Troubleshooting Guide

For Doctor Portable Series

Revision 1.5

May 2007

3 Raw Holdings

East Calder

West Lothian EH53 0HY, UK

T: +44 1506 885000

F: +44 1506 885501

W: www.iconresearch.co.uk

NOTICE

Information contained in this document is believed to be accurate and reliable. However, due to ongoing product developments and revisions, Icon Research

Ltd cannot guarantee the accuracy of this document after the date published nor can it accept responsibility for errors or omissions.

This document, and the software and/or hardware which it describes, is subject to change without notice.

Icon Research Ltd acknowledges that various products or trademark names referred to in this document are subject to copyright and/or trademark by their respective registered holders.

CONTENTS

CHAPTER 1 - Instrument Operation............................................................................ 1-1

1.1

Battery and Power Issues ............................................................................ 1-1

CHAPTER 2 - Problems with Taking Readings........................................................... 2-1

2.1

Checking the Pressure Sensor .................................................................... 2-1

2.2

Checking Operation of the Crank Pickup(s)................................................. 2-2

CHAPTER 3 - Inductive Pickups ................................................................................. 3-1

3.1

TDC ONLY Operation .................................................................................. 3-1

3.2

DUAL Operation........................................................................................... 3-1

CHAPTER 4 - Full Diagnostics for Inductive Pickups.................................................. 4-1

4.1

Single Pickup – No RPM indication at EPU ................................................. 4-1

4.2

Dual Pickup – No RPM indication at EPU.................................................... 4-3

CHAPTER 5 - Downloading Issues ............................................................................. 5-1

5.1

Cable specification....................................................................................... 5-1

5.2

No serial number entered ............................................................................ 5-1

5.3

Timing Issues ............................................................................................... 5-2

5.4

Incorrect Com Port Selected ........................................................................ 5-2

5.5

Problems with the PC’s RS232 connection ................................................. 5-2

5.6

Further tests ................................................................................................. 5-3

CHAPTER 6 - Issues with Results – Incorrect Power Results .................................... 6-1

6.1

TDC Offset ................................................................................................... 6-1

6.2

Sensitivity of sensor incorrectly entered ...................................................... 6-1

6.3

Incorrect dimensions in the database .......................................................... 6-1

6.4

Clogged or restricted indicator passageways .............................................. 6-1

6.5

Faulty indicator cocks .................................................................................. 6-2

CHAPTER 7 - Database Setup Issues ........................................................................ 7-1

7.1

Firing order incorrect .................................................................................... 7-1

7.2

Bank angle on V configuration engine incorrect .......................................... 7-1

Chapter 1 – Instrument Operation

CHAPTER 1 - Instrument Operation

1.1 Battery and Power Issues

The EPU screen should illuminate and show text indicating a test sequence on switching the instrument on. If this does not happen, it is likely that there is no power in the battery.

Try switching on with the battery charger connected. If the instrument switches on, the battery may either have been deep discharged, or it may require replacement.

If the Doctor is left switched on for an extended period, or occasionally on new units, the battery charging circuit may switch off before a full charge is reached.

If the battery seems to be losing charge quickly when in use, this may be the cause.

To remedy this, the following procedure should be used:

1. Connect the charge lead to the mains and check that the POWER light comes on. The CHARGING light should also come on, however if not, unplug, leave for

30 secs and try again.

2. Keep an eye on the unit for the first 10 to 20 mins of charging. If the

CHARGING light goes out during this time, repeat step 1. A full charge from a flat battery condition will take 2 to 3 hours.

3. Ideally, after a deep discharge, the battery should be cycled by fully charging it, fully discharging it and then fully charging it again. To discharge, leave the unit switched on and make sure the BATTERY LEVEL selection in the UTIL screen is set to 5.90. When the BAT warning appears in the top right of the screen, the unit is quite close to being discharged and can be charged up again.

4. The batteries in the Doctor are Ni-Cad batteries and these should be allowed to discharge before being charged up in normal operation of the system. Failure to do this or constant “topping-up” of the batteries can induce a “memory” in the battery that results in reduced battery capacity.

