Porsche training p90 electrical systems

AfterSales Training Electrical Systems P90 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Electrical Troubleshooting Logic - Do you understand how the electrical consumer is expected to operate? - Do you have the correct wiring diagram? - If the circuit contains a fuse, is the fuse okay & of the correct amperage? - Is there power provided to the circuit? Is the power source the correct voltage? - Is the ground(s) for the circuit connected? Is the connection tight & free of resistance? - Is the circuit being correctly activated by a switch, relay, sensor, microswitch, etc.? - Are all electrical plugs connected securely with no tension, corrosion, or loose wires? Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-ofworld English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2016 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne® Cayman®, Macan®, Panamera®, Speedster®, Spyder®, Tiptronic®, VarioCam®, PCM®, PDK®, 911®, RS®, 4S®, 718®, 918 Spyder®, FOUR UNCOMPROMISED®, and the model numbers and distinctive shapes of the Porsche automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc believes the specifications to be correct at the time of printing However, specifications, standard equipment and options are subject to change without notice Some options may be unavailable when a car is built Some vehicles may be shown with nonU.S equipment Please ask your authorized Porsche dealer for advice concerning the current availability of options and verify the optional equipment that you ordered Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P90 004 Edition - 10/16 Table of Contents Description Page Section – Basic Electricity Introduction Voltage Current Resistance What is a Circuit? Ohm’s Law Units of Measurement Types of Circuits Series Circuits and Ohm’s Law 10 Parallel Circuits 11 Series/Parrallel Circuits 12 Digital Volt-Ohm Meter 13 Voltage Testing 13 Amperage Testing 14 Inductive Clamp 15 Resistance Testing 15 Section – Electrical Components Introduction Switches Relays Resistors Lights Capacitors Inductive Sensors Temperature Sensors Photo Diode Potentiometers Hall-Effect Sensors Active Wheel Speed Sensors Solenoids 10 Electric Motors 10 Semiconductor 11 Diodes 12 Zener Diodes 13 Transistors 14 Section – Batteries, Starters and Generators General Information Battery Starter Starter Operation Generator Gateway Control Unit Electrical Systems Table of Contents Section – Control Units Control Units Function Flow Diagram Section – BUS Communications CAN Bus Networking Network Architechure Bus Logic MOST Bus Networking Boxster (981) Network Topology Cayman (981) Network Topology 911 (991) Network Topology 10 Cayenne (92A) Network Topology 11 Macan (95B) 12 Panamera (970) Network Topology 13 Section – Fuses & Relays Sports Cars (9x1) Cayenne (92A) Macan (95B) Panamera (970) 10 Panamera S E-Hybrid (970) 12 Section – PIWIS Tester Wiring Diagram Viewer Selecting Language Selecting Wiring Diagram Wiring Diagram Viewer/Functions Wiring Diagram Viewer Navigation Zooming the Wiring Diagram Lines (Wires) Selecting & Deselecting a Line/Filter Function Following the Line Routing into Another Wiring Diagram 11 Internal Circuitry 13 Connector View 14 Printing 15 Help 16 Operating Manual 17 Function Flow 18 Section – Worksheets Worksheet - Series Circuit Breadboarding Exercise Worksheet - Parallel Circuit Breadboarding Exercise Worksheet - Relay Circuit Breadboarding Exercise Worksheet - Transistor Circuit Breadboarding Exercise Section – Appendix Electrical Systems Basic Electricity Subject Page Introduction Voltage Current Resistance What is a Circuit? Ohm’s Law Units of Measurement Types of Circuits Series Circuits and Ohm’s Law 10 Parallel Circuits 11 Series/Parrallel Circuits 12 Digital Volt-Ohm Meter 13 Voltage Testing 13 Amperage Testing 14 Inductive Clamp 14 Resistance Testing 15 Electrical Systems Page 1.1 Basic Electricity Introduction Electrical power is essential for the operation of today’s vehicles Electrical energy must be available to provide enough power to operate the control units, sensors, motors, and accessories on the vehicle When the vehicle is not operating, there must be sufficient power to monitor certain systems, to provide power for accessories, and to allow the vehicle to be restarted Electricity is a form of energy similar to light, heat, mechanical and chemical energy Electricity has several advantages compared to these other forms of energy: • Large amounts of energy can be transported over long distances • It is easy to transform to other forms of energy, such as light, heat, mechanical and chemical • It can be used to operate electrical circuits and motors • It can be easily generated and stored (chemically in a battery) While mechanical systems are generally easily explained, electrical and electronic systems remain invisible while performing work This class will simplify