Related Manuals for ECM AFRecorder 2400G
Summary of Contents for ECM AFRecorder 2400G
- Page 1 AFRecorder 2400G Four Function Engine Diagnostic System Instruction Manual 6/03 Part Number 2400G-11...
- Page 2 COPYRIGHT 1992-2003 by ECM: ENGINE CONTROL AND MONITORING. All Rights Reserved. No part of this manual may be photocopied or reproduced in any form without prior written consent from ECM: ENGINE CONTROL AND MONITORING. Information and specifications subject to change without notice.
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Page 3: Table Of Contents
Table of Contents Introduction The AFRecorder 2400G AFRecorder Components List Important Operation Notes Air-to-Fuel Ratio Sensor Spark Timing and Engine Speed Inputs Manifold Pressure Input Physical Features and Hook-up Front Panel Rear Panel and Power Hook-up Air-to-Fuel Ratio Hook-up Engine Speed Hook-up... - Page 4 Remote Operation (using AFRemote Software) Software Operation Measurement Measurement with Direct Storage to Disk Recording Results and Plot Configuration Setup AFR Measurement Offset Specifications and Limits Measurements and Accuracy Recording Specifications Real-Time to Disk and Real-Time Plot to Disk Specifications Input Specifications and Limits Output Specifications and Limits General Information...
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Page 5: Introduction
Introduction The AFRecorder 2400G The AFRecorder 2400G is a portable, microcomputer-based engine development tool that is suitable for use either in a laboratory or on a test track. The AFRecorder integrates the features of several separate instruments into a single, compact, easy-to-use package. The... -
Page 6: Afrecorder Components List
AFRecorder Components List The following items are included with the AFRecorder 2400G package: Item No. Description Part Number AFRecorder 2400G 2400G Air-to-Fuel Ratio (AFR) Sensor 2400E-1 AFR Sensor Cable, 20 ft. 2400E-2 Spark Timing Pickup/Cable, 20 ft. 2400A-3 Engine Speed Pickup 2400A-4 Engine Speed Pickup Cable, 20 ft. -
Page 7: Important Operation Notes
Important Operation Notes Please read and follow all of the cautions contained in the Safety Warnings section on page 55 of this manual. Air-to-Fuel Ratio Sensor Read the AFR Measurement Calibration (“AIR CAL”) section on page 25. Do not use the air-to-fuel ratio (AFR) sensor with leaded fuel or in a heavily-sooting or crankcase-oil-burning engine because these conditions can shorten the life of the sensor. -
Page 8: Spark Timing And Engine Speed Inputs
Spark Timing Pickup/Cable (Part No. 2400A-3 provided with the AFRecorder) must be used. Use only the probes and cables provided with the AFRecorder or those approved by ECM. Route the spark timing and engine speed cables away from hot or moving objects. -
Page 9: Physical Features And Hook-Up
Physical Features and Hook-up Front Panel Once the power, sensors, cables, and outputs have been hooked up, all user interactions (in stand-alone mode) with the AFRecorder are made through the front panel. To enter or operate in remote mode, the front panel is not used although the status of this mode is indicated on the display. -
Page 10: Air-To-Fuel Ratio Hook-Up
seen from the back of the AFRecorder when the AC line input module's door is closed. 1 A Slow Blow fuses are required for 100-120 VAC power and 0.5 A Slow Blow fuses are required for 220-240 VAC power. All fuses must be rated for 250 VAC. DC power enters the AFRecorder through the smaller of the two keyed circular plastic connectors (CPCs) on the rear panel. -
Page 11: Engine Speed Hook-Up
Install the sensor by lightly coating its threads with a non-lead containing antiseize compound and tightening to 30 ±3 ft-lbf (40 ±4 Nm). Attach one end of the cable to the sensor and route the cable to the AFR sensor input on the back of the AFRecorder (the larger of the two keyed plastic connectors (CPCs)). - Page 12 Engine Speed and Spark Timing Sensing (page 46) for more information. RPM measurement may also be possible with other types of sensor signals and by tapping existing engine control system signals. Contact ECM for details on these other engine speed measurement techniques.