5. If the battery still fails to power the unit, or only powers the unit for a short time, the battery should be replaced. In most Doctor units, the battery is fitted with a quick change connector. If this is the case, then a new battery should be ordered from Icon. If there is no connector present, the EPU must be returned to Icon for fitting of a connector and replacement of the battery.

To check inside the unit for a connector

Before starting, switch on the instrument and go to the SET screen and take a note of any settings you have made in the instrument for your engines. Battery changing will not affect the memories in the instrument.

1-1

Chapter 1 – Instrument Operation

Switch the instrument off and remove the

10 screws holding the front panel.

Turn the panel over and place it in the case as a convenient support.

Note that newer units do not have the internal power supply fitted (lower right in picture)

Check to see if a connector is fitted to the battery.

Lift the panel slightly and move it towards you before tilting the back up to remove the chassis from the case.

1-2

CHAPTER 2 – Problems with Taking Readings

CHAPTER 2 - Problems with Taking Readings

If the unit fails to take a reading, but the screen is operating normally, it is best to determine if the pressure sensor and the crank pickups are functioning correctly.

2.1 Checking the Pressure Sensor

From the UTILS screen in the EPU, select READ PMAX. In this mode the instrument acts as a peak pressure gauge, independent of the crank pickups.

With the engine running, attach the pressure sensor to an indicator cock on a running engine, open the cock fully and press [ENT]. This will start peak pressure measurement. If a normal pressure reading is obtained, the pressure sensor and lead are OK.

If the pressure sensor gives a reading, but it is too low or too high, check that the sensitivity that has been entered for the sensor is correct.

If not, the following can be checked:

Thompson In very exceptional circumstances, the

Thompson Adapter may become clogged.

This is most likely to be due to incorrect storage (may be clogged with melted plastic for example if placed on plastic surface when hot).

Faulty extension lead Check lead for continuity and for shorts. If any problems are found, it is likely that a replacement will be needed.

No power to pressure sensor Check on the TNC connector on the EPU for

24V between the inner contact and the outer thread on the connector. If the voltage is found to be significantly lower than this, the instrument should be returned for investigation.

The pressure sensor can be visually inspected for damage. Removal from the

Thompson Adapter using the supplied tube spanner may assist this. It cannot be electrically checked. If the sensor is suspected to be the cause of lack of readings after other tests, it should be returned to Icon for repair or replacement.

2-1

CHAPTER 2 – Problems with Taking Readings

2.2 Checking Operation of the Crank Pickup(s)

In the EPU, press [UTIL] and select CRANK SETUP from the menu. This utility checks the crank pickups for the engine type selected in the MAIN screen.

Connect the instrument to the pickup(s) on the engine and press [ENT] to start the test.

For a TDC ONLY pickup, a steady RPM should be found and the RPM should be the correct value for the engine.

For a DUAL pickup, the RPM should be steady for both TDC and FLYWHEEL, and the

MAX TOOTH DEVIATION should be under 10%. Note that the deviation should be under 4% to get acceptable readings, however operation is possible up to 10%.

2-2

CHAPTER 3 – Inductive Pickups

CHAPTER 3 - Inductive Pickups

The most common faults found are:

3.1 TDC ONLY Operation

RPM is double expected. Two TDC markers on flywheel

RPM too low or unsteady. Unreliable signal – check gap, pickup and marker.

RPM too high.

No reading

Pickup too close to flywheel.

Check that the engine selected has TDC

ONLY selected in the SET screen.

3.2 DUAL Operation

RPM is double expected. Two TDC markers on flywheel.

RPM too low or unsteady. Unreliable signal – check gap, pickup and marker.

RPM too high. Pickup too close to flywheel.

RPM steady but number of teeth low and or unsteady.

Pickup too far from flywheel teeth. Check that target diameter is machined and there is no run-out on the flywheel.

RPM steady but number of teeth too high and /or target diameter is machined and free of burrs unsteady.

Pickup too close to flywheel teeth. Check or dents.