electricity and electronics and assist you in testing, diagnosing and repairing Porsche vehicles What is Electricity? Nu cleus (1 Proto n) us (29 Proto ns cle ) Electron Nucleus Electron Hydrogen 29 Electrons Copper Protons and electrons have equal but opposite magnetic charges Opposite (or unlike) charges attract, so the negatively charged electrons are held in their orbits around the nucleus by their attraction to the positively charged protons in the nucleus Since neutrons have no electrical charge, they not affect this relationship Different elements have different numbers of protons, neutrons and electrons Hydrogen is the simplest atom with one proton, one electron and no neutrons Helium has two protons, two electrons and two neutrons, while copper has 29 protons, 29 electrons, and a varying number of neutrons An atom is balanced (and has a neutral charge) when the number of protons and electrons are equal For example, a balanced hydrogen atom has one proton and one electron A balanced copper atom has 29 protons, and 29 electrons Electricity is the movement of electrons from one atom to another In order to understand electricity, we need to look at atoms An atom is the smallest particle of matter Matter is anything that has mass (weight) and occupies space Matter that is made up of only one kind of atom is called an element Copper, aluminum and oxygen are examples of elements Matter that is made up of more than one kind of atom is called a compound Water (which contains the elements hydrogen and oxygen) is a compound Parts of an atom: • Electrons - Negatively charged particles orbiting around the nucleus • Protons - Positively charged particles in the nucleus • Neutrons - Uncharged particles in the nucleus Page 1.2 Nu Electrical Systems Basic Electricity Positive and Negative Ions Protons Neutrons N eutro oto Pr n s ns Atoms can sometimes lose an electron and become positively charged because of the greater number of protons These atoms are called Positive Ions Atoms can also pick up or gain extra electrons and become negatively charged These atoms are called Negative Ions Negative ions will attempt to repel extra electrons and positive ions will attempt to attract them Electrons Balanced Atom Valence Ring Electrons orbit the atom in distinct rings Each ring can hold a specific maximum number of electrons and each ring is located progressively further from the nucleus The outermost ring is called the valence ring The valence ring can hold a maximum of eight electrons Additional Electron N Protons Neutrons eutro ns Electrons in the valence ring determine the atom's electrical properties If the ring has fewer than four electrons, then these electrons can be easily forced from their orbits and the element is therefore a conductor of electricity Progressively fewer electrons in the valance ring make the material a better conductor (e.g., copper, gold) If the valence ring has more than four electrons, its electrons are hard to force from their orbits and the element is an electrical insulator Progressively more electrons in the valence ring make the material a better insulator (e.g., glass, plastic) Electrons Negative Ion Atoms with four electrons in the valence ring are a special case and are considered to be semiconductors (e.g., silicon) They can be made into either conductors or insulators by adding impurities These materials are used in the manufacture of diodes, transistors, and integrated circuit chips Notes: Protons Neutrons Missing Electron Electrons Positive Ion Electrical Systems Page 1.3 Basic Electricity Electricity Defined Movement of electrons (current) A flow of electricity is the movement of electrons from the valence ring of one atom to the valence ring of another atom When a large number of electrons move together in the same direction, an electric current flows This does not mean that a single electron will travel the entire length of a wire Rather, electrons flow from atom to atom, displacing other electrons in the valence rings as a large number of electrons all move in basically the same direction Valence Ring Atoms that lose valence electrons become positive ions, and atoms that receive extra valence electrons become negative ions The positive ion will draw one of the free electrons from from another atom and become balanced The process repeats as electrons move from atom to atom Notes: More than Electrons = Insulator Valence Ring Fewer than Electrons = Conductor Voltage is the force, or electrical pressure that makes valence electrons move from atom to atom When a voltage is applied, this happens to billions of atoms simultaneously Page 1.4 Electrical Systems Basic Electricity Voltage Voltage, or electromotive force (EMF) is the electrical pressure or potential created by the difference between positive and negative charges The greater the difference between the positive and negative charge, the higher the attraction, and the higher