STARTERS

GUIDE

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CV-307N

The CV-307N is a test bench with a sturdy look and meant to last in the modern workshop. Its high power motor in combination with its computer controlled load bank makes it easy to test up to 300amps. The CV-307N is equipped with the latest testing technology for the modern workshop or production facility, such as API+ technology which automatically identifies COM protocols within 2 seconds. These protocols are displayed together with their ID codes, which makes development in remanufacturing easier, cheaper and more clear. A modern windows PC is included for internet support and to generate modern and extensive reports.

Test Bench

ENGLISH VERSION 2020

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IMPORTANT INFORMATION

Safety warning

Electrical devices should be installed and operated in such a way that all applicable safety requirements are met. It is your responsibility as an installer to ensure that you identify the relevant safety standards and comply with them. Failure to do so may result in damage to equipment and personal injury. In particular, you should study the contents of this guide carefully before installing or operating the equipment.

Only qualified people should work with this equipment!

People who start using this product should review carefully this Starters Guide, or have had a training from a qualified person.

The use of electrical equipment is entirely at your own risk and Motoplat® is under no circumstances re-sponsible for any incidental, consequential or special damages of any kind whatsoever, including but not limited to lost profits arising from or in any way connected with the use of the automated test equipment or this manual.

The tester should be connected to a properly grounded outlet.If the power cable is damaged, you must have it be replaced by the supplier or by another qualified person in order to avoid dangerous situations.

In case the tester comes without batteries (non EU-countries) or in case you have to replace the batteries, please be aware to use qualified batteries (preferably deep cycle AGM) only, as non-qualified batteries can affect during testing or can even damage the tester.

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EnvironmentThe tester should be installed in an weather protected area where heat, humidity or any other climate situation can not damage the tester. The tester should be installed on a level surface that is clear of debris and obstructions.

It is recommended that the box and packing materials be kept for possible reuse, should the tester be shipped again at a later time.

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Index

1 General Information 1.0 General information about the Motoplat CV-307N alternator testbench 4 1.1 Front view 5 1.2 Instrumental pannel 1 6 1.3 Instrumental pannel 2 7

3 Mounting and connection of the alternator 3.0 Intro 10 3.1 Mounting the alternator 10 3.2 Connecting the alternator 11

2 Installation and system connection 2.0 Requirements installation area 8 2.1 Power supply 8 2.2 Switch on/off alternator tester 9

4 Testing the alternator 4.0 PC software 12 4.1 Detailed information 13 4.2 Information LIN/BSS 15 4.3 Menu 16 4.4 Calibration 16 4.5 Add alternator/ alternator list 17 4.6 User test 18

5 Maintenance and Troubleshooting 5.0 Maintenance recommendations 19 5.1 Quick troubleshooting guide 19

6 Support 6.0 Contact Information 20

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1.0 General information about the Motoplat CV-307N alternator testbench: The Motoplat CV-307N test bench has a 380V 3-phase power supply and can test both 12 and 24 volt alternators. To test modern alternators that have a high output at low RPM, the CV-307N is equipped with a modern high power 7,5kW motor, which makes less noise than most other test benches on the market. The tester is equipped with the new API+ technology which automatically detects the LIN and BSS protocol more quickly. The LIN and BSS signals will be displayed in different protocols together with the ID code, which makes development in remanufacturing easier, cheaper and clearer. The CV-307N also tests PWM, C and PD-controlled alternators. An in-depth DFM tester is also built in, which displays the offset frequency of a DFM signal. For direct drive testing, the test bench can be equipped with a servo motor. The test bench is CE marked for use in any workshop or workplace that demands safe and reliable equipment.

Section 1 – General information

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1 Pneumatic belt tension valve 6 Instrumental planel 1

2 Power lead (+) 7 Emergency stop switch

3 Wire catch (+) 8 Platform to mount the alternator

4 Main circuit breaker switch 9 Cover switch

5 Instrumental planel 2 10 Display

1.1 Front view:

1 2 3 4

5

7

9

10

86

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1.2 Instrumental panel 1

1. ALTERNATOR CONNECTIONSconnect alternator using banana plugs

2. Alternator test connection „Automatic” harness connection

3. ButtonsCCW- couter clockwise rotationCW- clockwise rotation12V- 12 volt setting24V- 24 volt settingAUTO- automatic testing modeMANUAL- manual testing mode

4. Alternator TestOFF- turns alternator voltage off( for LIN and BSS only).12,5/13,5/15,5- set voltage setpoint for and alternator, works only if pressed, if not the voltage setpoint is by default 14,2 ( for LIN and BSS only).MODE- change alternator type, select mode- search(LIN and BSS), DFM, LAMP, PWM FORD LAND ROVER, PWM SCANIA, PWM GM, C HYUNDAI/KIA, C HONDA, C NISSAN, PD MAZDA, RLO TOYOTA, B+B-.RST- reset alternator type, go back to search( LIN and BSS only).