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Page 13: Spark Timing Hook-Up
AFRecorder! When these "direct" spark timing inputs are used, the "Spark Pickup" switch is set to "DIR". Contact ECM for details on "direct" spark timing measurement techniques. -
Page 14: Analog Outputs And Simulated Ego Sensor Output
Analog Outputs and Simulated EGO Sensor Output Linearized and programmable 0 to 5 VDC outputs are available for each measured parameter. Also available is a simulated EGO (exhaust gas oxygen) sensor output with a programmable switch point. These outputs are taken from the female DB9 connector on the back of the AFRecorder. -
Page 15: Stand-Alone Operation
Stand-Alone Operation Measurement and the SYS Key Upon power-up, the AFRecorder executes the following sequence: System initialization is done. The display shows "Initializing" and the "HIGH" and "LOW" alarm lights and internal buzzer are tested. If the AFR measurement function is enabled (see AFR Measurement Enable/Disable on page 26), a 45 second countdown is performed to allow the AFR sensor to reach operating temperature. - Page 16 When the %O in the exhaust exceeds 19.5%, the AFRecorder will automatically change from displaying AFR to %O This allows for the fast visual checking of the AFR measurement calibration when the engine is stopped and the exhaust contains pure air. When the engine is restarted, the AFRecorder will automatically change back to displaying AFR in the programmed units.
- Page 17 Main Menu Level 1 Level 2 Function MEASURE Measure & display RESULTS 1 REPLAY Slow motion playback 2 STATISTICS 1 AFR Recorded data statistics 2 SPK 3 RPM 4 Pman 3 POINT Display one recorded point (+: advance, -: back up) SETUP 1 DISPLAY 1 SIZE...
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Page 18: Recording
Recording Recording is started by pressing the "REC" (Record) key while the AFRecorder is displaying its measured parameter(s). During recording, the display will appear as shown in Figure 5. RECORDING 30/1250 AFR: 17.32 SPK: -23. RPM: 1500 PMAN: 15.0 Figure 5: AFRecorder Display During Recording In the four-line configuration, the upper row of the display shows the number of samples recorded and the total number of samples to be taken. - Page 19 RESULTS 1 REPLAY 3 POINT 2 STATISTICS 4 EXIT Figure 6: The Results Menu Results - Replay If "REPLAY" is selected from the results menu, the display replays the recorded data in slow-motion (see Figure 7). The display is updated with the measured parameters' values at each sample time.
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Page 20: Setup Menu
AVERAGE: 17.63 Sd: 0.012 SAMPLES: 251 Figure 9a: Example of Statistical Results Screen 1 MAXIMUM: 18.78 @T= 2.40 SEC MINIMUM: 17.62 @T= 5.20 SEC Figure 9b: Example of Statistical Results Screen 2 Choosing "EXIT" from the statistics menu will return the AFRecorder to the results menu. Results - Point Selecting "POINT"... - Page 21 SETUP - DISPLAY 1 SIZE 4 RATE 2 AFR UNITS 5 EXIT 3 PMAN UNITS Figure 11: Setup - Display Menu Setup - Display - Size The choice of "SIZE" from the setup - display menu allows the configuration of the display as a four-line display ("SMALL") or a single-line large character display ("LARGE").
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Page 22: Record Menu
The table also shows the number of measurements which are averaged to generate the information displayed for a given update interval. The averaging is performed on data sampled at 0.02 sec. intervals. Note that during recording, measurements are stored "raw" (not averaged) at the selected sample interval (see Setup - Record Menu on page 18). - Page 23 The analog outputs are updated every 0.02 seconds. See the Output Specifications and Limits section on page 41 for more information. Setup - Outputs - Sim EGO The choice of "SIM EGO" allows the setting of the AFR at which the simulated exhaust gas oxygen (EGO) sensor output transitions from its low (approximately 0.02 V) state to its high (approximately 0.8 V) state (or vice versa).