the voltage In a vehicle, the voltage is typically created by the battery (a chemical source of electricity) or the generator (an electromagnetic source of electricity) To illustrate this principle, compare electricity to a water system Electrical voltage is similar to water pressure The water in the pipe is under pressure when the valve is turned off, but water is not flowing Similarly, in an electrical circuit, there can be electrical pressure (voltage), but no flow of electrical current Current When there is a voltage (electrical pressure), and electrons are given a path to flow (a conductor), current flows Current is the actual flow of electrons as they move from negative ions to positive ions Since current is the movement of a negatively charged particle towards a positively charged particle, it moves from negative to positive This is called electron flow However, for many years, conventional electrical theory has described current flow from positive to negative This is the established standard in the automotive industry, and this is how we will refer to current flow in this class In the water system, water flows when the valve is opened The flow of water is similar to the flow of electric current Resistance A good conductor should not slow down or resist the flow of electricity In other words, a good conductor should have low resistance As we have said, good conductors have valence electrons that are easy to move from atom to atom Anything that opposes the movement of electrons through a conductor has resistance Resistance reduces the number of electrons that flow Using our analogy, the water pipe is a certain size and will allow a certain volume of water to flow If we add a restriction, we are effectively reducing the diameter of the pipe at that point and less water can flow This restriction is equivalent to electrical resistance In a circuit, voltage drops across each resistance when current flows, just like water pressure drops because of a restriction Voltage drops across each resistance only when current flows This will be discussed in greater detail when we discuss circuits Electrical Systems Page 1.5 Basic Electricity Various factors affect electrical resistance in a circuit: • Circuit length - Increasing the conductor length increases the resistance • Diameter (gauge) of conductor - Decreasing the conductor diameter (gauge) increases the resistance • Temperature - For most materials, increasing the temperature will increase the material’s resistance • Physical damage - Any damage will increase resistance • Material - Materials have a wide range of resistances Summary • The unit of measure for electrical pressure or potential is measured in Volts (V or E) • The unit of measure for current flow is the Ampere, or Amp (A or I) • The resistance of a circuit is measured in Ohms (W or R) In automotive circuits, the power supply or source of voltage is usually the vehicle battery or generator The circuit resistance could be many things: light bulbs, electric motors, resistors (these are loads, or devices that work in a circuit) The path or circuit itself may be insulated wires or it may be the the vehicle body or chassis The applied voltage in the circuit drops (or is “used up”) across each load or resistance in the circuit This is called Voltage Drop In a perfect circuit, all voltage drops will occur across the loads and not in wiring and connectors Most of the circuits that you will see have additional components such as switches, relays, connectors, etc., and will usually have a circuit protection device (a fuse or circuit breaker) to protect against short circuits and high current flow Switches and relays allow the current to be switched on or off by opening and closing the circuit Notes: What is a Circuit? A circuit is a complete path for electron (electrical current) flow A complete electrical circuit must have three things: • Voltage (electrical pressure, the “push” to move electrons in the circuit) • Resistance (a load or consumer, used to work and control current flow) • Conductors (wiring that forms a completed pathway between the power supply and the load) Resistance (Load) 12V Switch Conductor (wiring) When all three items are present, current (electrons) will flow in the circuit Page 1.6 Electrical Systems Worksheets Worksheet (Cont’d) Using the breadboard and supplied components, build the circuit on the previous page Do not apply power to the circuit yet When the circuit is complete, have your instructor inspect the circuit Operate the switch Do the lights illuminate? Turn the circuit switch OFF Install the ammeter at "A" in the circuit Remember that an ammeter is always used in series Turn the circuit switch ON and measure current in the base circuit (Remember that the base circuit is similar to the control circuit on a relay.) Turn the circuit switch OFF Install the ammeter at "B" in the circuit Turn the circuit switch ON and