LOFA EP250 Operation and Troubleshooting
Contents
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3. may damage electrical components When using a battery disconnect switch LOFA recommends using a 2 pole switch to disconnect both the battery and alternator output Battery Negative Connection Grounding Warning Improper grounding can cause electrical noise unreliable operation and may damage the control system or other components All ground connections must be free from foreign materials including paint which may interfere with proper grounding A reliable ground must be provided for the control system LOFA recommends the ground connection be made directly to the battery negative Grounding through frame members is not recommended All ground paths must be capable of carrying any likely fault currents Do not reverse the battery polarity Attempting to crank the engine when the polarity of the battery connections is reversed may damage the control system Note A maximum of three ring terminals should be connected to a ground stud in order to ensure integrity of the ground connection The use of more than three terminals can cause the connection to become loose Voltage Drop If control system voltage drops below 6 volts for more than one tenth of a second the control system may reset causing the self test to reactivate and the engine to shutdown after 10 seconds Resetting the control 463 3000 01 Rev C 1 28 Feb 2007 9 LOFA EP250 Operation and Troubleshooting system is equivalent to quickly turning the key switch to
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5. devices Added equipment will require additional protection 10 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting Welding on Equipment with Electronic Controls Proper welding procedures are required to avoid damage to electronic controls sensors and associated components The component should be removed for welding if possible The following procedure must be followed if the component must be welded while installed on equipment with electronic controls This procedure will minimize the risk of component damage Warning Do not ground the welder to electrical components such as the control ground or sensors Improper grounding can cause damage to electrical components Clamp the ground cable from the welder to the component being welded Place the clamp as close as possible to the weld to reduce the possibility of damage l Stop the engine Turn the key switch to the OFF position 2 Disconnect the negative battery cable from the battery 3 Open any installed battery disconnect switch 4 Unplug the control system if possible 5 Connect the welding ground cable as close as possible to the area to be welded 6 Protect the wiring harness from welding debris and spatter 7 Use standard welding methods to weld the materials 463 3000 01 Rev C 1 28 Feb 2007 11 LOFA EP250 Operation and Troubleshooting General Troubleshooting For additional information refer to engine manufacturer troubleshooting
6. guide No response from starter motor Possible Cause Possible Remedy No battery voltage to starter Verify wiring and battery connection power and ground Battery discharged Charge or replace battery verity alternator charging Tripped overcurrent protection Correct fault replace or reset overcurrent protection No signal from control system No power to control system see Control System Troubleshooting below Defective starter solenoid Replace starter solenoid Defective starter motor Replace starter motor Engine will crank but not start Possible Cause Possible Remedy Engine not getting fuel Check fuel level filter fuel pump verify no air in fuel lines Fuel run stop solenoid not engaged See Fuel Solenoid Run Stop Troubleshooting below Tripped overcurrent protection Correct fault replace or reset overcurrent protection No preheat cold condition See Preheat Troubleshooting Engine runs for 10 seconds and shuts down Possible Cause Possible Remedy Shutdown switch input active Verity shutdown source exists correct condition or correct faulty circuit Battery not charging Verity alternator charging see Alternator not charging battery below Control board did not sense start signal Engine started through alternate method i e manual air start push start etc Detective control system
7. off and back to run without starting the engine Since the control system did not sense a start signal the fuel run stop solenoid deactivates after 10 seconds Voltage drops can be caused by transients from external equipment improper wire sizes faulty wiring or nearby lightning strikes In the absence of a LOFA Power Box relays may be needed for long wire runs Suppression of Voltage Transients Spikes Warning The installation of voltage transient suppression at the transient source is required LOFA follows SAE recommended electrical environment practices Inductive devices such as relays solenoids and motors generate voltage transients and noise in electrical circuits Unsuppressed voltage transients can exceed SAE specifications and damage electronic controls Positive Positiva PK d T P j Relay with high side driver or switch Relay with low side driv r or switch Relays and solenoids with built in voltage transient suppression diodes are recommended whenever possible Refer to the illustration for proper installation of diodes when built in voltage transient suppression is not available Locate inductive devices as far as possible from the components of the electronic control system When using electric motors it may also be necessary to add isolation relays to eliminate voltage transients noise and prevent back feed Note LOFA harness assemblies typically include all required engine control suppression
