TroubleshootingGuide L6534 ECN

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L6534 • ECN 1-2408

Tr ou ble sh oo tin g Gu ide

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ECN 1-2408L6534_Rev1 2

IMPORTANT

Prior to proceeding:

• Ensure all wiring harness connections are securely connected to their mates.

• Inspect all wiring for signs of damage or wear that could cause electrical shorts or discontinuities.

• Ensure any extended lengths of harness do not exceed a span of 6 meters [20 feet] from controller.

Use your discretion to reset valve and restart engine after a shut-down event. Do NOT reset the valve until it is safe to do so. In most cases, it is recommended to wait until the cause is understood and shared with the necessary safety parties before restarting.

WARNING

• Do NOT cycle power until instructed to do so. In certain cases, cycling the power can cause the system to fail.

• Do NOT cycle power by removing connectors from controller. Cycle power by disconnecting at battery or removing main power fuse.

• Do NOT operate engine with any harness connections disconnected. This is dangerous and could cause system components to fail under extreme operating conditions.

• Unnecessary connection and disconnection of harness connections wears out plating on electrical contacts and will affect continuity.

General Troubleshooting Procedure

1. Confirm if fuses are inserted into Mode Selection Box. Refer to Programming Manual for more information.

2. Identify Operating Mode of system by checking which pattern the switch light is flashing:

a. Solid Light – Valve Closed

b. No Flash – Normal Operating Mode

i. Enter Test Mode to confirm which Trip Speed is active (Single Pulse vs Double Pulse).

c. Constant Slow Flash – Valve Activated and Awaiting Reset

i. Light will extinguish after 10 seconds of engine operation.

d. Constant Rapid Flash – Unprogrammed Mode

i. Enter Programming Mode to confirm which Trip Speed is active (Single Pulse vs Double Pulse).

e. Rapid Flash Interrupted by Single Pulse – Programming Mode or Test Mode (Primary Trip Speed) i. If Fuse 1 is inserted in Fuse Box, then Programming Mode is active.

f. Rapid Flash Interrupted by Double Pulse – Programming Mode or Test Mode (Secondary Trip Speed) i. If Fuse 1 is inserted in Fuse Box, then Programming Mode is active.

3. If issue is not related to harness connections / Mode Selection Box / Operating Mode, refer to the following detailed Troubleshooting Sections.

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ECN 1-2408L6534_Rev1 3

False Trip: System has automatically shut down engine at incorrect engine speed

Cause Solution

Wiring harness is loose • Ensure all connectors are fully seated.

Wiring harness is damaged • Inspect all wiring for signs of damage.

• Contact PowerHalt support for replacement harness if necessary.

Controller is not programmed for correct trip speed.

• Use TEST Mode to ensure controller was programmed correctly and re- program if necessary. Refer to Programming Manual for more information.

Speed sensor is not correctly

sensing engine speed. • See Speed Sensor troubleshooting section.

If applicable:

Auxiliary Input Signal is activated unexpectedly.

Auxiliary Input Signal allows system to accept a signal from an external auxiliary device to actuate the valve.

Applicable if: Auxiliary Input Signal (Grey Wire, Pin 11 on Connector A of PowerHalt harness) is connected to external device capable of supplying power.

• Investigate behaviour of connected device.

If applicable:

Secondary Trip Speed is unintentionally enabled (or disabled) and is causing system to trip unexpectedly.

System can be configured to force engine shutdown at 2 different engine speeds. Secondary Trip Speed is the additional trip speed and it is active when its input from the harness is supplied power.

Applicable if: Secondary Trip Speed input (Pink Wire, Pin 7 on Connector B of PowerHalt harness) is connected to external device capable of supplying power.

• Depending on application, ensure that Secondary Trip Speed is correctly enabled/disabled.

If applicable:

Improper wiring of

synchronized shut-off systems is resulting in signal noise and false trip of one or more connected valves.

Activation of multiple shut-off systems can be synchronized to ensure that all connected valves actuate at the same time.

Applicable if: Auxiliary Input Signal (Grey Wire, Pin 11 on Connector A of PowerHalt harness) and Auxiliary Output Signal (Brown Wire, Pin 4 on

Connector A of PowerHalt harness) are connected to another shut-off system.