measure current in the collector circuit (Remember that the collector circuit is similar to the load circuit on a relay.) Turn the circuit switch OFF 10 Compare the base current to the collector current 11 Can you think of at least two uses for transistors in automotive circuits? Page 8.10 Electrical Systems Appendix Wiring Diagram Symbols Pin Relay Pin Relay Battery Condenser Spark Plug Dual Filament Bulb Single Filament Bulb Dual Winding Solenoid Single Winding Solenoid Electronically Controlled Relay Fuse Ignition Coil Instrument (Gauge) Motor Motor With Potentiometer Push Button Switch Resistor Solenoid With Valve Solid State Device Steering Wheel Contact Wires Not Connected Wires Connected Diode LED - Light Emitting Diode Flags Weld Point Pressure Switch Connector (Multiple Pins) Connector (Single Pin) Electrical Systems a - In b - Out c - Bi-directional Module, Component, ECU Page 9.1 Appendix Wiring Diagram Symbols Double Contact Switch Options Page 9.2 Brake Pad Sensor Wiring Harness Bundle Speaker PTC - Positive Temperature Coefficient Shielded Wires Electrical Systems Twisted Pair Version A Twisted Pair Version B Antenna Bridge Plug Appendix Wire Color Codes DIN Standards English and German Abbreviations BK SW Black BN BR Brown BU BL Blue GD Gold GN GN Green GY GR Grey OG OR Orange PK RS Pink RD RO/RT Red SR Silver TQ TK Turquoise VT VI Violet WH WS White YE GE Yellow DIN Standards for Terminal Designations The following are examples of the common Porsche DIN list for terminal designations: 1a 1b 4a 4b 15 American Wire Gauge (AWG) Conversion to Metric 15a The conversion from AWG to Metric (mm2) is shown below 17 19 30 AWG 22 20 18 16 14 12 10 2 mm2 0.35 0.50 0.75 1.00 1.50 2.50 4.00 6.00 16.0 25.0 35.0 30a 30F 30SD 30TP 31 31b 31a 31c Electrical Systems Ignition coil, ignition distributor - Low voltage To contact breaker I (Ignition distributor with two separate circuits) To contact breaker II (Ignition distributor with two separate circuits) Ignition coil, ignition distributor - high voltage From ignition coil I (Ignition distributor with two separate circuits) From ignition coil II (Ignition distributor with two separate circuits) Switched (+) downstream of battery (output of ignition/driving switch) Output at ballast resistor to ignition coil and starter Glow plug and starter switch - Start Glow plug and starter switch - Preheat Input from battery (+) term., direct 12/24 V series-parallel battery switch Input from (+) terminal of battery II Power circuit controlled by Main Fuse Box shut down when there is a fault in the energy management system and when the vehicle has been quiescent for a sufficient period Power circuit controlled by Main Fuse Box supplys the power sockets in the vehicle interior shut down when the vehicle has been quiescent for a sufficient period Power circuit controlled by Main Fuse Box curcits are shut down during transport or controlled by 30F relay Battery negative terminal, or ground, direct Return line to battery negative terminal, or ground via switch or relay (switched negative) Return line to battery II, negative (12/24 V series-parallel battery switch) Return line to battery I, negative (12/24 V series-parallel battery switch) Page 9.3 Appendix Starting relay for sequential control of the engagement current during parallel operation of two starters Electric Motors 32 33 33a 33b 33f 33g 33h 33L 33R Return line Main terminal connection Self-parking switch-off Shunt field For second lower-speed range For third lower-speed range For fourth lower-speed range Counterclockwise rotation Clockwise rotation 50c 50d 50e 50f 50g 50h Input at starting relay for starter I Input at starting relay for starter II Start-locking relay Input Start-locking relay Output Start-repeating relay Input Start-repeating relay Output Wiper Motors Starters 45 Separate starter relay, output; starter, input (main current) Two-starter parallel operation - Starting relay for engagement current 45a 45b 48 Output, starter I, Input, starters I and II Output, starter II Terminal on starter & on start-repeating relay for monitoring starting Turn-signal Flashers (pulse generators) 49 49a 49b 49c Input Output Output, second circuit Output, third circuit 53 53a 53b 53c 53e 53I Lighting 55 56 56a 56b 56d 57a 57L 57R 58 Starter Control 50 50a 50b Page 9.4 Starter control (direct) Series-parallel battery switch - Output for starter control with parallel operation of two starters with sequential control Wiper motor, input (+) Wiper (+), self-parking switch-off Wiper (shunt winding) Electric windshield-washer pump Wiper (brake winding) Wiper motor with permanent magnet and third brush (for higher speed) 58b 58d 58L 58R Electrical Systems Fog light Headlight High beam, high-beam indicator light Low beam Headlight-flasher contact Parking light Parking light, left Parking light, right Side-marker, tail, license plate, and instrument panel lights Dimmer Dimmer