5 START and STOP buttons START- start the test in both automatic and manual mode. Note that when start is pressed, the general setting buttons are locked, untill stop is pressed. STOP- stop the test in both automatic and manual mode.

6. Charging lampIf lamp alternator is connected, it should be on, when alternator is charging it should be off.

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1.3 Instrumental panel 2

IN USE FOR MANUAL MODE ONLY

1. LOADSet alternator load in 4 steps (from 0A to 300A)

2. 0A-50AStepless regulation of Load between 0A and 80A

3. RPMStepless „revolution per minute” regulation

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Section 2 – Installation and system connection2.0 Requirements installation area: The tester must be placed on a flat and stable surface.The floor must be solid enough to easily bear the weight of the tester!Weight: 300kgPlease leave an extra square meter at the front and sides free to ensure a good and safe working environment. 2.1 Power supply Connect the alternator tester to a 400 V three phase voltage supply. Each phase must be protected by a 32 A fuse. Behind the front doors there is enough space to mount two 12 V batteries AGM with a capacity range of 40 to 100 ampere-hours (Ah) each. It is recommended that AGM batteries are used. They are designed to work with Start-Stop systems, as they are more resistant to voltage fluctuations and there is no risk they will dry out! CAUTION! The positive (+) and negative (-) poles must not be confused with each other. Otherwise, the alternator tester can be damaged. The poles are well marked on the batteries as well as on the wires. When the voltage is 24 V, the batteries are connected in series. Therefore, the batteries should be of the same brand, type and condition (age and usage level). It is preferable to use batteries with a capacity of 70 Ah. During every alternator test, the batteries are being charged and they should not become discharged. Nevertheless, the battery charge level should be checked periodically. If the need arises, the batteries should be charged by means of a rectifier. If the batteries are damaged, they must be replaced with new ones. Discharged or damaged batteries can have a significant influence on the test and test results. Connect compressed air supply on the back of the alternator tester. The compressed air of 8-10 bar is crucial for the pneumatic system controlling the tensioning of the drive belt. When the compressed air pressure is 8-10 bar, the drive belt tension is about 1000 N. Alternator mountingAll the parts needed to mount the alternator are included in the tooling equipment accompanying the alternator tester. After mounting the alternator, connect it to the electric circuit of the alternator tester. This differs per alternator: please refer to our web shop www.psh.nl or other.

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2.2 Switch on/off the alternator tester: Once the machine is installed and correctly connected to the power supply, you can power it up by following the next steps:

1. Switch the main circuit breaker switch (4*) from the “0” position to the “1” position (it will activate all displays and turn on the 12 V/24 V electrical system)

2. Press the“ON” button (10*) marked “POWER”.3. Set the direction of motor revolutions (left or right) by means of the “ROTATION” switch (9*)4. Close the safety cover5. The motor speed regulator (12*) marked “RMP” must be in the “0” position i.e., turned maximum left.

Otherwise, the motor will not start and an alarm will sound informing about the necessity to switch the motor speed regulator to the “0” position. After the motor speed regulator is in the “0” position and the safety cover is put down, the motor will start to slowly rotate at a speed of 10 RPM.

6. By turning the motor speed regulator to the right, one can increase the motor speed to 4000 RPM or decrease it by turning the motor speed regulator to the left.

Caution! If the alternator tester is being used, it does not have to be fully turned off (it is even not recommended to fully turn it off). It is preferable to use the “START” and “STOP” buttons (10*, 11*). That way, the alternator tester starts instantly without any delay. It can be connected to the power supply all the time, because in that state the power consumption of the alternator tester is minimum. It is not recommended to frequently turn off and on the alternator tester, as it contains a lot of advanced electronic measurement systems. In order to work properly, the advanced electronic measure systems should be connected to the power supply all the time rather than turned on and turned off in cycles.

