Overview of the MECP Program The Mobile Electronics Certified Professional (MECP) program is owned and operated by the Consumer Electronics Association (CEA). The program started in 1991 and serves as the only industry‐wide automotive electronics certifications program in the world. Since its founding, MECP has certified over 40,000 professionals and currently boasts over 3,900 active certifications. MECP‐certified professionals can be found in installation bays, retail outlets, and with electronics manufacturers throughout the United States and around the world. Levels of MECP Certification Basic Installation Technician: The MECP Basic level is meant as an “apprentice level” certification for those that have limited or no experience in the automotive electronics industry. The intent of this certification is to demonstrate a candidate's ability to understand the fundamentals required on the job. It is expected that the individual will follow the exam by gaining on‐the‐job experience and challenge themselves to move on to the next level. This certification is valid for two (2) years. Advanced Installation Technician: The MECP Advanced level is intended for technicians who have at least one year of on‐the‐job professional experience in automotive electronics. This certification level covers a greater depth of electronics and vehicle electrical systems, installation knowledge and technique, mobile audio and video systems, security and remote starters, in vehicle information systems, troubleshooting installations and more. This certification is valid for four (4) years. Master Installation Technician: The MECP Master level is meant to distinguish the “best of the best” in automotive electronics. This level requires three years of on‐the‐job experience and covers the electrical and troubleshooting aspects of the discipline, including Master‐level troubleshooting, audio, electronic components, OEM audio and video integration, security/remote start, wireless communications with modern technologies, and vehicle electrical systems. This certification is valid for four (4) years. Mobile Product Specialist (MPS): The MECP Mobile Product Specialist (MPS) Certification is for sales professionals in the industry. The purpose of this certification is to help sales people and installation technicians see eye‐to‐eye on many technical issues. This certification is intended to empower the sales people who go beyond the act of "selling boxes" to understand system design, some very basic electrical concepts, audio, video, security, remote starters, and navigation, as well as identifying what customers are Guide Prometric Proctored Level telling them. This certification is valid for four (4) Cost Test Cost Test Cost years. Basic $35 $85 $60 Advanced $55 $105 $80 Master $75 $125 $100 MECP Testing MPS $35 $85 $60 For each level of certification, there is a corresponding study guide and exam. Technicians are encouraged to purchase a study guide as this is the most effective way to study for and pass an exam. Passing the MECP exam with a score of 70 or better on each section is required to achieve certification. There are two ways to take an MECP exam. Technicians can make an appointment at any one of thousands of Prometric testing centers throughout the US. Technicians also have the option of arranging for a proctored test at an industry training school, public library or similar location. Test takers wishing to take a proctored test should contact mecp@mecp.com for more information. MECP tests are 100% supervised and computer‐based. Contact MECP Any questions about MECP should be e‐mailed to mecp@mecp.com. Answers to many basic questions can be found on our website at www.mecp.com. Study Guide Sample Pages Basic Installation Technician Study Guide Table of contents Introduction MECP Basic Installation Technician Study Guide Introduction.......12 Job Descripton – MECP Basic Installation Technician ....................13 What is an MECP Basic Installation Technician… And What Does it Mean to You?.....................................................17 The MECP Basic Installation Technician Exam and How it was Developed..............................................................19 How and Where to Take MECP Exams...........................................21 Reading the Study Guide and Preparing for the Exam.....................23 Notes About Registering, Scheduling, Rescheduling, or Cancelling an MECP Exam..............................................................24 How to Take the Exam....................................................................28 After the Exam.................................................................................29 Records Transfer..............................................................................30 MECP Database Access....................................................................30 Contacting MECP............................................................................33 CHAPTER 1. BASIC ELECTRONICS AND VEHICLE ELECTRICAL SYSTEMS Electrical Circuit Basics...................................................................36 Understanding Voltage, Current and Resistance..............................38 Series and Parallel Total Resistance Formulas . ...............................50 Electrical Power (Watt’s Law)..........................................................54 Ohm’s Law Quick Reference............................................................59 Kirchhoff’s Laws..............................................................................60 Electronic Components ..................................................................66 Batteries as a Voltage Source...............................................66 Switches ...........................................................................67 Resistors ............................................................................69 Potentiometers....................................................................72 Incandescent Light Bulbs....................................................73 Capacitors...........................................................................75 Inductors ...........................................................................78 Relays ...............................................................................81 Semiconductors .................................................................86 Diodes ...............................................................................87 Light Emitting Diodes.........................................................89 Automotive Electrical Power Supply and Charging Systems............90 The Battery ........................................................................90 The Alternator ...................................................................93 The Fuse Panel....................................................................97 The Ignition Switch ...........................................................99 Low Current Ignition Circuits.............................................102 Fuses and Circuit Breakers ................................................103 Choosing and Installing High Current Power Cables .........109 4 The basic installation technician study guide Remember BOTH sides of the circuit (Upgrading Grounds)..........................................................113 Importance of using a grommet when passing through metal ....................................................................113 Power Storage Capacitors ..................................................113 Sample Test Questions for Chapter 1 .............................................116 CHAPTER 2. ENTRY-LEVEL Installation Knowledge AND Technique Tools and Safety................................................................................................... 120 Hand Tools......................................................................................120 Specialty Installation Tools..............................................................124 Large Power and Pneumatic Tools...................................................130 Shop Safety......................................................................................131 Personal Safety.................................................................................131 Chemical Safety...............................................................................134 Fire Extinguishers............................................................................137 Keeping a Clean Shop.....................................................................139 Pre-Installation Guidelines and General Vehicle Disassembly..........140 Electronic Testing and Test Equipment...........................................147 Digital Multimeter (DMM)..................................................147 Test Lights (not recommended)..........................................150 Testing Wires/Circuits in a Vehicle.....................................154 Cautions of “Tapping In” to Low Current Ignition Systems.....166 General Installation Knowledge............................................................................ 167 Importance of Making Proper Connections.....................................167 Common Connection Types............................................................167 MECP Best Practices for Making Low and High Current Connections....185 Low Current Termination Techniques................................185 High Current Termination Techniques...............................186 Troubleshooting Common Installation Problems................................................... 187 Identify-Isolate-Eliminate …..The path to thinking it through!.......189 Testing Voltage Drops.....................................................................194 Short Circuits..................................................................................200 Open Circuits..................................................................................203 Blown Fuses....................................................................................204 Battery Mysteriously Drains.............................................................205 Understanding Wiring Diagrams – Vehicle Schematics...................206 Understanding Wiring Diagrams – Aftermarket Products................209 Sample Test Questions for Chapter 2..............................................211 Table of contents 5 Margin Notes CHAPTER 3. INTRODUCTION TO MOBILE AUDIO/VIDEO SYSTEMS Basics of Sound.................................................................................................... 214 Components of a Sound Wave........................................................214 Phase and Polarity...........................................................................219 Resonance........................................................................................222 Frequency Response – Where System Design Philosophies Begin...223 Filtering – Routing the signals to the right speakers........................226 Octaves and Harmonics...................................................................231 Signal to Noise Ratio (S/N)..............................................................236 Headroom.......................................................................................238 General Mobile Audio Installation Knowledge...................................................... 239 Overview of In-Dash Headunit Installation Best Practices................239 DIN and Double DIN Aftermarket Form Factors................240 Dash Kits............................................................................242 Wiring Harness Adaptors....................................................243 Antenna Adaptors...............................................................246 Important Integration Devices.............................................248 Overview of OEM Source Unit Retention........................................251 Adding Other Sources.........................................................252 Adding Amplifiers/Upgrading the Sound.........................................257 Line Output Converters......................................................257 Summing Devices...............................................................259 Turn-on Lead Issues...........................................................260 Application Specific Integration Devices – such as CAN bus, MOST apps.........................................262 MECP Best Practices for OEM Integration.......................................263 Overview of Preamp Level Processors..............................................264 Overview of Aftermarket Amplifier Installation Best Practices.........271 Setting the Input Gain (Simply, but Correctly)................................283 Overview of Replacement Speaker Installation Best Practices..........289 Observing Correct Speaker Polarity Connections................291 Proper Speaker Mounting...................................................292 Importance of Damping Vibrations and Resonant Panels....296 Installing the Passive Crossover on Component Speakers...299 Overview of Subwoofer Enclosures.................................................301 Why Subwoofers Need Enclosures......................................301 Basic Benefits/Drawbacks of Sealed and Vented Designs.....301 Calculating Volume.............................................................303 Construction Materials/Methods.........................................308 General Mobile Video Installation Knowledge.................................311 Overview of In-Dash Video vs. Rear Seat Entertainment.....311 In-dash or Driver Viewed Video.........................................312 In-Dash or “Driver Viewed” Monitors.................................313 Overhead Monitors.............................................................314 Headrest/Seat Back..............................................................315 6 The basic installation technician study guide Floor/Center Console..........................................................317 Running any 120VAC Devices............................................317 Wireless Headphones..........................................................318 Troubleshooting Common Mobile Audio System Installation Problems................. 