License-plate light, left License-plate light, right Appendix Generators and Voltage Regulators Directional Signals (turn signal flashers) 61 B+ BD+ DDF DF1 DF2 U,V,W 75 76 C C2 C0 Alternator charge-indicator light Battery positive Battery negative Dynamo positive Dynamo negative Dynamo field Dynamo field Dynamo field Alternator terminals Radio, cigarette lighter Speakers C3 L R Indicator light Indicator light Main terminal connection for separate indicator circuits actuated by the turn signal switch Indicator light (e.g., when towing two trailers) Turn-signal lights, left Turn-signal lights, right Switches Break contact (NC) and changeover switches 81 Input 81a Output 1, NC side 81b Output 2, NC side Make contact (NO) switches 82 Input 82a Output 82b Output 82z Input 82y Input Multiple-position switches 83 Input 83a Output, position 83b Output, position 83L Output, left-hand position 83R Output, right-hand position Switching Relays 85 86 Output, actuator (end of winding to ground or negative) Input, actuator (start of winding) higher potential Relay contact for break (NC) and changeover contacts 30 87 87b Input Output NCC (normally closed contact) Output NOC (normally open contact) Electrical Systems Page 9.5 Appendix Glossary Actuator An output device that receives electrical signal commands and acts mechanically to change the system being controlled Biasing Applying voltage to a junction of semiconductor materials Body Ground Using the vehicle's body frame (chassis) or engine to ground a circuit Alternating Current (AC) A flow of electricity through a conductor, first in one direction, then in the opposite direction Breakdown Voltage The voltage above which a Zener diode will allow reverse current flow Alternator See Generator Ammeter A test instrument used to measure current flow (amps) Brush A spring-loaded block of carbon or copper that rubs against a commutator or slip ring to conduct current Typically used in alternators/generators and starters Amperage The amount of current (amperes) flowing through a circuit Buss Bar A solid metal strip or bar used as a conductor in a fuse panel Ampere (amps) A unit for measuring the rate of electrical current flow Capacitance The ability of two conducting surfaces, separated by an insulator, to store an electric charge Analog A voltage signal that varies relative to the operation being measured or controlled Analog Meter An electrical test meter that uses a spring-loaded needle and a magnetic field to indicate a circuit value on the meter's scale Armature The moveable part in a relay, or the revolving part of a generator or electric motor Atom The smallest part of any element that still has all the characteristics of that element Base The central layer or semiconductor material in a transistor Battery A component that produces electrical current (DC) through a chemical reaction between positive and negative lead plates submerged in a sulfuric acid solution Battery Voltage Voltage measured between a battery's positive and negative terminals Page 9.6 Capacitors (Condensers) Components composed of two conductor plates with a dielectric between them Capacitors are used to store electrical current or Electromotive Force (EMF) Cell In a battery, one of the cases containing a set of positive and negative element suspended in electrolyte Each battery cell produces 2.1 to 2.2 Volts, and are connected in series Circuit (Closed Circuit) A complete path from the voltage source to an electrical load or device and back to the voltage source through a ground A circular or unbroken path through which electric current can flow Circuit Breaker A device that protects a circuit from excess voltage (overload) Coil Any electrical device or component consisting of wire loops wrapped around a central core Cold Cranking Amps A system that rates a battery by the amount of current it produces at -17° C (0° F) Electrical Systems Appendix Collector The outside layer of semiconductor material in a transistor that conducts current away from the base Digital Volt/Ohm Meter (DVOM) An electrical testing device that measures volts, amps, ohms, and displays results in a digital readout Commutator A segmented ring attached to one end of an armature in a direct current generator or motor, providing the electrical connection between the armature and the brushes In a generator, it rectifies the alternating current In a motor, it provides a direct current path to the armature Diode A semiconductor device made of P-material and N-material bonded together at a junction A diode allows current flow in one direction, while blocking current flow in the other direction Conductor A substance, usually metal, in which an electric current will flow easily Current flow is possible because of the many free electrons in the substance Connector A device that joins two conductors Contact One of the current-carrying parts of a relay or switch that engages or disengages