Lofa EP250 Operating instructions

EP250™Panel Operation
and Troubleshooting
463-3000-01 24-May-13 1
© 2006-2013 LOFA Industries, Inc. All rights reserved.
LOFA, the LOFA logo, CANplus and EP250 are trademarks of LOFA Industries, Inc. All rights reserved.
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EP250 Panel Operation and Troubleshooting
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SAFETY SYMBOLS
This manual uses the following conventions to present IMPORTANT SAFETY INFORMATION to you.
Please read and follow ALL SAFETY INSTRUCTIONS.
IMPORTANT SAFETY INFORMATION- A HAZARD THAT MAY,
IF NOT AVOIDED, CAUSE MINOR/ MODERATE INJURY.
IMPORTANT SAFETY INFORMATION- A HAZARD THAT
MIGHT CAUSE SERIOUS INJURY OR LOSS OF LIFE.
IMPORTANT and URGENT SAFETY INFORMATION- A
HAZARD THAT WILL, IF NOT AVOIDED, CAUSE SERIOUS
INJURY OR LOSS OF LIFE.
CAUTION
IMPORTANT SAFETY INFORMATION- A HAZARD THAT MAY,
IF NOT AVOIDED, CAUSE EQUIPMENT DAMAGE.
NOTE
ADDITIONAL IMPORTANT INFORMATION.
This document must be completely read and understood prior to installing, testing, or operating
the equipment described within. Further, this document must be retained for current and future
users of this equipment. Failure to strictly follow the warnings and dangers presented within this document could
result in damage to equipment, damage to property, bodily injury or death.
NOTE: THE SELLER HEREBY EXPRESSLY DISCLAIMS ALL WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND NEITHER ASSUMES NOR
AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY LIABILITY IN CONNECTION WITH THE SALE OF SUCH
PRODUCTS.
LOFA products are not designed or approved for use as critical components of any safety device or system
that is intended to prevent bodily injury, protect life, or prevent property damage.
The specifying Original Equipment Manufacturer (OEM) and/or Installer of any LOFA panel is responsible
for all safety labeling and operator education regarding the safe operation of this panel and the operation
of the specific machine that this panel is installed upon—including conformance to exhaust emissions regulations.
Only trained and qualified persons may perform installation, testing, service, or repair work on the LOFA
product.
LOFA products are not designed for, or intended for use on applications requiring explosive proof
components. Further, LOFA products are not designed for, or intended for application within hazardous or
explosive environments.
The installer of this LOFA product is solely responsible for ensuring that all OSHA, ANSI, CE, or other
applicable standards are met with respect to LOFA panel applicability, machine guarding, general safety
guidelines, labeling, and warnings.
The installer of this LOFA panel and/or LOFA harness is responsible for sizing and integrating a
suitable fuse/ breaker on the un-switched DC circuit supplying power to the LOFA panel.
NOTE: Please refer to www.LOFA.net for details on LOFA Industries, Inc. warranty policies.
LOFA Industries, Inc. has provided this document as a reference. We try to keep this document updated with the latest information regarding your LOFA product. However, changes do
occur and LOFA reserves the right to make changes to the design of the LOFA products and supporting documentation without notice.

EP250 Panel Operation and Troubleshooting
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NOTE: GENERAL EMISSIONS DISCLAIMER
This panel may include provision(s) for operator input such as FORCE REGENERATION, INHIBIT
REGENERATION, INTERLOCK, and others specific to US and International emissions regulations.
Responsibility for emissions related inputs and compliance with emissions regulations is solely that of
the owner and/or operator of the machine/ engine on which this panel is connected.
TYPICAL OPERATION:
1. Pull the AUX Engine STOP button “OUT” (away from the
panel face) to allow engine operation.
2. Push the AUX Engine STOP button “IN” (toward the
panel face) to initiate an AUXILLIARY Engine Stop.
AUXILIARY Engine Stop DISCLAIMER
This panel or harness may include an optional Auxiliary Engine Stop feature. The sole design intent of the Auxiliary
Engine Stop Feature is to provide for engine shutdown in the event of a key-switch malfunction. The panel key/
lever switch should always be used as the primary engine shutdown method.
Please note that the Auxiliary Engine Stop feature is NOT intended to function as the machine/ equipment
Emergency Stop, or be purposed as an Emergency Stop for safety purposes. The machine manufacturer must
provide a separate Emergency Stop switch to meet safety mandates or emergency machine shutdown
functionality.
AUTO- Start DISCLAIMER
This panel/machine may be equipped with an automatic engine start-up
system that could result in the automatic starting and stopping of the
engine/ machine at any time. As such:
The engine may start without warning or notice.
It is SOLELY the responsibility of the owner/ installer/ operator to provide
warning labels, visible warnings, and audible warnings to notify the
operator of an impending start-up.
ALWAYS use lockout/ tag out procedures prior to performing ANY
service or configuration operations.
DO NOT configure operator programmable features while the panel is in
“AUTO” mode (Key in auto-start position). The panel should be
configured ONLY when the key is in the “Run” position.