320 Identifying and Troubleshooting Audio System Noise.....................320 System Noises.....................................................................320 Limited Bass Response........................................................320 Enclosure Construction.......................................................321 Polarity Conflicts................................................................321 Position of subwoofer vs. other speakers............................321 Power Problems..................................................................323 Distortion at High Volumes................................................324 Clipping..............................................................................324 Voltage Drops.....................................................................326 Margin Notes CHAPTER 4. INTRODUCTION TO SECURITY AND CONVENIENCE SYSTEMS Remote Controls and RF.................................................................332 Basic Components of a Security System...........................................333 Inputs and Outputs of a Security System............................333 Sounding Devices...............................................................340 Visual Deterrents.................................................................341 Sensors................................................................................342 Engine Disables...................................................................345 LED (Status Indicator)........................................................347 Valet Switch........................................................................348 Backup Battery or Backup Battery Siren..............................349 Accessory Output Devices...................................................351 Using Relays.......................................................................352 Basic Components of a Remote Starter............................................355 Inputs and Outputs of a Remote Starter..............................355 Bypassing Transponder Keys...............................................359 Initial Programming or Updating Firmware on Interface Devices...............................................................................361 Safety Measures...................................................................362 Applications and Requirements for Remote Starters............364 Identifying Vehicle Circuits.............................................................365 Identify Positive Switching..................................................365 Identify Negative Switching................................................365 Identify Reverse Polarity Switching.....................................365 Identify Multiplex or Variable Voltage Switching................366 Basic Installation Tips......................................................................368 Preparing for the Installation..............................................368 Mounting Considerations for a Control Unit......................369 Wiring and Connections for the Control Unit.....................370 Tips on Performing the Installation.....................................372 Table of Contents 7 Margin Notes Troubleshooting Basic Security and Remote Starter System Installation Problems.........................................................................................373 Remote does not respond...................................................374 Security System Randomly Triggers....................................377 Other Basic Security System/Remote Starter Troubleshooting Tips.....................................................................................380 Sample Test Questions for Chapter 4..............................................382 CHAPTER 5. INTRODUCTION TO IN-VEHICLE INFORMATION AND SAFETY SYSTEMS Broadcast Entertainment..................................................................387 In-Band On-Channel (IBOC) Digital AM/FM Radio............387 Satellite Radio.....................................................................389 Introduction to Bluetooth Hands Free Communication..................401 Bluetooth Basics..................................................................401 Bluetooth Hands Free Communication Devices and Installation.....406 Hands Free Capability and Installation Kits........................406 Introduction to Navigation and Safety Related Systems...................412 How the GPS Satellites Work..............................................412 How and Where to Place GPS Navigation Antenna.............413 Rear View Camera Systems.................................................414 Reverse Sensor Systems.......................................................417 How to identify a reverse trigger input...............................418 Front View Camera Systems...............................................418 Sample Test Questions for Chapter 5..............................................420 Glossary of Terms................................................................................424 APPENDIX...................................................................................................462 RESOURCES FOR ADDITIONAL READING. ................................................467 Acknowledgements, Trademarks, etc...........................................468 index..........................................................................................................471 8 The basic installation technician study guide even caller ID functionality. Instead of just talking and listening, the HFP allows more control and access to the phone. Margin Notes The difference between HP and HFP In the past, there was no universal way for Bluetooth mobile phones and handsfree car kit systems to share enhanced information (such as voice dialing, address books, battery indicator, network signal strength, etc.) beyond the call itself. This made implementation of integrated features difficult for OEM vehicle manufacturers. Aftermarket solutions were slow to develop too, either because of cost or complexity. Just about every car manufacturer offers Bluetooth hands-free profile (HFP) solutions as an option, if not as standard equipment. Aftermarket in-car hands free Bluetooth solutions (for virtually any make or model of car) are also available from a variety of manufacturers, including Auto Page, Motorola, EGO, Nokia, Parrot, Scosche, NAV-TV, Sony Ericsson and others, some of which are HFP supported, not just HP (talk and listen) kits. The key is to check the fine print or technical specifications to know for sure. With a Bluetooth-enabled phone used in a factory supplied HFP set up, once inside the vehicle the driver generally only has to have their cell phone ON after the initial pairing. The phone typically links up with the Bluetooth HFP module in the car automatically. If multiple phones are paired, it may ask which you want to connect or it may default to the last connected phone. For speech recognition, the driver’s voice projects through a factory-installed microphone (generally located in the rearview mirror, overhead console, or A-pillar area) and broadcasts hands-free conversation through the vehicle’s OEM sound system (generally the driver’s side speakers). Many systems that are factory installed are voice activated to maintain a completely hands-free system from selecting the number to dial straight through the end of the call. This is a major consideration when adding aftermarket amplifiers and speakers to these vehicles as it’s sometimes the case that this Bluetooth HFP functionality for the audio input and output “lives” inside of the OEM amplifier, in which case removal is not a viable (or sensible) option. Many aftermarket HFP kits work in a similar manner to the OEM functionality; however, the equipment design and location are different. In particular, it depends on if it’s a universal product with a separate control panel/display or if Chapter 5. Introduction to in-vehicle information and safety systems 403 Margin Notes n Figure 213. Sealed enclosure design (also called “air suspension” or “acoustic suspension” designs) of enclosures. Some are better suited for one environment or the other. It’s always best to contact the manufacturer or read technical support resources to see what’s recommended for any particular subwoofer. The sealed enclosure is also referred to as air-suspension or acoustic-suspension. The sealed box is the easiest type of subwoofer enclosure to design and build, which makes this a good all around design if the subwoofer is suited for a sealed enclosure environment. The idea behind a sealed enclosure design is that the air trapped inside the box will work to assist the speaker’s suspension, which gives us the term air-suspension. As the speaker moves outward, the air behind it is pulled with it, creating a decrease in pressure inside the box. This acts like a vacuum and pulls the speaker back inward. Similarly, when the speaker moves in, the air that is compressed pushes out on the speaker. Logically, the more the speaker moves in or out, the greater these forces are. If the speaker were designed with a loose suspension and a long excursion, the sealed enclosure would provide smooth bass response, since the stiffer air pressure within the enclosure would control speaker excursions. n Benefits of Sealed Enclosure Designs – Box volume is small in comparison to other enclosure types. Good output for all music types. Easy to build and tolerant of small errors in calculation of volume or if you forget to subtract volume for a brace, etc. Many well built pre-fabricated sealed enclosures available offer good results. n Drawbacks of Sealed Enclosure Designs – Poor response below 30 Hz when compared with a vented enclosure. Low-end response gets worse as enclosure size decreases. Typically requires more power for a given output when compared to a vented enclosure. Vented enclosures are also called ported enclosures or bass-reflex enclosures. It adds a vent through which air resonates in tune with the speaker at the enclosure’s resonant frequency, effectively increasing the output. You can hear the principle of vented box design at work by simply blowing air across the opening of a filled soda bottle. In this case the tuning hole is fixed, but you can change the length of the vent by taking a drink. Blowing air again, you will hear a lower pitch. If you could alter the size of the opening or use a different size bottle altogether, the pitch would also change. Vented enclosures are more complicated to design than sealed enclosures. There is a delicate relationship between the enclosure size (box volume), port size (both 302 The basic installation technician study guide Margin Notes 5. According to the MECP Basic Installation Technician study guide, when measuring a low current (MUX) ignition circuit, what setting of the DMM is used to determine the various values of each key switch position? a) AC Volts. b) DC Volts. c) Ohms. d) Continuity. 6. How should the jaw of a crimp tool be positioned in reference to the seam of the crimp connector? a) The jaw should face away from the connector’s seam. b) The jaw should be positioned on the connector’s seam. c) The jaw should not be used at all with seamed crimp connectors. d) The position of the jaw is irrelevant in seamed crimp connectors. 7. For in vehicle measurements, test lights are recommended by MECP because they always provide a measured, numeric value to the technician? a) True. b) False. 8. What are the 3 MECP recommended steps to troubleshooting noise problems: a) Insulate, Evaluate, Innovate. b) Isolate, Evaluate, Insulate. c) Identify, Insulate, Innovate. d) Identify, Isolate, Eliminate. 9. Testing for blown electrical system fuses in a vehicle fuse panel should be done with which setting on the DMM? a) AC Volts. b) DC Volts. c) Ohms. d) Continuity. 