Max tooth variation > 5% and RPM and No of teeth steady.

Teeth probably worn or damaged – move pickup to a more uniform diameter on teeth or revert to TDC ONLY operation.

RPM correct but tooth The gap between the tooth readings is reading fails at higher insufficient. Move the tooth pickup to a larger

RPM’s. diameter where the gaps are larger or use a smaller diameter pickup with a higher response.

RPM very high Check that the engine selected has DUAL selected in the SET screen.

3-1

CHAPTER 3 – Inductive Pickups

3-2

CHAPTER 4 – Full Diagnostics for Inductive Pickups

CHAPTER 4 - Full Diagnostics for Inductive Pickups

4.1 Single Pickup – No RPM indication at EPU

Check for 24V at pin E on Mil spec connector on

EPU.

2

Check EPU operates normally otherwise and if so, return

EPU to Icon for investigation.

3

Check 24V at Junction boxes on terminal E of

Mil Spec connector and to all power connections

(brown wires).

3

Check pickup for physical damage.

2

Check CIC-3 cable for continuity and shorts. If faulty, either repair or replace.

2

Damage normally impairs operation. Replace pickup.

3

Check that the LED is lit when metal is present in front of the pickup.

3

2

Replace pickup.

Check that the LED is NOT lit when metal is

NOT present in front of pickup.

3

With LED lit (metal in front of pickup) check voltage on black wire from pickup. This should be 24V.

3

2

Check wiring and if correct, replace pickup.

2

Replace pickup.

With LED lit (metal in front of pickup) check voltage on terminal 2 in junction box (signal wire after resistor pack). This should be 5V.

3

With LED NOT lit (no metal in front of pickup) check voltage on terminal 2 in junction box

(signal wire after resistor pack). This should be

0V.

3

Check for continuity and no shorts back to Pin A of CIC-3 cable at EPU end. Check for 5V here with LED lit and for 0V with LED not lit.

3

Rotate flywheel on engine slowly and check LED on pickup goes on when target is in front of pickup and off when not.

2

Check resistor values and connections. Remedy any faults found.

2

Replace pickup.

2

Repair or replace CIC-3 cable.

2

Check pickup gap and that the pickup is far enough away from flywheel surface when target is not in front of pickup.

3

Check that the engine selected in the EPU has

TDC ONLY set in the SET screen.

2

Alter EPU SET screen setting to TDC ONLY.

4-1

CHAPTER 4 – Full Diagnostics for Inductive Pickups

3

With the engine running and EPU connected to crank pickup, enter UTILS screen. Select

2

If OK on other engines, review above. If problems persist,

CRANK SETUP and follow on-screen instructions to test TDC ONLY pickup. RPM contact Icon for advice. should be correct and steady.

3

Crank pickup is operating correctly.

4-2

CHAPTER 4 – Full Diagnostics for Inductive Pickups

4.2 Dual Pickup – No RPM indication at EPU

Check for 24V at pin E on Mil spec connector on

EPU.

2

Check EPU operates normally otherwise and if so, return

EPU to Icon for investigation.

3

Check 24V at Junction boxes on terminal E of Mil

Spec connector and to all power connections

(brown wires).

3

2

Check CIC-3 cable for continuity and shorts. If faulty, either repair or replace.

Check pickups for physical damage.

2

Damage normally impairs operation. Replace pickup.

3

Check that each LED is lit when metal is present in front of the pickup.

2

Replace pickup. Note that the system can be re-configured for TDC only operation as a stand-by until a replacement is available.

3

Check that the LED is NOT lit when metal is NOT present in front of each pickup.

3

2

Check wiring and if correct, replace pickup.

With LED lit (metal in front of pickup) check voltage on black wire from each pickup. This

2

Replace pickup. should be 24V.

3

With flywheel LED lit (metal in front of pickup) check voltage on terminal 2 in junction box

(signal wire after resistor pack). This should be

5V.

2

Check resistor values and connections. Remedy any faults found.

Repeat for TDC pickup and terminal 6.