• Confirm if systems are connected to common battery ground (single battery bank for all devices or separate batteries with connected ground terminal) OR different battery grounds (independent batteries).

• Refer to Installation Manual and connect wiring harness as per identified battery ground configuration.

Unable to program trip speed

sensing the engine speed. • See Speed Sensor troubleshooting section.

Toggle switch is unresponsive. • See Toggle Switch troubleshooting section.

Mode Selection Box is unresponsive.

• Check fuses and replace if necessary.

• Use test light to confirm 12VDC is measured at Pin 3 on Mode Selection Box.

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ECN 1-2408L6534_Rev1 4

Automatic shutdown function fails to actuate valve at programmed Trip Speed

Wiring harness is loose • Ensure all connectors are fully seated.

Controller is not programmed for correct trip speed.

sensing engine speed. • See Speed Sensor troubleshooting section.

Actuator is damaged. • Inspect actuator for any visible damage.

• Perform Manual Trip and listen for movement to determine if it has seized.

• Remove wiring harness and ensure actuator coil resistance is equal to 0.1522Ω ± 6% (12V system) at 25°C.

• Identify valve serial number and contact PowerHalt support.

System is not receiving adequate power.

• Ensure system voltage is not less than 10VDC (12V system) or 20VDC (24V system) and replace/charge battery if necessary.

• Check main power fuse at battery and replace if necessary.

If applicable:

Secondary Trip Speed is unintentionally enabled (or disabled) and is causing system to trip unexpectedly.

System can be configured to force engine shutdown at 2 different engine speeds. Secondary Trip Speed is the additional trip speed and it is active when its input from the harness is supplied power.

Applicable if: Secondary Trip Speed (Pink Wire, Pin 7 on Connector B of PowerHalt harness) is connected to external device capable of supplying power.

• Depending on application, ensure that Secondary Trip Speed is correctly enabled/disabled.

If applicable:

Improper wiring of

synchronized shut-off systems is resulting in signal noise and preventing one or more valves from actuating.

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ECN 1-2408L6534_Rev1 5

Manual Trip (Toggle Switch) fails to actuate valve

Switch is damaged. • See Toggle Switch troubleshooting section.

Wiring harness is loose • Ensure all connectors are fully seated.

Actuator is damaged. • Inspect actuator for any visible damage.

• Remove wiring harness and ensure actuator coil resistance is equal to 0.1522Ω ± 6% (12V system) at 25°C.

• Ensure system voltage is not less than 10VDC (12V system) or 20VDC (24V system) and replace/charge battery if necessary.

If applicable:

Improper wiring of

Engine fails to shut down when valve actuates

Leak in system is allowing air to continue entering engine.

• Inspect all piping/hoses for leaks and repair or replace parts if necessary.

• Ensure any crankcase breather connections to intake system are located upstream of shut-off valve.

Valve is installed backwards. • Ensure the activation solenoid points in direction of air flow.

• Refer to Installation Manual for more information.

If applicable:

Improper wiring of

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ECN 1-2408L6534_Rev1 6

Engine will not start

Valve is stuck in closed position. • Confirm position of toggle switch and ensure it is returned to OFF position.

• Confirm if red light is illuminated or exhibiting slow constant flash.

• Confirm position of valve by inspecting position indicator on top of valve:

• Attempt to manually reset valve position with the reset knob.

• Attempt to actuate the valve with the toggle switch. Listen for valve movement.

• Inspect valve for any physical obstructions and remove if possible.

• Ensure all wiring harness connectors are fully seated.

• Inspect all wiring for signs of damage.

Latching mechanism is

damaged • Inspect valve reset mechanism for any visible damage.

Actuator is damaged

• Inspect actuator for any visible damage.

• Remove wiring harness and ensure coil resistance is equal to 0.1522Ω ± 6%

(12V system) at 25°C.

Speed sensor is malfunctioning and causing system to trip unexpectedly.

• See Speed Sensor troubleshooting section.

If applicable:

Stock vehicle speed sensor is being misread – potential interference from PowerHalt T- Jumper Harness.

PowerHalt T-Jumper Harness is a special harness that senses engine speed by connecting to the factory installed speed sensor.

Applicable if: PowerHalt T-Jumper Harness is being used to sense engine speed.

• Attempt to disconnect PowerHalt T-Jumper Harness and install factory harness as originally connected. Contact PowerHalt support for replacement T-Jumper Harness if necessary.

