognizing the amp clamp, others do not) 5. Install amp clamp around either the POS or GND cable of the battery. NOTE: Some vehicles have dual or split feed cables so insure you are on the correct one. Both cables will carry can starter current. 6. Crank the engine for 5 seconds and capture the pattern. 7. After screen capture, adjust the time base of the captured pattern until the number of current “humps” show clearly (usually about 2-5 seconds across screen). Remember that with current, the highest part of the pattern represents the highest starter draw. Analyze the captured pattern. The pattern will show an initial high current draw as the starter begins to crank the engine and then settle into a constant fluctuation. An acceptable pattern will have peaks and valleys of similar size and shape. (amplitude)[height] and frequen- cy [length] Each rise in current indicates when a cylinder is coming up on the compression stroke. If the current does not rise on one of the cylinders, this is an indication of low compression in that cylinder. If a trigger was used, the pattern will be displayed in the engines firing order. 95-145S-GM05 SA-17 — Relative Compression Test (Current) consulab.com info@consulab.com 30 8. If desired, use the DSO’s horizontal voltage cursors to measure actual individual cylinder amperage draw. 9. Analyze the results and determine if they are acceptable or if there is a problem indicated. (see next page for example waveforms of this test.) 10. If possible, print a copy of your waveform capture and test results to hand in with this assignment. RELATIVE COMPRESSIVE CURRENT MEASUREMENT — SAMPLE DSO CAPTURED PATTERNS RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER 95-145S-GM05 SA-18 — Relative Compression Test (Voltage) consulab.com info@consulab.com 31 SA-18 Relative Compression Test (Voltage Measuring Method) The RELATIVE COMPRESSION TEST can be quickly performed on an engine and if conducted properly, can give valuable diagnostic information without taking much time to perform. The term “relative” is used because the test compares the compression of each cylinder to each other. It does not measure actual compression. A smooth running engine in good condition should have close to equal compression in each cylinder. The test measures the electrical load on the starter as it cranks the engine. Individual cylinder compression factors affect the starter draw as the engine is cranked. Low compression does not require as much electrical load on the star- ter as normal compression would. There are two methods of measuring starter electrical load. One is using an amp clamp to measure starter cur- rent (SA-17 TEST) and the other is measuring the battery cranking voltage (SA-18 TEST). Both tests use an auto- motive oscilloscope. The oscilloscope is a voltmeter able to display voltage in a set amount of time. A scope can ONLY measure voltage. Whatever else we ask to scope to do must be converted to a voltage. The second is the voltage measuring method. As the engine is turned over the starter current will fluctuate as each cylinder comes up on the compression stroke providing greater resistance to rotation. The voltage waveform will drop at the highest compression starter draw. (opposite of current = Ohm’s Law). VOLTAGE MEASUREMENT METHOD - PROCEDURE: This test will require a DSO (Digital Storage Oscilloscope). The scope leads will be connected directly to the batte- ry positive and negative terminals. As the engine is turned over the starter voltage will fluctuate as each cylinder comes up on the compression stroke providing greater resistance to rotation. The changes in the displayed voltage should be similar for each cylinder. 1. Disable the fuel injection system (usually the fuel pump relay is removed) and run the engine out of fuel. 2. Connect the DSO to the battery (signal lead to battery positive and scope ground lead to battery negative terminals) and adjust DSO settings to read battery voltage. NOTE: Refer to SA-17 TEST CURRENT MEASURING METHOD procedure (Steps 2 & 3) for information on using the trigger function of the DSO for specific cylinder identification. 3. Crank engine for 5 seconds and capture pattern. 4. After screen capture, adjust the DSO time base settings so that the voltage humps are clearly seen. (usual- ly 2-5 seconds on screen) 5. Remember that with voltage, the voltage waveform will «drop» at the highest current draw. Low compres- sion would result in higher than normal voltage waveforms) 6. Analyze the captured pattern. An acceptable pattern will have peaks and valleys of similar size and shape. Voltage is displayed [up] and frequency or time is displayed [across]. Each drop in voltage indi- cates when a cylinder is coming up on the compression stroke. It the voltage does not drop on one of the cylinders, this is an indication of low compression in one cylinder. 7. If possible, print a copy of your waveform capture and test results to hand in with this assignment. . 95-145S-GM05 SA-18 — Relative Compression Test (Voltage) consulab.com info@consulab.com 32 RELATIVE COMPRESSIVE VOLTAGE MEASUREMENT — SAMPLE DSO CAPTURED PATTERNSRELATIVE COMPRESSION VOLTAGE MEASUREMENT SAMPLE DSO CAPTURED PATTERNS SYNCED KNOWN GOOD WAVEFORM SYNCED WAVFORM WITH LOW COMPRESSION IN CYL #3 IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 GOOD WAVEFORM ALL HUMPS ARE EQUAL IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 VERY LOW COMPRESSION CYL # 3 TEST #7 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION VOLTAGE MEASUREMENT SAMPLE DSO CAPTURED PATTERNS SYNCED KNOWN GOOD WAVEFORM SYNCED WAVFORM WITH LOW COMPRESSION IN CYL #3 IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 GOOD WAVEFORM ALL HUMPS ARE EQUAL IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 VERY LOW COMPRESSION CYL # 3 TEST #7 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION VOLTAGE MEASUREMENT SAMPLE DSO CAPTURED PATTERNS SYNCED KNOWN GOOD WAVEFORM SYNCED WAVFORM WITH LOW COMPRESSION IN CYL #3 IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 GOOD WAVEFORM ALL HUMPS ARE EQUAL IGNITION SYNC #1 FIRING ORDER – 1 3 4 2 1 3 4 2 VERY LOW COMPRESSION CYL # 3 TEST #7 WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER 95-145S-GM05 SA-19 — Cranking In-Cylinder Pressure Test consulab.com info@consulab.com 33 SA-19 Cranking In-Cylinder Pressure Test Using Pressure Transducer Measuring in-cylinder pressures with transducers is a very accurate test that can reveal extreme details of cylinder “health”, valve timing, cam/crank synchronization, valve sealing and much more. The tests require a DSO (Digital Storage Oscilloscope) and a pressure transducer compatible with the scope. A “transducer” is a device that changes whatever is being measured into a voltage that the DSO can recognize and display. The are many types of transdu- cers available for automotive technicians and they can be used to test both pressures and vacuum of any system in the vehicle. Engine specific tests using transducers can be intake manifold vacuum, in-cylinder pressures and exhaust system pressure. Each test has its own set of specific procedures and requirements that must be correctly followed for success. In order for these tests to be a valuable diagnostic tool, the user must learn and understand how to in- terpret each different waveform obtained during the tests. Thankfully, there are many, many diffe- rent sources of training classes, videos, printed materials and Facebook professional forum discussions covering these topics. It is necessary to develop one’s skills by continually practicing these tests on a vehicle. There are available waveform libraries of known good and known bad examples of test results. Be sure to fami- liarize yourself with them. This in-cylinder pressure test is conducted with the engine cranking (learning resources are listed at the end of this document). CRANKING IN-CYLINDER PRESSURE TEST USING TRANSDUCER - PROCEDURE: 1. Obtain the correct pressure transducer for in-cylinder pressures and make sure it is compatible with your DSO. 2. Adjust the DSO’s V/div and T/div settings to match pressure transducers requirements. NOTE: Many DSO’s have pre-set values for several transducers that automatically select proper settings. Check with your DSO and pressure transducer. 3. NOTE: It is recommended to NOT use the hose from a standard mechanical compression tester due to potential hose flexibility issues affecting waveform and test accuracy. Use only the hoses that are included with the transducer kit. 4. Remove the spark plug of cylinder being tested. Either disable to coil primary to that cylinder or ground the spark plug wire or install a spark tester. DO NOT let ignition system run with an open vol- tage on the plug wire. 5. Disable the fuel injector for the cylinder being tested. (usually remove the injector electrical connecter) 6. If you wish to use a trigger, set trigger on the ignition pulse signal for the cylinder being tested, but ne- cessary only if you are checking for proper ignition timing. 7. Install the transducer’s pressure hose with adapter into the spark plug hole of cylinder being tested. 8. Confirm that all test leads and hoses are clear of any engine rotating components. 9. Crank engine for at least 5 seconds and capture the displayed pattern. 10. Using the zoom feature of the DSO expand pattern until a pattern matching the below example (only 2 TDC humps displayed). 