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Page 24: Options Menu
Setup - Outputs - Cal D/A The choice of "CAL D/A" allows the calibration and the verification of the accuracy of the D/A (digital to analog) conversion process of the AFRecorder. If this option is selected, the AFRecorder will calibrate its analog outputs with respect to its internal voltage reference and will hold the analog outputs at 1 V and 4 V so that they may be verified externally. -
Page 25: Constants Menu
Setup - Options - Alarms The "ALARMS" option in the setup-options menu allows the visual limit alarms and the buzzer limit alarms to be independently armed. If the H:C, O:C, or N:C ratio of the fuel is changed then the AFR alarms must be reprogrammed. See Setup - Outputs - Alarms on page 19 for more information. - Page 26 oxygen (Io ), carbon monoxide (Ico), and hydrogen (Ih ). These constants are factory determined and provided with every sensor. If any AFR sensor parameter is entered (including reentering the same number), the AFRecorder assumes that a new sensor is being used and resets the "AGE FACTOR"...
- Page 27 "RPM from SPK" in Setup - Options - Sensors on page 20) then the number of spark pulses per 2 crankshaft revolutions should be entered here. If the spark timing pickup is clamped around a cylinder's spark plug wire, one (1) should be entered for a 4-stroke engine and two (2) for a 2-stroke engine.
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Page 28: Afr Measurement Offset
If the answer to the first display ("RPM PULSES/2 REV") is greater than eight (8), then the measurable range of spark timing of the AFRecorder will be reduced from 90 deg. (ie. -60 to 30) to 60 deg., and a sixth display will appear asking “MAX SPARK ADVANCE (-60 TO - 30)”. -
Page 29: Afr Measurement Calibration ("Air Cal")
AFR Measurement Calibration (“AIR CAL”) The selection of "AIR CAL" from the main menu field-calibrates the AFR measurement function with air as the calibration gas. "AIR CAL" requires that the user enter the %O air in Setup - Constants - Air and only needs to be performed if the AFRecorder does not display this entered value when the AFR sensor is held in stationary air. -
Page 30: Afr Measurement Enable/Disable
AFR Measurement Enable/Disable Selecting "ENABLE" from the main menu allows the AFR sensor to be powered down ("DISABLED") and up ("ENABLED") for sensor removal. To avoid AFR sensor damage, the sensor should only be removed or attached when the sensor is disabled or when the AFRecorder is off. -
Page 31: Remote Operation (Using Afremote Software)
The commands used by AFRemote to interact with the AFRecorder may be used in a user- written program. Contact ECM for information on communicating with the AFRecorder. AFRemote is a menu-driven program. Thus, operation of the AFRecorder in remote mode is not unlike its operation in stand-alone mode in that the user is prompted for entries. - Page 32 Figure 17 shows an example of the PC's main menu screen after starting AFRemote and selecting one of the pull-down menus. Along the top of the screen are the main menu's choices: "File", "Setup", "Commands", "Analysis", and "Plots". The bottom line of the screen is a status line which indicates "AFRecorder Disconnected"...
- Page 33 similar progression in the connection (i.e. acknowledgment, uploading setup data, connected) as shown in Figure 20. When the connection is complete, the status "AFRecorder Connected" is shown in the bottom, left corner of the screen. REMOTE MODE SENDING DATA... REMOTE MODE IDLE Figure 18: AFRecorder Display During Software Connection After the software connection has been completed, operation of the AFRecorder can be...
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Page 34: Measurement
Figure 19: PC Screen During Software Connection Measurement Measured parameters can be viewed on the PC's screen in two forms: real-time display or real-time plotting. With both forms, the parameters and their units are those selected in setup (see Setup - Display Menu on page 16 and Setup - Options - Sensors on page 20). The update interval and the measurement averaging are at the "FAST"... -
Page 35: Measurement With Direct Storage To Disk
Real-Time Plotting Real-time plotting turns the PC into an oscilloscope showing the values of the measured parameters as a function of time (see Figure 20). Real-time plotting is started by selecting "Plots" followed by "Draw Real-Time Plot". Pressing any key on the PC's keyboard or the mouse's left button will suspend the plotting. Pressing any key (except for "Esc") or the left button again will continue the plotting. - Page 36 sample intervals less than 0.13 seconds, with every other data point for sample intervals between 0.13 seconds and 0.25 seconds, and with every data point for sample intervals greater than 0.25 seconds. Note that this data is not averaged as it is for the options "Real- Time Display"...