• Refer to OEM procedure to ensure sensor is working correctly and replace if necessary.

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ECN 1-2408L6534_Rev1 7

Auxiliary Output Signal is unable to power connected external device

If applicable:

Auxiliary Output Signal is overloaded.

Auxiliary Output Signal is a 12VDC signal that becomes active when the valve is actuated via overspeed signal or toggle switch. The signal can be used to power an external device and is able to output a maximum of 330mA – exceeding this load will result in tripping of an internal controller fuse.

Applicable if: Auxiliary Output Signal (Brown Wire, Pin 4 on Connector A of PowerHalt harness) is connected to external device.

• Disconnect external device to allow internal controller fuse to automatically reset itself.

• Use relay to switch high load devices.

Toggle Switch and/or light are unresponsive

Switch/light are improperly wired.

• Re-confirm switch/harness pin-outs are connected correctly. Refer to Installation Manual for details.

Switch is damaged. • Check for continuity across toggle switch contacts when closed. Refer to Installation Manual for details.

• Contact PowerHalt support for replacement switch if necessary.

Light is damaged. • Check for continuity across switch light contacts or apply power and ground to test. Refer to Installation Manual for details.

• Contact PowerHalt support for replacement switch if necessary.

• Ensure system voltage is not less than 10VDC (12V system) or 20V (24V system) and replace/charge battery if necessary.

Speed Sensor is not correctly sensing engine speed

Sensor is damaged. • Inspect sensor tip and wiring leads for visible signs of damage.

• Contact PowerHalt support for replacement sensor if necessary.

Sensor is not installed to the correct depth.

• Ensure push-in type sensor is fully inserted and correctly torqued.

• Ensure thread-in type sensor was fully threaded into port so that it contacts flywheel teeth and then backed off ½ turn. Remove sensor and measure depth of port to confirm.

• Use bottoming tap to clear impeding dirt and burrs from port threads.

• Ensure sensor is centered over flywheel teeth. Contact PowerHalt support if sensor is not centered over flywheel teeth.

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ECN 1-2408L6534_Rev1 8 Installed sensor is not

compatible with installed controller.

• Only certain controllers are compatible with certain speed sensors.

• Ensure installed controller and installed speed sensor are compatible. Refer to Product Datasheet for further details or contact PowerHalt support. In

general:

Controller Part Number Compatible Sensor

C20646-2 2 Wire Speed Sensors (Including R-Terminal)

C20646-3 3 Wire Speed Sensors

C20646-4 J1939 with 250kbps Signal C20646-5 J1939 with 500kbps Signal C20646-7 2 Wire Generator Applications

C20646-8 250/500/1000kbps CAN (J1939 or OBDII) Variable Reluctance (2 Wire)

sensor or R-Terminal Harness is faulty.

• With sensor/harness installed on engine, use multi-meter to ensure that frequency of VAC output at sensor/harness leads changes with changes in RPM.

• For R-Terminal Harness, ensure the second lead is grounded directly at the battery to suppress any noise.

Hall Effect (3 Wire Sensor is faulty

• Test by using a 12VDC power source to supply power to Pin A and ground to Pin B of the sensor. Use a multi-meter to ensure that 5 VDC is being read at Pin C of the sensor when it is away from a steel plate. Reading should drop to 0VDC when sensor is touching the plate.

Gen-End speed sensor (2 wire with integrated circuit) is faulty

• With the generator operating, measure for correct voltage and frequency at the frequency sensor connection point. The voltage must be between 110 and 250 VAC and the frequency should match the unit’s nominal operating

frequency (50 or 60 Hz).

• If voltage is not present, check to ensure there are no switches, fuses, or circuit breakers between the generator and the frequency sensing module that could prevent voltage from reaching the module.

• If the frequency sensing module has been incorrectly connected to a higher voltage, it may have been damaged.

Incorrect CAN (J1939 or OBDII) wire polarity

• If splicing into J1939 ensure the yellow wire is connected to

CANHI/CANH/CAN+ and the green wire is connected to CANLO/CANL/CAN-.

Incorrect CAN baud rate (C20646-4-5 only)

• Ensure the correct controller is selected for the vehicle. Incorrect baud rate may cause a “Data Link Error” or “Bus Off” to be displayed on vehicle dash.