Waekon PWM Power Pro 78065 User manual

User Guide

2
Safety Information
Before using this equipment, carefully read, understand and follow instructions and safety messages
on equipment and in this guide.
This guide cannot anticipate or provide advice and cautions for all situations encountered by
technicians. With this in mind, always follow and refer to the manuals provided by the manufacturer
of the vehicle or equipment being tested or used for all information and testing procedures whenever
diagnosing, repairing or operating such vehicle or equipment.
Failure to follow the instructions, cautions and warnings provided here as well as those provided by the
vehicle and equipment manufacturers can result in re, explosion, bodily injury and property damage.
In addition to the information listed below, additional warnings and cautions are listed throughout the
guide. Please read them carefully.
Fuel vapors are toxic and explosive, which can cause severe injury or death.
• Useproperventilationtoavoidbreathingfuelvapors.
• Minimizecontactwiththeskinwiththeuseofgloves(suchasnitrilegloves)whenthereis
possibility of getting methanol fuel on your hands.
• Iftheskinisdirectlyexposed,washtheareaimmediatelyandchangeanyclothesthathave
become wet with fuel.
• Alwayswearapprovedsafetyglasseswhentesting.Shouldfuelgetintoeyes,usheyes
immediately with water and consult your physician.
Vehicles emit ammable vapors which can ignite.
• Keepames,sparks,cigarettesandotherignitionsourcesawayfromthevehicleatalltimes.
• Incaseofre,neverusewatertoghtamescausedbymethanolormethanolblendedgasoline.
Thiswillcausetheamestospreadinsteadofextinguishingthem.
• Useadrychemicalextinguishertoghtames(preferablyonemarkedABC,thoughBCis
acceptable).AfoamextinguisherisacceptableonlyifitisARFgrade,whichisresistanttoalcohol.
Before beginning any tests, make sure the test environment is safe and the vehicle meets these conditions:
• Testareashouldbewellventilated.
• Vehicleshouldbeinpark.
• Wheelsshouldbeblocked.
• Engineshouldbeatnormaloperatingtemperature.
• Vehicleshouldhavenormalexhaustow.
• Keepalltestercablesclearofexhaustmanifoldsandradiatorfanblades.
• Usecautionwhentestingonavehiclewhiletheengineisrunning(surfacesmaybecomehot,
electriccoolingfansmayturnonunexpectedly,etc.)

3
Contents
Overview ......................................................................................... 4
PWMPowerProComponents....................................................................................... 4
UsingtheControlsandConnections ......................................................................... 5
Using the PWM Power Pro.............................................................. 6
TwoWireTesting&HookupProcedure ..................................................................... 6
OneWireHookupTesting&HookupProcedure.................................................... 7
FuseBoxTesting&HookupProcedure...................................................................... 8
TotalCircuitDemandTesting&HookupProcedure ............................................. 9
Error Codes & Specications........................................................ 10
ErrorCodes ........................................................................................................................10
Specications....................................................................................................................10
Contact Information..................................................................... 11
Warranty........................................................................................ 12

4
Overview
PWM Power Pro Components
Tester–Usedalongwiththesuppliedadapters,connectstothesuspect
component(standaloneoronvehicle)providingpowerandmeasuringcurrent
draw.ThetestercontrolstheselectedDutyCycle/PWMtothecomponentwhile
monitoring current usage.
Power Cable with Banana jacks – When used along with the Removable Power
Clips, connects to the vehicle’s battery to supply power to the tester. Banana
jacksalsoallowyoutouseanalternatepowersource.Note: Once it is connected to
power, the tester turns on automatically and performs a self test (the LED Readout and
the Error LED briey turn on). If the PWM Power Pro does not perform a self test, check
the battery voltage and/or polarity of the power cable hookup to the vehicle battery.
40A Test Leads –1redand1black.Usealongwithoneofthesuppliedexprobe
adapters or clips to connect the tester to the component you are testing.
Flex Probe Adapters and Clips – 2 female spade terminal probes, 1 male spade
terminal probes, and 2 alligator clips are included. The probes are used along with
the leads to connect to the component you are testing.
Optional 77202 Spade Flex Probe Kit and 77203 Round Flex Probe Kit (not
shown)–Bothkitscontainanassortmentofterminalprobestoprovidefora
larger coverage of connectors.
2–FemaleSpade
Terminal Probes
1–MaleSpade
Terminal Probes
2–AlligatorClips
2–3ft40ATestLeads
Tester
2Removable
PowerClips
PowerCable
BananaJacks

