User manual 740306
Contents
1. PHYSIK 03 15 W10 Wei Instruction Manual 740 306 BDEDAILIAD LH QI LEYBOLD aD 1 Voltage Supply and Voltage Conduit Terminal 30 2 Voltage Supply and Voltage Conduit Terminal 15 3 Display 4 Input Signal Selector Switch 5 Connection of the Preheating Indicator Light La 6 Input Signal Measurement Bridging Plug 7 Connection of the Battery Positive 8 USB Socket 9 Diagnostic Signal Output 10 Ground 11 Connection of Terminal 15 protected 12 Current Measuring Shunts 1 4 13 Connection of the Battery Negative 14 View Port for the Glow Plug Q10 15 Bore for the Temperature Sensor 16 View Port Q12 17 Viewing Window Q13 18 Connection of the Preheating Indicator Light 19 Output Pressure Signal 20 Glow Plug Q13 with Pressure Sensor CHEMIE TECHNIK BIOLOGIE romm L L DIDACTIC Diesel Quick Start System A 3 D QD 19 S yah DIESEL SCHNELLSTART SYSTEM 3 MY 21 Glow Plug Q12 22 Glow Plug Q11 23 Glow Plug Q10 24 Measurement Points for the Glow Plugs 1 4 25 Fuse 26 START STOP Button 27 Operation LED 28 Multifunction Adjustment Knob 29 MODE Button 30 Temperature Selection LED 31 Pulse Width Selection LED 1 Description The diesel quick start system consists of the following compo nents Motor control unit substitute Electronic glow plug control unit Instant start glow plug Data interface 740 306 Diesel Quick Start System The glow plugs are actuat2. Seat belt buckle control Display b o When Terminal 15 is selected the preheating process is activated by turning on Terminal 15 and is stopped by turning off Terminal 15 Also pressing Pushbutton 16 cancels the preheating process When Terminal 50 is selected the preheating process is started or cancelled at temperatures of lt 5 C and pulse widths of lt 10 by pressing Pushbutton 26 Without manual cancellation it stops automatically af ter the calculated time When the Door Control is selected the preheating process is started or cancelled at temperatures of lt 25 C and pulse widths of lt 10 by pressing Pushbutton Fax 02233 604 222 e mail info Ild didactic de Printed in the Federal Republic of Germany Technical alterations reserved Page 3 6 10 26 Without manual cancellation it stops automatically after the calculated time When the Seat Control is selected the preheating process is started or cancelled at temperatures of lt 25 C and pulse widths of lt 10 by pressing Pushbutton 26 Without manual cancellation it stops automatically after the calculated time When the Seat Belt Buckle Control is selected the preheating process is started or cancelled at tempera tures of lt 25 C and pulse widths of lt 10 by press ing Pushbutton 26 Without manual cancellation it stops automatically after the calculated time Fault Display of the activated faults from FO to F5 Temperatur
3. RT STOP as well until LED 30 and LED 31 blink and the number of the current fault is displayed in Display 3 Now you can release both pushbuttons Using Multifunctional Knob 28 select the desired fault Interruption of Terminal 30 Short circuit to Ground of Glow Plug Q10 Interruption of Glow Plug Q12 Interruption of Terminal 87 Interruption of Actuation Signal To activate the fault press and release Pushbutton 26 and Pushbutton 29 at the same time If this is not confirmed this operation mode is automat ically exited after approx 5 seconds and any activated faults that might be there are turned off D 50354 H rth www ld didactic com 7 Page 4 6 The faults of Glow Plug Q10 and Glow Plug Q12 are measurable between Socket 24 and Socket Ground Software This program makes it possible to access the self diagnostic functions to activate internal faults and to transfer new operat ing software firmware to the device The following functions are supported Read and reset the fault memory log Measured values display Actuator test Coding Alignment Fault Memory Lo Phone 02233 604 0 lt Error memory gt Diagnosis byte 0x01 Error in glow pin O10 Get error messages Delete error messages Stored faults can be read The fault memory log can then be deleted Fax 02233 604 222 e mail info ld didactic de Printed in the Federal Republic of Germany Technical alterations reserve