3

With flywheel LED NOT lit (no metal in front of pickup) check voltage on terminal 2 in junction box (signal wire after resistor pack). This should be 0V.

Repeat for TDC pickup and terminal 6.

3

2

Replace pickup.

Check for continuity and no shorts on the green and yellow wires back to the junction box with the

Mil spec connector.

3

Check for continuity and no shorts back to pins A and B of CIC-3 cable at EPU end. Check for 5V here on each with LED lit and for 0V with LED not lit.

Repair or replace connecting cable or make connections good.

2

Repair or replace CIC-3 cable.

4-3

CHAPTER 4 – Full Diagnostics for Inductive Pickups

3

Check that pin A on the CIC-3 connector at the

EPU end corresponds to the Flywheel pickup

(monitors the teeth on the flywheel) and that pin

B corresponds to the TDC pickup (monitors bolt in the flywheel).

3

2

Swap connections for pickups at junction box nearest to flywheel.

Rotate flywheel on engine slowly and check LED on pickup goes on when target is in front of pickup and off when not. Check that the flywheel pickup flashes each time that a tooth is in front of the pickup. or replace with smaller pickup.

3

Check that the engine selected in the EPU has

DUAL set in the SET screen.

3

2

Alter EPU SET screen setting to DUAL.

With the engine running and EPU connected to crank pickup, enter UTILS screen. Select

2

If OK on other engines, review above. If problems persist, contact Icon for advice. CRANK SETUP and follow on-screen instructions to test DUAL pickups. RPM should be correct and steady. The MAX TOOTH

DEVIATION should be under 10% as a maximum (note that for good readings this should be under 4%).

3

Crank pickup is operating correctly.

2

Check pickup gap and that the pickup is far enough away from flywheel surface when target is not in front of pickup.

Note that flywheel pickups should have at least twice the pickup diameter as free space between each tooth. If not, move pickup to achieve this,

4-4

CHAPTER 5 – Downloading Issues

CHAPTER 5 - Downloading Issues

5.1 Cable specification

A download from the Doctor EPU to the Doctor software in a PC is made using an

RS232 crossover cable. The pin-out of the connector on the instrument is shown below.

For connection to the 9-pin connector on a PC, an industry-standard PC AT-AT DB9 cable is recommended. Alternatively, a cable as shown in the diagram below can be used.

For connection to a PC fitted with USB ports, a USB to serial converter will work quite adequately with the RS232 cable supplied.

5.2 No serial number entered

Check that the RS232 cable is connected at both ends and that the instrument is switched on.

From your database, click on the Yellow Box Button and you should see the dialogue for transfer of results.

If the programme requests a serial number, this can be found on the cover of the CD that was used to install your software.

You will only be able to download data using a fully licensed copy of the Doctor software. The first time you download, the following window appears. Enter your serial number to continue.

5-1

CHAPTER 5 – Downloading Issues

5.3 Timing Issues

On a very few older PC’s, the timing for the RS232 may be incompatible with the EPU.

For such cases, the EPU has a SLOW transfer mode. To select this, in the EPU, enter the UTILS screen and select the SLOW option for SERIAL TRANSFER.

5.4 Incorrect Com Port Selected

The COM port that is selected by default is COM 1. If this is not the one you are using, it is possible to change the port. If you know the COM port number for the socket you have used, you can enter it, however if you don’t know, you can keep trying until one works.

There are 8 COM port selections to choose from. Note that if you are using a USB to serial adapter, you will always need to change from the default setting of COM 1.

If connection is unsuccessful, you will see the following window.

From the drop down menus, select Download… Comms Setup and choose the COM port you need. Click on OK and try downloading again.

Click on the button after the correct COM port has been selected.

5.5 Problems with the PC’s RS232 connection

As an initial test, it may be easiest to install the Doctor programme on another PC and test downloading. If this works, then the cable and the EPU are OK.

To check further, the following tests can be made.

To test RS232 operation of EPU, cable and PC, the unit displays a short message on start-up.

If you connect HyperTerminal using the following settings you will get a message on the PC saying "I'm Alive" when you switch on the EPU.