10. What does the blue section of the NFPA 704 Diamond represent with respect to safety considerations? a) Health. b) Fire. c) Reactivity. d) Special Information. Answers to Chapter 2 Questions 1. B, 2. A, 3. A, 4. D, 5. C, 6. A, 7. B, 8. D, 9. B, 10. A 212 The basic installation technician study guide Margin Notes n Floors should be swept as often as possible. Stray screws can easily find their way into tires and cause tire problems. The last thing you want is to be responsible for a customer’s flat tire (particularly with the high cost of some high end performance tires). n Reels of wire/cable should be put back on their racks and stored in an orderly fashion. n Boxes that equipment came in should be put in the owner’s car or properly recycled. n Promptly clean up metal chips from power nibblers or metal cutting other tools. Never leave them on the floor to be swept up later, or these chips can find their way into customers’ tires, the interior of their cars and the bottoms of your shoes. You can use old speaker magnets to easily pick up stray nibbler chips or small metal shavings and keep them from being tracked all over the shop. n A heavy-duty shop vacuum is essential for cleaning up the floor and the vehicle’s carpets, particularly with small bits of wire or insulation that inevitably end up on the floor carpet. n Whenever possible, do wood working or any other fabrication in a separate, ventilated area so unnecessary dust is not settling on the vehicle. n Always leave a customer’s vehicle cleaner than you found it. Pre-Installation Guidelines and General Vehicle Disassembly Everyone has habits. Some of them are good and some of them are not so good. MECP best practices are about establishing good habits in the shop that can save time and money as well as assuring a positive customer experience. MECP installation technicians should exemplify professionalism in everything they do. Before Beginning the Install The installation process actually begins long before a vehicle enters the shop. It is a cooperative effort between the sales staff as well as the installation staff. The process begins when a consumer enters the store. Before attempting to sell anything, the MECP certified sales associate should check their database to learn everything necessary about the customer’s vehicle (see the next paragraph for details). The associate should know about vehicle wiring specifications, interface issues, and anything that may require additional parts, labor, or other considerations before attempting to sell a customer anything. Depending on the shop’s policies, the 140 The basic installation technician study guide for security and remote starter interface applications, you will often find that 5% or even 1% tolerances are recommended to avoid intermittent circuit behavior caused by out of range values. n Margin Notes Figure 34. The resistor color code chart indicates the resistance and tolerance of 2 watt or smaller carbon resistors Since resistors almost always open (break the circuit) when they go bad, troubleshooting resistive problems is pretty straight forward. An open resistor in a series circuit will stop current from flowing in the circuit. An open resistor in a parallel circuit will increase the circuit resistance and decrease the total current. Schematically, a resistor is represented by zig-zag lines that straighten out at either end. When there are multiple resistors in a circuit, they are assigned the letter “R” with a subscript number (such as R1, R2, R3, etc.) just like the characteristic of resistance. While the resistor schematic represents a specific component, resistance that does not come from a resistor can appear in the circuit path from things like poor connections, corrosion, etc., that should not be there under normal operational circumstances. In some cases for problem solving, the symbol for the resistor may Chapter 1. BASIC ELECTRONICS AND VEHICLE ELECTRICAL SYSTEMS 71 An atom for electrical purposes breaks down like this: n The center of an atom is the nucleus. n Nucleus contains protons (positive charge) and neutrons (neutral Margin Notes charge). n The outer parts of the atom contain electrons (negative charge). n The outermost orbit of are called valence electrons. n Ions ARE atoms except they are atoms with either extra electrons or missing electrons. n An ion will exhibit the charge of the parts that are greater (positive if more protons, negative if more electrons). n Valence electrons are easiest to “break away” and change the charge of the atom left behind. These are called free electrons. n When valence electrons leave an atom, the ion becomes positively charged and “attracted to” free electrons n When negatively charged electrons move to the next ion with an open spot that the previous electron left behind, this is how electricity begins to move in a circuit. This gets repeated over and over. n Figure 2. Electrons moving from one atom to another is how electricity moves in a circuit. Electricity simply means electrons moving. Once you have that basic idea down, you’re one step closer to understanding the puzzle in electrical circuit behavior. At this point it’s really just the details of what terms describe how the circuit performs and moves electrons in a path from beginning to end. Electrons moving are really what electrical circuits are all about. When, how, how much, and why those electrons move or don’t move is all part of this chapter. Sounds a little complicated at first, but really it’s not. Chapter 1. BASIC ELECTRONICS AND VEHICLE ELECTRICAL SYSTEMS 37 Advanced Installation Technician Study Guide TABLE OF CONTENTS HEADLINE Introduction.................................................................................................................................... 13 Contacting MECP .................................................................................................................... 36 CHAPTER 1 — ADVANCED ELECTRONICS AND VEHICLE ELECTRICAL SYSTEMS History of Vehicle Electronics ......................................................................................................... 40 Electrical Circuit Fundamentals ...................................................................................................... 40 Understanding Voltage, Current and Resistance............................................................................. 42 The Relationship of Voltage, Current, and Resistance (Ohm’s Law) ....................................... 42 Calculating Series and Parallel Resistance ................................................................................ 53 Ohm’s Law and Electrical Power (Watt’s Law) ............................................................................... 57 Law of Conservation of Energy................................................................................................ 58 Watt’s Law ............................................................................................................................... 59 Kirchhoff’s Laws ............................................................................................................................. 63 Kirchhoff’s Voltage Law ........................................................................................................... 63 Kirchhoff’s Current Law .......................................................................................................... 65 Which way does DC Current really flow? ............................................................................... 67 Applications of Electronic Components ......................................................................................... 68 Batteries as a Voltage Source.................................................................................................... 69 Switches................................................................................................................................... 70 Resistors................................................................................................................................... 72 Potentiometers ......................................................................................................................... 78 Incandescent Light Bulbs ......................................................................................................... 80 Capacitors ................................................................................................................................ 81 Inductors ................................................................................................................................. 87 Relays....................................................................................................................................... 94 Semiconductors ..................................................................................................................... 101 Diodes ............................................................................................................................. 103 Light Emitting Diodes (LED’s)......................................................................................... 107 Transistors ....................................................................................................................... 109 Integrated Circuits (IC’s) ................................................................................................. 114 Microprocessors .............................................................................................................. 115 Automotive Electrical Power Supply and Charging Systems ........................................................ 115 The Automotive Battery ......................................................................................................... 116 The Alternator ....................................................................................................................... 124 The Fuse/Power Distribution Panel ....................................................................................... 127 The Ignition Switch ............................................................................................................... 130 Traditional Ignition Circuits .................................................................................................. 130 Low Current Ignition Circuits ............................................................................................... 132 Fuses and Circuit Breakers .................................................................................................... 133 Choosing and Installing High Current Power Cables ............................................................ 140 Power Storage Capacitors ...................................................................................................... 143 Bringing it all Together – System Architecture and Design .......................................................... 146 The Electrical System Backbone ............................................................................................ 146 The Process of Evaluation in a Design ................................................................................... 150 Best Practices Choosing Power Cables for Everyday Installations.......................................... 160 Digital Fundamentals .................................................................................................................... 164 Data-bus Communications .................................................................................................... 164 Control Modules and Diagnostic System Acronyms.............................................................. 165 Multiplexing .......................................................................................................................... 165 The Binary System ................................................................................................................. 167 Integration into a Databus ..................................................................................................... 170 D2B (Domestic Digital Bus)............................................................................................. 173 4 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE Class 2 (General Motors) ................................................................................................. 174 CAN BUS ........................................................................................................................ 175 MOST .............................................................................................................................. 181 Installation Related Databus Tips .......................................................................................... 185 Sample Test Questions ................................................................................................................. 187 CHAPTER 2 — ADVANCED INSTALLATION KNOWLEDGE AND TECHNIQUE Professionalism ............................................................................................................................. 192 Installation Guidelines – Best Practices Before, During and After ................................................. 193 Safety and Tools............................................................................................................................ 198 Personal Safety ....................................................................................................................... 199 Chemical Safety ..................................................................................................................... 201 Fire Extinguishers .................................................................................................................. 204 Keeping a Clean Shop ........................................................................................................... 207 Tools ............................................................................................................................................. 207 Hand Tools ............................................................................................................................ 208 Specialty Installation Tools .................................................................................................... 213 Electrical Measurement Tools ................................................................................................ 219 Digital Multimeter (DMM) .............................................................................................. 220 Test Lights and why they are not recommended ............................................................ 225 Oscilloscopes ................................................................................................................... 229 Test Leads and Probes ..................................................................................................... 236 Hall-Effect Current Clamp .............................................................................................. 