PSH MOTOPLAT CV-623A Series User manual

USER
MANUAL
www.motoplat.nl
CV-623A
The CV-623A series test benches are high-end for Lab and
production use with a sturdy look and meant to last in the
modern workshop. Its high power motor in combination with its
computer controlled load bank and Siemens PLC’s makes it easy
to test up to 600amps and guaranteeing high reliability.
The CV-623A is equipped with the latest testing technology
for the modern workshop or production facility, such as API+
technology which automatically identies COM protocols
within 2 seconds. The protocols are displayed together with
their ID codes and in-depth communication data, which makes
development in remanufacturing easier, cheaper and more clear.
A modern windows PC is included for internet support and to
generate modern and extensive reports.
Test Bench
ENGLISH
VERSION 2020

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IMPORTANT INFORMATION
Safety warning
Electrical devices should be installed and operated in such a way that all applicable safety requirements
are met. It is your responsibility as an installer to ensure that you idenfy the relevant safety standards and
comply with them. Failure to do so may result in damage to equipment and personal injury. In parcular,
you should study the contents of this guide carefully before installing or operang the equipment.
Only qualied people should work with this equipment!
Prior to using this product, you should carefully review this instrucon manual or undergo training from a
qualied person.
The use of electrical equipment is enrely at your own risk and Motoplat is in no circumstances responsi-
ble for any incidental, consequenal or special damages of any kind whatsoever, including but not limited
to lost prots arising from or in any way connected with the use of the automated test equipment or this
manual.
The tester should be connected to a properly grounded outlet.
If the power cable is damaged, it must be replaced by the supplier or by another qualied person in order
to avoid dangerous situaons.
In the event that the tester comes without baeries (non-EU countries) or if you have to replace the bat-
teries, please ensure that you use approved baeries (preferably deep cycle AGM) only, as non-approved
baeries may have an adverse eect during tesng or may even damage the tester.
- Motoplat® -
Environment
The tester should be installed in a weather-protected area where heat, humidity or any other climate situa-
on will not damage the tester.
The tester should be installed on a level surface that is clear of debris and obstrucons.
It is recommended that the box and packing materials be kept for possible re-use, should the tester be
shipped again at a later me.

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Index
1 General Informaon
1.0 General informaon about the Motoplat CV-623A alternator test bench 5
1.1 Front view 6
1.2 Back view 7
1.3 Main specicaons 7
3 Alternator mounng
3.0 Intro 13
3.1 Side mounng 14
3.2 Connecng the alternator 15
2 Panels
2.0 Connecon panel descripon 9
2.1 Instrumental panel descripon 10
2.2 Instrumental panel (manual) descripon 11
Support
Contact Informaon
4 Soware
4.0 PC soware 17
4.1 Detailed informaon 19
4.2 Informaon LIN/BSS 21
4.3 Menu 22
4.4 Add alternator / alternator list 23
Technical Informaon
Technical informaon

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Section 1
General
Information
www.motoplat.nl