8. volt system 28 volts on a 24 volt system while the engine is running indicates the battery is charging properly Tachometer The tachometer indicates engine RPM using a frequency signal derived from the engine This signal may be provided by an alternator frequency tap proximity switch An optional amplifier divider can be added for use with a magnetic pickup Note If the alternator is not excited not charging no frequency is generated and the tachometer will indicate O RPM The tachometer is factory calibrated to indicate correctly when the panel is preconfiguring or field calibrated with a Diagnostic Programming Gauge DPG The tachometer can be calibrated using standard procedures if the configuration is not performed see Tachometer Calibration Instuctions for details Oil Pressure Gauge The gauge measures oil pressure with a resistance sender on the engine referenced to ground When a sender switch combination is used on the engine the marking G generally indicates the gauge terminal The gauge expects a low resistnace for low pressure and a higher resitance for higher pressure If the gauge is not connected to the sender the gauge will read full scale pegged A defective sender or shorting the gauge input to ground will cause the gauge to read O pressure When using sender switch combinations swapping the WK and G terminal prevents the gauge from working and may cause unintended shutdowns 6 463 3000 01 Rev C 1 28 Feb 20
9. 07 LOFA EP250 Operation and Troubleshooting Warning Low oil pressure is an indication of engine wear not an accurate indication of low oil level Note Senders and gauges must be matched to indicate correctly Most senders are grounded through the sender body Do not use insulating sealant i e Teflon tape when installing senders Temperature Gauge The gauge measures engine temperature with a resistance sender on the engine referenced to ground When a sender switch combination is used on the engine the marking G generally indicates the gauge terminal The gauge expects a high resistnace for low temperatures and a lower resitance for higher temperatures If the gauge is not connected to the sender the gauge will read O A defective sender or shorting the gauge input to ground will cause the gauge to read full scale pegged When using sender switch combinations swapping the WK and G terminal prevents the gauge from working and may cause unintended shutdowns Warning If the temperature sensor is not in contact with coolant due to coolant loss the gauge will not accurately indicate engine temperature Note Senders and gauges must be matched to indicate correctly Most senders are grounded through the sender body Do not use insulating sealant i e Teflon tape when installing senders Some thermostat housings are composites and do not provide ground for the sender Hourmeter The hourmeter is connected to the fuel
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11. 3000 01 Rev C 1 28 Feb 2007 5 LOFA EP250 Operation and Troubleshooting the shutdown input to ground can cause fault indications The system can be configured for auxilary 1 failure to indicate only A blinking AUX 1 LED indicates SW input failure The control system typically senses failure using a ground contact switch The SW input is equipment specific and determined by the equipment manufacturer A detective switch or shorting the shutdown input to ground can cause fault indications WA AUX 2 LED Red A solidly illuminated AUX 2 LED indicates auxiliary 2 failure i e air flow restriction fuel level etc but by detault does not cause a shutdown The control system typically senses failure using a ground contact switch Auxiliary inputs are equipment specific and determined by the equipment manufacturer A defective switch or shorting the shutdown input to ground can cause fault indications The system can be configured for auxilary 2 failure to indicate only OO Preheat LED Red A solidly illuminated Preheat LED is the system preheat indication When the LED extinquishes the preheot period is complete and the engine may be cranked The LED illuminates again to indicate afterglow Gauges Voltmeter The voltmeter is connected to the fuel run stop solenoid output If the voltmeter does not indicate in the run position this indicates a problem with the solenoid circuit A battery voltage reading of approximately 14 volts on a 12
12. D indicates high engine temperature failure The control system typically senses high temperature from a ground contact switch on the engine When a sender switch combination is used on the engine the marking WK or W generally indicates the switch terminal This input typically expects a normally open switch ground contact when engine temperature is too high A defective switch or shorting the shutdown input to ground can cause over temperature fault indication Additionally when using sender switch combinations swapping the WK or W and G terminal can cause unintended shutdowns The system can be configured for temperature failure to indicate only Warning If the temperature switch is not in contact with coolant due to coolant loss the engine is not protected from overheating For best possible protection LOFA recommends using our solid state coolant level shutdown switch Note Most shutdown switches are grounded through the switch body Do not use insulating sealant i e Teflon tape when installing switches Some thermostat housings are composites and do not provide ground for the switch AUX 1 LED Red A solidly illuminated AUX 1 LED indicates auxiliary 1 failure i e coolant level oil level belt breakage hydraulic pressure etc The control system typically senses failure using a ground contact switch Auxiliary inputs are equipment specific and determined by the equipment manvfacturer A defective switch or shorting 463
