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75 views

3.3_Electrical_System_Testing_rev2012_joao

Uploaded by

Daniel Souza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Electrical System Testing

AE Basics Brasil 2012

Joao Moretto
August, 2012
Agenda
 AEB24.53 – Cummins Branded Starters & Alternators
 General Wiring Practices
 Cranking System
– Starter & battery selection
– Test procedure
 Run, Stop, and Crank Controls
– Design and Wiring Guidelines
– Test procedure
 Charging System
– Alternator, wiring, fuse selection
– Test procedure

2 8/2/2012 Cummins Confidential


General Wiring Practices
 Starter ground must be connected directly to the battery
or a common ground.
 Alternator must be grounded directly to battery, common
ground, or starter ground lug.
 Cables sized appropriately to ensure starter receives
adequate current and to meet maximum resistance
requirement (0.002 ohm).

3 8/2/2012 Cummins Confidential


Equipment Required

 Digital Camera
 Calterm Equipped Laptop & Inline Kit
– Used for overriding fueling, rpm, general engine monitoring.
 Multimeters (5)
 Current Probe or Clamp
 Thermocouple
 Optional – Datalogger

4 8/2/2012 Cummins Confidential


Cranking System - Starter & Battery Selection
 Number of starts per day
 Equipment duty cycle (intermittent, cyclical, or steady
state)
 Electrical loads (load vs. engine RPM)
 Aftermarket accessories (lights, radios, etc.)
 Battery type (starting, high cycle, deep cycle)

5 8/2/2012 Cummins Confidential


Starter & Battery Selection cont…
 For batteries in parallel, CCA values add. For
batteries in series, CCA value is the same as that for
a single battery.

6 8/2/2012 Cummins Confidential


Cranking/Charging Requirements
Base Engine Datasheet

Fuel Rating Datasheet

7 8/2/2012 Cummins Confidential


Cranking Test
 Test should be run with engine oil temp <105F (40C)
– Measure at beginning of test through dipstick tube.

8 8/2/2012 Cummins Confidential


Cranking Test cont.
 Current during cranking = Amps
– Is the current ≤ 700 max allowed continuous crank amps?
 Cranking speed = rpm
– Is the engine speed ≥ 75rpm?
 Engine oil temp = °F
 Vbat – Vst =
 (V+) + (V-) =
– Is this value within 10% of Vbat – Vst?
 Ω(ohms) = (Vbat-Vst) / Ist = ohms
– Is this value less than the max allowable resistance for the
starter used? Req. ≤ 0.002 ohm

9 8/2/2012 Cummins Confidential


Cranking Motor Capacity
 AEB121.17 - Starter Performance Curves
 Ist = Amps  Ptest = kW

10 8/2/2012 Cummins Confidential


Minimum Unaided Start Temperature

 Pmin = (Ptest*(180% / %)) = kW


 Pmotor = 3.2kW
 Is (Pmotor – Pmin) ≥ 0?
 Is the engine cranking rpm ≥ 130 rpm?
11 8/2/2012 Cummins Confidential
Run, Stop, and Crank Test
 Test performed to help determine whether or not the
starter solenoid is receiving the minimum voltage
required.

12 8/2/2012 Cummins Confidential


Run, Stop, and Crank Test
 Measure:
– Vbatt =
– Vsol =
– Vs+ =
– Vs- =
 Calculations:
– Vbat – Vsol =
– (Vs+) + (Vs-) =
• Is this value within 10% of Vbat – Vsol?

 Starter Solenoid Voltage Drop


– Vdrop = Vbat – Vsol
• Is the total voltage drop ≤ 1.0 V?

13 8/2/2012 Cummins Confidential


Charging System Testing
 Cummins recommends sizing the alternator with
15% more capacity than max power draw.
 Alternator fuse should be sized 20-50% above
alternator rated output.
 Charging system max voltage drop ≤ 0.5 V

14 8/2/2012 Cummins Confidential


Charging System Test
 Pre-Test - Measure Valt and ensure voltage is between
13.5-15.5V
 Ialt_rated = 120 A

15 8/2/2012 Cummins Confidential


Charging Test – Alternator Wiring Vdrop
 Measure at idle with all machine acc. turned on:
– Vbat =
– Valt =
– V+ =
– V- =
– Ialt_test =
 Calculate:
– Valt – Vbat =
– (V+) + (V-) =
• Is this value with 10% of Valt – Vbat?
– Vdrop = (Ialt_rated / Ialt_test) * (Valt – Vbat) =
• Is Vdrop ≤ 0.5V?

16 8/2/2012 Cummins Confidential


Charging Test – Alternator Capacity
 Measure with typical  Measure with extreme
electrical loading: electrical loading:
– Low idle – Low idle
• Engine speed = • Engine speed =
• Vbat @ start = • Vbat @ start =
• Vbat after 2 min = • Vbat after 2 min =
– High idle – High idle
• Engine speed = • Engine speed =
• Vbat @ start = • Vbat @ start =
• Vbat after 2 min = • Vbat after 2 min =

 Did the batteries maintain their charge during all tests?


 Batteries should not discharge more than 0.25 V

17 8/2/2012 Cummins Confidential


Key Watch Outs / Tips
 Loose connections on OEM’s wiring
– ex. Star washers, heat sources, friction wearing.
 Routing of test equipment wires
– Crimping, heat, sharp edges, fan blades
 Jump start protection cover will need to be removed
to perform cranking tests.
 Starter lockout engages after 30 seconds of
continuous cranking and resets every 120 seconds.
 Cummins requires a master disconnect on the starter
positive cable for all electronic engines.

18 8/2/2012 Cummins Confidential


QUESTIONS ????

19 8/2/2012 Cummins Confidential

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