to open or close an electrical circuit Continuity A continuous or unbroken circuit Conventional Theory The current flow theory that describes electron flow from the positive to negative Current The flow of electrons through a conductor measured in amperes Cycling Battery electrochemical operation from a charged state, to a discharged state, and back Depletion Region An area near the junction of a diode where P-material is depleted of holes, and N-material is depleted of electrons Dielectric The insulating material between two conductive plates in a capacitor Digital Multimeter (DMM) An electronic test instrument that can measure volts, amps, and ohms; same as a DVOM Digital Signal A voltage signal that has only two states: on/off, or high/low Direct Current (DC) A flow of electricity in one direction through a conductor Doping The addition of a small amount of a second element to a semiconductor element Draw The amount of current a given resistance will pull or conduct with a given voltage Draw increases with low resistance and decreases with high resistance Duty Cycle The percentage of the total time that a solenoid is energized during pulse width modulation, as determined by a timed voltage pulse from a control unit Electricity The movement of electrons from one body to another Electrolyte The chemical solution in a battery that conducts electricity and reacts with the plate materials to produce electricity Electromagnet A soft iron core wrapped in a coil of a current-carrying conductor When current flows through the conductor, a magnetic field is created Electromagnetic Induction The creation of voltage within a conductor when relative motion occurs between the conductor and a magnetic field Electromagnetic Interference (EMI) An undesirable form of electromagnetism created by rapid changes in field strength when current starts and stops Electromotive Force (EMF) The force that causes electrons to move from one atom to another atom Electrical Systems Page 9.7 Appendix Electron A negatively charged particle of an atom Electron Theory The current flow theory that describes electron flow from the negative to positive Emitter The outside layer of semiconductor material in a transistor that conducts current to the base Equivalent Resistance The total resistance of a parallel circuit The single mathematical equivalent of all the parallel resistance Farad The unit of measurement used in measuring capacitance Field Circuit The charging system circuit that delivers current to the alternator field Flux Density The number of flux lines in the magnetic field area The more flux lines, the stronger the magnetic field at that point Forward Bias The application of a voltage to produce current flow across the junction of a semiconductor Free Electrons Three or fewer electrons in an atom's outer orbit (valence ring) Free electrons are easily forced out of orbit, allowing them to flow in a conductor Full Wave Rectification A process by which all of an AC sine wave voltage is rectified and allowed to flow as DC Fuse A circuit protection device containing a metal strip designed to melt at an excessive voltage (overload) opening the circuit Fusible Link A circuit protection device consisting of a piece of wire smaller in size than the wire in the protected circuit, An overload causes the link to melt, opening the circuit Gage An alternate spelling of "gauge," sometimes used when referring to wire size to avoid confusion with automotive gauges Page 9.8 Ganged Switch A switch having two or more wipers that operate in unison from a single contact Gauge An instrument panel display used to monitor engine conditions; also a measurement of wire size Generator An engine-driven component that produces electric current through magnetism by converting rotary motion into electricity Ground The portion of a circuit that completes the path back to the voltage source after the load Ground Cable Battery cable connecting the negative pole to the chassis Ground-Side Switch A circuit where the switch is located between the load and the ground Half Wave Rectification A process by which only one-half of the AC sine wave voltage is rectified and allowed to flow as DC Hall Effect Switch A signal generating switch that develops a transverse voltage across a current carrying semiconductor, when subjected to a magnetic field Harness A group of electrical wires bundled together for neatness or ease of handling Hold-In Winding The coil of a small-diameter wire in a solenoid that is used to create a magnetic field to hold the solenoid plunger in position within the coil Hole In an atom, the space in the valence ring where another electron could fit Impurities The doping elements added to pure silicon or germanium to form semiconductor materials Induced Voltage The voltage that appears in a conductor when relative motion occurs between it and magnetic flux lines Electrical Systems Appendix Induction