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Section 3 – Alternator – mounting and connecting3.0 Intro:All the elements needed to mount the alternator are included in the equipment accompanying the alternator tester. After mounting the alternator, connect it to the electric circuit of the alternator tester. All electrical connection cables are included in the equipment accompanying the alternator tester. Electrical connections are made with several kinds of test leads, depending on the alternator connectors and terminals.

3.1 Mounting the alternator:In order to mount the alternator, use a platform that is placed on the left side of the alternator tester. In the case of the alternators with a so called pad mounting solution, first attach a support that is placed on the side of the alternator tester with spindles that have a proper diameter. The spindles are also placed on the side of the alternator tester:

Next, mount the alternator by putting adequate spindles into the holes that are placed on both sides of the support:

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To mount alternators that are longitudinally mounted use only spindles (that have a proper diameter) without the support:

3.2 Connecting the alternator:After mounting the alternator, connect it to the electric circuit of the alternator tester.Connect the power lead to the positive clamp of the alternator stator winding (2, Figure 1.) In the absence of sufficient space for a proper connection, use one of two contact terminals (24, Figure 3) located on the left side of the alternator tester :

Then, depending whether it is a computer-controlled alternator or a conventional one, use the adequate test cables, connectors and buttons on the connect and control panel (20*).

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Section 4 – System

1. Main screen - go to main screen of the software. We have 3 different main screens for 3 different tests( alternator test, starter test, regulator test). Chosen test procedure(alternator/starter/regulator) is shown on the orange filed below the ‘main screen’ button. It shows basic information of ( alternator/starter/regulator)

2. Detailed information - go to detailed information. Contains all the parameters of alternator in real time during the test

3. Information LIN-BSS - Detailed information about LIN and BSS type alternator, connection definition... 4. Results - Results table that is filled during and after the test. Possibility to print or save report as pdf5. Start - Start the test procedure 6. Stop - Stop the test procedure 7. Add alternator - Wizard to put alternator in database. Simply connect desired alternator and follow on

screen instructions. After test is done it will be added to testbench database for further comparison test8. Alternator list - Alternator database. It contains all the alternators that are saved in database for further

comparison testing 9. Select model - Select regulator model10. Comparative test - compare 2 alternators without adding it to database 11. Test settings - Choose test procedure: slow, standard( default), fast and „user” test. User test- test

parameters can be defined by user.

4.0 PC software

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12. Oscilloscope - Start oscilloscope software 13. Selection - Field showing test settings and part number of an alternator from database( if chosen)14. Diameter - Set alternator pulley diameter15. Voltage - set-point setting. Default setting is 13,5 16. Delay - Set delay for alternator with soft-start 17. Text field - Shows current test information, pass/fail.

This screen shows detailed information about the tested alternator and test-bench System- alternator systemvoltage regulator- manufacturer of voltage regulator( com alternator only)com code- code of the Lin/bss regulatortransmission speed- com regulator speed( 9600 or 19200)cycle time- test procedure durationcom rpm- some alternators send the rpm information in com transmissionelectrical error- electrical error send by regulator mechanical error- mechanical error reported by regulator temperature error- temperature error reported by regulator scania test- yes/no – 24V PWM alternator test

4.1 Detailed information

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Voltage/duty- refers to scania test, shows voltage/duty in 24V PWM testrequested voltage- shows requested voltage by the test-benchvoltage set point- shows voltage set-point of regulatorc regulation- „C” alternator functionQuiescent voltage- voltage of the test-bench before the testW frequency- frequency [Hz] of W terminal or tachoRipple- show ripple of alternator in AmpsEfficiency- efficiency of alternator shown in %Torque- max torque used during the testMotor power- Power[kW] of motor used during the testOperation mode- „auto” or „manual” selected voltage- show if 12V or 24V is selecteddirection- direction of the motor- CW or CCW auto report print- on/off- if on the report will be printed automatically after every testserial number- Siemens PLC soft serial number version – Siemens PLC soft version system version – Siemens PLC system version vc-07 version - “07” upgrade version VC07 keyboard – instrumental panel software version counter – number of test procedures ran by the test-bench

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This screen shows different detailed information about the LIN/BSS protocol

4.2 Information LIN/BSS

This screen shows detailed LIN/BSS information. System- alternator system( LIN or BSS)Voltage regulator- manufacturer of voltage regulator COM code- code of LIN or BSS transmission Data speed – speed of transmission( 9600 or 19200)RPM COM- some of regulators send RPM in com transmissionElectrical/mechanical/temperature error- error reported by voltage regulatorConnection definition- detailed information about LIN/BSS( Tx and Rx frames)

Results After every test the software will go to this screen, so operator can see the results of the test. From that screen operator can choose to print of save report.