4. SG Glow Plug from Volkswagen can be used The warranty of the entire device will be void if parts other than those listed above are used If you do not think you can handle replacing the parts yourself you may send the unit in for repair Addresses contact persons and repair requests can be found on the internet at www d didactic de To accomplish the replacement you will only need a long flat head screwdriver and a ring or fork key NW10 and NW13 re spectively for the PSG Glow Plug Proceed as follows e Turn the device off and remove all cables e Wait until the device has cooled to room temperature e Place the blade of the screwdriver on the bottom edge of the connector grommet and gently pry it upwards e Extract the connection cable approx 2 cm from the device Remove the plug upwards Loosen the glow plug using the wrench and unscrew it Install the replacement in the reverse order The tightening torque should not exceed 10 Nm Be sure that the connector properly clicks into place For the PSG Glow Plug it should also be noted that after unscrewing the Teflon tape must be unwound from the threat and wound onto the new glow plug clockwise when viewed from the tip Remark If you have new Teflon tape on hand you may also use this LD DIDACTIC GMBH Leyboldsir 1 D 50354 H rth Phone 02233 604 0 by LD DIDACTIC www ld didactic com Page 6 6 Fax 02233 604 222 e mail info ld didactic
5. This is where the diagnostic signal can be measured which provides Control Unit J179 for the motor control unit in the event of a fault The signal has a resting level of 3 3 V and emits an 8 bit word with the start bit low and the stop bit high The following information is included Bit 1 Fault Glow Plug 1 Bit 2 Fault Glow Plug 2 Bit 3 Fault Glow Plug 3 Bit 4 Fault Glow Plug 4 Bit 7 Fault Short circuit to Ground high Fault Interruption low A bit is tai 32 ms long thus the total length of the 10 bit word results in 320 ms The subsequent pause is 680 ms so that a total cycle time of exactly 1 second results Short circuit to ground Terminal 31 to transmit to other TPS devices on the right side and to supply the internal electronics 11 12 13 14 17 14 15 16 17 18 19 20 21 22 23 25 26 740 306 Diesel Quick Start System Measurement sockets for measuring the signal from Terminal 15 and for simulating faults for example through the Fault Simulation Bridging Plugs 500 593 4 Current sensing resistors shunts for indirect meas urement of the glow plug current The voltage drop for each glow plug can be measured here at a low re sistance and thus the individual currents are calculat ed No voltage may be applied to any of the sock ets Power connection for supply the glow plugs The black 62 mm cable is connected here coming out of the Lead Set 738 05 from the negative
6. amp KL87 REL4 Open circuit contro signal REL5 be This is where a fault can be selected The fault remains after exiting the software If a fault is active when the software starts it will be applied If the file error ini is missing from the program directory only Fault 1 etc will be displayed Language 4 No error y Error 1 Error 2 Error 3 l Error 4 Error 5 This approach is useful when students are asked to work with the software independently Info About Pre glow a to Pre Glow Automatic 740306 Version 1 0 0 Copyright by LD DIDACTIC GmbH 2014 2015 Written by Sebastian Weber LEYBOLD 740 306 Diesel Quick Start System 8 Replacing the Glow Plugs Glow plugs are consumable items which must be regularly inspected in real vehicles and possibly replaced Since original heating elements are used in this system it is possible that they may break in rare case Burnt out glow plugs are not covered by the warranty The device has an automatic pause circuit between two heating processes in order to optimally protect the glow plugs and maximize service life However should a glow plug be defective it is easily replacea ble Spare glow plugs are available under item number 689 0820 Glow Plugs 4 4 V and 689 0821 Glow Plugs PSG 4 4 V from LD Didactic GmbH Alternatively the original parts with the replacement part numbers of 059 963 319J and O3L 905 061F for the P
7. d Page 5 6 Measured Values Display r Battery valtage 11 34 GRR 11 159 fe aio an Q12 Q13 Current N o Voltage Current SS 4 Voltage 2 623 2 730 2 734 2 641 Current S o Voltage Current N o Voltage Reistance 0 506 0 518 0 518 0 496 Resistance Resistance Resistance Power Power Power Power 13 587 14 376 14 441 14 074 Energy Energy Energy Energy 34 615 35 167 35 488 36 259 Total current Total power 56 478 Pressure Total energy 141 529 Reset energy Leave Electrical measurements can be displayed individually for all four glow plugs In addition the system voltage the total cur rent and the total power energy can be displayed The signal of the pressure measuring glow plug is directly dis played as pressure using hPa units Actuator test The glow plugs are actuated for 7 seconds at 20 Coding Amount of cylinders 0 3 evylinders 4 cylinders 3 or 4 glow plugs can be selected here for an engine with a corresponding number of cylinders 740 306 Diesel Quick Start System Alignment Duty cycle j temperature scale Celsius l 1 Fahrenheit The temperature and pulse width can be directly adjusted here Moreover the display can be switched from C to F Fault Error control Language _Info d Noerror J Open circuit clamp 30 RELI Ground circuit glow pin Q10 REL2 Open circuit glow pin Q12 REL3 Open circuit cl