11. If possible, use the DSO’s internal features to insert engine cycle lines between the two TDC vertical lines. Some DSO’s have this feature built in to the software. 95-145S-GM05 SA-19 — Cranking In-Cylinder Pressure Test consulab.com info@consulab.com 34 12. Analyze the pattern by comparing each portion of the pattern with a known good to evaluate any va- riations which may indicate an abnormal condition within that cylinder. (See example patterns on next pages) 13. Repeat test on other suspect cylinders or obtain a “known good” pattern for that engine from a normal- ly operating cylinder. 14. Remove pressure transducer hose and reinstall spark plug and restore fuel and ignition system. 15. If possible, print a copy of your waveform capture and test results to hand in with this assignment. SAMPLE WAVEFORMS – IN-CYLINDER CRANKING PRESSURE TEST 1st OBTAINED WAVEFORM AT CRANKING SPEED 2ND OBTAINED WAVEFORM ZOOMED IN UNTIL (KNOWN GOOD WAVEFORM) TDC PEAKS ARE SHOWN – INSTALL VERTICAL CURSORS AT EACH TDC PORTION. (KNOWN GOOD) KNOWN GOOD WAVEFORM 3RD OBTAINED WAVEFORM WITH CYCLE LINES INSERTED WITH EXPLANATIONS TEST #8 TDC COMPRESSION EXHAUST VALVE OPENS INTAKE VALVE OPENS INTAKE VALVE CLOSES POWER EXHAUST INTAKE COMPRESSION TDC COMPRESSION 1ST CYLINDER IN WAVEFORM DID NOT HAVE A FULL COMPRESSION STROKE WHEN STARTER WAS FIRST ENGAGED WAVEFORMS COURTESY OF BRANDON STECKLER RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER IN-CYLINDER CRANKING PRESSURE TEST — SAMPLE DSO CAPTURED PATTERNS SAMPLE WAVEFORMS – IN-CYLINDER CRANKING PRESSURE TEST 1st OBTAINED WAVEFORM AT CRANKING SPEED 2ND OBTAINED WAVEFORM ZOOMED IN UNTIL (KNOWN GOOD WAVEFORM) TDC PEAKS ARE SHOWN – INSTALL VERTICAL CURSORS AT EACH TDC PORTION. (KNOWN GOOD) KNOWN GOOD WAVEFORM 3RD OBTAINED WAVEFORM WITH CYCLE LINES INSERTED WITH EXPLANATIONS TEST #8 TDC COMPRESSION EXHAUST VALVE OPENS INTAKE VALVE OPENS INTAKE VALVE CLOSES POWER EXHAUST INTAKE COMPRESSION TDC COMPRESSION 1ST CYLINDER IN WAVEFORM DID NOT HAVE A FULL COMPRESSION STROKE WHEN STARTER WAS FIRST ENGAGED WAVEFORMS COURTESY OF BRANDON STECKLER SAMPLE WAVEFORMS – IN-CYLINDER CRANKING PRESSURE TEST 1st OBTAINED WAVEFORM AT CRANKING SPEED 2ND OBTAINED WAVEFORM ZOOMED IN UNTIL (KNOWN GOOD WAVEFORM) TDC PEAKS ARE SHOWN – INSTALL VERTICAL CURSORS AT EACH TDC PORTION. (KNOWN GOOD) KNOWN GOOD WAVEFORM 3RD OBTAINED WAVEFORM WITH CYCLE LINES INSERTED WITH EXPLANATIONS TEST #8 TDC COMPRESSION EXHAUST VALVE OPENS INTAKE VALVE OPENS INTAKE VALVE CLOSES POWER EXHAUST INTAKE COMPRESSION TDC COMPRESSION 1ST CYLINDER IN WAVEFORM DID NOT HAVE A FULL COMPRESSION STROKE WHEN STARTER WAS FIRST ENGAGED WAVEFORMS COURTESY OF BRANDON STECKLER 95-145S-GM05 SA-19 — Cranking In-Cylinder Pressure Test consulab.com info@consulab.com 35 RELATIVE COMPRESSION CURRENT MEASUREMENT SAMPLE DSO CAPTURED PATTERNS UNSYNCED KNOWN GOOD WAVEFORM SYNCED WAVEFORM WITH LOW COMPRESSION IN CYLINDER #2 TEST #6 WAVEFORMS COURTESY OF BRANDON STECKLER ABNORMAL CONDITION — CRANKING IN-CYLINDER CRANING PRESSURE TEST SAMPLE WAVEFORMS – IN-CYLINDER CRANKING PRESSURE TEST 1st OBTAINED WAVEFORM AT CRANKING SPEED 2ND OBTAINED WAVEFORM ZOOMED IN UNTIL (KNOWN GOOD WAVEFORM) TDC PEAKS ARE SHOWN – INSTALL VERTICAL CURSORS AT EACH TDC PORTION. (KNOWN GOOD) KNOWN GOOD WAVEFORM 3RD OBTAINED WAVEFORM WITH CYCLE LINES INSERTED WITH EXPLANATIONS TEST #8 TDC COMPRESSION EXHAUST VALVE OPENS INTAKE VALVE OPENS INTAKE VALVE CLOSES POWER EXHAUST INTAKE COMPRESSION TDC COMPRESSION 1ST CYLINDER IN WAVEFORM DID NOT HAVE A FULL COMPRESSION STROKE WHEN STARTER WAS FIRST ENGAGED WAVEFORMS COURTESY OF BRANDON STECKLER ABNORMAL CONDITION – CRANKING IN-CYLINDER CRANING PRESSURE TEST 1ST OBTAINED WAVEFORM – SINGLE CYLINDER REPEATED PATTERN IS SHOWN THERE IS A LOWER CYLINDER SEALING PROBLEM 2ND OBTAINED WAVEFORM ZOOMED IN TO SHOW TWO TDC SPIKES DETAIL IS SHOWN IS LOSS OF CYLINDER SEALING EXCESSIVE LOWER CYLINDER LEAKAGE DUE TO WORN RINGS OR FUEL WASHDOWN AFFECTING RING SEALING TEST BEGINS TEST ENDSSINGLE CYLINDER BEING TESTED TEST #8 WAVEFORMS COURTESY OF BRANDON STECKLER 95-145S-GM05 SA-20 — Running In-Cylinder Pressure Test consulab.com info@consulab.com 36 SA-20 Running In-Cylinder Pressure Test Using Pressure Transducer Measuring in-cylinder pressures with transducers is a very accurate test that can reveal extreme de- tails of cylinder “health”, valve timing, cam/crank synchronization, valve sealing and much more. The tests require a DSO (Digital Storage Oscilloscope) and a pressure transducer compatible with the scope. A “transducer” is a device that changes whatever is being measured into a voltage that the DSO can recognize and display. The are many types of transducers available for automotive technicians and they can be used to test both pressures and vacuum of any system in the vehicle. Engine specific tests using transducers can be intake manifold vacuum, in-cylinder pressures and exhaust system pressure. Each test has its own set of specific procedures and requirements that must be correctly followed for success. In order for these tests to be a valuable diagnostic tool, the user must learn and understand how to interpret each different waveform obtained during the tests. Thankfully, there are many, many different sources of training classes, videos, printed materials and Facebook professional forum discussions covering these topics. It is necessary to develop one’s skills by continually practi- cing these tests on a vehicle. There are available waveform libraries of known good and known bad examples of test results. Be sure to familiarize yourself with them. This in-cylinder pressure test is conducted with the engine running. Again, it is suggested that you refer to the list of learning resources at the end of the document. Certain safety factors must be carefully followed to prevent engine damage or fires. This test is done on one cylinder at a time and the engine should be at operating temperature. Many experts suggest to perform four different running tests.1- Idling, 2- Snap throttle, Decel and Brake Torque. Each test will allow certain specific engine conditions to be easier seen than if just one test is done. RUNNING IN-CYLINDER PRESSURE TEST USING TRANSDUCER - PROCEDURE: 1. Obtain the correct pressure transducer for in-cylinder pressures and make sure it is compatible with your DSO. 2. Adjust the DSO’s V/div and T/div settings to match pressure transducers requirements. NOTE: Many DSO’s have pre-set values for several transducers that automatically select proper settings. Check with your DSO and pressure transducer. 3. NOTE: It is recommended to NOT used the hose from a standard mechanical compression tester due to potential hose flexibility issues affecting waveform. Use only the hoses that are included with the transducer kit. 4. Remove the spark plug of cylinder being tested. Either disable to coil primary to that cylinder or ground the spark plug wire or install a spark tester. DO NOT let ignition system run with an open voltage on the plug wire. (Secondary ignition voltage is capable of damaging sensitive electronics inside the transduc- er) 5. Disable the fuel injector for the cylinder being tested. (Usually remove the injector electrical connecter.) 6. If you wish to use a trigger, set trigger on the ignition pulse signal for the cylinder being tested, but ne- cessary only if you are checking for proper ignition timing. 7. Install the transducer’s pressure hose with adapter into the spark plug hole of cylinder being tested. 8. Confirm that all test leads and hoses are clear of any rotating components. 9. Start engine and run at idle speed, then capture the displayed pattern. Shut off engine. 95-145S-GM05 SA-20 — Running In-Cylinder Pressure Test consulab.com info@consulab.com 37 10. Using the zoom feature of the DSO expand patter until a pattern matching the below example is achie- ved. 11. If possible, use the DSO’s internal features to insert engine cycle lines between the two TDC vertical lines. Some DSO’s have this feature built in to the software. 12. Analyze the pattern by comparing each portion of the pattern with a known good to evaluate any varia- tions which may indicate an abnormal condition within that cylinder. (See example patterns below) 13. Repeat test on other suspect cylinders or obtain a “known good” pattern for that engine from a normal- ly operating cylinder. 14. Remove pressure transducer hose, reinstall spark plug and restore fuel and ignition system. 15. If possible, print a copy of your waveform capture and test results to hand in with this assignment. TYPICAL NORMAL CONDITION RUNNING ENGINE PRESSURE WAVEFORM EXPLAINED TYPICAL RUNNING ENGINE PRESSURE WAVEFORM PORTIONS OF WAVEFORM DETAIL EXPLANATION PORTION OF WAVEFORM EXPLANATION OF WHAT IS TAKING PLACE . 1- TDC – Compression pressure is at the maximum. 2- Piston is going down – Crank rotates 30o past TDC, cylinder pressure should be about ½ of maximum between points #1 and #4. 3- Piston is about ½ way down to BDC. Pressure at this point is about atmospheric (14.7). As cylinder volume continues to increase, a lower pressure (vacuum) is developed. 4- Just before BDC, the exhaust valve opens. Pressure starts to increase due to incoming exhaust pressure from exhaust system being higher than cylinder pressure. 