Product Training - Basic Electronics

Welcome to Basic Electronics

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Product Training - Basic Electronics

What is voltage?
Voltage:
• related to potential energy
• always have a reference, usually ground
• there is a potential difference between the battery terminals
• a battery has negative charge on one terminal (-) and positive charge on the other (+)
• the unit is volts, V

electron

proton

neutron

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Product Training - Basic Electronics

What is current?

Current:
• a flow of electrons from a negatively charged potential to a positively charged pole
• however, the current is going from positive to negative
• charge in Coulombs passing a point in a particular time, 1 Coulumb is appr 6x1018 electrons
• the unit is ampere, A
• 1 Coulumb/second = 1 A

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Product Training - Basic Electronics

What is resistance?

Resistance:
• the flow of charge passing through a material meets an opposing force called resistance
• resistance depends on:
• material
• length
• cross sectional area
• temperature
• the unit is ohm, Ω

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 Product Training - Basic Electronics

How to use the multimeter when measuring DC voltage

Connect the test wires to correct DC Be sure you have the correct
12.57 V
connections on the multimeter. setting, “DC voltage or “ V”
Normally the gates marked “com ”
and “ V ”.

The circuit must The voltage is measured across the load.

be closed when
measuring the
voltage.
Load

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 Product Training - Basic Electronics

How to use the multimeter when measuring DC current

Connect the test wires to correct

DC
gates on the multimeter. Normally 84.07 mA
the gates marked “ com ” and “ A
or mA “ . Use the gate marked “
mA” only when you are sure the Be sure you have the correct
A
current is less then maximum setting, “DC Current or “ mA ”
current allowed for this gate.

The circuit must be The current is measured in series with the load.
closed when measuring
the current.

Load

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Product Training - Basic Electronics

How to use the multimeter when measuring resistance

Connect the test wires correct 24.8 kΩ

to the multimeter. Normally the

gates marked “ com ” and “ Ω ”.

Be sure you have the

correct setting, “ Ω “.

The resistance is measured in

series with the object. The
The circuit must be voltage must be switched off
closed when measuring before measuring resistance.
resistance.

Load

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A reminder about the most common prefixes

Be aware of prefixes when reading measured values

0.L M Ω infinite 1.50 kΩ 1500 Ω 1.50 m Ω 0.0015 Ω

resistance

0.L = infinite resistance

1 MΩ = 1000 000 Ω
1 kΩ = 1000 Ω
1 mΩ = 0.001 Ω

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Product Training - Basic Electronics

Resistors in series

Black=0
R1 R2 R3 Brown=1
Red=2
2.2k 2.7k 3.3k Orange=3
Yellow=4
Rtot. = R1+R2+R3 Rtot.
Green=5
Blue=6
Purple=7
1st ring: 1st digit 8.2k Gray=8
2nd ring: 2nd digit White=9
3rd ring: 3rd digit/number of zeros
4th ring: number of zeros

Total: The total resistance is ALWAYS greater

value? value? 570Ω than the value of the HIGHEST resistor
560Ω 10Ω

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Resistors in parallel

R1
Black=0
560k
Brown=1
1/Rtot. = 1/R1+1/R2+1/R3 Red=2
Rtot. R2 Orange=3
Yellow=4
100k Green=5
620k
Blue=6
Purple=7
R3
Gray=8
value? 470k
150k
White=9

value? 390k The total resistance is ALWAYS less

than the value of the SMALLEST resistor
Total: 213k

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Product Training - Basic Electronics

Temperature dependent resistors

NTC - negative temperature coefficient

PTC - positive temperature coefficient

Resistance Resistance

Temp. Temp.
NTC PTC

NTC - mainly used in sensors, e.g. VP:s temp. sensors

PTC - used in protection circuitry, e.g. over current protection

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Product Training - Basic Electronics

Variable resistors, potentiometers

Potentiometer - voltage divider Reostath - variable resistor

Linear and logarithmic versions

Resistance Resistance

Rotation. Rotation.
Linear Logarithmic

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Product Training - Basic Electronics

Capacitors

• consists of two parallel conductive plates separated by an insulator

• a fully charged capacitor appears like an open circuit to dc circuits
• capacitance is a measure of a capacitors ability to store charge on its plates
• a capacitor has a capacitance of 1 farad if 1 coulomb of charge is deposited on the
plates by a potential difference of 1 volt
• the insulating material between the plates is called a dielectric
• different dielectrics cause different amounts of charge to be stored
• the capacitance is determined by the size of the plates, the distance between the
plates and the dielectric
• placing capacitors in parallel increases the overall capacitance
• placing capacitors in series decreases the overall capacitance

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Product Training - Basic Electronics

Capacitors

Non polarity dependent Polarity dependent

Film cap. Electrolytic cap.
Ceramic cap. Tantalum cap.
Polyester cap. ...
Polypropylen cap. ...
...
...