8. de Printed in the Federal Republic of Germany Technical alterations reserved
9. e Units The selected units will be shown to display the temperature in C or F Change over between an external control signal for example from an original motor control unit via the rear 7 pin connector or the control panel with the oper ating elements 26 31 La output for connecting a Heating Indicator Light for example from 738 151 The preheating status is dis played at temperatures below 5 C 45 F as contin uously lit Additionally a fault is indicated by a flashing indicator light until the next time the ignition is turned off The signal is transmitted to the right side of the de vice Socket 18 Thus the indicator light unit can be placed to the left or to the right Measurement sockets for measuring the control signal and for simulating faults for example through the Fault Simulation Bridging Plugs 500 593 Power connection for supply the glow plugs The red 62 mm cable is connected here coming out of the Lead Set 738 05 from the positive pole on the car battery This lead is internally protected once more on a 40 amp safety fuse This is where a PC with an MS Windows operating system can be connected to run the corresponding di agnostic software After the first time it is connected a driver is installed for the device so that it is known to the computer New firmware can be transferred to the device via the diagnostic software The current version of the software can be found at www ld didactic de
10. ed with pulse width modulation and phase shift and the function of the glow relay is replaced by electronic amplifiers in the glow plug control unit 3 instant start glow plugs as well as an instant start glow plug with pressure measurement PSG Each of the four glow plugs is capable of handling the diagnosis on its own The control unit is used in vehicles of the VAG Group for 4 and 6 cylinder engines It is based on an electronic circuit IC such as the L9524C from STMicroelectronics When the following informative instruction manual was prepared the English data sheet can be viewed at http www st com web en resource technical document datasheet CD00134658 pdf Many of the specifications and descriptions can be applied to the system used here The following operating modes can be studied e Preheating e Starting e Emergency heating 2 Scope of Delivery 1 TPS unit 1 USB Cable 3 Safety Instructions LD DIDACTIC GMBH Leyboldstr 1 D 50354 H rth by LD DIDACTIC www ld didactic com Phone 02233 604 0 Page 2 6 4 Start up Also required 1 Car Battery 12 V 738 04 044 1 Battery Connection Kit 734 043 1 Set of Connection Leads 738 05 1 Set of Safety Bridging Plugs 500 59 Connect the positive pole of the battery using the positive ter minal and the red connection cable 6 mm with Positive Con nection 7 Insert the 4 mm safety bridging plug in Positions 6 11 and 24 Connect the connection t
11. erminal 30 1 with the permanent positive terminal of the battery Connect the negative pole of the battery using the negative terminal and the black connection cable 6 mm with Negative Connection 13 Result The device performs a self test For this purpose it also briefly switches on the LEDs and the display This is not a mal function The test takes approx 2 seconds The device is then ready for use The display will show 1 5 Connect the device to Ignition Switch 738 10 and turn the igni tion on The device carries out one glow actuation for testing Description of Components 1 31 1 Connection Terminal 30 permanent positive terminal to transmit to other TPS devices on the right side and to supply the internal electronics 2 Connection Terminal 15 Connected positive terminal to transmit to other TPS devices on the right side and to supply the glow plug control unit 3 Two digit 7 segment multi function display to display the following sizes Temperature Display of 19 to 85 C or 2 to 189 F When set to F only the last two digits are displayed for values gt 99 F An additional period to the right of it indicates that it is for a value gt 99 F Pulse width Display of the pulse width in from 6 to 36 Operation mode Display of the operation mode It can be adjusted as follows Terminal 15 Display 1 5 Terminal 50 Display 5 0 Door control Display d o Seat control Display S E
