Innovate Motorsports LC-1 Manual de usuario

Document # 11-0053 11-0053 LC-1_Manual_1.6.doc

LC-1 Digital Air/Fuel Ratio (Lambda)

Sensor Controller Manual

Warning!

The Oxygen Sensor used in this device gets very hot in operation.

Do not touch the hot sensor. Do not let a hot sensor touch a

combustible surface. Do not use the sensor with or near flammable

liquids or gases. Failure to heed these warnings may result in severe

burns, explosions or fires.

When installed in the exhaust, the oxygen sensor MUST be

connected and operating with the LC-1 whenever the car is running.

An un-powered oxygen sensor will be quickly damaged when

exposed to hot exhaust gases.

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1Overview................................................................................................................................... 3

2Mounting and Connecting the LC-1 ......................................................................................... 4

2.1 Indicator LED and Calibration button hookup: .................................................................. 5

2.2 Connecting the LC-1 to an external analog AFR display.................................................. 5

2.3 Connecting the LC-1 to an ECU or data logger ................................................................ 5

2.4 Mounting the sensor using a Bung. .................................................................................. 6

2.5 How to fabricate a copper heat sink ................................................................................. 8

3First Time Use .......................................................................................................................... 8

4Calibration ................................................................................................................................ 9

4.1 Free air calibration ............................................................................................................9

4.2 Sensor heater calibration .................................................................................................. 9

4.3 Calibration Schedule....................................................................................................... 10

5Remote display and recording of Lambda and/or AFR.......................................................... 10

5.1 Analog Lambda/AFR instrument..................................................................................... 10

5.2 Digital XD-1 Instrument................................................................................................... 10

5.3 Laptop recording of AFR or Lambda .............................................................................. 10

5.4 Multi channel AFR recording with multiple LC-1’s and/or LM-1...................................... 11

6Programming the LC-1 ........................................................................................................... 12

6.1 Installing the LM Programmer Software ......................................................................... 12

6.2 Hooking up the LC-1 device to the computer ................................................................. 12

6.3 Resetting the calibration data ......................................................................................... 13

6.4 Updating the Firmware.................................................................................................... 13

6.5 Programming the analog outputs.................................................................................... 13

6.5.1 Advanced output programming................................................................................ 14

7Tips, Tricks and Troubleshooting ........................................................................................... 15

7.1 General measurement requirements .............................................................................. 15

7.2 Vehicles with ‘smog-pumps’............................................................................................ 15

7.3 Measuring at the tail-pipe................................................................................................ 15

7.4 Single Cylinder Engines.................................................................................................. 15

7.5 Diesel Engines ................................................................................................................ 15

7.6 Reference cell or Pump cell circuit open or shorted errors............................................. 15

7.7 Sensor Timing Errors ...................................................................................................... 16

7.8 Calibration tricks and hints................................................ Error! Bookmark not defined.

7.9 Analog Output tricks/hints ............................................................................................... 16

8Advanced Topics.................................................................................................................... 16

8.1 Connecting the LC-1 to simulate a narrow band oxygen sensor.................................... 16

Appendix A: LC-1 Cable Pinouts.................................................................................................. 18

Appendix B: LED blinking codes .................................................................................................. 19

Appendix C: LC-1 Error Codes and Troubleshooting Tips........................................................... 20

Appendix C: Limited Warranty...................................................................................................... 21

Revision History............................................................................................................................. 22

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1 Overview

The LC-1 is a stand-alone Wideband Controller used to measure the Air/Fuel Ratio (AFR) or

Lambda for an engine. For gasoline-driven engines, the theoretically optimal air fuel ratio is 14.7

pounds of air for every pound of fuel. At this ratio, theoretically, all available oxygen in the air

combines with all available fuel. This ratio is called the stoichiometric ratio. Stoichiometric for

different fuels are as follows:

Gasoline 14.7

LPG (Propane) 15.5

Methanol 6.4

Ethanol 9.0

CNG 17.2

Diesel 14.6

The measurement Lambda is the actual air fuel ratio over the stoichiometric ratio. A Lambda

measurement of “1” equates to the air fuel ratio of 14.7 (for gasoline engines). When Lambda is

less than 1 the engine runs “rich”, i.e., unburned fuel exists in the exhaust stream. If lambda is

greater than 1 the engine runs lean, i.e., free oxygen (02) is present in the exhaust. Depending on

the engine, maximum power is typically delivered when the engine runs slightly rich (for example

at lambda values of 0.8 to 0.9 for most engines). This instrument provides a means to measure

the actual air fuel ratio or lambda in the engine in operation directly from the exhaust. For this a

special wide-band oxygen sensor is used to measure the lambda value derived from the oxygen

content (or lack thereof) of the exhaust gases.