Farad, F - very large value

1 μF - 1 microfarad - 0.000001 F
1 nF - 1 nanofarad - 0.000000001 F
1 pF - 1 picofarad - 0.000000000001 F

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Capacitors

G
12 VAC 12 VAC

- +
12 V
12 VDC 0V

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Product Training - Basic Electronics

Capacitors

R
- +
63%
12 V
C

Rise time

Volts
Rise time (63%):
T=RxC

Example:
63% V=10V
R=100k
T
Time C=100μF
T=10s (6.3V)

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Why a specific cable area?

Cranking current: Up to 550 A when using 12 V system

Up to 900 A when using 24 V system

12.0 V 11.0 V

The voltage drop is caused by the cable resistance ( V = Rcable x I ). Another effect from the
cable resistance is that the temperature rises in the cables and may cause fire. If the voltage
drop is too high the starter engine will not receive enough power ( P = V x I ) to initiate the
rotation.

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Product Training - Basic Electronics

Battery cables, 12V

To avoid problems caused by voltage drop, Volvo Penta recommends cable areas as below.

2010, 2020, 2030 (12V):

Cable length in meter 1,5 1,5-2 2-3 3-4 4-5,5 55,-7
2
Cable area in mm 25 35 50 70 95 120
2040, MD22 L, P, TMD, TAMD (12V):
Cable length in meter 1,5 1,5-2 2,0-2,5 2,5-3,5 3,5-4,5
2
Cable area in mm 35 50 70 95 120
31-44 (12V):
Cable length in meter 1 1-1,5 1,5-2 2-3 3-4
2
Cable area in mm 35 50 70 95 120
60-70 (12 V):
Cable length in meter 1 1-1,5 1,5-2,5 2-3
2
Cable area in mm 50 70 95 120
Gasoline (12V):
Cable length in meter 1,5 1,5-2 2,0-2,5 2,5-3,5 3,5-4,5
2
Cable area in mm 35 50 70 95 120

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Product Training - Basic Electronics

Battery cables, 24V

To avoid problems caused by voltage drop, Volvo Penta recommends cable areas as below.

63 (24 V):
Cable length in meter 2 2-3 3-4,5 4,5-6 6-7,5
2
Cable area in mm 35 50 70 95 120
73 (24 V):
Cable length in meter 2 2-3 3-4 4-5
2
Cable area in mm 50 70 95 120
10L (24V):
Cable length in meter 2 2-3 3-4
2
Cable area in mm 70 95 120
12L (24 V):
Cable length in meter 2,5 2,5-3,5 3-4,5 4,5-5,5
2
Cable area in mm 50 70 95 120
16L (24 V):
Cable length in meter 1,5 1,5-2,5 2,5-3,5 3-4
2
Cable area in mm 50 70 95 120

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Battery charge status

The charge state is controlled by measuring the specific gravity of the acid in the battery.

Specific gravity at 20°C (68°F) Specific gravity at different temperatures Freezing point at different
in different charge state in a fully charged battery charge levels
1.28 100% +30 (86° F) 1.273 100% - 70 (-94° F)
1.26 85% +20 (68° F) 1.280 40% - 30 (-22° F)
1.24 70% +10 (50° F) 1.287 10% - 10 (+ 14° F)
1.22 55% 0 (32° F) 1.294
1.20 40% -10 (14° F) 1.301
1.18 25% - 20 (- 4° F) 1.308
1.16 10% - 30 (-22° F) 1.315

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Battery condition
The condition of the battery is checked by measuring the pole voltage when a specific
load is connected to the battery.

12.1 DC
V

The value of the inner resistance is a good

indication of the condition. Poor battery
status → high inner resistance → low pole
voltage when loading the battery.

Load

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Product Training - Basic Electronics
When selecting battery size, it is vital to look at both momentary and long-term capacity
The rating norm for long-term
capacity the C20 norm is used
(batteries marked with Ah)
• C20 means the amount off
current able to take out from
the battery during 20 h
Ex. 1: 60 Ah = 20 x 3 A/h
Ex. 2: 100 Ah = 20 x 5 A/h
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Battery size
When selecting the momentary capacity there are 3
different norms used:
• Cranking current according to SAE; the current taken
out from the battery at -18° without a voltage drop below
7,2 V within 30 sec.
• Cranking current according to DIN; the current taken out
from the battery at - 18° without a voltage drop below 9V
within 30 sec. and 6V within 150 sec.
• Cranking current according to EN (IEC 95-2); the current
taken out from the battery at - 18° without a voltage drop
below 7,5V within 10 sec. And thereafter 60% (0,6xI) of
original current without a voltage drop below 6V within 90
sec.
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Product Training - Basic Electronics

Diode
Be sure you have
the correct setting,
O.L
0.65 V
“Diode check “ or
IF
“ “

-200V VAC
0.6V

Cathode
Anode Cathode
Anode

Current flow in one direction only(“non-return valve”)

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 Product Training - Basic Electronics

The relays

• Relays are used to switch high currents with relatively low control currents.
• VP relay is made for either 12 V or 24 V.
• The diode is a protection against transients and sparks occurring when manoeuvring the relay.
• The transients may cause interference in the electronics if the energy is sufficient.