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Introduction
This document provides general information on LOFA™ EP250 panel operation and troubleshooting. EP250
control panels are a 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, over speed 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.
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
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:
Automatic Start/Stop Operation
Precision Actuator Control
Custom OEM Solutions
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.
CAUTION: EXHAUST EMISSIONS COMPLIANCE/ AUTO-START DISCLAIMER
This panel is equipped with operator programmable parameters that could result in the automatic
starting and stopping of the engine/ machine. The engine/ machine, as a function of the emissions
system can/ could initiate, via the engine ECU, certain required emissions operations such as
regeneration of the DPF, or other emissions system maintenance, while the engine is running. The
owner/ operator of the engine/ machine is solely responsible for any adverse effects or damage to the
engine, engine emissions system, or other damage that could occur as a result of starting or stopping
the engine/ machine during any ECU initiated emissions event.

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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.

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Operation
Turning the panel 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 Options). 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 crank the engine again 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 panel, 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.
Panel instrument power, including the hour meter 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).
After the engine starts, the panel 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
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 panel 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.

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To prevent unintentional engine shutdowns caused by intermittent conditions (i.e., pressure spikes, coolant
movement) the panel 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 panel can be configured to shutdown with no delay.
The panel has the ability to shut down the engine for over speed. Over speed will be indicated via a
blinking Battery Charge LED. The panel senses RPM either by the frequency terminal of the alternator,
proximity switch or magnetic pick-up with the optional magnetic pick-up amplifier/divider.
Preheat Options
Preheat Output
Preheat is a 750 mA 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. 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. Depending on
specific controls and configuration, this input can be configured to accept either high side (battery
positive) or low side (ground) control.
Indicators
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 indicate a failing
charge circuit. The panel can be configured for battery charge failure to indicate only.
Over Speed Indication
A regularly blinking Battery LED indicates the configured over speed RPM has been exceeded. Over speed
is a configurable option that is disabled by default.

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Oil Pressure LED (Red)
A solidly illuminated Oil Pressure LED indicates low oil pressure failure. The panel 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 panel 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.
Temperature LED (Red)
A solidly illuminated Temperature LED indicates high engine temperature failure. The panel 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 panel 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 panel 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

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shutdown input to ground can cause fault indications. The panel can be configured for auxiliary 1 failure to
indicate only.
A blinking AUX 1 LED indicates SW input failure. The panel typically senses failure using a ground contact
switch. The SW input is equipment specific and determined by the equipment manufacturer. A defective
switch or shorting the shutdown input to ground can cause fault indications.
AUX 2 LED (Red)
A solidly illuminated AUX 2 LED indicates an auxiliary switch 2 fault (i.e., air flow restriction, fuel level, etc.)
but by default does not cause a shutdown. The panel 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 panel can be configured with
auxiliary 2 shutdown.
Preheat LED (Red)
A solidly illuminated Preheat LED is the panel preheat indication. When the LED extinguishes the preheat
period is complete and the engine may be cranked. The LED illuminates again to indicate afterglow.

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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 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 0 RPM.
The tachometer must be calibrated to the engine using standard procedures (see Tachometer Calibration
Instructions 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 Ggenerally indicates the gauge terminal.
The gauge expects a low resistance for low pressure and a higher resistance for higher pressure. If a
powered 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 no pressure. When using
sender/switch combinations, swapping the WK and G terminal prevents the gauge from working and may
cause unintended shutdowns.
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 Ggenerally indicates the gauge
terminal. The gauge expects a high resistance for low temperatures and a lower resistance for higher