5
Overview
Using the Controls and Connections
Output Jack –Connecttheredtestleadhere.Outputspowerorgroundtodrive
the components that already have one side tied to the vehicle wiring.
LED Readout—Displaystheaveragecurrent(amperage)thecomponentisusing
atanydutycycle.Also,whenthereisanerror,itdisplaysatwodigiterrorcode
(seetherearpanelofthetesterforalistingoferrorcodesorrefertotheError Code
section in this guide for details.
Load Polarity Output Switch –Setsthedrivepolarityoftheoutputjackand
enablesthePWMcontrolknob.
Heat Sink–Usedtodissipateheatgeneratedduringtesting.
Ground Jack–Connecttheblacktestleadhere.Suppliesgroundforcomponents
thatneedatwowirehookup.
Error LED–Lightstoindicateanerrorandthattheoutputjackhasbeendisabled.
Also,theLEDreadoutdisplaystheerrorcode.Seetherearpanelofthetesterfora
listing of error codes or refer to the Error Code section in this guide for details.
PWM Control Knob–Setsthedutycycleofthesupplydeliveredtotheoutput
jackforvariableloadcurrent.
HeatSink
LEDReadout GroundJack
OutputJack
ErrorLED
PWMControlKnob
LoadPolarity
OutputSwitch
CAUTION! The Heat Sink can become
extremely hot during use. Therefore,
avoid contact with your skin or any of
the vehicle’s components.

6
Using the PWM Power Pro
Two Wire Testing & Hookup Procedure
Usethisprocedureforany
of the following conditions:
• Benchtesting
• Componentisstill
connected to the vehicle
but is disconnected from
the vehicle’s harness.
Procedure
1. SettheOutputPolarity
SwitchtotheOFF
positionandthePWM
ControlKnobtoOFF.
2. Connectthetester’s
power cable to the battery. The tester will power up and perform a self
test.Oncethetestiscompleted,theLEDReadoutdisplaysazero.Note:
If the unit becomes unresponsive, remove and reconnect the power cable
connections to the battery.
3. Selecttheprobes(orclips)thatmostcloselymatestothecomponentsand
then connect to the test leads.
4. Plugtheredtestleadintotheoutputjackandtheblacktestleadintothe
groundjack.IMPORTANT! To avoid possible damage, do not let the tips of the
leads touch once they are connected to the tester.
5. Disconnectthecomponentfromthecircuitandconnectthepositive(+)
andnegative(–)leadstothecomponentperthevehicle’sshopmanual.
6. SettheOutputPolaritySwitchto+androtatethePWMControlknobto
increase(ordecrease)theamount(%)desiredtotestthecomponent.The
amountofcurrentthecomponentisdrawingisdisplayedintheLEDReadout.
•For best duty cycle control on smaller loads (<2A), connect one side of the
component to power and the other side to the output jack. Set the lead
polarity to (–) minus.
• Forreversingmotorssuchaspowerwindowsandlocks,reversethetest
leads to drive the motor in the opposite direction.
7. Makenoteoftheresultsandrefertothespecificationslistedinthevehicle’s
shop manual to determine the course of action needed for repairs.
+
–
OUTPUTOUTPUT
Tester RedTestLead
Component
VehicleHarness
BlackTest
Lead
IMPORTANT! The tester GROUND JACK
is not protected. If connected to the
battery’s positive ( + ) terminal, it will
fail and become inoperable (see Error
Code 04).

7
Using the Power Pro
One Wire Hookup Testing & Hookup Procedure
Usethisprocedurefor
in-circuit testing a
component connected to
a harness.
Procedure
1. SettheOutputPolaritySwitchtotheOFFpositionandthePWMControl
KnobtoOFF.
2. Connectthetester’spowercabletothebattery.Thetesterwillpower
upandperformaselftest.Oncethetestiscompleted,theLEDReadout
displaysazero.Note: If the unit becomes unresponsive, remove and reconnect
the power cable connections to the battery.
3. Selecttheprobethatmostcloselymatestothecomponent’sharnessand
connect it to a test lead.
4. Plugthetestleadintotheoutputjack.
5. Connecttheoutputleadtothecomponentbybackprobingthedriveside
of the component per the vehicle’s shop manual.
6. SettheOutputPolaritySwitchto+or–basedonthecomponent’scircuit
operationperthevehicle’sshopmanualandrotatethePWMControlknob
toincrease(ordecrease)theamount(%)desiredtotestthecomponent.
TheamountofcurrentthecomponentisdrawingisdisplayedintheLED
Readout.
7. Makenoteoftheresultsandrefertothespecificationslistedinthevehicle’s
shop manual to determine the course of action needed for repairs.
OUTPUTOUTPUT
Tester
TestLead
Component
Vehicle
Harness