238 Polarity Tester ................................................................................................................. 239 Real Time Analyzer (RTA) ............................................................................................... 240 Power and Pneumatic Tools .................................................................................................. 242 General Vehicle Disassembly ........................................................................................................ 247 Use of Proper Tools ............................................................................................................... 247 Interior Panel Evaluation and Removal ................................................................................. 248 Electronic Testing and Test Equipment ........................................................................................ 252 Understanding Wiring Diagrams – Vehicle Schematics......................................................... 256 Testing Wires in a Vehicle ..................................................................................................... 263 Taking DC Voltage Measurements .................................................................................. 264 Taking AC Voltage Measurements................................................................................... 267 Taking Resistance Measurements .................................................................................... 269 Checking Continuity ....................................................................................................... 271 Taking Standby (Parasitic) Current Draw Measurements................................................ 272 Taking High Current Measurements with a Hall Effect Clamp ....................................... 275 Specific Vehicle Electrical Tests .................................................................................................... 277 Battery and Charging System Testing .................................................................................... 277 State of Health (SOH) Test with a DMM and Hall-Effect Clamp .................................... 287 Low Current (MUX) Ignition System Testing ........................................................................ 298 Tachometer Signal Testing..................................................................................................... 300 Vehicle Speed Sensor (VSS) Testing ...................................................................................... 302 Audio Output Testing............................................................................................................ 304 NTSC Video Signal Testing ................................................................................................... 308 Databus Testing (Copper Wires) ........................................................................................... 312 Testing Voltage Drops ........................................................................................................... 315 Short Circuit Testing ............................................................................................................. 321 Open Circuit Testing ............................................................................................................. 323 Troubleshooting Installation Problems ......................................................................................... 323 Identify-Isolate-Eliminate…The path to thinking it through!................................................ 325 CHAPTER TABLE OF CONTENTS 5 Powerline Noise .............................................................................................................. 328 Radiated Noise ................................................................................................................ 330 Ground Loop Noise......................................................................................................... 332 Accessory Noises ............................................................................................................. 334 System Noises..................................................................................................................334 General Installation Knowledge .................................................................................................... 335 Importance of Making Proper Connections........................................................................... 335 Soldering ......................................................................................................................... 335 Crimping (Butt Connectors)............................................................................................ 337 Connection Types Not Recommended............................................................................ 338 MECP Best Practices for Making Low and High Current Connections ................................. 339 Proper Speaker Mounting...................................................................................................... 341 Noise Control ........................................................................................................................ 346 Basics of Aftermarket Amplifier Installation.................................................................................. 349 Getting power at the battery (or direct battery feed) ............................................................. 349 Grounding (especially in Uni-body Cars) .............................................................................. 350 Getting Signal into the Aftermarket Amplifier ....................................................................... 352 Speaker Connections to an Amplifier Channel...................................................................... 353 Understanding the Function of Input Gain Adjustment........................................................ 356 Amplifier Mounting Location ................................................................................................ 371 Sample Test Questions ................................................................................................................. 373 CHAPTER 3 — ADVANCED MOBILE AUDIO/VIDEO SYSTEMS Vehicle Disassembly for Audio and Video System Installations.................................................... 378 Audio and Video Source Formats ................................................................................................. 384 Analog AM/FM Radio ............................................................................................................ 384 Digital AM/FM Radio ............................................................................................................. 386 Digital Satellite Radio............................................................................................................. 386 Disc Formats.......................................................................................................................... 387 CD — Compact Disc ...................................................................................................... 387 HDCD ............................................................................................................................. 388 DVD-Video ...................................................................................................................... 389 DVD-Audio ..................................................................................................................... 389 SACD............................................................................................................................... 390 Blu-ray Disc ..................................................................................................................... 391 Older Source Format Technologies ....................................................................................... 396 Digital Music Files ................................................................................................................. 394 Lossy and Lossless Audio Compression .......................................................................... 396 Compression of Digital Audio Files – How it’s Done ...................................................... 399 Perceptual Coding ........................................................................................................... 399 Haas Effect....................................................................................................................... 400 Recommended Bit Rates for Lossy Audio Compression .................................................. 401 Mobile Audio Source Units........................................................................................................... 401 Head Unit Mounting Types ................................................................................................... 401 Source Unit Audio Output Types (Analog and Digital)......................................................... 404 Source Unit Audio Output Characteristics ............................................................................ 409 Signal to Noise Ratio (S/N) .............................................................................................. 409 Preamp Output Voltage................................................................................................... 410 Output Impedance .......................................................................................................... 410 External Source Inputs .......................................................................................................... 411 Steering Wheel Control (SWC) Adapters .............................................................................. 416 Analog SWC .................................................................................................................... 416 6 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE Digital SWC .................................................................................................................... 417 Head Unit Installation Specific Considerations ..................................................................... 420 Audio Signal Processing................................................................................................................ 425 What is Signal Processing? .................................................................................................... 425 Analog vs. Digital Signal Processing ...................................................................................... 425 Preamp Equalizer................................................................................................................... 428 Graphic EQ ..................................................................................................................... 429 Parametric EQ ................................................................................................................. 430 Active Crossovers................................................................................................................... 431 “Q” and Slopes....................................................................................................................... 432 Decoders for Multi-channel Audio Formats .......................................................................... 433 Installation Specific Signal Processing Considerations ........................................................... 434 Audio Signals in OEM Systems..................................................................................................... 438 Stumbling Blocks for The Aftermarket .................................................................................. 438 Technician Knowledge .......................................................................................................... 439 OEM Audio Signal Voltage Level .................................................................................... 440 OEM Audio Signal Reference Ground............................................................................. 442 OEM Audio Channel Bandwidth Limitations.................................................................. 443 OEM Audio Channel Equalization Curve(s) ................................................................... 444 OEM Interface Devices ................................................................................................................. 445 Input Devices......................................................................................................................... 446 Output Devices ...................................................................................................................... 450 OEM Integration Installation Specific Considerations ........................................................... 458 Analyzing OEM Audio Signal Characteristics ........................................................................ 460 Mobile Audio Amplifiers............................................................................................................... 465 Power Supply Section ............................................................................................................ 465 Audio Section ........................................................................................................................ 466 Channel Configurations......................................................................................................... 466 Mobile Audio Amplifier Circuit Topologies........................................................................... 