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14. LOFA EP250 Operation and Troubleshooting Introduction This document provides general information on LOFA Industries EP250 control systems operation and troubleshooting EP250 control systems are a very flexible platform for diesel engine control monitoring and protection featuring LOFA s powerful First Fault Diagnostics FFD After pinpointing the initial failure FFD stores it in memory and alerts the end user via a single bright LED FFD monitors battery charge low oil pressure high temperature overspeed and up to three additional contact closure inputs The field configurable expandable microprocessor based solid state design uses high power semiconductors instead of outdated electromechanical relays to ensure reliable high current switching The EP250 features LOFA s new modular Function Enhancement Packs FEP The plug and play FEP modules allow various feature upgrades to be easily added to the standard platform FEPs include Diagnostic Program Gauge DPG Auto Start with Real time Clock Data Logging Closed Loop Speed Control Precision Actuator Control Custom OEM Solutions The Diagnostic Program Gauge DPG features a backlit LCD display with three push buttons all in a compact 2 inch gauge The LCD is clearly readable in both bright sunlight as well as total darkness The DPG provides a complete user interface for other Function Enhancement Packs and allows each system to be field configured to suit the customer s unique req
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16. See Control Panel Troubleshooting below Engine runs longer than 10 seconds and shuts down Possible Cause Possible Remedy Shutdown switch input active Correct engine fault verity shutdown switch wiring Circuit overload protection tripped Correct overload keep control system from overheating over 185 F 85 C Voltage transients spikes Add suppressor diodes protect from nearby lightening strikes shield induced spikes from other equipment add electric motor control relay Defective control system See Control System Troubleshooting below Alternator not charging battery Possible Cause Possible Remedy Broken or slipping alternator drive belt Adjust or replace alternator drive belt Alternator not excited Verity excitation circuit connected replace faulty regulator add additional excitation resistor Alternator output not connected Install charge wire Alternator not grounded Clean or add ground connection Alternator faulty Replace faulty alternator 12 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting Fuel Run Stop Solenoid Troubleshooting Engine does not stop immediately Possible Cause Possible Remedy Back feed from motor i e cooling fan Add relay or blocking diode Sticking solenoid linkage Repair or replace solenoid linkage Fuel valve without ch
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18. ate a failing charge circuit The system can be configured for battery charge failure to indicate only Overspeed Indication A regularly blinking Battery LED indicates the configured overspeed RPM has been exceeded The overspeed RPM can be verified changed or disabled see the EP250 Configuration Manual for details 4 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting NI Oil Pressure LED Red A solidly illuminated Oil Pressure LED indicates low oil pressure failure The control system typically senses low oil pressure from a ground contact switch on the engine When a sender switch combination is used on the engine the marking WK generally indicates the switch terminal This input typically expects a normally closed switch ground contact when oil pressure is low A defective switch or shorting the shutdown input to ground can cause low pressure fault indication Additionally when using sender switch combinations swapping the WK and G terminal can cause unintended shutdowns The system can be configured for oil pressure failure to indicate only Warning Low oil pressure is not an indication of low oil level For best possible protection LOFA recommends using our solid state oil level shutdown switch Note Most shutdown switches are grounded through the switch body Do not use insulating sealant i e Teflon tape when installing switches F Temperature LED Red A solidly illuminated Temperature LE
19. e connector Note For harness length in excess of 10 ft a relay must be added to the start solenoid circuit LOFA offers starter relay kits for mounting near the engine 8 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting Battery Circuit Requirements Battery Positive Connection The electronic control system operates on either a 12 VDC or 24 VDC electrical systems The unswitched battery positive connection to the control system is made at the weather proof connector The control system provides switched positive battery protected by a 15 Amp fuse 12 V or 24 V system Protection for the unswitched battery positive circuit is dependent on specific equipment configuration The overload protection should not exceed 125 of the sum of all output currents plus 5 Amps for the control system Powering the control system through dedicated circuits with appropriate overload protection reduces the possibility of system damage Circuit breakers are preferred over in line fuses for circuit protection Over current protection devices should ideally be located in a central location If automatic reset circuit breakers are used consideration of the environment of the breaker is critical and may affect the trip point The trip point of some circuit breakers can be significantly reduced below the rated trip point if the circuit breaker is exposed to high temperatures Warning Disconnecting the battery while the engine is running
20. eck valve Install or repair check valve Fuel run stop solenoid does not engage Possible Cause Possible Remedy No power to solenoid Locate reason for lack of power and correct Circuit overloaded Failed suppressor diode Faulty wiring No power to solenoid pull coil Correct faulty wiring check pull control circuit see Power Box Troubleshooting below Incorrect linkage adjustment Adjust solenoid linkage Faulty solenoid Replace solenoid Failed suppressor diode Correct wiring diode reversed replace suppressor diode Optional e stop engaged Disengage e stop Engine not getting fuel Possible Cause Possible Remedy Empty fuel tank Fuel engine Clogged filter Replace filter Air in fuel lines Bleed fuel lines Low fuel pressure Replace faulty fuel pump and or clogged filter Faulty fuel pump Replace fuel pump correct wiring fault electric fuel pump Preheat Troubleshooting Engine is hard to start in cold conditions Possible Cause Possible Remedy Start attempt before preheat complete Wait for preheat time to elapse crank as soon as time elapses Incorrect preheat specification Correct control system configuration install correct control system Heater faulty Replace heater Heater relay faulty Replace relay Preheat control not functioning Correct wiring correct control sys