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General informaon about the Motoplat CV-623A alternator test bench:
The Motoplat CV-623A test bench has a 380V 3-phase power supply and can test both 12 and 24 volt
alternators. (48V ready).
To test modern alternators that have a high output at low RPM, the CV-623A is equipped with a modern
high power 22 kW(30Hp) motor and motor drive, which makes less noise than most other test benches on
the market.
The tester is equipped with the new API+ technology which automacally detects the LIN and BSS protocol
more quickly. The LIN and BSS signals will be displayed in dierent protocols together with the ID code,
which makes development in remanufacturing easier, cheaper and clearer.
The CV-623A also tests RVC, PWM, C, DFM, externally regulated and PD-controlled alternators.
An in-depth DFM tester is also built in, which displays the oset frequency of a DFM signal.
The test bench is CE marked for use in any workshop or workplace that demands safe and reliable
equipment.
Requirements installaon area:
The tester must be placed on a at and stable surface.
The oor must be solid enough to easily bear the weight of the tester!
Weight: 800 kg
Please leave an extra square meter at the front and sides free to ensure a good and safe working
environment.
Power supply
Connect the alternator tester to a 400 V three phase voltage supply. Each phase must be protected by a 32
A fuse.
Behind the front doors there is enough space to mount two 12 V baeries AGM with a capacity range of 40
to 100 ampere-hours (Ah) each. It is recommended that AGM baeries are used. They are designed to work
with Start-Stop systems, as they are more resistant to voltage uctuaons and there is no risk they will dry
out!
CAUTION!
The posive (+) and negave (-) poles must not be confused with each other. Otherwise, the alternator
tester can be damaged. The poles are well marked on the baeries as well as on the wires. When the
voltage is 24 V, the baeries are connected in series. Therefore, the baeries should be of the same brand,
type and condion (age and usage level). It is preferable to use baeries with a capacity of 70 Ah. During
every alternator test, the baeries are being charged and they should not become discharged. Nevertheless,
the baery charge level should be checked periodically. If the need arises, the baeries should be charged
by means of a recer. If the baeries are damaged, they must be replaced with new ones. Discharged
or damaged baeries can have a signicant inuence on the test and test results. Connect compressed
air supply on the back of the alternator tester. The compressed air of 8-10 bar is crucial for the pneumac
system controlling the tensioning of the drive belt. When the compressed air pressure is 8-10 bar, the drive
belt tension is about 1000 N.
Secon 1 – General informaon

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1Two-way pneumac belt tension valve 8Instrumental panel (manuel use)
2Power lead (+) 9Alternator mounng panel
3Addional socket (+) 10 Connecon panel
4Emergency stop switch 11 Instrumental panel
5Plaorm control up/down when the alternator is
mounted on the front
12 Secondary screen
6Insulated support (+) 13 Main screen
7Main switch
123 4 5 67
9
10
1.1 Front view:
Figure 1.
8
11
12 13

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2Compressed air connecon
3Data plate
1.2 Back view:
1.3 Main Specicaons:
Measurements
Width 120 cm
Depth 88 cm
Height 150 cm
Weight ca. 800 kg
(depending on the weight of the baeries)
Electric equipment
Motor Three-phase, supply voltage 600V, power 22kW/55A
Motor
RPM
“Le/right” switching, stepless speed control in the
range of 0-6000 RPM.
Inverter Winner V-60 15 kW/18.5 kW
Resistors 10 units with total current capacity of 600 A, step-
bystep load adjustment, including one with stepless
adjustment from 0-80 A.
Tester-alternator communicaon
A. Load indicator lamp 12 V/24 V (convenonal)
B. Digital (based on three types of BSS signals and 35
types of LIN signals used in cars from 2000 to 2018).
In the event of the introducon of new computer
alternator communicaon systems, the updates
with the latest command signals database will be
available.
C. Using informaon from the alternator about the
actual value of the rotor current (DFM+ and DFM-) –
aer pressing the DFM key, detailed frequency and
oset data on the COM display will appear.
D. Using C for Hyundai, Mitsubishi and Nissan and C1
signals characterisc for Honda.
Security and key safety informaon
This product fully complies with
actual CE requirements.
Safety and protecon elements MUST
NOT BE MODIFIED!
Main circuit breaker switch
Emergency stop switch
Safety cover lock protecon switch
Electric circuit wires
Metal safety cover
Figure 3.
Figure 2.

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Section 2
Panels
www.motoplat.nl