471 Amplifier Power Terminology ............................................................................................... 479 Passive Crossover Networks ......................................................................................................... 482 Construction of a Crossover .................................................................................................. 484 Orders of Response ......................................................................................................... 488 Speaker Installation ...................................................................................................................... 489 Speaker Types........................................................................................................................ 489 Subwoofer Enclosures................................................................................................................... 491 Calculating Volume ............................................................................................................... 493 Enclosure Construction ......................................................................................................... 498 Infinite Baffle Designs ............................................................................................................ 503 Semi Closed Aperiodic Designs ............................................................................................. 506 Sealed Enclosure Designs ...................................................................................................... 507 Vented Enclosure Designs ..................................................................................................... 511 Bandpass Enclosure Characteristics ....................................................................................... 518 Single Reflex Bandpass Designs ............................................................................................. 519 Dual Reflex Bandpass Design................................................................................................. 520 Transmission Line / Quarter Wave Designs........................................................................... 522 Sound in the Vehicle .................................................................................................................... 524 Low Frequency Transfer Function ........................................................................................ 524 Uninvited Noises ................................................................................................................... 525 Importance of Damping Vibrations and Resonant Panels...................................................... 526 Speed of Sound ..................................................................................................................... 527 Speaker Positioning and Installation ............................................................................................. 527 CHAPTER TABLE OF CONTENTS 7 Positioning Speakers for Optimum Performance................................................................... 532 Mobile Video Entertainment Systems ........................................................................................... 541 Review ................................................................................................................................... 541 Video Sources ........................................................................................................................ 543 Video Screens ........................................................................................................................ 547 Mobile Video Input/Output Formats ..................................................................................... 549 Analog Composite Video Output (The Yellow RCA Plug) .................................................... 549 Analog RGB – Red/Green/Blue .............................................................................................. 552 Digital Mobile Video Formats ................................................................................................ 555 Mobile Video System Installation Considerations.................................................................. 560 Mobile Video Installation Safety ............................................................................................ 560 Infrared and RF Wireless Headphone Systems ...................................................................... 567 DC-AC Power Inverters ......................................................................................................... 567 Troubleshooting Common Video System Installation Problems ........................................... 570 Sample Test Questions ................................................................................................................. 573 CHAPTER 4 — ADVANCED SECURITY AND CONVENIENCE SYSTEMS Vehicle Disassembly for Security and Convenience Installations.................................................. 579 OEM Anti-Theft Systems .............................................................................................................. 580 Identifying an OEM Anti-Theft system .................................................................................. 580 Keyless Entry / Security System Misconceptions ................................................................... 582 Advanced Security Topics............................................................................................................. 583 Range and RF Interference .................................................................................................... 584 Inputs and Outputs of a Security System .............................................................................. 587 Identifying Vehicle Circuits .......................................................................................................... 591 Identify Positive Switching .................................................................................................... 593 Identify Negative Switching ................................................................................................... 593 Identify Reverse Polarity Switching ....................................................................................... 595 Identify Multiplex or Variable Voltage Switching .................................................................. 596 True Variable Voltage Switching ..................................................................................... 596 True Multiplex Switching (Unique Digital Messaging).................................................... 598 Identify High Speed or Medium Speed CAN Voltages .................................................... 601 Identify Low Speed, Fault Tolerant CAN Voltages .......................................................... 602 Identify Single Wire CAN Voltages ................................................................................. 603 Unique Interfacing Challenges............................................................................................... 604 Interior Lighting Circuits (included isolated zones, time delayed, etc.) .......................... 604 Special Application Door Lock Circuits .......................................................................... 605 Special Application Lighting Circuits (Some European Lighting Circuits) ...................... 607 Advanced Relay Applications........................................................................................................ 608 Inverting Polarity ................................................................................................................... 609 Amplify or Increase Current .................................................................................................. 609 Turning Something ON ......................................................................................................... 610 Turning Something OFF ....................................................................................................... 612 Dual Purpose Applications .................................................................................................... 612 Isolation ................................................................................................................................. 614 Wiring Relays ........................................................................................................................ 614 Security System Placement and Mounting .................................................................................... 617 Mounting Considerations for a Control Unit......................................................................... 617 RF Range Concerns ............................................................................................................... 617 Electromagnetic and Inductive Coupling Concerns .............................................................. 618 Vibration Concerns................................................................................................................ 619 Wiring and Connections for the Control Unit....................................................................... 620 8 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE Troubleshooting Common Security System Problems........................................................... 628 Security and Convenience System Accessories ............................................................................. 629 Long Range Notification and Communication ...................................................................... 629 Backup Power Sources .......................................................................................................... 632 Window and Sunroof Automation ........................................................................................ 633 Alternative Security System Applications ...................................................................................... 638 Boats ...................................................................................................................................... 638 Motorcycles and Snowmobiles .............................................................................................. 639 Tractors ................................................................................................................................. 639 Hybrid Gas-Electric Vehicles ................................................................................................. 639 Remote Start Systems.................................................................................................................... 640 Remote Starter System Overview ........................................................................................... 640 Remote Starter Vehicle Applications ...................................................................................... 644 Automatic and Fuel-Injected Vehicle Applications.......................................................... 644 Carbureted Applications.................................................................................................. 644 Manual Transmission Applications ................................................................................. 645 Diesel Applications .......................................................................................................... 646 Hybrid Gas-Electric Vehicles ........................................................................................... 647 Identifying Critical Remote Starter Connections........................................................................... 649 Ignition Switch Positions and Measurements ........................................................................ 649 Traditional Positive Switching Ignition Systems .............................................................. 650 Low Current Ignition Circuits ......................................................................................... 653 Databus Ignition Switches/Modules ................................................................................ 654 Push to Start (PTS) or Push Button Starting Systems ...................................................... 654 Parking Light Circuit ............................................................................................................. 658 Autolamp Circuit ................................................................................................................... 660 Tachometer Signal ................................................................................................................. 662 Fuel Injector Pulse Signal ...................................................................................................... 662 Alternator Signal (Voltage Change) ....................................................................................... 664 Foot Brake Switch.................................................................................................................. 664 Parking Brake Switch............................................................................................................. 665 Neutral Safety Switch ............................................................................................................ 665 Hood Pin Switch.................................................................................................................... 666 Clutch Switch ........................................................................................................................ 