5- BDC – Pressure increases due to exhaust system pressure is higher than cylinder pressure. If #5 is from 170o to 195o after TDC, the valve timing is assumed to be correct. 6- Pressure is cylinder is now equal to the exhaust system pressure. 7- Exhaust is being pushed out of cylinder by cylinder beginning to move up. Pressure is about equal to atmospheric at this point. NOTE- waveform ripples are from exhaust pulses in the exhaust stream from other cylinders and/or exhaust configuration. 720O TDC BDCTDC TDCBDC INTAKEPOWER COMPRESSIONEXHAUST TEST #9 USED WITH PERMISSION OF AUTODITEX www.autoditex.com 95-145S-GM05 SA-20 — Running In-Cylinder Pressure Test consulab.com info@consulab.com 38 TYPICAL NORMAL CONDITION RUNNING ENGINE PRESSURE WAVEFORM EXPLAINED TYPICAL RUNNING ENGINE PRESSURE WAVEFORM PORTIONS OF WAVEFORM DETAIL EXPLANATION PORTION OF WAVEFORM EXPLANATION OF WHAT IS TAKING PLACE . 1- TDC – Compression pressure is at the maximum. 2- Piston is going down – Crank rotates 30o past TDC, cylinder pressure should be about ½ of maximum between points #1 and #4. 3- Piston is about ½ way down to BDC. Pressure at this point is about atmospheric (14.7). As cylinder volume continues to increase, a lower pressure (vacuum) is developed. 4- Just before BDC, the exhaust valve opens. Pressure starts to increase due to incoming exhaust pressure from exhaust system being higher than cylinder pressure. 5- BDC – Pressure increases due to exhaust system pressure is higher than cylinder pressure. If #5 is from 170o to 195o after TDC, the valve timing is assumed to be correct. 6- Pressure is cylinder is now equal to the exhaust system pressure. 7- Exhaust is being pushed out of cylinder by cylinder beginning to move up. Pressure is about equal to atmospheric at this point. NOTE- waveform ripples are from exhaust pulses in the exhaust stream from other cylinders and/or exhaust configuration. 720O TDC BDCTDC TDCBDC INTAKEPOWER COMPRESSIONEXHAUST TEST #9 USED WITH PERMISSION OF AUTODITEX www.autoditex.com 8- Intake valve begins to open, exhaust valve is still open (overlap) which creates a scavenging effect in cylinder. 9- Exhaust valve is now closed and cylinder pressure begins to equalize with intake manifold pressure. Correct intake valve timing can be confirmed if the center of section #9 is within 370o to 390o after TDC for non-VVT engines. For VVT engines, the center of section #9 should be within 380o to 400o after TDC. 10- Pressure in cylinder is now equal to intake manifold pressure. Intake valve is still open. 11- Piston is moving down filling cylinder with air. Cylinder pressure does not drop because air is entering cylinder through open intake valve. The piston is just ready to begin the compression stroke while the intake valve is closing. The air driven by inertia continues to rush into the cylinder which improves the filling of the cylinder with a fuel/air mixture (port fuel engines-naturally aspirated engines). The small ripples in this section will remain as long as the intake valve is open. 12- The intake valve is closed and from this moment on, the cylinder pressure begins to increase rapidly. If the intake valve is completely closed from 560o to 600o after the previous TDC, the valve timing can be considered to be correct. 13- At this point, pressure in the cylinder will be close to atmospheric (14.7psi), but the compression will now continue to increase rapidly due to both valves being closed. 14- At this point, cylinder pressure is approximately ½ of the minimum pressure at point #12 and the maximum cylinder pressure at point #1. As the piston passes this point, the compression continues to build until it reaches TDC. ADDITIONAL LEARNING RESOURCES BOOKS https://www.aeswave.com/cart.php?m=search_results&headerSearch=Y&search=Bs-10 Book by Brandon Steckler “Pressure Waveform Acquisition and Analysis from the Inside Out” https://www.amazon.com/Automotive-Oscilloscopes-Waveform-Graham-Stoakes/dp/0992949262 Book by Graham Stoakes – “Automotive Oscilloscopes – Waveform Analysis” https://www.aeswave.com/Engine-Mechanical-Testing-In-Cylinder-Pressure-Transducers-by-John-Thornton-p9652.html Book by John Thornton “Engine Mechanical Testing: In-Cylinder Pressure Transducers” VIDEOS https://www.youtube.com/watch?v=bmIEbnglVj0 (Motor Age – Pete Meier (understanding the waveform – 25 minutes) https://www.youtube.com/watch?v=811OPlwP7lc&pbjreload=101 (Bernie Thompson 47-minute video) https://www.youtube.com/watch?v=smSdJG_LC2w Brandon Steckler & Mario Rojas 25 min (Vacuum and cranking amps tests) https://www.youtube.com/watch?v=ZsNtJ1zto64 (8 minute video – basic operation) TEST #9 USED WITH PERMISSION OF AUTODITEX www.autoditex.com 95-145S-GM05 Additional Learning Resources consulab.com info@consulab.com 39 BOOKS https://www.aeswave.com/cart.php?m=search_results&headerSearch=Y&search=Bs-10 Book by Brandon Steckler “Pressure Waveform Acquisition and Analysis from the Inside Out”. https://www.amazon.com/Automotive-Oscilloscopes-Waveform-Graham-Stoakes/dp/0992949262 Book by Graham Stoakes – “Automotive Oscilloscopes – Waveform Analysis”. https://www.aeswave.com/Engine-Mechanical-Testing-In-Cylinder-Pressure-Transducers-by-John-Thornton-p9652.html Book by John Thornton “Engine Mechanical Testing: In-Cylinder Pressure Transducers”. VIDEOS https://www.youtube.com/watch?v=bmIEbnglVj0 (Motor Age – Pete Meier (understanding the waveform – 25 minutes). https://www.youtube.com/watch?v=811OPlwP7lc&pbjreload=101 (Bernie Thompson 47-minute video). https://www.youtube.com/watch?v=smSdJG_LC2w Brandon Steckler & Mario Rojas 25 min (Vacuum and cranking amps tests). https://www.youtube.com/watch?v=ZsNtJ1zto64 (8 minute video – basic operation). ARTICLES AND OTHER RESOURCES www.automotivetestsolutions.com Auto Test Solutions website (resources and training on pressure transducer testing and more). https://driveabilityguys.com/software-and-tools (Piston Chart download). https://www.picoauto.com/library/automotive-guided-tests/in-cylinder-compression-idle-petrol/ Pico article. https://autoditex.com/page/cylinder-pressure-sensor-64-1.html (PDF on in-cylinder pressure testing). There are several technical articles located within membership to Diagnostic Network. This is a subscription based re- source but has excellent technical resources and a forum. From any browser, type in: diag.net . https://www.searchautoparts.com/motorage/underhood-service-repair/introduction-cylinder-pressure-testing Motor Age article by Bernie Thompson. https://www.searchautoparts.com/motorage/underhood-service-repair/engine-mechanical-testing-using-cylinder-pres- sure-transducer Motor Age article by Scott Manna. Additional Learning Resources https://www.aeswave.com/cart.php?m=search_results&headerSearch=Y&search=Bs-10 https://www.amazon.com/Automotive-Oscilloscopes-Waveform-Graham-Stoakes/dp/0992949262 https://www.aeswave.com/Engine-Mechanical-Testing-In-Cylinder-Pressure-Transducers-by-John-Thornton-p9652.html https://www.youtube.com/watch?v=bmIEbnglVj0 https://www.youtube.com/watch?v=811OPlwP7lc&pbjreload=101 https://www.youtube.com/watch?v=smSdJG_LC2w https://www.youtube.com/watch?v=ZsNtJ1zto64 http://www.automotivetestsolutions.com https://driveabilityguys.com/software-and-tools https://www.picoauto.com/library/automotive-guided-tests/in-cylinder-compression-idle-petrol/ https://autoditex.com/page/cylinder-pressure-sensor-64-1.html https://www.searchautoparts.com/motorage/underhood-service-repair/introduction-cylinder-pressure-testing https://www.searchautoparts.com/motorage/underhood-service-repair/engine-mechanical-testing-using-cylinder-pressure-transducer https://www.searchautoparts.com/motorage/underhood-service-repair/engine-mechanical-testing-using-cylinder-pressure-transducer consulab.com info@consulab.com 40 95-145S-GM05 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. All rights reserved. Product Description Educational Advantages: SA-1 Basic Component Identification SA-2 Engine Specific Identification SA-3 Sensor Identification SA-4 Actuator Identification SA-5 Charging System SA-6 Cylinder Head Removal SA-7 Cylinder Head Inspection SA-8 Valve Train Inspection SA-9 Cylinder Block Inspection SA-10 Piston Removal, Inspection and Measurement SA-11 Crankshaft Removal, Inspection and Measurement Testing Engine Mechanical Condition SA-12 Cylinder Balance Test SA-13 Engine Running Vacuum Test SA-14 Static Engine Compression Test SA-15 Running Compression Test SA-16 Cylinder Leak Down Test SA-17 Relative Compression Test (Current Measuring Method) SA-18 Relative Compression Test (Voltage Measuring Method) SA-19 Cranking In-Cylinder Pressure Test Using Pressure Transducer SA-20 Running In-Cylinder Pressure Test Using Pressure Transducer Additional Learning Resources Notes