• When connecting and measuring the relay, take the diode into consideration.

The current passes through,

no resistance 86 87a 87
86 87a 87
85 30

Diode

No current passes through 85 30

Coil

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Zener diode
8.5 V

IF
Power supply

15.00 V
15

Zener “knee”
0 30
-8.5V VAC
0.6V

Anode

0.6V 0.6V 0.6V 0.6V 0.6V Cathode

3.0V

+ - + -
- + 0.6V

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Product Training - Basic Electronics

Checking temperature sensors

1.8 kΩ

30000

25000

20000

15000

10000

5000

0
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100110120130

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Checking pressure sensors(passive)

10.2 Ω

140

120

100

80

60

40

20

0
0 2 4 6

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Checking pressure sensors(active)

0.50 V

Power supply

5.00 V
5 15
4.5
4
3.5 0 30
3
2.5
2
1.5
1
0.5
0
0 1 2 3 4 5 6 7

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A fully electronic engine

• The engine is controlled by an electronic unit, an engine management system.
• Injectors and engine starter are all controlled by the engine management system.
• The engine management system controls the following:
• Controls each injector individually
• Engine speed, measured both on cam wheel and flywheel
• Injection control
• Cylinder balancing
• Boost temperature and pressure
• Oil temperature and pressure
• Low fuel pressure
• Water in fuel
• Coolant temperature
• Low coolant level
• Engine protection, low ambient air pressure
• Frequency select switch
Switch between 1500rpm (50Hz) and 1800rpm (60Hz)
• Idle select switch. To limiting idle rpm.
Condition to activate ramp down idle rpm, load is >500Nm during 400 ms.
• Synchronization / Load sharing
Fine adjust RPM at nominal speed (1500/1800rpm) with controls or by external control system
• Run indication (analog or CAN-bus)
Giving the operator or external system signal when engine is running at nominal speed
• Over speed alarm
Activated if rpm exceeds nominal speed with 20% and is deactivated if nominal speed is below10%
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 Product Training - Basic Electronics
Product Features and Benefits
• Emission compliant • Electronically controlled injection timing
• Compliant with stage 2 emission • Injects the right quantity of fuel at the
legislation right time (precise metering)
• Minimizes quantity of unburned fuel
• Dual speed / frequency availability • Produces virtually no visible smoke
• Possible to switch between 50Hz and
60Hz
• Possibility to serve different
• 4-valve cylinder head
markets/needs • Optimises engine performance
• with one engine i.e. rental business • Optimises engine efficiency
• Fast and easy to switch between • Ensures efficient combustion
different • Optimises fuel consumption
• frequencies saving time and cost.
• High pressure 5-hole injector nozzles
• High power and compact dimensions • Improves engine performance
• More power requiring less installation • Improves engine efficiency
volume • Ensures efficient combustion
• Reduces fuel consumption
• Electronic Unit Injectors
• Optimises fuel flow
• Ensures efficient combustion
• Reduces fuel consumption and
emissions

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Product Features and Benefits

• Low operational cost
• Engine technology gives low fuel consumption for low operational cost.

• Ease of service
• Serviceability during operation saves time and money

• High quality
• Built in the most automated diesel engine plant in the world by a totally robotic machining
and assembly line, ensures the highest level of quality.

• High reliability and long term durability

• The new Volvo Penta generating set engines is a further development of the well proven
Volvo Penta in-line six concept which ensures high quality and long term durability.

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Environmental responsibility
• We all want to live in a clean, healthy environment, where we can breathe clean
air, see healthy trees, have clean water in lakes and seas, and be able to enjoy
the sunlight without fearing for our health. Unfortunately, this is not a matter of
course these days, it is something all of us must work for.
• As an engine manufacturer, Volvo Penta has particular responsibility and for this
reason, environmental care is an obvious foundation of our product development.
Volvo Penta has a wide engine program these days, where considerable
progress has been made in reducing exhaust fumes, fuel consumption, engine
noise etc.
• We hope that you will want to preserve these values. Always observe the advice
in the Operators Manual about fuel grades, operation and maintenance, to avoid
unnecessary environmental impact. Please contact your Volvo Penta dealer if
you notice any changes such as increased fuel consumption or increased
exhaust smoke.
• Please remember to always hand in hazardous waste such as drained oil,
coolant, old batteries etc. for destruction at an approved recycling facility.
• If we all pull together, we can make a valuable contribution to the environment
together.

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Electric welding
• Remove the positive and negative cables from the batteries. Then
disconnect all cables connected to the alternator. Disconnect both
connectors from the engine control module.

• Always connect the welder earth clamp to the component to be

welded, and as close as possible to the weld site. The clamp must
never be connected to the engine or in such a way that current can
pass through a bearing.

• When welding is completed: Always connect the cables to the

alternator and engine control unit connector before reconnecting
the battery cables.

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