667 Rear Defrost (and other heated accessories) .......................................................................... 669 Status Output or Ground When Running (GWR)................................................................. 670 RAP Circuit............................................................................................................................ 671 Programmable Parameters for Remote Starters ...................................................................... 672 OEM Security Interface and Bypass for Remote Starters............................................................... 674 Disarming the Factory Security System ................................................................................. 674 OEM Anti-Theft Methods ...................................................................................................... 676 Resistor Keys (VATS, PASSkey I) .................................................................................... 676 PASSlock 1 & 2............................................................................................................... 678 Passive Transponder Based Immobilizers ........................................................................ 684 Active Transponder Based Immobilizers ......................................................................... 686 OEM Anti-Theft System Integration Modules............................................................................... 687 Safety Considerations While Installing a Remote Start System ..................................................... 695 Testing the Remote Starting System ...................................................................................... 695 Educating Customer on Responsible Use .............................................................................. 697 Troubleshooting Common Remote Starter Installation Problems ................................................. 697 Sample Test Questions ................................................................................................................. 703 CHAPTER TABLE OF CONTENTS 9 CHAPTER 5 — IN-VEHICLE INFORMATION AND CONTROL SYSTEMS Information on the Move.............................................................................................................. 708 How Information on the Road Works ................................................................................... 709 Bringing Outside Data into the Vehicle via Satellite ..................................................................... 710 GPS Satellites ......................................................................................................................... 710 Subscriber Radio Satellites ..................................................................................................... 716 Proprietary Data Satellites ...................................................................................................... 716 Terrestrial Repeaters (of satellite signals) ............................................................................... 717 Data in and out of the Vehicle via Radio Frequency Networks .................................................... 717 Federal Oversight .................................................................................................................. 718 What are Proprietary Networks? ........................................................................................... 719 What are Subscriber Networks? ............................................................................................ 723 RF Communication Network Technology ............................................................................. 729 WiFi 101 ............................................................................................................................... 731 Mobile Hotspots .............................................................................................................. 732 Tethering a Phone ........................................................................................................... 732 Dedicated In-Vehicle WiFi .............................................................................................. 734 Bluetooth Communications .......................................................................................................... 735 Bluetooth Device Compatibility ............................................................................................. 735 The Primary Bluetooth Device Profiles .................................................................................. 737 Profiles Relating to Hands-Free Communications ................................................................. 738 Headset Profile (HP) ........................................................................................................ 738 Hands Free Profile (HFP) ................................................................................................ 738 Phone Book Access Profile (PBAP) .................................................................................. 739 Profiles Relating to Advanced Audio Entertainment .............................................................. 740 Advanced Audio Distribution Profile (A2DP).................................................................. 740 Audio Video Remote Control Profile (AVRCP) ............................................................... 741 Other Bluetooth Profiles ........................................................................................................ 742 Bluetooth Hands Free Communication Devices and Installation .......................................... 745 Hands Free Capability and Installation Kits .................................................................... 754 Hands Free Microphone.................................................................................................. 746 Enabling Functionality between the HF Car Kit and Phone ........................................... 749 Firmware Updates ........................................................................................................... 749 In-Vehicle Navigation and Route Guidance Systems .................................................................... 750 Core Purposes for Navigation ................................................................................................ 750 Navigation System Inputs ...................................................................................................... 752 GPS Satellite Data ............................................................................................................ 752 Gyroscope ....................................................................................................................... 752 Vehicle Speed Sensor ...................................................................................................... 753 Testing the VSS Circuit – Speed Pulse ............................................................................ 753 Testing the Route Guidance System ...................................................................................... 753 HD Radio and Digital Satellite Radio ............................................................................................ 755 In-Band On-Channel (IBOC) Digital AM/FM Radio .............................................................. 755 Satellite Radio ........................................................................................................................ 757 Installing Satellite Radio Antennas......................................................................................... 761 Mounting/Wiring Dedicated Receivers .................................................................................. 763 Troubleshooting Common Satellite Radio Problems ............................................................. 767 Integration and Interface with On-board Safety Systems .............................................................. 768 Safety Devices (General Overview) ........................................................................................ 768 FMVSS Review ................................................................................................................ 769 10 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE Tire Pressure Monitoring Systems (TPMS) ...................................................................... 772 OEM Rear View Cameras and Reverse Sensors ............................................................... 776 Aftermarket Rear View Mirrors ....................................................................................... 779 Radar and Laser Detection ............................................................................................................ 783 How Radar Detection Works................................................................................................. 784 How Laser Detection Works.................................................................................................. 785 Differences between Radar and Laser .................................................................................... 785 Minimizing Speeding – The Importance of Safety ................................................................. 789 Sample Test Questions ................................................................................................................. 790 Glossary ........................................................................................................................................ 794 Automotive Service Websites........................................................................................................ 842 Additional Reading Resources ...................................................................................................... 848 Index............................................................................................................................................. 852 CHAPTER TABLE OF CONTENTS 11 Margin Notes Amplifier 6. What is the nominal impedance of the subwoofers shown as they are wired to the amplifier? a. 1 ohm b. 2 ohms Load c. 4 ohms at the Amplifier? d. 8 ohms BRIDGED Left + (+) (-) 2 Ohm Left - Right + Right - (+) (-) 2 Ohm 7. Which type of crossover listed is appropriate for a tweeter? a. 3.5 kHz High Pass b. 120Hz Low Pass c. 400 Hz Notch Filter d. 120Hz-3.5 kHz Bandpass 8. A subwoofer with an EBP of 37 indicates a vented (ported) enclosure is the preferred enclosure? a. True b. False 9. What is the electrical power consumption of an amplifier drawing 15 amperes of current with a supply of 13.8 volts? a. 92 Watts b. 175 Watts c. 205 Watts d. 207 Watts 10. A customer complains of poor quality sound when listening to a portable media audio device through a head unit you just installed. The problem does not exist when listening to any other source. You also do not have the problem when using an alternate portable media player connected the same way. Which one of the following initial diagnoses is valid? a. The head unit’s AUX input cable is defective and needs replacement b. The audio files on the media player are highly compressed c. One or more speakers are blown and they need to be replaced d. One or more speaker wires are shorted and need replacement 574 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE in different ways for different applications. For example, a four-channel amplifier can have two channels bridged while the remaining two channels operate in stereo. This creates a three-channel system. A six-channel amplifier can have two channels bridged while the remaining four operate in stereo. You can accomplish any number of combinations with multi-channel amps. For example, you can use a four-channel amp in three-channel mode, where the low pass crossover sends bass to the mono channel for subwoofer input, while the remaining stereo signal drives a pair of components in the doors in a high pass mode. Margin Notes 2,4, and 6 Channel Amplifier Default Configurations Bridging Channels Two main factors limit the output power in a common two-channel mobile audio power amplifier: Q The impedance of the speaker(s) connected to the amplifier Q The internal power supply voltage An amplifier’s bridging capabilities depend upon the load impedance connected to the output terminals and internal power supply voltage. CHAPTER 3. ADVANCED MOBILE AUDIO/VIDEO SYSTEMS 467 way the audio system will maintain a better quality of sound over the entire range of useable volume. Margin Notes The other concern is that with increases in the gain overlap, a more notable “hiss” to the system becomes noticeable with the volume all the way down. It’s best to limit any gain overlap to 10dB or less for this reason. MECP recommends +5-6dB of overlap on amplifiers connected to mid/tweeter components (only if needed) and not more than +10dB of overlap on subwoofer amplifiers. If the mid/tweeter component amplifiers are already powerful and don’t really need added gain, the benefit to you is that leaving the adjustments at 0dB with no overlap will keep any amplifier hiss (also called “floor noise”) to an absolute minimum. Keeping a very low noise floor with a high dynamic range is why some mobile audio systems use a bigger amplifier on mid/high speakers, but leave the extra power in “reserve” for when the music demands those big peaks of power. Amplifier Mounting Location Choosing an amplifier mounting location has many more variables than simply where it will fit and look good. Amplifiers in modern vehicles must be able to adequately dissipate heat while maintaining a safe distance from sensitive electrical system components. In addition, amplifiers