21. frequency terminal of the alternator proximity switch or magnetic pick up Preheat Options Preheat Output Preheat is a 1A output for control of an external power relay with predetermined preheat and afterglow times A relay should be selected with appropriate amperage capacity for the installed cold starting aid glowplug intake air heater etc Applications using multiple cold starting aids may require multiple relays Optional or additional components may allow preheat time to be modified by sensing ambient temperature Depending on specific configuration this output may provide either high side battery positive or low side ground control Note Consult engine documentation when selecting cold starting aid power relay and heating specifications Preheat Indication Input With this option the preheat LED provides indication for an external preheat control system Depending on specific controls and configuration this input can be configured to accept either high side battery positive or low side ground control Battery LED Red A solidly illuminated Battery LED indicates a battery charge failure A battery charge failure may be caused by a faulty alternator broken drive belt or the alternator not excited A battery voltage reading of approximately 14 volts on a 12 volt system 28 volts on a 24 volt system while the engine is running indicates the battery is charging properly Irregular blinking of the Battery LED may indic
22. normally closed shutdowns Add suppressor diodes protect from nearby lightening strikes shield illuminate for one second induced spikes from other equipment add electric motor control relay control system reset Testing Shutdown Inputs Shutdown switches signal a fault by ground contact in most systems Shutdown operation can be verified by grounding the shutdown inputs individually It may be necessary to remove the wire from the shutdown switch to perform this test Note Most shutdown switches are grounded through the switch body Do not use insulating sealant i e Teflon tape when installing switches Some thermostat housings are composites and do not provide ground for the switch Revision History Initial Release Rev A 22 May 2006 Corrected typographical errors Rev B 26 Oct 2006 Add symbols to Indicators corrected typographical errors Rev C 8 Jan 2007 Updated schematics removed Power Box information Rev C 1 28 Feb 2007 Added part numbers 14 463 3000 01 Rev C 1 28 Feb 2007 Sl S IoJ9p JO UOLO OJSU JO SIUDWAYIS 2iyi eds eu eec UOIJO DJSU O4 uOHD DISur WOL AIDA S IDIje soiouueups DJIdA moys sebod Bulmoyjo eu s3iuyDuiou s PIIJAAL Guyooysa qnouj puo uoyoredQ 0OGZdJ VION L00C 993 86 L O 94 LO QOOE E9 y 00Z 994 8Z LD 94 L0 000 9p 91
23. ppropriate safety rules and precautions should be followed with any tool work method or operating procedure Improper procedures tools and materials may cause damage or make the equipment unsafe to operate Only persons with appropriate training skills and tools should perform these functions Improper operation maintenance or repair of this product can be dangerous and may result in injury or death Do not operate or perform any maintenance or repair on this product until all operation maintenance and repair information is read and understood The information specifications and illustrations in this publication are based on information available at the time of publication All items are subject to change at any time without notice 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting Turning the control system key to the run position starts a self test which causes all LEDs to illuminate once activates the alarm output for one second and enables the fuel run stop solenoid output After self test the LEDs indicate the state of the inputs they monitor The normal indications are battery charge and oil pressure on most applications If these LEDs are not illuminated at this time it may indicate the inputs are not properly connected The Preheat LED is illuminated when the key switch is turned to the run position if automatic preheat is configured or if an external preheat control is connected See Preheat O
24. ptions Preheat time varies from application to application After waiting for the Preheat LED to extinguish the engine is cranked by turning and holding the key switch in the start position until the engine starts The key switch is spring loaded to return automatically to the run position when released The Preheat LED is illuminated during afterglow if enabled Note The key switch is equipped with a mechanical start locking device An attempt to re crank the engine can only be made by turning the key switch to the off position to reset the start locking mechanism If the engine is not started within 10 seconds of turning on the system the fuel run stop solenoid output is turned off to prevent battery discharge when the key switch is left in the run position The fuel run stop solenoid output is turned off after 10 seconds even if preheating As soon as the key switch is turned to the start position the solenoid output is enabled The afterglow cycle begins when the key switch returns to the run position Note If conditions do not warrant preheat the engine may be started by turning the key to the start position without waiting for the preheat time to expire Control system instrument power including the hourmeter and voltmeter is provided by the fuel run stop solenoid output If the instruments do not power up when the key is turned to the run position this indicates a problem with the solenoid circuit see Troubleshooting Atte