8
Using the Power Pro
Fuse Box Testing & Hookup Procedure
Usethisprocedurefor
fusebox/relaytesting. OUTPUTOUTPUT
TestLead
Component
Tester
Fuse/Relay
Box
Procedure
1. SettheOutputPolaritySwitchtotheOFFpositionandthePWMControl
KnobtoOFF.
2. Connectthetester’spowercabletothebattery.Thetesterwillpower
upandperformaselftest.Oncethetestiscompleted,theLEDReadout
displaysazero.
3. Connectthemalespadeterminaltoatestlead.
4. Plugthetestleadintotheoutputjack.
5. Removethefuse(orrelay)andconnecttheoutputleadtothecomponent
side of the fuse or relay per the vehicle’s shop manual.
6. SettheOutputPolaritySwitchto+androtatethePWMControlknobto
increase(ordecrease)theamount(%)desiredtotestthecomponent.The
amountofcurrentthecomponentisdrawingisdisplayedintheLEDReadout.
7. Makenoteoftheresultsandrefertothespecificationslistedinthevehicle’s
shop manual to determine the course of action needed for repairs.

9
Using the Power Pro
This procedure uses the same hookup as the Fuse Box Testing Procedure
Total Circuit Demand Testing & Hookup Procedure
1. SettheOutputPolaritySwitchtotheOFFpositionandthePWMControl
KnobtoOFF.
2. Connectthetester’spowercabletothebattery.Thetesterwillpower
upandperformaselftest.Oncethetestiscompleted,theLEDReadout
displaysazero.
3. Connectthemalespadeterminaltoatestlead.
4. Plugthetestleadintotheoutputjack.
5. Removethefuse(orrelay)andsettheOutputPolaritySwitchto+and
rotatethePWMControlknobto100%.
6. Probe the component side of the suspect circuit fuse or relay with all of
thecomponent(s)turnedon(oroff,asdesired).Determinethedemandby
readingtheampsdisplayedintheLEDReadout
7. Makenoteoftheresultsandrefertothespecificationslistedinthevehicle’s
shop manual to determine the course of action needed for repairs.

10
Error Codes & Specications
Error Codes
ErrorcodesareindicatedbythelitRedLEDlocatedonthefrontofthetesteralongwith
atwodigitcodedisplayedintheLEDReadout.Usethefollowingcharttodetermine
thecauseoftheerrorcodeandthecourseofactionyouneedtotake.To clear an error
code,settheLoadPolarityswitchtotheOFF position.
Error
Code Required Action
01 Over Temperature — Turn the tester o and allow to cool. Prolonged
high current usage can cause overheating as well as damage to the load
under test. CAUTION! The Heat Sink can become extremely hot during use.
Therefore, avoid contact with your skin or any of the vehicle’s components.
02 OverCurrent—Excessivecurrentdrawmaybecausedbyhighstart-
updemandonthecomponentbeingtested.Startfrom0%and
slowlyincreasethecurrent.OverCurrentcanalsobecausedbyfailing
component or excessive testing run time.
03 LowBattery—Thetesterdetectedlowbatteryvoltage.Checkthe
vehicle’sbatteryand/orconnections.
04 GroundJackInoperable—Thetesterdetected(atpowerup)thatthe
groundjackisopen.Thetesterisstillusablebutyoumustrunaseparate
groundjumper.TocorrecttheerrorthetestermustbesentintoHickok/
Waekonforservice
05 TimedOut—Toprotectthevehicle,theAuto-otimevarieswiththe
current.
Specications
PowerSupply 11–18VDC
OperatingCurrent <100mA
OutputCurrent 0–40A(highside/lowsidedrive
GroundJack 0–40A(unprotected)
CurrentDisplay 0–40A(0.1Asteps)
PWMRate 15kHz
PWMRange 0–100%duty
OverTemperature HeatSink>120°F(outputdisabled)
OverCurrent >40A(outputdisabled)
ContinuousOnTime 2minutes@40amps,10minutes@20amps,
25minutes@10amps,30minutes@5amps