must be placed out of harm’s way so that the heat sink is not covered by packages in a trunk or the electronics are not damaged by an accidental spill. Avoid mounting amplifiers upside-down because the heat transferred into the heat sink has no way to dissipate. When mounted upside down, the convection process of heat sink thermal management only keeps the heat sink running hotter. If you must mount an amplifier upside-down, consider adding a fan and do not run heat inducing loads like 2, 1, or ½ ohm loads. Keep it at 4 ohms and the amplifier will have fewer thermal problems overall, especially when mounted upside down. Another mounting orientation to avoid is mounting amplifiers directly to a subwoofer enclosure. The excessive panel vibration produced by low frequency information may vibrate critical solder joints on the circuit board loose. Additionally, excessive external vibration can also cause a power supply oscillation. One general consideration for any amplifier placement is that routinely warm (even hot) climates often generate temperatures in excess of 130°F in the trunk area of the vehicle. Most amplifiers have a thermal protection circuit that shuts the amplifier down at 170-180°F, which is a relatively small range considering the way some amplifiers are continually required to pound out hours of sound. CHAPTER 2. ADVANCED INSTALLATION KNOWLEDGE AND TECHNIQUE 371 Margin Notes Passive crossovers often contain many types of inductors to filter or pass specific frequency ranges. As current changes (such as in AC applications), the inductive reactance opposes the change in current flow by the stability of the magnetic field. Remember, while resistance limits or opposes current flow in a circuit (regardless of the frequency), inductance opposes a change in current flow. High frequency signals represent rapidly changing currents. Therefore, inductors can limit the strength of higher frequency signals, while still allowing lower frequencies to pass. The larger the inductance value, the more it will oppose changes in current flow. Where it applies to frequency, larger values of inductance are required to block or oppose frequency as it drops. An inductor wired in series with a subwoofer allows the low frequency audio signal to pass to the speaker but blocks the higher frequency signal. This is an example of a basic low pass passive crossover. In this case, the AC is the audio output from an amplifier. More complex passive crossovers like the kind that are included with mid/tweeter component speakers may have multiple small inductors in them. Examples of Air Core and Iron Core inductors as well as a ring shaped toroidally wound iron core inductor. 88 THE ADVANCED INSTALLATION TECHNICIAN STUDY GUIDE Margin Notes How to easily use Ohm’s Law to figure out an unknown. Example 1 Suppose you have a single resistor with a measured value of 8 Ohms (R = 8), and you measure the amount of current that flows through the resistor at 2 amperes (I = 2). What is the voltage supply in that circuit? Simply apply Ohm’s Law: To find Voltage, simply cover it up and do the math of the remaining parameters. Q Q Q Q Q Q Q R=8 I=2 Cover up the parameter “E” in the Ohm’s Law “T-I-R-E” chart. What’s left is current and resistance so you’ll multiply those. E=IxR E=2x8 E = 16 Volts supplied in that circuit CHAPTER 1. ADVANCED ELECTRONICS AND VEHICLE ELECTRICAL SYSTEMS 51 Master Installation Technician Study Guide TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii CHAPTER 1: VEHICLE ELECTRICAL SYSTEMS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Advanced Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Zener Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Current Limitations of Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bipolar PNP and NPN Transistors . . . . . . . . . . . . . . . . . . . . . . . . . . 6 JFETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MOSFETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operational Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ICs in Headunits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Logic Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 The “AND” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 The “OR” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 The “NOT” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 The “NAND” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 The “NOR” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 The “XOR” Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 The “XNOR” Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Switching Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Data Bus Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Serial Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electronic Control Units and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 OBD-II (the most basic of data bus communications) . . . . . . . . . . . . . . . . . . . . 24 OBD Scan and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 OBD-Compliant Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Overview of Multimedia and Control Networks . . . . . . . . . . . . . . . . . . . . . . . . 29 What is this type of network and why is it there? . . . . . . . . . . . . . 29 In what vehicles or applications are networks found? . . . . . . . . . . 29 What types of network messages are there? . . . . . . . . . . . . . . . . . . 30 How can you identify the network (visually, electrically and operationally)? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 What areas or OEM components of the vehicle are affected?. . . . . 31 How does this change my installation process or how does it affect my job? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 What are some things NOT to worry about? . . . . . . . . . . . . . . . . . 32 What are some of the things TO worry about? . . . . . . . . . . . . . . . . 33 What—if anything—is an aftermarket solution or approach? . . . . 34 ANSI/CEA-2012-A Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hybrid Gas-Electric Vehicle Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 High-Voltage System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Integrated Starter Alternator (ISA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TABLE OF CONTENTS v Cold-Start Wire (Second Starter). . . . . . . . . . . . . . . . . . . . . . . . . . 264 Key-Sense Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Tachometer Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Transponder Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Interfacing Advancements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 GM PASSKey 3+ Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Programming a Transponder Key . . . . . . . . . . . . . . . . . . . . . . . . . 270 Toyota/Lexus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Ford, Lincoln, Mercury PATS (1996, 1997, some early 1998 models) . . . . . . . . . . . . . 271 Ford, Lincoln, Mercury PATS (most 1998, 1999 and up) . . . 272 Ford Focus and Escape (2001 and up) . . . . . . . . . . . . . . . . . 272 Mazda Tribute (2001 and up) . . . . . . . . . . . . . . . . . . . . . . . . 272 GM PassKey III (PK3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 GM PassKey III+ (PK3+ on 2001 and up GM vehicles) . . . . 273 Chrysler (Sentry Keys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Remote-Start Suggestions for Smart Key Applications . . . . . . . . . 274 Remote-Start Integration with Retained Accessory Power Circuits . . . . . . . . . . . . . . . . . . . . 275 Disarming Factory Security Systems . . . . . . . . . . . . . . . . . . . . . . . 276 Troubleshooting Remote-Starter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Vehicle Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 No Lights Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Does Not Crank, But Lights Flash. . . . . . . . . . . . . . . . . . . . . 277 Cranks, But Not Long Enough To Start. . . . . . . . . . . . . . . . . 277 Starts Up and Shuts Down Early . . . . . . . . . . . . . . . . . . . . . . 277 Pre-Bypass Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Programming or Setting up Bypass Modules . . . . . . . . . . . . . . . . . . . . . . . . . 279 Troubleshooting Factory Hood Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Sample Test Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 CHAPTER 5: IN-VEHICLE INFORMATION SYSTEMS Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Regulatory Groups and Rules Affecting Mobile CE. . . . . . . . . . . . . . . . . . . . . 285 National Highway Traffic Safety Administration (NHTSA) . . . . . 285 Federal Communications Commission (FCC) . . . . . . . . . . . . . . . 287 Occupational Safety and Health Administration (OSHA) . . . . . . 287 Wireless Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Bluetooth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 Headset Profile (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Hands-Free Profile (HFP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 Advanced Audio Distribution Profile (A2DP) . . . . . . . . . . . . . . . 293 Audio/Video Remote Control Profile (AVRCP) . . . . . . . . . . . . . . . 293 Object Push Profile (OPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 Phone Book Access Profile (PBAP) . . . . . . . . . . . . . . . . . . . . . . . . 294 WWAN, WiMax, and other Network Access Solutions . . . . . . . . 294 Telematic Systems Using Wireless Communications . . . . . . . . . . 295 Vehicle Infrastructure Integration . . . . . . . . . . . . . . . . . . . . . . . . . 295 TABLE OF CONTENTS xi As with all semiconductors, voltage drop between terminals (also called “breakdown voltage”) is a design limitation. Breakdown voltages must be taken into account for each combination of terminals (i.e., Vce, Vbe and Vcb). However, Vce (collector-emitter voltage) with open base, designated as Vceo, is usually of most concern and defines the maximum circuit voltage. Basically this is the “unloaded” operation of the transistor, which should never happen unless the protection circuit of a device creates that open circuit in an effort to save the transistor from destruction. Margin Notes What about the term “Darlington”? It’s used quite often in mobile electronics, especially in amplifier output topologies. Darlington transistors contain two transistors connected in an emitter-follower configuration, while sharing the same collector contact, all within the same case. This structure can be fabricated with the same technology as a single bipolar transistor, which means you cannot really tell by just looking at the outside of the transistor. ■ Figure 7. The water flow analogy for an NPN transistor demonstrates electron flow (negatively charged particles) moves from emitter to collector and the rate is determined by the faucet valve (which is the base). The key advantage of the Darlington configuration is that the total current gain (or beta) of the circuit equals the product of the current gain of the two devices. The disadvantage is the larger saturation voltage. Since the two devices share the same collector, the saturation voltage of the Darlington pair equals the forward bias voltage of transistor Q2 plus the saturation voltage of transistor Q1. Since the forward bias voltage is much larger than the saturation voltage, the saturation voltage of the Darlington pair is also significantly larger. This larger voltage results in larger on-state power dissipation in the device. CHAPTER 1. VEHICLE ELECTRICAL SYSTEMS ✍ Beta or H FE is the gain of the transistor ■ Figure 8. A schematic representation of an NPN Darlington pair. In practice, this would be in a single transistor package and look just like other transistors of the same package type but has a much higher beta. 9 Margin Notes A serial data stream contains bits that each hold a specific place in the data stream. Bits can represent a message being sent or even a separation (pause) between messages. These bits are being sent at precise time intervals. The speed at which bits are transmitted is known as baud rate. The digital messages are sent one after the other in a single direction. In order for electronic control module number two to understand the signal from electronic control module number one, they must be synchronized with an internal clock, which is based on the prescribed baud rate. It is also possible for two computers to send and receive on the same conductor (or group of conductors). The very basis of a “network” using control modules in modern vehicles is multi-tasking electrical signals over a common conductor path. This is often called “multiplexing” in electrical terms, but the implementation and evolution in vehicle electrical systems has changed dramatically. ✍ Data messages with arbitration bits allow the more important message to win if 2 or more messages are transmitted to the same receiving device at the same time. “Synchronous” refers to data signals that are constant, meaning the signal never stops as long as the computers are active. “Asynchronous” refers to signals that are sent only when necessary, meaning they are NOT constant. The computer that sends messages includes start and stop codes with the asynchronous signal so that the computer that receives the data can correctly interpret the information and understand when the message is finished. These are often called start of frame (SOF) and end of frame (EOF) identifiers. In data bus systems that transmit asynchronous data, there is usually another section of the messages that contains a section called “arbitration.” This means that when two or more messages are sent and arrive at a particular destination at the same time, one must always “win” as a matter of priority. For instance if an ABS brake signal and an oil level warning signal arrived at a computer at the same time, the ABS brake signal would take priority. ■ Figure 17a. This is an example of a low resolution GM Class 2 data bus signal shown on the scope screen of a diagnostic scan tool. ■ Figure 17b. This is an example of a low resolution CAN-BUS (2.0B) data bus signal, both HI and LOW signal components, shown on the scope screen of a Fluke 124 oscilloscope. Simultaneously reading these signals with an oscilloscope requires a dual input capacity. 