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COM Computer communicaon (API+) LIN or BSS
DFM- / DFM+ Informaon from the alternator about the present value of the rotor current in percentage depending on
the type of current control (current is transferred to the posive polarity brush (DFM+) or negave polari-
ty brush (DFM-)).
C
RLO
SIG
PWM control system used on Nissan, Hyundai and Mitsubishi applicaons.
Toyota “Sense” PWM control system.
PWM computer control signal used on Ford, Land Rover and Asian applicaons.
WFrequency- frequency [Hz] of W terminal or tacho
DRIVE Mazda alternator voltage control terminal.
PHASE/DRIVE (PD) Mazda control system (PHASE – output of the alternator phase).
B+ Posive connecon (connuous supply).
15 IGN, ignion or switched B+
GND Ground connecon.
LAMP Lamp connecon (convenonal terminal).
Fuse Automac 5A fuse used for protecon of connecon panel
F1/F2 External regulator connecon. The testbench is equipped with external regulator for alternators that
require this. Simply connect f1 and f2 terminals for alternator.(Chrysler)
Alternator test „Automac” pre-connected harness connecon(set included)
Only rev generator Reversible alternator harness connecon(Start/Stop units)
Regulator test Regulator test harness connecon. Connect regulator-less alternator for tesng the regulator (Set only
included with the CV-623A)
Scope Oscilloscope probe connecon(started from the soware for addional tesng)
2.0 Connecon panel descripon:

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2.1 Instrumental panel descripon:
ALT TEST alternator tesng mode
REG TEST regulator tesng mode
STARTER TEST starter tesng mode
CCW couter clockwise rotaon
CW clockwise rotaon
12V 12 volt seng
24V 24 volt seng
AUTO automac tesng mode
MANUAL manual tesng mod
2. Regulator Test (acve only if reg test is on)
4A/5A/6A/7A/8A- rotor resistance seng. To test a regulator, depending on rotor resistance. This will simulate the rotor
load or alternator load. It can be checked with mulmeter or on an alternator where you want to test the regulator. Set the
resistance (4A,5A,6A,7A,8A) that you get from the mulmeter (Alternator without regualtor is included only with the CV-623A
with harness set)
3. Alternator Test( acve only if alt test is on)
OFF turns alternator voltage o( for LIN and BSS only)
12,5/13,5/15,5 set voltage setpoint for and alternator, works only if pressed, if not the voltage setpoint is by default 14,5
( for LIN and BSS only)
MODE scroll through the control modes, select mode- Search(LIN and BSS), DFM, LAMP, PWM FORD LAND
ROVER, PWM SCANIA, PWM GM, C HYUNDAI/KIA, C HONDA, C NISSAN, PD MAZDA, RLO TOYOTA, B+B-
RST resets the regulator control computer and goes back to search( LIN and BSS only)
4. Starter test( acve only if starter test is on, or IST(start/stop) type alternator is connected)
Vmeter connect wire to the starter eld, between motor and selenoid to measure voltage drop
STARTER connect to solenoid 15(switch connecon)
STARTER BUTTON starts the starter test, works for 3 sec. only.

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5 START and STOP buons
START start the test in both automac and manual mode. Note that when „start” is pressed, the general seng
buons are locked, unll „stop” is pressed.
STOP stop the test in both automac and manual mode
6. FCN/+/-/OK
NOT IN USE (for future use and upgrades)
7. Charging lamp
If lamp alternator is connected, it should be on, when alternator is charging it should be o
2.2 Instrumental panel (manual) descripon:
IN USE FOR MANUAL MODE ONLY
1. LOAD
Set alternator load in 12 steps of 50amps each(from 0A to 600A)
2. 0A-50A
Stepless regulaon of Load between 0A and 50A
Only funcons when the „LOAD” knob is in the rst or any other poson except the rst.
3. RPM
Stepless „revoluon per minute” regulaon (only to be used in „Manual Mode”)

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Section 3
Alternator
Mounting
www.motoplat.nl

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Secon 3 – Alternator – mounng
3.0 Intro:
Depending on the construcon of the alternator, it can be mounted on the alternator tester in such a way
that it can be powered directly by the motor (direct drive) by means of proper connecng elements or
belt (side mounng). All the parts needed to mount the alternator are included in the tooling equipment
accompanying the alternator tester. Aer mounng the alternator, connect it to the electric circuit of the
alternator tester. This diers per alternator: please refer to our webshop www.psh.nl or other.