Advanced electronics Moduponent™ kit MD-4000-22_053343 Rev. 2025/04 MD-4000-22_053343 Advanced electronics moduponent kit consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL ADVANTAGES FEATURES LIST OF INCLUDED MODUPONENTS® OPTIONS TECHNICAL INFORMATION The ConsuLab MD-4000-22 is a versatile and adaptable electrical/electronic training series that allows students to build electronic circuits. • Can be used for teaching basic Ohm’s law or complex electronic circuits • Self-contained unit has a protected built-in adjustable power supply and holds up to 16 different Moduponents™ • Includes 15 different Moduponents™ from the entire MD-4000 series • Uses industry standard schematic symbols • Can assist you in the instruction of many tasks in area A6 and others of the ASE Education Foundation (NATEF) • Operation manual included • Protected with removable metal cover • Adjustable and protected power supply (2-14VDC) • Moduponent® attachment rails allow up to 16 individual Moduponents® • CL-1011A_52958 Desktop Moduponent Case • CL-1012-03_52320 Set of 26 jumper leads • MD-4000_53061 DC Power Supply • MD-4010_53062 Resistors (4) • MD-4020_53097 Capacitors (4) • MD-4030_53070 Potentiometer • MD-4040_53068 12VDC 5-pin ISO Relay • MD-4052_53067 NCT thermistor • MD-4056_53080 Ultrasonic Sensor • MD-4070_53063 Incandescent & LED Light Bulbs • MD-4071_53098 LED (4) • MD-4091_53065 DPDT toggle switches (2) • MD-4111_53073 Fan • MD-4114_53134 Solenoid • MD-4140_53075 Diodes • MD-4141_53076 Optical sensors (3) • MD-4142_53077 Transistors • Dimensions : 22 x 20 x 10 in (55.8 x 50.8 x 25.4 cm) • Weight : 33 lb (15 kg) • CL-1918-10B or CL-1918-10S 1918 upright stand or tabletop stand • MD-4000-4U_053359 Upgrade kit, convert a 1918 stand for use with MD-4000 Moduponents™

Student Assignments for for EM-140D-FC03_053347 Consulink™ 2017 Ram 6.7L Diesel Engine Trainer EM-140D-FC03_053347-95_V2024-2 © ConsuLab Educatech Inc, 2024. All rights reserved. EM-140D-FC03_053347-95 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, 2024. 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 053347 and above. Table of Contents Warning and Notices 3 WARNING for RAM Cummins 6.7L 3 NOTICE for Regeneration and Connector Location 3 NOTICE for Scan Tool Compatibility 3 Student Assignments SA-1 — Basic Component ID 4 SA-2 — Engine Specific ID 6 SA-3 — Component Identification — SENSORS 8 SA-4 — Component Identification — ACTUATORS 10 SA-5 — Charging System Verification 11 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel 12 SA-7 — Expected Voltages — ECM Breakout Box Panel 18 SA-8 — Measured Voltages — ECM Breakout Box Panel 19 SA-9 — Case Study Diagnosis — CS01 20 SA-9 — Case Study Diagnosis — CS02 21 SA-9 — Case Study Diagnosis — CS03 22 SA-9 — Case Study Diagnosis — CS04 23 SA-9 — Case Study Diagnosis — CS05 24 SA-9 — Case Study Diagnosis — CS06 25 SA-9 — Case Study Diagnosis — CS07 26 SA-9 — Case Study Diagnosis — CS08 27 SA-9 — Case Study Diagnosis — CS09 28 SA-9 — Case Study Diagnosis — CS10 29 SA-9 — Case Study Diagnosis — ICS11 30 SA-9 — Case Study Diagnosis — ICS12 31 SA-9 — Case Study Diagnosis — ICS13 32 SA-9 — Case Study Diagnosis — ICS14 33 SA-9 — Case Study Diagnosis — ICS15 34 SA-9 — Case Study Diagnosis — ICS16 35 SA-9 — Case Study Diagnosis — ICS17 36 SA-9 Case Study Diagnosis — ICS18 37 SA-9 Case Study Diagnosis — ICS19 38 SA-9 Case Study Diagnosis — ICS20 39 SA-9 Case Study Diagnosis — ICS21 40 SA-9 Case Study Diagnosis — ICS22 41 SA-9 Case Study Diagnosis — ICS23 42 SA-9 — Advanced Case Study Diagnosis Template 43 consulab.com info@consulab.com 3 EM-140D-FC03_053347-95 Warning and Notices WARNING for RAM Cummins 6.7L EM-140D-FC03_053347 Dash Information Display Notifications You may encounter notifications on the dash display that are present at every start up. Some examples are tire pressure, brake light out, license plate light out, washer fluid, etc. These notifications cannot be erased by disconnecting the battery. These notifications are set by the component not being present and communicating on the bus. For example, the tire pressure sensors are not present on the trainer. The notifications listed above do not turn on the MIL (Malfunction Indicator Light) but do generate a message on the instrument cluster display. APPLICABLE VEHICLES: 2018 RAM TRUCKS NOTICE for Regeneration and Connector Location Using the Deutsch connector on the right side of the dash allows you to connect in parallel with diagnostic port 3 as shown in the schematics for the vehicle. Connecting the appropriate data link connectors to a PC equipped with Cummins InSite software will allow access to complete a forced regeneration cycle. (NEXIQ style communication adapter and Cummins InSite not supplied by ConsuLab). NOTICE for Scan Tool Compatibility This vehicle has a manufacturer installed security gateway module, that does not allow common scan tools to clear all codes, through the OBD II connector, without the purchase of a yearly subscription. You will need an OEM scan tool subscription to do this. (not supplied by ConsuLab) Some aftermarket scan tools (e.g. Autel) may have access to clear codes after the purchase of AutoAuth. For more information see your scan tool user’s manual and the following link about AutoAuth: https://info.autoauth.com/ 2/28/24, 3:38 PM MotoLogic Color Wiring: Computer Data Lines: (4 of 5) • 2018 Dodge Ram 2500 (6.7L Turbo Diesel) - DJ • MotoLogic https://www.motologic.com/car/2018_dodge_dj_ram_2500_pickup_6_7l_i6_cummins_turbo_diesel/article/ba45fbc3c0ce858adecaf0a945b58457_wra… 2/3 586642 12 11 8 7 22 21 14 13 12 11 10 9 D IA G C AN C (+ ) C AN C (+ ) A T C AN C (+ ) G N D FS D IG N R U N D IA G C AN C (- ) C AN C (- ) A T C AN C (- ) C AN IH S (-) D IA G C AN IH S (-) C AN IH S (-) A T FS D B + G N D C AN IH S (+ ) D IA G C AN IH S (+ ) C AN IH S (+ ) A T CAN J1939 4 (-) CAN J1939 4 (+) CAN C (+) CAN C (-) 20 19 18 17 16 15 14 13 10 9 6 5 4 3 2 1 CAN C (+) CAN C (-) 20 19 18 17 16 15 8 7 6 5 4 3 2 1 CAN J1939 2 (-) CAN J1939 2 (+) CAN J1939 4 (+) CAN J1939 4 (-) CAN J1939 4 (+) CAN J1939 4 (-) CAN J1939 4 (+) CAN J1939 4 (-) CAN IHS (-) AT CAN C (-) AT CAN C (+) AT CAN IHS (+) AT CAN C (-) CAN C (+) CAN C (+) CAN C (-) 1 2 3 4 5 6 7 8 9 10 11 12 C 1 87654321 C 2 C I2855 3 2 4 3 C1 I530 8 7 C1 39 27 12 6 I311C1 B A 2 3 2 3 1 2 1 12 2 11 C1 24 I311 36 12 11 12 13 1 C3 2 YEL BRN WHT/BRN YEL TAN TAN WHT WHT YEL VIO/WHT YE L G R Y W H T/ BR N BL K PN K/ G R N TA N YE L YE L W H T TA N D K BL U R EDBL K VI O /W H T W H T W H T WHT/GRN WHT/BLU WHT/DK BLU WHT/DK GRN WHT/DK GRN WHT/DK BLU DK BLU YEL YEL BRN/WHT YEL YEL/GRY YEL/DK BLU YEL VIO YEL ORG YEL DK BLU/WHT YEL RED PNK/GRN WHT/DK GRN WHT/DK BLU W H T/ D K G R N W H T/ D K BL U YEL VIO YEL VIO YEL YEL/DK BLU YEL DK BLU/WHT WHT/GRN WHT/DK BLU WHT/DK GRN WHT/DK BLU WHT/DK BLU WHT/GRN WHT/DK BLU WHT/DK GRN BLK BLK/WHT WHT/DK BLU WHT/DK GRN WHT DK BLU GRY YEL YEL BRN WHT/BLU WHT/GRN DK BLU YEL DK BLU YEL BRN/WHT YEL YEL YEL/GRY YEL ORG D 42 8 D 43 6 D 35 1 Z9 12 F9 48 D 42 7 D 43 5 D 35 0 D 35 2 D 43 3 D 43 8 A9 37 Z9 12 D 35 3 D 43 4 D 43 7 D78 D77 D40 D134 D135 D196 D197 D39 SELECTIVE CATALYTIC REDUCTION MODULE UREA QUALITY SENSOR NOX SENSOR 1/2 PARTICULATE MATTER SENSOR RADIO RADIO FREQUENCY HUB MODULE CLUSTER PARK ASSIST MODULE TRAILER TOW MODULE G309 SECURITY GATEWAY MODULE DIAGNOSTIC PORT 3 (LEFT SIDE OF ENGINE) (MIDDLE OF UNDER SIDE OF VEHICLE, BEHIND TRANSMISSION) (RIGHT CENTER OF DASH) (LEFT REAR OF ENGINE, IN TRANSMISSION HARNESS) (ON UREA TANK) (LEFT REAR OF ENGINE, IN TRANSMISSION HARNESS) (UNDER VEHICLE, IN RIGHT CHASSIS HARNESS) (UNDER VEHICLE, IN RIGHT CHASSIS HARNESS) (AT OUTLET OF SELECTIVE CATALYTIC REDUCTION CATALYST) (NEAR INLET TO DPF) (CENTER REAR OF CAB WALL) (LEFT KICK PANEL) (LOWER LEFT CENTER OF DASH) (6.7L TURBO DIESEL) (6.7L TURBO DIESEL) (6.7L TURBO DIESEL) 2500 HD (6.7L TURBO DIESEL) SD134B SD135A SD134C SD135C consulab.com info@consulab.com 4 EM-140D-FC03_053347-95 SA-1 — Basic Component ID SA-1 Basic Component ID In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location EM-140D-FC03 Engine Application : Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug consulab.com info@consulab.com 5 EM-140D-FC03_053347-95 SA-1 — Basic Component ID Component Function Location Oil dipstick Air Filter Fuel Filter Throttle (body) Batteries Positive Crankcase Ventilation system Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box – power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 6 EM-140D-FC03_053347-95_V2024-1 SA-2 — Engine Specific ID SA-2 Engine Specific ID In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information EM-140D-FC03 Engine Application : Engine Type Gasoline Diesel Vehicle Identification Number VIN : Engine Displacement Number of Cylinders Cylinder numbering Firing Order Direction of Engine Rotation Compression Ratio Camshaft Configuration OHV SOHC DOHC Turbo Type Charge Air Cooler location & function Aspiration Turbo N/A Supercharged consulab.com info@consulab.com 7 EM-140D-FC03_053347-95_V2024-1 SA-2 — Engine Specific ID Engine system Engine specific information Fuel System Type DEF Fluid reservoir CAN Bus Display Unit Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other Technologies Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 8 EM-140D-FC03_053347-95 SA-3 — Component Identification — SENSORS SA-3 Component Identification — SENSORS In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step three in getting familiar with this trainer and related sensors. Sensor Function Location BOB Pin #’s EM-140D-FC03 Engine Application : Accelerator Pedal Position 1 Accelerator Pedal Position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankshaft Position Crankcase Pressure DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure consulab.com info@consulab.com 9 EM-140D-FC03_053347-95 SA-3 — Component Identification — SENSORS Sensor Function Location BOB Pin #’s Exhaust Gas Recirculation (EGR) temp EGR Differential Pressure Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel Insert Any Sensors Specific To This Engine Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 10 EM-140D-FC03_053347-95 SA-4 — Component Identification — ACTUATORS SA-4 Component Identification — ACTUATORS In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location BOB pin #’s EM-140D-FC03 Engine Application : INSERT ANY ADDITIONAL ACTUATORS SPECIFIC TO THIS ENGINE HERE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 11 EM-140D-FC03_053347-95 SA-5 — Charging System Verification SA-5 Charging System Verification In preparation to diagnosing any engine management issue, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first ! EM-140D-FC03 Engine Application : Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accurate Voltage Drop Test Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging ? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceeding with diagnosing engine performance issues ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 12 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel SA-6 Wiring Diagram Practice — ECM Breakout Box Panel Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C1 In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step six in getting familiar with this trainer and wiring to the ECM. In the chart below, fill in the blanks with the correct information for each of the PIN wire’s identified. Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) EM-140D-FC03 Engine Application : 1 2 3 4 9 10 11 14 16 17 18 22 23 24 25 26 27 28 31 32 33 34 35 36 42 consulab.com info@consulab.com 13 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) 44 45 46 47 48 49 50 51 52 54 55 56 57 58 59 60 61 62 63 64 65 66 68 69 70 71 72 73 74 75 78 79 80 Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C1 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel consulab.com info@consulab.com 14 Name : Group : Date : Instructor : Grade : Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) 81 82 83 90 92 93 94 95 96 Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C1 consulab.com info@consulab.com 15 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C2 In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step six in getting familiar with this trainer and wiring to the ECM. In the chart below, fill in the blanks with the correct information for each of the PIN wire’s identified. Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) EM-140D-FC03 Engine Application : 1 2 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 32 33 35 35 36 37 consulab.com info@consulab.com 16 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 56 57 58 59 60 62 64 65 71 72 73 74 75 76 77 79 Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C2 EM-140D-FC03_053347-95 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel consulab.com info@consulab.com 17 Name : Group : Date : Instructor : Grade : Pin wire Color Circuit # Function (Signal / Control / Reference/ ?) 81 82 83 86 87 88 89 95 96 Wiring Diagram Practice — ECM Breakout Box Panel — Connecter C2 consulab.com info@consulab.com 18 EM-140D-FC03_053347-95 SA-7 — Expected Voltages — ECM Breakout Box Panel SA-7 Expected Voltages — ECM Breakout Box Panel Expected Voltages — ECM Breakout Box Panel — Connecter Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This step seven is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage mea- surements at the ECM BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Your instructor will select certain circuits and systems with the maximum learning opportunity. PIN System/Voltage Key OFF Service Mode KOER EM-140D-FC03 Engine Application : EXAMPLE APP sensor 1 signal ...0 V 0.9 V 0.9 V Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 19 EM-140D-FC03_053347-95 SA-8 — Measured Voltages — ECM Breakout Box Panel SA-8 Measured Voltages — ECM Breakout Box Panel Measured Voltages — ECM Breakout Box Panel — Connecter In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step eight in getting familiar with this trainer and ECM breakout box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Your instructor will select certain circuits and systems with the maximum learning opportunity. PIN System/Voltage Key OFF Service Mode KOER EM-140D-FC03 Engine Application : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 20 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS01 SA-9 Case Study Diagnosis — CS01 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS01 Customer Concern The customer states that the vehicle has failed the government mandated emissions test. The check engine light is on. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 21 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS02 SA-9 Case Study Diagnosis — CS02 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS02 Customer Concern The customer brings you their truck and states there is a light on the dash stating there is water in their fuel. The customer assures you they only used high quality fuel and put no water in. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 22 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS03 SA-9 Case Study Diagnosis — CS03 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS03 Customer Concern Customer states that the engine has poor performance, sluggish acceleration and fuel economy is down. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 23 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS04 SA-9 Case Study Diagnosis — CS04 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS04 Customer Concern Customer states that the engine seems to crank longer than normal but will always start up. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 24 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS05 SA-9 Case Study Diagnosis — CS05 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS05 Customer Concern Customer states that the engine seems to crank longer than normal but will always start up. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 25 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS06 SA-9 Case Study Diagnosis — CS06 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS06 Customer Concern Customer states that the engine will turn over but does not start up. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 26 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS07 SA-9 Case Study Diagnosis — CS07 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS07 Customer Concern Sometimes the truck takes a long time to start, or doesn’t start. Other times it starts and runs great! Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 27 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS08 SA-9 Case Study Diagnosis — CS08 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS08 Customer Concern The check engine light is on. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 28 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — CS09 SA-9 Case Study Diagnosis — CS09 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS09 Customer Concern Check engine light on, truck is sluggish. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 29 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — CS10 SA-9 — Case Study Diagnosis — CS10 EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study. NOTE : For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. CS10 Customer Concern The check engine light is on. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 30 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS11 SA-9 — Case Study Diagnosis — ICS11 EM-140D-FC03 Engine Application : This is an instructor led lesson where an Intake Manifold Air Temperature sensor DTC is created. When the case study is activated, the IAT signal is interrupted and a simulated signal is introduced. You will sometimes hear a slight difference in the tone of the motor while running. Intake manifold air temperature sensor lesson WARNING: You must clear all codes before starting this lesson. This should be an instructor led lesson. Start with Key ON/Engine OFF then compare scan data to data with the engine run- ning. With ICS11 inserted, the IAT sensor fault is toggled on and set to approx 4.1V with NO intermittence and will set a DTC P0113. Start the engine. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS011 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 31 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS12 SA-9 — Case Study Diagnosis — ICS12 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Engine Coolant Temperature sensor signal is interrupted and a simulated sig- nal is introduced. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the engine coolant temperature sensor (ECT) signal between PIN 2 of the sensor and BOB PIN C1-83 and introducing a new signal into the circuit at 4.98V, the scan tool will show -40 C or -40 F. DTC P0118 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS02 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 32 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS13 SA-9 — Case Study Diagnosis — ICS13 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Engine Coolant Temperature sensor signal is interrupted and a simulated sig- nal is introduced. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the engine coolant temperature sensor (ECT) signal between PIN 2 of the sensor and BOB PIN C1-83 and introducing a new signal into the circuit at 2.6V, the scan tool will show 126 C or -258 F. DTC P0217 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS03 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 33 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS14 SA-9 — Case Study Diagnosis — ICS14 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Engine Coolant Temperature sensor signal is interrupted and a simulated signal is introduced. The vehicle will now think it is almost oveheating. The fan will be on max (you will hear it!), the temp sensor on the instrument cluster will be at 3/4. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the engine coolant temperature sensor (ECT) signal between PIN 2 of the sensor and BOB PIN C1-83 and introducing a new signal into the circuit at 0.63V, the scan tool will show 91 C or 195 F. No code is present. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS04 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 34 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS15 SA-9 — Case Study Diagnosis — ICS15 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Exhaust Gas Temperature sensor #5 signal is interrupted and a simulated signal is introduced. The dash will give a warning “exhaust system service required - see dealer”. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Exhaust Gas Temperature sensor #5 signal between PIN 1 of the sensor and ECU/ BOB PIN C2-37 and introducing a new signal into the circuit at 0.5V, the scan tool will show 1000 C or 1832 F. DTC P2482, P214D You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS05 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 35 EM-140D-FC03_053347-95 SA-9 — Case Study Diagnosis — ICS16 SA-9 — Case Study Diagnosis — ICS16 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Fuel Rail Pressure sensor signal is interrupted and a simulated signal is intro- duced. The engine will be hard to start, sometimes with a long crank. After multiple starts, the code P0191 will appear. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Fuel Rail Pres- sure sensor signal between PIN 5 of the sensor and ECU/ BOB PIN C1-59 and introducing a new signal into the circuit at 1.15V, the scan tool will show approx 350 bar or 5000 psi. DTC P0191 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 36 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS17 SA-9 — Case Study Diagnosis — ICS17 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Fuel Rail Pressure sensor signal is interrupted and a simulated signal is intro- duced. If this case study is activated with the engine off, the engine will not start. If the case study is activated with the engine running, it will start hunting and running poorly, and after some time will code. After running for a while, the code P0191 will appear. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Fuel Rail Pres- sure sensor signal between PIN 5 of the sensor and ECU/ BOB PIN C1-59 and introducing a new signal into the circuit at 0.25V, the scan tool will show approx -96 bar or -1400 psi. DTC P0191 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 37 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS18 SA-9 — Case Study Diagnosis — ICS18 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Fuel Rail Pressure sensor signal is interrupted and a simulated signal is intro- duced. If this case study is activated with the engine off, the engine will not start. If the case study is activated with the engine running, it will start hunting and running poorly, and after some time will code. After running for a while, the code P0193 will appear. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Fuel Rail Pressure sensor signal between PIN 5 of the sensor and ECU/ BOB PIN C1-59 and introducing a new signal into the circuit at 4.4V, the scan tool will show approx 2200 bar or 32,000 psi. DTC P0193 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 38 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS19 SA-9 — Case Study Diagnosis — ICS19 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Boost pressure sensor signal is interrupted and a simulated signal is intro- duced. With this case study activated, the turbo will whistle and the code P0107 will appear. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Boost Pressure (BP) sensor signal between PIN 1 of the sensor and BOB PIN C1-45 by introducing a new signal into the circuit at 0.1V, the scan tool will show 0 kPa. DTC P0107 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 39 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS20 SA-9 — Case Study Diagnosis — ICS20 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Boost pressure sensor signal is interrupted and a simulated signal is intro- duced. With this case study activated, the turbo will whistle until the codes P0106 and P2580 appear. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Boost Pressure (BP) sensor signal between PIN 1 of the sensor and BOB PIN C1-45 by introducing a new signal into the circuit at 4.0V, the scan tool will show 215 kPa, once code sets pressure drops to 0 kPa. DTC P0106, sometimes, eventually P2580 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 40 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS21 SA-9 — Case Study Diagnosis — ICS21 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Exhaust differential pressure sensor (AFT DPF outlet pressure sensor) signal is interrupted and a simulated signal is introduced. With this case study activated, the check engine light will come on with code P2455. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Exhaust Differ- ential Pressure Sensor (DPS or AFT DPF outlet pressure) sensor signal between PIN 3 of the sensor and ECU/BOB PIN C2-42 by introducing a new signal into the circuit at 4.75V, the scan tool will show 38 kPa, after coding it will normally go to 0 kPa. DTC P2455 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 41 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS22 SA-9 — Case Study Diagnosis — ICS22 EM-140D-FC03 Engine Application : This is an instructor led lesson where the Exhaust differential pressure sensor (AFT DPF outlet pressure sensor) signal is interrupted and a simulated signal is introduced. With this case study activated, the check engine light will come on with code P2454. WARNING: Clear all codes before beginning each case study. This condition is created by adjusting the Exhaust Differ- ential Pressure Sensor (DPS or AFT DPF outlet pressure) sensor signal between PIN 3 of the sensor and ECU/BOB PIN C2-42 by introducing a new signal into the circuit at 0.1V, the scan tool will show 0 kPa. DTC P2454 You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 42 EM-140D-FC03_053347-95_V2024-1 SA-9 — Case Study Diagnosis — ICS23 SA-9 — Case Study Diagnosis — ICS23 EM-140D-FC03 Engine Application : Customer states that engine acceleration feels different, feels slow on response. Check and advise. WARNING: Clear all codes before beginning each case study. This case study causes a customer concern of a poor throttle response and check engine light on. This condition is created by a momentary glitch in the circuit between PIN 2 of the APP and BOB PIN C2-10, this can be viewed on an oscilloscope. The engine will still have throttle response due to a redundant circuit but a hard active code is indicated. DTC P2121. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ICS06 Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 43 EM-140D-FC03_053347-95 SA-9 — Advanced Case Study Diagnosis Template SA-9 — Advanced Case Study Diagnosis Template — ACSF EM-140D-FC03 Engine Application : Clear all DTC’s before beginning each case study This is an ADVANCED lesson where a issue can be demonstrated. Follow the OEM troubleshooting sequence using linked documents for wiring diagrams and ECM breakout box information. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instructor. ACSF Reverse engineer the customer con- cern based on the demonstrated case study and vehicle performance. Student Observation Explain Strategy Tests Performed Fault Component Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 44 EM-140D-FC03_053347-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved.