20 THE MASTER INSTALLATION TECHNICIAN STUDY GUIDE SAMPLE TEST QUESTIONS Margin Notes In the process of reviewing your knowledge of Chapter 1 subject matter, please remember that this guide assumes you have mastery of the information presented in the MECP Advanced Installation Technician Study Guide. If necessary, please review that guide prior to proceeding with sample test questions. 1. Choose an appropriate substitute for a relay in a low current DC switching application? a. A potentiometer. b. A Silicon Controlled Rectifier (SCR). c. An NPN transistor. d. A Zener diode. 2. What is the time constant formula for capacitors? a. 1 Time Constant = R × C (Resistance times Capacitance). b. 1 Time Constant = R / C (Resistance divided by Capacitance). c. 1 Time Constant = C / R (Capacitance divided by Resistance). d. 1 Time Constant = (C + R)2 (Capacitance plus Resistance squared). 3. What device can be placed on a relay to protect transistorized outputs on an ECU? a. Silicon Diode. b. Carbon Resistor. c. Iron Core Inductor. d. Another Relay. 4. How would the device from question 3 above be placed on the relay? a. In series between the load and terminal 30. b. In parallel across the coil terminals. c. In parallel between terminal 30 and 86. d. In series between the trigger and terminal 85. 5. What is the electrical power consumption of a device with 13.8 volts of supply and a current draw of 150 milliamps? a. 0.01 Watts b. 0.092 Watts c. 2.07 Watts d. 10.87 Watts CHAPTER 1. VEHICLE ELECTRICAL SYSTEMS 57 for high-volume production runs. Many instrument panel manufacturers can produce surface to color (mold-in color) or finish the instrument panels with soft touch coatings that are colored in a post-production process. Margin Notes Vacuum forming allows consistent production of larger panels in which flexible plastics are used. This is an ideal process for door and side panel parts, as well as other large dimension interior panels. Such parts create greater challenges in integrating aftermarket mobile electronics products because of the type of material used, the color and the texture. All of these points must be considered in an integration job. ■ Figure 8. Large industrial vacuum forming machines often make interior panels and dashboards. Making repairs or modifications to the plastic panels requires identifying the specific plastic involved. Over the years that has become more and more challenging. A simple way of looking at OEM plastics is to break them down into three basic types: flexible, semi-rigid and extra rigid. This further separates thermoplastics and thermosets by the “gray area” of semi-rigid plastics, which may have attributes of both types. Once you identify which type of plastic you are working with (or considering modifying), you stand a much better chance of achieving a “factory-like” result with the adhesion, surfacing and finishing. Flexible Plastics (definitely thermoplastics) ■ PUR (polyurethane) ■ TPUR (thermoplastic polyurethane) Semi-Rigid Plastics (generally thermosets, but may have a thermoplastic “character”) ■ ABS (acrylontrile butadiene styrene) ■ TPO (thermoplastic olefin) ■ TPE (thermoplastic elastomer) ■ UP (polyester thermoset) ■ EPDM (ethylene propylene diene monomer) CHAPTER 2. INSTALLATION KNOWLEDGE AND TECHNIQUE 67 Margin Notes ■ Figure 34a. This is the setup for the Hall Effect current clamp. A. Prepare the DC current clamp for a measurement. On most clamps, you will have to “zero out” the display so that your measurement has the highest probable accuracy. Note: If you are using a powered accessory clamp (such as the Fluke i410, i1010 or equivalent), you will plug into the volt/ohm and COM jacks on your DMM and set the meter to the DC millivolt (mV) setting. The clamp has an internal battery that converts high current into a safe, lowvoltage signal that the meter will safely display. In the case of the Fluke i410 or i1010 clamp, 1mV on the DMM display = 1a of current flow measured through the clamp. B. Clamp the meter around the positive cable connecting the alternator to the battery. Make sure no other wiring is inside the clamp jaw because this will skew the measurement. You may see an arrow on the clamp jaws. This is a current flow indicator. It should point toward the alternator. ■ Figure 34b. Step 8 is a reference charging current measurement with no accessory loads done at 2000 RPM. Remember 1mV on the meter equals 1A measured at the Hall Effect Clamp jaw. C. With hands and test leads clear of any obstructions, start the motor. D. All accessories should be off. E. Advance engine speed to 2000 rpm. F. Read and record the DC current measurement. If your measurement reads out in negative numbers (e.g., “–22” instead of “22”), you simply have the clamp placed backward on the wire. Reverse it if you wish to confirm the measurement. Note: Record the highest measurement you see, but leaving the “MAX” function off allows you to see how frequently that measurement holds. This is because the loads on the alternator are dynamic. Current: No Load, No Accessories, Car RUNNING (2000 rpm) ___________ Step 9 Perform a loaded current measurement on the charging system at 2000 rpm. You will load up the electrical system again to see how the charging system handles the load with the same accessory loads as in previous measurements. CHAPTER 2. INSTALLATION KNOWLEDGE AND TECHNIQUE 89 SAMPLE TEST QUESTIONS Margin Notes In the process of reviewing your knowledge of Chapter 2 subject matter, please remember that this guide assumes you have mastery of the information presented in the MECP Advanced Installation Technician Study Guide as well as a minimum of three years of hands-on professional experience. 1. Which direction does the bit move in a router table setup? a. Clockwise b. Counter-clockwise c. It oscillates vertically d. It oscillates left to right 2. What is the shielding gas used for MIG welding carbon steel? a. 100% Carbon Dioxide b. 75% Carbon Dioxide and 25% Argon c. 75% Argon and 25% Carbon Dioxide d. 100% Argon Carbon Dioxide 3. What is the threshold for AC ripple measurements to cause concern for engine noise issues? a. 0.3 volts b. 3 volts c. 12.66 volts d. 13.8 volts 4. Which one of the devices listed measures DC current over 10 amperes? a. Incandescent Test Light b. OBD-II Scan Tool c. Inductive Clamp d. Hall Effect Clamp 5. When spraying professional grade upholstery adhesives from an HVLP gun, what is the minimum recommended ambient temperature? a. 40 degrees F / 4 degrees C b. 50 degrees F / 10 degrees C c. 65 degrees F / 18.3 degrees C d. 72 degrees F / 22.22 degrees C CHAPTER 2. INSTALLATION KNOWLEDGE AND TECHNIQUE 143 Margin Notes ■ Figure 38. Adhesive sheet damping materials on the inside skin and outer skin are important for controlling any unwanted resonances. that the speaker fires parallel to the windshield and is located as close to it as possible, then reflections can be minimized or eliminated. Some reflections in a car will be unavoidable. No car audio system will ever be able to control all reflected energy because reflected energy is what human hearing systems cue on to determine the sense of space in which we are listening. Therefore, it’s a good idea to experiment with controlling reflections that occur close to the speakers—or close to our ears—that can have negative effects on the overall soundstage, imaging and frequency response. A good technique for controlling reflections off of surfaces like the side windows and windshield is to attenuate the energy from the speaker acoustically pointed toward that surface before it can reach the offending reflective surface. For example, the direct sound from the speaker is the desired sound, the sound you want. If the speakers in the right kick panel have a direct path to the listener’s right ear, that is good. However, if the sound from the right speakers can also travel directly to the left side window, and be reflected back to the listener, that can cause problems. Since it is not possible to place absorptive material on the left side window, why not place foam material between the right side speaker and the left side window? Place the foam so that it does not affect the direct path to the listener, but does attenuate the path toward the left side window. Another technique for controlling reflections is to re-orient panels in the vehicle to direct reflected energy to areas where it will not affect the desired sound. An example might be a reflection off of the center console from the kick panel-mounted speakers. The console panels could be reconstructed so that the reflection is directed elsewhere, preferably into an absorptive panel. An absorptive material’s effectiveness at controlling a reflection depends on its density, surface type and thickness. The lower the frequency of the reflec- CHAPTER 3. MOBILE A/V SYSTEMS 201 Margin Notes AUX-IN via OEM Integration Device Many of the latest OEM integration devices that are intended to allow adding an aftermarket amplifier on to the OEM headunit offer one or more auxiliary inputs. This is an excellent option for sound quality and to gain the benefits of that particular device, whether it is equalization, signal buffering or something else. However, the drawback is that there must be an external volume control to be able to vary the signal so it can closely match the signal levels of the OEM system inputs. This can be the volume control on the carry-in device itself, or a separately installed volume knob elsewhere in reach of the user. Typically in this scenario, the user would set the level of the connected portable device(s) as well as the OEM headunit, and use a single volume control for the volume function on all the sources. CUSTOM MODIFICATIONS Although this is an alternative handled on a case-bycase basis depending on the vehicle year/make/model and trim level, there are instances where custom modifications can allow “clean” preamp-level aux input into an OEM headunit. These modifications are not at all intended to be completed in most shops, but rather by experienced bench technicians with the ability to disassemble, examine and test these units out of the vehicle. ✍ OEM Amplifiers sometimes perform master volume, balance, and fader functions even though it is initiated from the headunit. ■ Figure 46. Circuit board level aux input modifications like this BMW 7 Series weather band tuner input are reserved for only the most skilled technicians and are not practical for everyday install shops. Some vehicles can simply use a changer cable that is interrupted via solidstate switching to allow input as if the audio were coming from a changer, but still maintain the changer communication loop. Other, more intense modifications take place inside the unit, which may reside in the dash or even in a hidden location for a tuner or factory amplifier. The modification usually involves using an audio source input that already exists (such as the weather band tuner in BMWs) and making modifications. That gives the installation technician a set of full-range, preamp-level analog inputs. Again, this is a case-by-case basis and is the audio equivalent of the “engine tuners” modifying ECUs in modern street-racing cars. ADDING A HEADUNIT TO AN OEM AMPLIFIER Exchanging headunits can be difficult without the use of adapters. While this is the ultimate source input (changing the entire source unit), issues must be addressed with regard to the audio-input differences between what the aftermarket source unit offers and what the OEM amplifier will accept. 226 THE MASTER INSTALLATION TECHNICIAN STUDY GUIDE SAMPLE TEST QUESTIONS Margin Notes In the process of reviewing your knowledge of Chapter 3 subject matter, please remember that this guide assumes you have mastery of the information presented in the MECP Advanced Installation Technician Study Guide as well as three years of hands-on professional experience installing mobile audio and video systems including designing systems and troubleshooting installation related issues. 1. How much power does 40 volts of output into 4-Ohms on a single amplifier channel produce? a. 10 Watts b. 160 Watts c. 400 Watts d. 6400 Watts 2. Asymmetrical crossover points are described as? a. Crossover points sharing the same cut off frequency. b. Crossover points sharing different cutoff frequencies. c. Crossover points beyond 24dB/Octave slope. d. A crossover that is either HP or LP designated by a switch. 3. When the size of a vented enclosure decreases and the vent area stays constant, which is true of vent length? a. It must be longer to maintain the same tuned frequency. b. It must be shorter to maintain the same tuned frequency. c. If it remains the same length, so will the tuned frequency. d. Vent length is dependent on the subwoofer not the enclosure volume. 4. What is the default file format of iTunes music management software for the iPod? a. AAC b. MP3 c. WAV d. WMA 5. In audible terms, which of the following statements is correct? a. White noise has more audible low frequency than pink noise. b. Pink noise has more audible low frequency than white noise. c. Pink noise and white noise have identical audible low frequency content. d. Neither pink noise nor white noise has any audible low frequency content. CHAPTER 3. MOBILE A/V SYSTEMS 255