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4.1 Side mounng
In order to mount the alternator on the side of the alternator tester, use a plaorm that is placed on the
le side of the alternator tester. In the case of alternators with a pad mounng soluon, rst aach a
support that is placed on the side of the alternator tester with spindles that have the correct diameter. The
spindles are also placed on the side of the alternator tester (Photo below).
Next, mount the alternator by pung appropriate spindles into the holes that are placed on both sides of
the support (Photo below).

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To mount alternators that are longitudinally mounted, use only spindles (with the correct diameter)
without the support (Photo below).
3.2 Connecng the alternator
Aer mounng the alternator, connect it to the electric circuit of the alternator tester. Connect the power
lead to the posive terminal of the alternator B+ (2, Figure 1). Then, depending upon whether it is a
computer-controlled alternator or a convenonal one, use the correct connectors and buons on the
connect and control panel (21, Figure 1).

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Section 4
Software
www.motoplat.nl

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1. Main screen
Main screen of the soware. We have 3 dierent main screens for 3 dierent tests( alternator test, starter test, regulator test).
Chosen test procedure(alternator/starter/regulator) is shown on the orange eld below the „main screen” buon. Shows
basic informaon of ( alternator/starter/regulator).
2. Detailed informaon
Go to detailed informaon. Contains all the parameters of alternator in real me during the test.
3. Informaon LIN-BSS
Detailed informaon about LIN and BSS type alternator, connecon denion.
4. Results
Results table that is lled during and aer the test. Possibility to print or save report as pdf.
5. Start
Start the test procedure.
4.0 PC Soware

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6. Stop
Stops the test procedure.
7. Add alternator
Wizard to add alternator to the database. Simply connect desired alternator and follow the instrucons step by step on the
screen. Aer the test is done it will be added to test-bench database for further comparison test.
8. Alternator list
Alternator database. It contains all the alternators that are saved in database for comparison tesng.
9. Select model
Select regulator control method see “instrumental panel” paragraph above “Modes”.
10. Comparave test
Quick test to compare 2 alternators without adding it to database.
11. Test sengs
Choose test procedure: slow (Endurance test), standard (default), fast (Producon) and „user” test. User test- test parameters
can be custom dened by the user.
12. Oscilloscope
Start oscilloscope soware (picosope built-in).
13. Selecon
Field showing test sengs and part number of an alternator from database (if chosen).
14. Diameter
Set the actual alternator pulley diameter
15. Voltage
Load voltage set-point seng. (Default seng is 13,5) Can be edited.
16. Delay
Set me delay for alternator with so-start.
17. Text eld
Shows current test informaon, pass/fail.

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4.1 Detailed informaon
This screen shows detailed informaon about the tested alternator and test bench
System alternator system
Voltage regulator manufacturer of voltage regulator (com alternator only)
Com code code of the LIN/BSS regulator
Transmission speed com regulator speed (Bauderate 9600 or 19200Kb)
Cycle me test procedure duraon
Com rpm Start/stop alternators send rpm informaon in com transmission
Electrical error electrical error send by regulator
Mechanical error mechanical error reported by regulator
Temperature error thermal error reported by regulator
Scania test yes/no 24V PWM alternator test for RVC/PWM controlled 24V units
Voltage/duty refers to Scania test shows voltage/duty cycle in 24V PWM test
Requested voltage shows requested voltage demanded from the test bench
Voltage set point shows voltage set-point of regulator
C regulaon „C” alternator funcon
Quiescent voltage Inial baery voltage of the test bench before the test starts

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This screen shows detailed informaon about the tested alternator and test bench
Ripple shows the ripple of alternator in Amps
Eciency eciency of alternator shown in %
Torque max torque in Nm used during the test
Motor power Power[kW] of motor used during the test
Operaon mode „auto” or „manual”
Selected voltage show if 12V or 24V is selected
Direcon direcon rotaon of the motor CW or CCW
Auto report print on/o if on the report will be printed automacally aer every test
Serial number Siemens PLC soware serial number
Version Siemens PLC so version
System version Siemens PLC system version
VC-07 version “07” upgrade version
VC07 keyboard instrumental panel soware version
Counter number of tests ran by the test bench