- Page 37 Real-Time Plot to Disk Data can be directly stored on a floppy disk, a hard disk, or a RAM disk while being plotted on the PC's screen by selecting "Plots" followed by "Real-Time Plotting to Disk". Activation of this option is very similar to "Real-Time to Disk" (see Real-Time to Disk on page 31) except that the data is plotted while being stored to disk.
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Page 38: Recording
Recording Recording is initiated by selecting "Commands", followed by "Start Recording". At this command, the PC will trigger the recording of the measured parameters by the AFRecorder. The "Reset" command may be used to stop a recording session in progress. Note that recording is different from real-time to disk or real-time plot to disk data storage in that recorded data is stored in the AFRecorder before being uploaded and stored in the PC. -
Page 39: Setup
Plot Modification "Plots" followed by "Draw Static Plot" plots the data currently within AFRemote. The static plot is drawn using data at each sample interval (not averaged). The plot type and scales can be modified by "Set Plot Type" and "Set Plot Scales". Hardcopy of Plots To print hardcopies of static plots on the PC's screen, a screen-dump utility such as GRAPHICS (from DOS 5.0) must be executed prior to entering AFRemote. -
Page 40: Specifications And Limits
Specifications and Limits Measurements and Accuracy Parameter Units Range Response Accuracy Measured Time ±0.1 (stoichiometric) Air-to-Fuel Ratio 6.0-150.0 < 150 ms ±0.2 (12<AFR<18) ±0.5 (elsewhere) φ 0.10-2.5 < 150 ms ±0.006 (stoich.) ±0.008 (0.8<φ<1.2) ±0.009 (elsewhere) λ 0.4-10.0 < 150 ms ±0.006 (stoich.) ±0.008 (0.8<λ<1.2) ±0.009 (elsewhere) -
Page 41: Recording Specifications
Recording Specifications Sample Selection: Choose 1, 2, 3, or 4 parameters to record. If a sensor is not selected, a zero (0) is stored for its value. Sample Size: Up to 5000 measurements. Recording Duration: 1.0 second to memory limit (programmable). Sample Interval (time between samples): 0.02 seconds to 30.0 minutes (programmable in increments of 0.02 seconds). - Page 42 Do not use the AFR sensor with leaded fuel or in a heavily-sooting or crankcase- oil-burning engine because these conditions will severely shorten the life of the sensor. • Maximum allowable levels of fuel "impurities": Lead: 0.012 gm/gal. Phosphorous: 0.0008 gm/gal. Sulfur: 0.035 % by weight •...
- Page 43 • Connector on AFR sensor: Sanwa SNW-1608-ACM-5 (Optional Connector) Pin 1: Heater + Pin 5: Ip-, Vs cell - Pin 2: Heater - Pin 6: Vs cell + Pin 3: Ip cell + Pin 7: Cal resistor Pin 4: Cal Resistor Pin 8: Ip-.
- Page 44 Manifold Pressure: • Measurement Range, Response Time, Accuracy: See the section entitled Measurements and Accuracy on page 36. • Proof Pressure: 60 Psia (damage will occur at higher pressures). • Sensor Material: All wetted surfaces are stainless steel. • Connector: 1/8" barbed brass male hose fitting. •...
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Page 45: Output Specifications And Limits
Output Specifications and Limits Analog Outputs: • Air-to-Fuel Ratio (AFR, φ, λ, or %O Programmable Ranges for: ), Spark Timing, Engine Speed, and Manifold Pressure. • Minimum Programmable Ranges (value at 5 V minus the value at 0 V): 5 AFR, 0.5 φ, 0.5 λ, 5 %0 2 20 degrees spark 500 RPM 5 Psi, 0.35 atm, 10 inHg, 35 kPa... - Page 46 where: AFR is the compensated AFR value. is the programmed AFR for 0 Volts. is the programmed AFR for 5 Volts. V is the voltage calculated from Equation B. Note that the “AFR” in Equation A is replaced by λ or φ if those are the chosen AFR units.