25. r the engine starts the control system electronics ignore all shutdown conditions for the first 10 seconds This delay eliminates the requirement to hold a by pass override button during starting and allows the system conditions such as oil pressure to normalize The 10 second timer starts when the key switch returns to the run position Note Starter input is required for correct system operation If the starter motor input is not activated connected to battery positive and the engine is started through another means i e air starter the engine will shutdown 10 seconds after the key switch is turned to the run position 463 3000 01 Rev C 1 28 Feb 2007 3 LOFA EP250 Operation and Troubleshooting To prevent unintentional engine shutdowns caused by intermittent conditions i e pressure spikes coolant movement the control system requires a constant 1 second fault input to cause engine shutdown Warning When used in combination with mechanical float type switches engine vibrations may prevent constant contact closure The control system can be configured to shutdown with no delay See the EP250 Configuration Guide for detailed preheat control instructions The control system has the ability to shut down the engine for over speed Over speed will be indicated via a blinking Battery Charge LED If the control system is equipped with the DPG the display will also indicate over speed shutdown The control system senses RPM either by the
26. run stop solenoid output If the hourmeter does not count in the run position this may indicate a faulty hourmeter or a problem with the solenoid circuit If the engine shutsdown or is not started within 10 second the hourmeter stops counting Additional Gauges Additional gauges can be added by removing blind covers and installing the gauge Power connections are provided with the standard configuration 463 3000 01 Rev C 1 28 Feb 2007 7 LOFA EP250 Operation and Troubleshooting Sealed Connectors The provided sealed weather proof plug includes a grey locking device which must be released to separate the connectors Press the tab on the connector housing to release the connectors Warning LOFA does not recommend using dielectric grease or sealant with sealed connectors These chemicals may cause seal damage and allow water entry Use LOFA provided cavity plugs to seal the connector if wires are removed Unsealed Connectors For unsealed connectors exposed to the elements LOFA recommends using dielectric grease to protect contacts Warning LOFA does not recommend using sealant with unsealed connectors Sealant traps moisture in the connector and encourages corosion Harness Routing The minimum routing of radius of the wiring harnesses should be at least two times the diameter of the wiring harness Bends should be avoided within 1 inch 25 mm of any connector in order to avoid seal distortion allowing moisture to enter th
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28. tem configuration Faulty control system See Control System Troubleshooting below Engine produces excessive white smoke after starting Possible Cause Possible Remedy Afterglow not enabled Reconfigure control system Heater faulty Replace heater Heater relay faulty Replace relay Preheat control not functioning Correct wiring correct control system configuration Faulty control system See Control System Troubleshooting below 463 3000 01 Rev C 1 28 Feb 2007 13 LOFA EP250 Operation and Troubleshooting Control System Troubleshooting Control system does not perform self test Possible Cause Possible Remedy Tripped overcurrent protection Correct fault replace or reset overcurrent protection Faulty connection to battery Correct battery connections see Battery Circuit Requirements above Control system performs normal self test engine cranks runs and shuts down Possible Cause Possible Remedy Only Battery LED illuminated Correct battery charge failure see Battery not charging above Only Oil Pressure LED Correct low oil pressure condition or faulty switch correct wiring fault Illuminated Only Temperature LED Correct overheating condition or faulty switch correct wiring fault Illuminated Only Aux LED Illuminated Correct fault condition i e v belt coolant level or faulty switch correct wiring fault All
29. uirements After configuring the DPG can be removed in cost sensitive applications Some of the EP250 configurable features include Automatic preheat duration Afterglow duration Failure indication with shutdown or indication only Over speed shutdown Normally open or normally closed shutdown switches All standard panels include feature a 12 inch wiring harness terminating into a sealed weather proof plug This robust universal wiring connection performs well in harsh environments and allows interchanging a number of different panels and harnesses This design allows for simplified installation as well as a flexible means to incorporate custom plug and play engine wiring harnesses and standard harness extension Note The engine harness is not included with the panel A number of standard engine harnesses are available or LOFA can develop a custom harness for you exact needs Generic harnesses in various lengths are available for field customization 463 3000 01 Rev C 1 28 Feb 2007 LOFA EP250 Operation and Troubleshooting Warning When replacement parts are required LOFA Industries recommends using replacement parts supplied by LOFA or parts with equivalent specifications Failure to heed this warning can lead to premature failure product damage personal injury or death Important Safety Information The warnings in this publication are not all inclusive LOFA Industries cannot anticipate every potential hazard A
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