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2 Mounting and Connecting the LC-1

1. Find a suitable location under your vehicle where the LC-1 body can be mounted. Using

zip ties or other suitable method, fasten the body of the LC-1 device securely to the frame-

rails or other mounting points as far away from the heat of the exhaust system as the sensor

cable allows. DO NOT zip-tie the LC-1 by the cables.

2. Route the cables from the LC-1 (except sensor cable) into the car interior under the dash.

3. LC-1 Cable connections:

A. Interface and power cables with 7 stripped ends*:

a. Red 12V supply

b. Blue Heater Ground

c. White System Ground

d. Yellow Analog out 1

e. Brown Analog out 2

f. Green Analog Ground

g. Black Calibration wire

B. Serial In connection, 2.5mm stereo (female) marked as IN

C. Serial Out connection, 2.5 mm stereo (female) marked as OUT.

* 3.1 If you have an LC-1 with only 6 stripped ends (early production) the wiring is as follows:

a. Red 12V supply

b. Blue Heater Ground

c. Metallic System Ground

d. Yellow Analog out 1

e. Brown Analog out 2

f. Black Calibration wire

4. Connect the RED wire to a switched 12V source in your car. A switched 12V source

goes on as soon as the ignition on the car is on Make sure the connection is fused with a

minimum fuse size of 5A.

5. The BLUE, WHITE, and GREEN wires should all be grounded to the same ground source

and although these grounds are of the same source, the BLUE wire should be wired

separate from the WHITE and GREEN wires to avoid analog ground noise.

6. Optionally, the YELLOW (Analog out 1) and/or BROWN (Analog out 2) can be connected

to the analog inputs of other devices such as data loggers and ECUs. If either one or both of

these wires are not being used isolate and tape the wire(s) out of the way. Note: The LC-1’s

heater ground, system ground, and analog ground wires should be grounded at the

analog input’s ground.

7. Optionally connect a momentary push-button switch between ground and the BLACK

calibration wire. Please refer to section 2.1.

Note: The use of the calibration wire is not necessary if the LC-1 is connected to Innovate

Motorsports’ XD-1 digital gauge. If the wire is not are not being used, isolate and tape the

wire out of the way.

8. Optionally connect a indication LED (1.2-2.2V, 1-30mA is recommended) between the

calibration wire and ground. Please refer to section 2.1

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2.1Indicator LED and Calibration button hookup:

To monitor LC-1 status, connect the red wire (Anode) of the included LED to the calibration wire (black) of

the LC-1 and connect the black wire (Cathode) of the LED to the ground wire of the momentary switch.

a. Note: The included LED will fit the following hole size and panel thickness: a 5/32” (0.155” -

0.158”) hole size and a panel thickness of 28–16gauge (0.031” - 0.062”).

b. Optionally, any 1.2V - 2.2V (1mA- 30mA) LED may be used. A typical LED has 2 wires called

Anode and Cathode. The Cathode side is typically the shorter of the 2 wires (refer to the

component data sheet of the selected device for details).

Pressing the push-button or connecting it quickly to ground starts a free air calibration process in

the LC-1. MAKE SURE THE SENSOR IS IN FREE AIR FOR THAT. See chapter 4 for details.

2.2Connecting the LC-1 to an external analog AFR display

2.3Connecting the LC-1 to an ECU or data logger

All Innovate MTS devices like the LC-1 with dual serial ports should have their system grounds

connected together to a common ground point. If an external data logger or ECU is to be fed by

an MTS device, the MTS ground should be located at or near the ECU or data logger’s input

signal ground. Some ECU’s or data loggers have differential inputs. A differential input has a

separate ground INPUT for each sensor input. This ground input MUST be connected also to

ground as shown in these diagrams. If one analog output of the LC-1 is used to drive an AFR

display and the other output is used to connect to an ECU, the AFR display ground should be

connected to the ECU ground.