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4.3 MenuCalibration – allows to calibrate the test-bench It is necessary to calibrate once a year using certified multimeter. Tolerance - allows to set general tolerance of the test-bench( default 10%). All the parameters will be tested according to that settinglanguage- choose language of the software

choose model- the software is designed to operate with both models of test-benches- CV-623 and CV-307N. It is necessary to choose the right model. Once its chosen the setting will be saved for the future use.

4.4 Calibration In order to calibrate, place an alternator on the bench and put testbench in manual mode. Let the alternator run at 3000rpm and put at least 1 level for ressistors on( using the LOAD knob)The upper windows( voltage,voltage drop, current 600A, current 80A) show values measured by testbench. The lover windows( voltage offset...) show offset that can be configured. Using a certified mulimeter measure the voltage and current. If there is a difference, change the offset using + and – buttons, nest press save. There is always a possibility to go back to default setting by pressing “Factory settings”

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4.5 Add alternator/ alternator list

The software is equipped with SQL database. The software can perform a comparison test. First operator needs to put an alternator on the test-bench and run a wizard. Follow the on screen instruction. The wizard will „learn” the alternator and save its parameters in SQL database. Next, choose the alternator form database( alternator list). It can be searched by „part number” and „reference number”. Once its chosen the test-bench is set to run a comparison test. There is an option to put the alternator into the database manually. We do not advise to do so, but and option like this is also available. One can put desired information by pressing „add to database”. All of the provided parameters will be compared in comparison test.

Selection- select database entry no selection- cancel selection refresh- refresh database( in case there are more then one testbench and database is running on server and entry has been made on other bench) Edit- edit database entryremove- remover database entryadd to database- manualy add alternator to database search- search database

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4.6 User test

These parameters are used for every test( slow,standart,fast) but we also give the operator an option to design custom test. Explanation of parameters:

Increase load step 6000 RPM -resistors increase at 6000RPM. Example: value 16 means that 16amps increase per 50 milliseconds at 24V, 8 amps per 50 milliseconds at 12V

Increase load in limit step 6000 RPM- resistors increase in 6000rpm step, when desired voltage setpoint is searched. Example: if voltage set-point is set to 13,4, limit 0,2V up and down, when value is 6 it means it increase 6A in 24V and 3A in 12V

Decrease load step 6000 RPM – analogically to increase,but in this case its decreasing amps

increase, decrease other steps – analogically, increase and decrease in other steps than 6000rpm

Step pass time – time of pass of in seconds of every step.

motor acceleration (rpm/100ms) – RPM increase before charging lamp is off.

RPM tolerance % - not in use because Siemens controls the rpm

cycle timeout - timeout of the test cycle in seconds

step timeout - timeout of every step in seconds

ford test alt RPM – set the RPM for additional FORD PWM test. At the end of the test the motor will run desired RPM, load 50A and check voltage by every 10% of PWM.

Lamp step time – waiting time in seconds at charging lamp off. Test-bench waits desired time to check if lamp doesn’t go on again

step 1800 rpm time – waiting time at 1800rpm, before alternator starts to charge

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Section 5 – Maintenance and Troubleshooting5.0 Maintenance recommendationsRegularly clean the alternator tester.Charge regularly the batteries in case of intense use.

5.1 Quick troubleshooting guide:In case of a malfunction or a failure on the alternator tester, please verify these following points:

The tester does not start:Verify the machine is connected to the power gridVerify the main fuses on the rear side are still on.Verify emergency STOP mushroom pushbutton is unlocked.

The motor does not start:Verify the protection cover is closed and the safety switch is not defective.

No alternator excitation:Verify the belt doesn’t slide: alternator speed can be not sufficient.

Charging the batteries is impossible, there is always a big load current:Batteries should be replaced.

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