Operation Manual for EM-140D-FC03_053347 Consulink™ 2017 Ram 6.7L Diesel Engine Trainer EM-140D-FC03_053347-93_V2024-4 © ConsuLab Educatech Inc, 2024. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space EM-140D-FC03_053347-93 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 3 © ConsuLab Educatech Inc, 2024. 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 053347 and above. Table of Contents General Description 5 Standard Equipment 5 Optional Equipment 5 Component Identification and Locations 6 Dashboard Components 6 Bench Components 7 ECM Breakout Box (BOB) 8 DLC Breakout Box 9 Warning and Notices 10 WARNING for RAM Cummins 6.7L 10 NOTICE for Regeneration and Connector Location 10 NOTICE for Scan Tool Compatibility 10 ConsuLink™ Student Learning Platform 11 STUDENT FACING Accessible Features 11 INSTRUCTOR FACING Accessible Features 13 Automatic Regulated 12-V Battery Charger 14 Safety Instructions 14 Installation and Maintenance 14 EM-140D-FC03_053347-93 Teacher Resources consulab.com info@consulab.com 4 EM-140D-FC03-95 Student Assignments — Table of Contents EM-140D-FC03-96 Instructors Guide — Table of Contents EM-140D-FC03_053347-95 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, 2024. 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 053347 and above. Table of Contents Warning and Notices 3 WARNING for RAM Cummins 6.7L 3 NOTICE for Regeneration and Connector Location 3 NOTICE for Scan Tool Compatibility 3 Student Assignments SA-1 — Basic Component ID 4 SA-2 — Engine Specific ID 6 SA-3 — Component Identification — SENSORS 8 SA-4 — Component Identification — ACTUATORS 10 SA-5 — Charging System Verification 11 SA-6 — Wiring Diagram Practice — ECM Breakout Box Panel 12 SA-7 — Expected Voltages — ECM Breakout Box Panel 18 SA-8 — Measured Voltages — ECM Breakout Box Panel 19 SA-9 — Case Study Diagnosis — CS01 20 SA-9 — Case Study Diagnosis — CS02 21 SA-9 — Case Study Diagnosis — CS03 22 SA-9 — Case Study Diagnosis — CS04 23 SA-9 — Case Study Diagnosis — CS05 24 SA-9 — Case Study Diagnosis — CS06 25 SA-9 — Case Study Diagnosis — CS07 26 SA-9 — Case Study Diagnosis — CS08 27 SA-9 — Case Study Diagnosis — CS09 28 SA-9 — Case Study Diagnosis — CS10 29 SA-9 — Case Study Diagnosis — ICS11 30 SA-9 — Case Study Diagnosis — ICS12 31 SA-9 — Case Study Diagnosis — ICS13 32 SA-9 — Case Study Diagnosis — ICS14 33 SA-9 — Case Study Diagnosis — ICS15 34 SA-9 — Case Study Diagnosis — ICS16 35 SA-9 — Case Study Diagnosis — ICS17 36 SA-9 Case Study Diagnosis — ICS18 37 SA-9 Case Study Diagnosis — ICS19 38 SA-9 Case Study Diagnosis — ICS20 39 SA-9 Case Study Diagnosis — ICS21 40 SA-9 Case Study Diagnosis — ICS22 41 SA-9 Case Study Diagnosis — ICS23 42 SA-9 — Advanced Case Study Diagnosis Template 43 Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space EM-140D-FC03_053347-96 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, 2024. 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 053347 and above. Table of contents General description 3 Standard Equipment 3 Optional Equipment 3 Component Identification and locations 4 Dashboard Components 4 Bench Components 5 Warning and Notices 6 WARNING for RAM Cummins 6.7L 6 NOTICE for Regeneration and Connector Location 6 NOTICE for Scan Tool Compatibility 6 Safety Rules 7 Introduction to the EM-140D Family of Light Diesel Engine Benches 9 Introduce the New ConsuLink™ Student Learning Platform 12 Student Facing 12 Instructor Facing 14 Additional Features 15 Student Assignments - Basic Orientation and Troubleshooting 16 Instructor Answers for Case Studies 21 EM-140D-FC03 Wiring Diagram w/ Fault Location for Case Studies 29 consulab.com info@consulab.com 5 EM-140D-FC03_053347-93 General Description General Description The EM-140D-FC03_053347 diesel engine trainer is a fully operational engine mounted on a mobile stand. Trainer is based on 2017+ RAM trucks with Cummins 6.7L Vin L turbo-diesel engine platform used in RAM 2500/3500 heavy duty models — Equipped with tablet-based ConsuLink™ Student Learning Platform de- signed to enhance student engagement. The trainer is features easy for students and to work around all ma- jor components, wiring and connectors match OEM configurations — Equipped with safety guards covering all rotating components. Standard Equipment : • Engine – 2017+ Ram 2500/3500 Truck with Cummins 6.7L Vin L turbo diesel engine compliant with EPA 2017 standards • ConsuLinkTM student learning platform • High Pressure Common Rail (HPCR) fuel system • 6-speed automatic transmission • Diesel Particulate Filter (DPF) • Variable Geometry Turbocharger (VGT) • Exhaust Gas Recirculation system (EGR) • Selective Catalytic Reduction (SCR) w/ DEF injection • Steel tubing engine stand with four removable casters, two locking • Closed Crankcase Ventilation System • Fuel tank • DEF tank • Radiator • Charge-air cooler • Intake throttle • Batteries with master disconnect switch • Automatic regulated 12V battery charger • Custom instrument panel protection • Safety covers for all rotating devices • Custom coolant flow sight glass for V-8 diesel engine • Comes with only one OEM key • Fork lift bars • Scan tool tray Optional Equipment : • Vinyl dust cover • Secondary key with programming EM-140D-FC03_053347-93 Component Identification and Locations consulab.com info@consulab.com 6 Component Identification and Locations Dashboard Components 1 Emergency Stop Switch 15 Voice Recognition 2 ConsuLink Student Learning Platform 16 Volume Up 3 ConsuLink Instructor Mode Lockout 17 Volume Down 4 ConsuLink Power Button 18 Accept Call 5 Key Ignition Switch* 19 Scroll Right 6 Data Link Connector Breakout Box 20 Scroll Left 7 Data Link Connector 21 4WD Control Switch 8 ECM Breakout Box 22 Parking Brake Switch 9 Fuel Level 23 Cruise Control Buttons 10 DEF Level 24 Integrated Trailer Brake Module 11 Tachometer 25 Traction Control OFF 12 Instrument Cluster Display 26 Tow/Haul Mode 13 Speedometer 27 Exhaust Brake 14 Battery Indicator * Depending on the model, it is possible to have an ignition key or a smart key 8 2 7 3 5 4 131211 10 9 6 15 16 17 18 19 20 1 14 24 25 26 27 22 21 23 EM-140D-FC03_053347-93 Component Identification and Locations consulab.com info@consulab.com 7 Bench Components 1 Emergency Disconnect Switch 10 Turbocharger Outlet 19 Fuel Return Line 28 Power Distribution Center and Fuse Box2 Air Filter Housing 11 Charge Air Cooler 20 High Pressure Common Rail 3 Clean Intake Air to Turbocharger 12 Variable Geometry Turbo Control 21 Engine Air Intake 29 Engine Oil Pan 4 Exhaust Manifold 13 Turbocharger 22 EGR Valve 30 Batteries 5 Turbocharger Inlet Tube 14 Turbocharger Exhaust Outlet 23 Engine Oil Fill & Valve Cover 31 Battery Maintainer 6 Engine Coolant Reservoir 15 Exhaust Aftertreatment 24 Coolant Flow Indicator 32 Master Disconnect Switch 7 Alternator 16 DEF Tank Assembly 25 Power-steering Reservoir 33 Fuel Filler Spout and Tank 8 Air Conditioning Condenser 17 DEF Filler Assembly 26 Radiator 34 Transmission Output 9 Fan Shroud 18 Flywheel Housing Support 27 Engine Electronic Control Unit 11 2 3 4 6 1 8 9 10 7 5 1 12 13 14 15 1 16 23 22 19 18 17 21 201 25 26 32 313029 2827 11 33 34 24 consulab.com info@consulab.com 8 EM-140D-FC03_053347-93 ECM Breakout Box (BOB) ECM Breakout Box (BOB) The EM-140D-FC03_053347 ECM Breakout Box is designed for easy testing of input and output signals com- ing from various sensors and actuators in the complete engine operational system. The identification of all test points match OEM ECM pinout diagrams. Testing at the Breakout Box (BOB) is the same as back probing the ECM harness without any danger of damaging pins! • C1 & C2 connectors (Chrysler’s terminology for ECM labeling). • 2 mm test receptacles to accept most multimeter and oscilloscope test leads. • Faults with variable values; students must use either a scan tool or the ECM BOB for obtaining their diag- nostic measurements. • Students are not allowed to back-probe or measure at the faulted sensor as there will be false readings. • This is because when a fault with a variable value is selected, the “real” sensor signal is still present at the sensor. • When using open circuit faults students may back-probe or measure at the sensor as required, at instruc- tors discretion (Case Studies 1-9). • The ECM BOB pin numbers match OEM service information. • Some pins are not used for specific vehicle and trainer applications. ECM BREAKOUT BOX consulab.com info@consulab.com 9 EM-140D-FC03_053347-93 DLC Breakout Box DLC Breakout Box • Specifically designed for use in educational environments with robust 2mm test pins and LED CAN Bus activity indicators for all 16 pins of a standard OBD DLC. • Y-harness configuration allows for replaceable DLC installation on the trainer. • The ability to replace the Y-harness subassembly allows for a cost effective repair in case the connector gets damaged. • LED lights indicate data communication is occurring. # Color Signal Description 1 N/A N/A No Connect 2 N/A N/A No Connect 3 GY D157 CAN IHS (+) 4 BK Z910 GROUND 5 BK Z911 GROUND 6 GY/WH D57 CAN C (+) 7 N/A N/A No Connect 8 N/A N/A No Connect 9 N/A N/A No Connect 10 N/A N/A No Connect 11 WH D158 CAN IHS (-) 12 N/A N/A No Connect 13 N/A N/A No Connect 14 YE D58 CAN C (-) 15 N/A N/A No Connect 16 RD A900 FUSED B(+) DLC BREAKOUT BOX EM-140D-FC03_053347-93 Warning and Notices consulab.com info@consulab.com 10 WARNING for RAM Cummins 6.7L EM-140D-FC03_053347 Dash Information Display Notifications You may encounter notifications on the dash display that are present at every start up. Some examples are tire pressure, brake light out, license plate light out, washer fluid, etc. These notifications cannot be erased by disconnecting the battery. These notifications are set by the component not being present and communicating on the bus. For example, the tire pressure sensors are not present on the trainer. The notifications listed above do not turn on the MIL (Malfunction Indicator Light) but do generate a message on the instrument cluster display. APPLICABLE VEHICLES: 2018 RAM TRUCKS NOTICE for Regeneration and Connector Location Using the Deutsch connector on the right side of the dash allows you to connect in parallel with diagnostic port 3 as shown in the schematics for the vehicle. Connecting the appropriate data link connectors to a PC equipped with Cummins InSite software will allow access to complete a forced regeneration cycle. (NEXIQ style communication adapter and Cummins InSite not supplied by ConsuLab). NOTICE for Scan Tool Compatibility This vehicle has a manufacturer installed security gateway module, that does not allow common scan tools to clear all codes, through the