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7-wire LC-1 connection

6-wire LC-1 connections

2.4Mounting the sensor using a Bung.

Using a bung is the preferred method for mounting the O2sensor for both catalytic and

non-catalytic cars.

On CATALYTIC CONVERTER equipped vehicles:

Install the oxygen sensor’s bung upstream from the catalytic converter (a bung and plug is

included in the LC-1 kit). Any decent muffler or exhaust shop can do this for you. The wide-

band oxygen sensor is then installed into the bung to take a reading. (Insert the plug into the

bung when not in use). The bung must be installed in the exhaust pipe at the side or on

top, NOT on the bottom of the exhaust pipe.Best position is between 10:00 and 2:00

position.

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On NON-CATALYTIC converter vehicles:

You have the option with non-catalytic cars to also use a Bung as described above. Use of a

bung is the preferred method for mounting the 02sensor for both catalytic and non-catalytic

cars.

On TURBO CHARGED vehicles:

Install the bung downstream from the turbo before the catalytic converter. The high exhaust

pressure before the turbo interferes with the lambda measurement and the high exhaust

temperatures encountered there can damage the sensor.

Do NOT install the Bung below the 3 o'clock or 9 o'clock position.

Condensation can form in the exhaust pipe and permanently damage the sensor.

6 o’clock is the absolute worst position to mount the sensor.

Wide band oxygen sensors – like the one shipped optionally with the LC-1

– are designed to work with unleaded gasoline. Using them with leaded gasoline

will significantly reduce the lifespan of the sensor. The reduction is directly

proportional to the metal content of the fuel. In most cases, a wide band sensor

will provide accurate measurements somewhere between 50 hours and 500 hours

with leaded fuel.

WHEN INSTALLED IN THE EXHAUST, THE OXYGEN SENSOR

MUST BE CONNECTED AND OPERATING WITH THE LC-1

WHENEVER THE CAR IS RUNNING. AN UN-POWERED OXYGEN

SENSOR WILL BE DAMAGED WHEN EXPOSED TO EXHAUST GAS.

The maximum temperature of the sensor at the bung (the sensor hexagon)

should not exceed 500 oC or 900 oF. If these temperatures are exceeded in your

application you should either install a copper heat sink (instructions below) or the

Innovate Motorsports Heat-Sink Bung extender (HBX-1).

The bung extender is recommended for situations where airflow is restricted or

the encountered heat is higher than a heat sink can handle.

It is NOT a good idea to connect the LC-1 permanently to 12V and switch it

on with a separate switch before the vehicle is started. Depending on the climate

and the sensor position in the exhaust, condensation water can form in the

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exhaust pipes. This condensation water could then be blown by the exhaust

stream against the hot sensor when the car is started. The resulting heat shock

can permanently damage the sensor.

2.5How to fabricate a copper heat sink

Use a 4” x 4” (10cm x 10 cm) sheet of copper sheet metal 14ga (1.5mm) thick. Drill a hole in the

center with the same diameter of the oxygen sensor threads ~3/4” (19mm).

Fold the sides up 45 deg and mount it between the sensor and the bung like you would a big

washer. Orient it such that the sides are exposed to good airflow.

3 First Time Use

1. Do not connect the sensor yet.

2. Switch 12V supply to the LC-1 on and wait for 10 seconds.

3. Switch the 12V supply off after 10 seconds.

4. Connect the sensor to the sensor interface connector. The sensor must be exposed to air

for the first time calibration.

5. Switch the LC-1 on and wait for 2 minutes.

If you connected a LED to the calibration button, you will at first see the LED blink slowly and

steadily. If it blinks for a fixed number of pulses, then switches off for 2 seconds and then repeats,

you have an error code. See Appendixfor details.

Slow and steady blinking indicates that the sensor is warming up to its optimum operating

temperature. The warm-up period will last for about 30 seconds for a cold sensor, depending on

the sensor type used.

After the sensor is warmed up the meter automatically calibrates the sensor heater controller to

the particular sensor. During this 20-second period the LC-1 collects and calculates sensor

specific data required to quickly reach operating temperature in the future. After the first time use

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the meter will use these values to regulate the sensor's temperature. During the heater calibration

the optional LED will blink fast and steady.