12. pole on the car battery Caution During continuous operation at the max imum heating time the assembly block of the glow plugs can achieve a surface temperature of 80 C 176 F View port for observing the tip of Glow Plug Q10 The opening is as small as it is so that reaching into it is not possible No objects should be instered into this opening since the glow plug could otherwise be destroyed Bore for inserting the temperature sensor The tip of the temperature sensor thereby contacts the glow plug Thus the heating rate and the temperature of Glow Plug Q11 can be measured Over this is a view port for observing the glow plug the tip is not visible here No objects should be instered into this opening since the glow plug could otherwise be destroyed View port for observing the tip of Glow Plug Q12 The opening is as small as it is so that reaching into it is not possible No objects should be instered into this opening since the glow plug could otherwise be destroyed Viewing window for observing the tip of Pressure Measuring Glow Plug Q13 The chamber is pressure sealed so that the heating of the glow plug tip causes an increase in the pressure of the trapped air This signal can be measured at 19 The safety glass must not be touched during and shortly after the pre heating process Risk of burning La output coming to connect a heating indicator light for example from 738 151 from Socket 5 see Point 5 O
13. t left reduces the numerical values by 1 and turning it right increases them MODE pushbutton for changing over the display in Display 3 between temperature duty cycle and opera tion mode With the Temperature Display LED 30 lights up per manently as well with the Pulse Width Display LED 31 lights up permanently as well and with the Opera tion Mode Display both LED 30 and LED 31 light up permanently as well If the pushbutton is pressed and held the LED will begin to blink If the pushbutton START STOP is pressed and held Display 3 changes to display the connected fault FO after the initial start up and both LEDs blink If nothing is changed this operation mode is automatically exited after approx 5 seconds and all faults are deactivated Displays that the temperature or the operation mode can be adjusted Displays that the pulse width or the operation mode can be adjusted Solid light Displays and selects the operating mode Blinking light Displays and selects the fault 5 Technical Data Supply voltage max 14 3 V DC Current consumption max 25 A Display 7 segments 2 digits Fuse 5A Mini blade fuse Dimensions 297 x 500 x 180 mm Approx weight 3 kg Sockets SIBUS 4 mm 6 Operation To adjust a fault on the device complete the following steps LD DIDACTIC GMBH Leyboldstr 1 by LD DIDACTIC Press and hold Pushbutton MODE 29 until LED 30 blinks Do not let go Now press and hold Pushbutton 26 STA
14. utput of a voltage signal for display of the pressure measured in Pressure Chamber 17 Here 10 V corre sponds to one MPa The voltage range is between 0 and 10 V Connection of the 4 pin original multi function plug to Pressure Sensing Glow Plug Q13 Connection of the 1 pin original plug to Glow Plug Q12 Connection of the 1 pin original plug to Glow Plug Q11 Connection of the 1 pin original plug to Glow Plug Q10 Measurement sockets for the glow plug actuation sig nal of Q10 to Q13 Voltage cannot be applied here Protection of Control Unit J179 via a 5A mini blade fuse Only replacement fuses of the same type from Replacement Fuse Set 689 0808 should be used START STOP Pushbutton for starting and stopping the heating process Once the heating process is started if it is not manually stopped by pressing this pushbutton it will be automatically terminated after the calculated time This prevents the glow plugs from overheating 740 306 Diesel Quick Start System 2 28 29 30 31 30 31 Pressing and holding the pushbutton switches the temperature display between C and F This LED indicates that the heating process is active with a white light Subsequently it indicates a delay be fore the next glowstart with a red light This can be started only when the LED turns off again Multifunctional knob for adjusting the temperature pulse width fault number operation mode or tempera ture unit Turning i
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