5-2

CHAPTER 5 – Downloading Issues

To use HyperTerminal, use Start… All Programs… Accessories…

Communications… HyperTerminal.

Use the Set up a New Connection option (this will appear automatically the first time you use HyperTerminal).

Enter a name for your connection, e.g. Doctor.

From the drop down list, choose COM1, or the COM port number you are testing.

Set up the following:

•

9600 Bits per Second

•

8 Data Bits

•

No Parity

•

1 Stop Bit

• No Flow Control

Click OK and HyperTerminal is ready to use.

Connect up to the EPU and then switch on the EPU. If you get the message “I’m Alive” then the correct port has been selected and communication is established.

HyperTerminal must be closed before a transfer with the Doctor software.

5.6 Further tests

If the computer has only one serial port, an additional computer will be required to perform all of the tests.

Firstly using HyperTerminal, connect to the suspected faulty serial port using the settings of:

•

9600 Bits per Second

•

8 Data Bits

•

No Parity

•

1 Stop Bit

•

No Flow Control

If HyperTerminal states that it cannot connect it may be due to one of the following:

•

The serial port does not exist - Check using the Windows Device Manager which is found in the Control Panel - System Tools.

5-3

CHAPTER 5 – Downloading Issues

•

The hardware driver for the serial port is faulty - Check using the Windows

Device Manager.

•

Another application is currently using the serial port - this must be closed before it can be used by the Doctor Software.

If the computer has another serial port, repeat the process above using a second copy of HyperTerminal, or else use a second computer.

Connect your RS232 cable between the serial ports, and type a message on each of the HyperTerminal windows. The message should be displayed on the other

HyperTerminal window. If it does not it may be due to one of the following:

•

The cable is not actually connected to the correct serial port on the computer

•

The cable is not a crossover cable or is faulty

•

One or other of the serial ports if faulty

If the message only appears on one of the HyperTerminals it may be due to one of the following:

• The cable is not a crossover cable or is faulty

• One or other of the serial ports is faulty

If the serial port works correctly, HyperTerminal can also be used to check the workings of the DK-2 unit (Firmware Version 3.xx only). To do this:

• Start HyperTerminal in the same manner as above.

• Connect the DK-2 to the computer using the serial cable.

• Switch on the DK-2 and observe a single line message displayed.

5-4

CHAPTER 6 – Issues with Results – Incorrect Power Results

CHAPTER 6 - Issues with Results – Incorrect Power

Results

6.1 TDC Offset

By far the most common reason for unacceptable results is that the TDC offset has not been correctly adjusted.

A 1º error in TDC adjustment will give an error in power of 7% or so.

The manual for the software fully covers how this adjustment may be made.

Alternatively, Icon provides a service for initial results free of charge. To use this service, just send an archived database to [email protected]

6.2 Sensitivity of sensor incorrectly entered

The sensitivity of the pressure sensor must be correctly entered into the database in the software on the PC. The default value is 20mV/bar, and all sensors supplied today are close to this value. Older sensors had a sensitivity of 25mV/bar, and if the two are confused a 20% to 25% error in pressure and power values can result.

6.3 Incorrect dimensions in the database

The values for bore, stroke and con rod length all need to be correct in the database to provide correct power values.

6.4 Clogged or restricted indicator passageways

Partial clogging of the indicator cock or passageways will affect the results.

6-1

CHAPTER 6 – Issues with Results – Incorrect Power Results

6.5 Faulty indicator cocks

If a cock has a damaged seat inside, the results often look like the ones shown below. The cylinders affected will show much higher power than is actually present in the cylinder.

6-2

CHAPTER 7 –Database Setup Issues

CHAPTER 7 - Database Setup Issues

7.1 Firing order incorrect

Incorrect entry of the firing order can result in traces like this. A similar effect is seen if readings are taken starting at the wrong end of the engine.

7.2 Bank angle on V configuration engine incorrect

The graph below shows the effect of an incorrectly entered bank angle for a V engine

7-1