After that period the LC-1 will automatically perform a free air calibration. During this 2 second

period a connected LED will go off. The LC-1 will now calibrate itself by using air as a reference

gas with known oxygen content.

After the free air calibration is finished the LED should light up steady and continuously,

indicating correct operation of the LC-1.

4 Calibration

There are two types of calibration for the LC-1: free air calibration and sensor heater calibration.

Sensor heater calibration and first free air calibration is automatically performed the first time a

new sensor is used, while free air calibration should be executed frequently.

4.1Free air calibration

To achieve maximum precision, the LC-1 and its sensor needs to be recalibrated frequently.

The sensor MUST be operated in free air for calibration.

If the wide-band sensor is installed in a vehicle, wait 6-8 hours after running the engine so that all

exhaust gas is dissipated from the exhaust tract of the vehicle. Better yet, disengage the oxygen

sensor and expose the sensor to air (away from the exhaust) for calibration purposes:

1. Connect the LC-1 to 12V from the vehicle and switch it on.

2. After the sensor has warmed up, either press the pushbutton or connect the calibration wire

to ground for a brief period.

3. After the calibration is complete, switch the LC-1 off and wait for 30 seconds before you start

the car.

If a LED indicator is connected to the calibration wire, it will be off during free air calibration.

4.2Sensor heater calibration

If you change the sensor – either with a replacement sensor or a new type of sensor --, the

heater circuit of the LC-1 needs to be recalibrated as well. (See steps in chapter 4 'First Time

Use'). The heater calibration data in the LC-1 will be reset when the device is operated from 12V

without a sensor connected for at least 5 seconds. You can force a reset by doing this, and then

recalibrate by turning the unit off, reconnecting the sensor, and turning the unit on.

After the sensor is warmed up the meter automatically calibrates the sensor heater controller to

the particular sensor. During this 20-second period the LC-1 collects and calculates sensor-

specific data required to quickly reach operating temperature in the future.

Note: When using the Bosch Sensors the LC-1 may perform multiple calibration passes.

This is normal and need not cause concern. When it completes, the LC-1 also will perform

a free air calibration. Make sure the sensor is operating in free air for the heater and free

air calibration.

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4.3Calibration Schedule

Normally aspirated daily driver:

- Calibrate before installation of new sensor

- Calibrate new sensor again after 3 month of use

- Thereafter calibrate once a year or every 20,000 miles, whichever comes first

Turbo car, daily driver (tuned rich):

- Calibrate before installation of new sensor

- Calibrate new sensor again after 3 month of use

- Thereafter calibrate twice a year or every 10,000 miles, whichever comes first

Race car

- Calibrate before first installation of new sensor

- Calibrate once per race weekend

Dyno use

- Calibrate a new sensor

- Calibrate every 2-3 days, depending on usage

5 Remote display and recording of Lambda and/or AFR

In many applications it may be desirable to monitor the air-fuel data remotely using a dash-

mounted instrument. The LC-1 provides two options for that application.

5.1Analog Lambda/AFR instrument.

There are many analog lambda/AFR displays on the market. They are essentially voltmeters for a

voltage between 0 and 1 V and measure the analog voltage of a narrow band oxygen sensor.

Some are true analog instruments while others provide a LED bar. Because of the very limited

sensing range of a narrow band sensor they are essentially useless as true AFR meters. With the

LC-1, connecting these meters to the second analog output of the LC-1 allows them to be used

as true remote AFR meters, provided the LC-1 analog output is programmed to the

characteristics of the used meter. The LC-1's analog output 2 is factory programmed to provide a

linear output between 0V and 5V for an AFR of 7.35 to 22.39. Any other linear output range

between 0 and 5V can be programmed. See chapter 6.5: Programming the analog outputs for

details.

5.2Digital XD-1 Instrument

1. Connect the Serial OUT connection (unmarked) to the Serial IN connection of the XD-1

(marked) with the included 2.5mm to 2.5mm cable. Make sure the XD-1 is programmed as

AFR instrument for the first channel like for an LM-1.

2. Connect the terminator plug (2.5mm male plug with no cable) into the Serial IN connection of

the LC-1.

3, If real-time recording with the Innovate LogWorks software, connect the included 2.5mm stereo

to DB-9 cable to a serial port on your laptop.

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