The creation of an electrical current in a conductor caused by passing the conductor through a magnetic field Momentary Contact Switch A switch with a spring-loaded contact that keeps it from completing (or breaking) a circuit except when the button is pressed Insulator A non-conducting substance that oppose electron flow because of their many bound electrons (lack of free electrons) Used to prevents leakage of electricity from a conductor Mutual Induction Creation of voltage in one conductor by the rise and collapse of the magnetic field surrounding another conductor Ion An atom which is unbalanced due to losing or gaining an electron It can be positively or negatively charged Ionization The process of making an atom positively charged by losing an electron or negatively charged by gaining an electron Jumper Wire A length of wire used to form a temporary connection between two points in a circuit Junction The area where two types of semiconductor materials (N- and P-material) are joined Junction Box A box in which connections are made between different wires or cables See Pin-out Box Lead A connecting wire, such as a test lead, or a battery lead Light Emitting Diode (LED) A gallium-arsenide diode that emits energy as light Negative Temperature Coefficient (NTC) A type of resistor that has increasing resistance as the temperature decreases (and conversely, decreasing resistance as the temperature increases) Neutral Junction The center connection of the three windings in a Ytype stator Neutron A particle in an atom that has no charge and is electrically neutral N-Material A semiconductor material that has excess (free) electrons because of the type of impurity added It has a negative charge and will repel additional electrons Normally Closed (NC) When the rest position of the switch closes the circuit Normally Open (NO) When the rest position of a switch opens the circuit Nucleus The center core of an atom, comprised of protons and neutrons and has a positive charge Load Any device that converts electrical current into light, heat, or motion to perform work in an automotive electrical system Ohm The unit for measuring electrical resistance When one volt pushes one ampere through a circuit, the resistance present is one ohm Abbreviated by the Greek capital letter Omega (W) Magnetic Field The area surrounding a magnet that is influenced by the magnet's energy Ohmmeter A testing device used to measure resistance to current flow in a circuit, measured in Ohms Magnetic Shunt A piece of metal on a voltage regulator coil that controls voltage output at varying temperatures by affecting the coil's magnetic field Ohm's Law A series of formulas that express the relationship among volts, amps, and resistance in an electrical circuit When any two values are known, the third can be calculated using the formula V = A x R Electrical Systems Page 9.9 Appendix Open Circuit A condition where the circuit path is broken and current cannot flow Parallel Circuit A circuit that has more than one path through which current can flow Peak Inverse Voltage (PIV) The highest reverse bias voltage that can be applied to a junction of a diode before its atomic structure breaks down and allows current to flow Potentiometer A variable resistor with three terminals Return signal voltage is taken from a terminal attached to a moveable contact that passes over the resistor Power-Side Switch A circuit where the switch is located between the voltage source and the load Primary Windings The coil windings made of a few turns of heavy wire that uses battery current to create a magnetic field Permeability A measure of the ease or difficulty with which materials can be penetrated by magnetic flux lines Iron is more permeable than air Printed Circuit A circuit in which the interconnecting wires have been replaced by conductive strips printed or etched onto an insulating board Photoelectricity Voltage caused by the energy of light as it strikes certain materials Proton A positively charged particle found within the nucleus of an atom Piezoelectricity Voltage caused by physical pressure applied to the faces of certain crystals Pull-In Winding The coil of large diameter wire in a solenoid used to create a magnetic field to pull the solenoid plunger into the coil Pin-out Box A box in which connections are made between different wires or cables P-Material A semiconductor material that has holes for additional electrons because of the type of impurity added It has a positive charge and will attract additional electrons Polarity Having poles, such as the north and south poles of a magnet The poles of a battery or an electrical circuit are its positive and negative poles Pole The areas of a magnetized body where the lines of magnetic force are concentrated One end of a magnet Positive Charge An electrical charge with fewer electrons than normal Potential Voltage between two points Latent or unreleased electrical