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Page 47: General Information
• "LOW" Indication: Low light (green) and low buzzer (slow repetition rate). • "LOW" Activation: Occurs when chosen parameter's value is less than the programmed value. RS-232 Communication: • Data Format: Bi-directional, 4800,8,N,1. • Connector: Male DB9. Pin 2: Tx from AFRecorder Pin 3: Rx to AFRecorder Pin 5: Shield ground and signal ground All other pins: Not connected... - Page 48 Case Ground: Electrically connecting the AFRecorder's case to the vehicle's chassis, the engine block, or the negative terminal of the battery using braided cable may provide improved noise rejection in some environments. Inside the AFRecorder, there is a 2.2K resistor connecting the case ground and the power ground. Dimensions: 10.2"...
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Page 49: Theory Of Operation
Theory of Operation Air-to-Fuel Ratio Sensing The AFRecorder determines an engine's air-to-fuel ratio (AFR) by measuring the concentrations of O (oxygen), CO (carbon monoxide), and H (hydrogen) in the engine's exhaust. The concentrations of O , CO, and H in an engine's exhaust change as a function of AFR, as shown in Figure 22. -
Page 50: Engine Speed And Spark Timing Sensing
Ico, and Ih respectively. These sensitivities are factory-determined and provided with each AFR sensor. The degree to which an engine's exhaust approaches chemical equilibrium is defined as ICCl, ICCs, and ICCr. ICC stands for "incomplete combustion" and the suffixes "l", "s", and "r" stand for "lean", "stoichiometric", and "rich". -
Page 51: Manifold Pressure Sensing
The raw value of spark timing (SPKraw) is calculated from: SPKraw = (ANGLE OF RPM EDGE) + (t_spk/t_rpm) x (720/(RPM PULSES/2 REV)) Note that the engine speed (i.e. t_rpm) is required to calculate the raw spark timing. The setup input for the number of pulses in the spark timing signal per two crankshaft revolutions (SPK PULSES/2 REV) is used by the AFRecorder to detect missing spark pulses. - Page 52 Display, Recording, and Storage The values taken at the 0.02 sec. intervals are available for use by the AFRecorder and the software program AFRemote. The AFRecorder's display is updated with an average of these values. The averaging and the display update interval are selectable (see Table 1 on page 17). AFRemote's real-time display and real-time plotting options use data processed at the "Fast"...
- Page 53 Figure 24: Measurement of Parameters by the AFRecorder Theory of Operation...
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Page 55: Maintenance
Maintenance Unit-Specific Information AFRecorder 2400G Serial No.: __________ AFR Sensor Serial No.: __________ : __________ Ico: __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ : __________ ICCl (lean): 5.0 (for typical production engines) -
Page 56: Errors Reported On The Afrecorder's Display
(if already correct) followed by an “AIR CAL”. If an incorrect setup parameter cannot be found and normal operation cannot be restored, contact ECM with the error number and the entered setup parameters. -
Page 57: Auto-Resetting Of The Afrecorder
Auto-Resetting of the AFRecorder The AFRecorder contains self-monitoring circuitry ("watchdog") that will reset the AFRecorder when abnormal operation is detected. After being reset, the AFRecorder will act as if it was just turned on. Conditions that will cause the AFRecorder to reset itself are: Unreliable or "noisy"... -
Page 59: Safety Warnings
Safety Warnings In installation and use of this product, comply with the National Electrical Code and any other applicable Federal, State, or local safety codes. Always wear eye protection when working near engines, vehicles, or machinery. During installation, turn off the power and take all other necessary precautions to prevent injury, property loss, and equipment damage. -
Page 61: Warranty And Disclaimers
Warranty and Disclaimers WARRANTY The products described in this manual, with the exception of the AFR sensor, are warranted to be free from defects in material and workmanship for a period of 365 days from the date of shipment to the buyer. Within the 365 day warranty period, we shall at our option replace such items or reimburse the customer the original price of such items which are returned to us with shipping charges prepaid and which are determined by us to be defective. - Page 64 Los Altos, CA 94023-0040 • USA • (408) 734-3433 • Fax: (408) 734-3432 www.ecm-co.com...