OBD II connector, without the purchase of a yearly subscription. You will need an OEM scan tool subscription to do this. (not supplied by ConsuLab) Some aftermarket scan tools (e.g. Autel) may have access to clear codes after the purchase of AutoAuth. For more information see your scan tool user’s manual and the following link about AutoAuth: https://info.autoauth.com/ 2/28/24, 3:38 PM MotoLogic Color Wiring: Computer Data Lines: (4 of 5) • 2018 Dodge Ram 2500 (6.7L Turbo Diesel) - DJ • MotoLogic https://www.motologic.com/car/2018_dodge_dj_ram_2500_pickup_6_7l_i6_cummins_turbo_diesel/article/ba45fbc3c0ce858adecaf0a945b58457_wra… 2/3 586642 12 11 8 7 22 21 14 13 12 11 10 9 D IA G C AN C (+ ) C AN C (+ ) A T C AN C (+ ) G N D FS D IG N R U N D IA G C AN C (- ) C AN C (- ) A T C AN C (- ) C AN IH S (-) D IA G C AN IH S (-) C AN IH S (-) A T FS D B + G N D C AN IH S (+ ) D IA G C AN IH S (+ ) C AN IH S (+ ) A T CAN J1939 4 (-) CAN J1939 4 (+) CAN C (+) CAN C (-) 20 19 18 17 16 15 14 13 10 9 6 5 4 3 2 1 CAN C (+) CAN C (-) 20 19 18 17 16 15 8 7 6 5 4 3 2 1 CAN J1939 2 (-) CAN J1939 2 (+) CAN J1939 4 (+) CAN J1939 4 (-) CAN J1939 4 (+) CAN J1939 4 (-) CAN J1939 4 (+) CAN J1939 4 (-) CAN IHS (-) AT CAN C (-) AT CAN C (+) AT CAN IHS (+) AT CAN C (-) CAN C (+) CAN C (+) CAN C (-) 1 2 3 4 5 6 7 8 9 10 11 12 C 1 87654321 C 2 C I2855 3 2 4 3 C1 I530 8 7 C1 39 27 12 6 I311C1 B A 2 3 2 3 1 2 1 12 2 11 C1 24 I311 36 12 11 12 13 1 C3 2 YEL BRN WHT/BRN YEL TAN TAN WHT WHT YEL VIO/WHT YE L G R Y W H T/ BR N BL K PN K/ G R N TA N YE L YE L W H T TA N D K BL U R EDBL K VI O /W H T W H T W H T WHT/GRN WHT/BLU WHT/DK BLU WHT/DK GRN WHT/DK GRN WHT/DK BLU DK BLU YEL YEL BRN/WHT YEL YEL/GRY YEL/DK BLU YEL VIO YEL ORG YEL DK BLU/WHT YEL RED PNK/GRN WHT/DK GRN WHT/DK BLU W H T/ D K G R N W H T/ D K BL U YEL VIO YEL VIO YEL YEL/DK BLU YEL DK BLU/WHT WHT/GRN WHT/DK BLU WHT/DK GRN WHT/DK BLU WHT/DK BLU WHT/GRN WHT/DK BLU WHT/DK GRN BLK BLK/WHT WHT/DK BLU WHT/DK GRN WHT DK BLU GRY YEL YEL BRN WHT/BLU WHT/GRN DK BLU YEL DK BLU YEL BRN/WHT YEL YEL YEL/GRY YEL ORG D 42 8 D 43 6 D 35 1 Z9 12 F9 48 D 42 7 D 43 5 D 35 0 D 35 2 D 43 3 D 43 8 A9 37 Z9 12 D 35 3 D 43 4 D 43 7 D78 D77 D40 D134 D135 D196 D197 D39 SELECTIVE CATALYTIC REDUCTION MODULE UREA QUALITY SENSOR NOX SENSOR 1/2 PARTICULATE MATTER SENSOR RADIO RADIO FREQUENCY HUB MODULE CLUSTER PARK ASSIST MODULE TRAILER TOW MODULE G309 SECURITY GATEWAY MODULE DIAGNOSTIC PORT 3 (LEFT SIDE OF ENGINE) (MIDDLE OF UNDER SIDE OF VEHICLE, BEHIND TRANSMISSION) (RIGHT CENTER OF DASH) (LEFT REAR OF ENGINE, IN TRANSMISSION HARNESS) (ON UREA TANK) (LEFT REAR OF ENGINE, IN TRANSMISSION HARNESS) (UNDER VEHICLE, IN RIGHT CHASSIS HARNESS) (UNDER VEHICLE, IN RIGHT CHASSIS HARNESS) (AT OUTLET OF SELECTIVE CATALYTIC REDUCTION CATALYST) (NEAR INLET TO DPF) (CENTER REAR OF CAB WALL) (LEFT KICK PANEL) (LOWER LEFT CENTER OF DASH) (6.7L TURBO DIESEL) (6.7L TURBO DIESEL) (6.7L TURBO DIESEL) 2500 HD (6.7L TURBO DIESEL) SD134B SD135A SD134C SD135C https://info.autoauth.com/ consulab.com info@consulab.com 11 EM-140D-FC03_053347-93 ConsuLink™ Student Learning Platform ConsuLink™ Student Learning Platform • To turn ON, locate the tablet start button and press it to allow tablet to boot up. STUDENT FACING Accessible Features : • Operation Manual Button : - Optional equipment - Fuel System - Exhaust System - ECM BOB - DLC w/BOB - ConsuLink™ student learning platform operation • How to navigate : - Hit “HOME” button. • Case Studies Button : - Note : Student Assignments SA-1 to SA-8 are different than case studies and need to be completed before Case Studies are assigned. - Student Assignment SA-9 consists of ten (10) student led discovery Case Studies already programmed into the ConsuLink™ student learning platform. - Opening up the case studies : - Select the Case Study assigned by your instructor - Student will have an assignment sheet to complete for each case study - Case studies are written similar to a repair order - Student will need to check for any DTC’s first that may have been left from previous exercises. - Any stored DTC must be cleared before starting on a new case study diagnosis. - Each case study page has a quick link to : - Wiring diagrams - ECM BOB diagrams - Press GREEN button to start Case Study with ENGINE OFF to begin lesson. - REMOVE Case Study only after engine shut down. - Verify DTC’s and clear after each lesson is completed. consulab.com info@consulab.com 12 EM-140D-FC03_053347-93 ConsuLink™ Student Learning Platform • Wiring Diagrams Button : - How to navigate : - Pinch & Zoom - OEM diagrams with PIN numbers matching the trainer • Breakout Box (BOB) Button : - How to navigate : - Pinch & Zoom - OEM diagrams with PIN numbers matching the trainer • Component Locator Button : - “Call outs” and information it reveals. - Use this with Student Assignment SA-1,2,3 & 4. • Scenario Number Button : - Scenario numbers are just a different way for your instructor to assign case studies. • Demonstrate safety ! - This is an expensive piece of equipment, so please respect it ! - Safety glasses required to operate this equipment every time. - No ear buds – complete attention is required when working with this trainer ! - ALWAYS connect trainer to an exhaust removal system before operating. - Locate emergency STOP switch : - NOTE : sometimes the emergency STOP switch can be “disturbed” and result in a crank / no start con- dition. If there is ever a no start situation ALWAYS push and release the emergency STOP switch and try again to start it up. - There will also be an illuminated red light in the switch if it is open and needs to be reset. - If there is ever a no start condition not related to any case studies, ALWAYS push the emergency STOP button first, then rotate it allowing it to “POP” back up into the closed position, and try to start the engine again. Open circuit Close circuit consulab.com info@consulab.com 13 EM-140D-FC03_053347-93 ConsuLink™ Student Learning Platform INSTRUCTOR FACING Accessible Features : • Refer to Instructors Guide for how to access Instructor Mode • Instructors Guide Button : - All the resources that an instructor will need to ensure student learning and engagement occur! • Case Studies – Instructor Button : - Instructor mode includes 13 more Instructor led case studies (ICS). • Wiring Diagrams with Faults Button : - Instructor mode includes access to a different set of wiring diagrams. • Fault Insertion Button – Custom Case Study Creation - New case studies can be created by the instructor in addition to intermittent faults, resulting in almost infinite possibilities. - A selection of 16 advanced faults are already programmed into the tablet. consulab.com info@consulab.com 14 EM-140D-FC03_053347-93 Automatic Regulated 12-V Battery Charger Automatic Regulated 12-V Battery Charger With a current capacity of 1.5 A, the automatic regulated 12V battery char- ger installed on our mobile gas engine training benches has been designed to provide years of reliable service, only if the user thoroughly follows instruc- tions. Safety Instructions • Always disconnect the power cord by pulling on the cord plug and not the cord. • If an electrical extension cord is used with this trainer, make sure it is a 3-wire grounded type cord and made with 16ga or larger wire. • Do not operate the charger with a damaged cord or plug. Replace it immediately. • Do not operate the charger that has received a sharp blow, been dropped or otherwise damaged in any way. Call ConsuLab for repair service. • Do not disassemble the charger when service or repair is required. • Be sure the battery charger power cord is disconnected before making any connections, doing mainte- nance or cleaning unit. • Be careful when you connect the charger to a 12V battery. Batteries generate explosive hydrogen gas during normal operation. Read and follow all battery manufacturer instructions before installing and turn- ing on the charger. Installation and Maintenance • The charger uses a voltage regulating control circuit that continually monitors the battery voltage and automatically turns the output on and off, safeguarding against battery overcharge. To disconnect the charger, unplug the AC cord first. • Be careful against sparks that may cause the explosion of the battery. AC and DC cords must be well handled properly to avoid any damage by tools, blades or moving engine parts. • Once the battery charger has been properly connected to the battery and AC outlet, the red LED is turned on continuously to indicate that the battery is in charging mode. Depending on the state of charge at the time the charger is connected to the AC outlet, the red LED is flashing on and off to indicate that the voltage output is regulated. The charger is turned off when DC is higher than 14.1 and is turned on with voltage lower than 13.1. Voltage regulation is enabled until the end of battery charging. • Minimum care is required to provide years of reliable service. Keep the battery charger clean and dry. Use a damp cloth to clean the case and cables. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. General Description Standard Equipment : Optional Equipment : ECM Breakout Box (BOB) DLC Breakout Box ConsuLink™ Student Learning Platform STUDENT FACING accessible features : INSTRUCTOR FACING accessible features : Automatic regulated 12-V battery charger Safety Instructions Installation and Maintenance