energy Page 9.10 Rectification The process that changes Alternating Current (AC) into Direct Current (DC) Reference Voltage (VREF) A constant source of voltage regulated and supplied from a control unit Regulator A device used to regulate the output of a generator or alternator by controlling the current and voltage Relay A switch consisting of a control and a power circuit that uses a small current to control a larger current Resistance The opposition to current flow through an electrical circuit, measured in ohms Resistor A device used to limit current flow in an electrical circuit due to its high resistance Electrical Systems Appendix Rheostat A variable resistor with a moveable wiper that increases or decreases resistance as the wiper moves away from or toward the source voltage Used to control a load Sensor A device that provides input data in the form of a voltage signal to a control unit Specific Gravity The weight of a volume of liquid divided by the weight of the same volume of water at a given temperature and pressure Water has a specific gravity of 1.00 Splice A joining of two or more wires permanently without the use of a connector Series Circuit One path for current to follow Stepper Motor A DC motor that moves in incremental steps from deenergized to fully energized Series-Parallel Circuit A circuit arrangement that combines two or more loads in parallel, with one or more loads in series Switch A mechanical or electrical device that breaks or completes the path of the current in an electrical circuit Short Circuit (Short) An unintentional routing of current, bypassing part of the original circuit Temperature-Sensitive Switch A switch containing a bi-metallic element that completes or breaks a circuit when the switch is heated to a certain temperature Short To Ground A condition in which an unwanted path is created between the positive side of a circuit and the ground side Short To Power A condition in which an unwanted path for power to a load is present Signal An electrical quantity that conveys information from one point to another Single Wire The wiring system used in most automobiles in which one wire carries current to the load and the vehicle's frame acts as the return path (ground) to the source voltage Solenoid An electromagnet with a moveable core or plunger that converts electrical current into mechanical motion Source The field-effect transistor (FET) which supplies currentcarrying holes or electrons (similar to the emitter of a bipolar transistor) Thermister A Negative Temperature Coefficient resistor Thyristor A silicon-controlled rectifier (SCR) that normally blocks all current flow A slight voltage applied to one layer of its semiconductor structure will allow current flow in one direction while blocking current flow from the other direction Transducer A device that converts one form of energy into another For example, a sensor that converts light into voltage Transformer A device for transforming an electric current to a higher or lower voltage without changing the total energy Two-Wire Circuit A wiring system that uses a second wire instead of the chassis as a return path to the source voltage Valence Ring The outermost electron shell in an atom Variable Resistor A resistor with a range of resistances available through two or more taps and a moveable control Volt The unit used to measure electrical force or pressure in a circuit Electrical Systems Page 9.11 Appendix Voltage The electrical pressure in a circuit Voltage Drop The change in electrical pressure (voltage) between two points in a circuit, caused by the loss of electrical pressure as current flows through resistance The amount voltage drops between two points in a circuit is determined by the resistance of the circuit and the number of loads in the circuit Voltmeter A testing device for measuring voltage in an electrical circuit Watt The unit used to measure electrical power or "work." Wattage The power rating of a component Calculated by multiplying voltage times amps (P = I x E) Wiper The moveable portion of a switch that establishes contact between the input and output poles Zener Diode A junction of semiconductor materials that has been heavily doped so that the junction will allow reverse current flow without damage at any voltage above a specified value Page 9.12 Electrical Systems Part Number - PNA P90 004 ... CA T 00 V ! 1000V MAX II M AX 10 resistor 12 v Notes: Electrical Systems Page 1.15 Basic Electricity Notes: Page 1.16 Electrical Systems Electrical Components Subject Page Introduction ... 15 Electrical Systems Page 1.1 Basic Electricity Introduction Electrical power is essential for the operation of today’s vehicles Electrical energy must be available... operate electrical circuits and motors • It can be easily generated and stored (chemically in a battery) While mechanical systems are generally easily explained, electrical and electronic systems