PLM User’s Manual MoTeC Contents Introduction ...................................................................... 3 Meter Operation ................................................................ 4 PLM Connections ..........................................................................................................4 Connectors .............................................................................. 4 Analog Output..........................................................................
MoTeC PLM User’s Manual CAN Unit Number Display .........................................................................................26 RS232 Messages ........................................................................................................27 Specifications...................................................................28 Meter .................................................................................... 28 Appendices .........................................................
MoTeC PLM Setup Software Introduction The MoTeC Professional Lambda Meter measures Lambda (or Air Fuel Ratio) over a wide range of mixtures with fast response time. The display may be set to Show Lambda, Air Fuel Ratio (for Petrol, Alcohol, Gas, Diesel or ‘blend’ fuel), equivalence ratio or percentage oxygen. The PLM provides a differential Analog Output Voltage proportional to Lambda that may be connected to an Analog Meter or other measurement instrument such as an ECU, Data Logger or dynamometer.
Meter Operation Meter Operation PLM Connections Connectors The PLM has a male and a female D-9 pin connector. See Appendix D – PLM Connector Details for a description of the PLM pinout. Male Connector The loom supplied with the PLM is fitted to the male PLM connector, for connection to the sensor and to a power supply. The Power supply must provide enough current (up to 5 Amps at start up) for both the meter and the sensor heater element.
MoTeC Meter Operation 5 The analog output is provided as a differential voltage using two connector pins (Analog Out+ and Analog Out-). For correct operation Analog Out- must be connected to the ground reference on the monitoring system. The analog output can be configured as a wide band sensor input into a MoTeC ECU for tuning, as described below. See Appendix F – PLM to ECU Wiring Details for wiring details. M4/M48 ECU PLM Configuration Output Function = ‘LA V1’ table La = 0.000, Aout = 0.
Meter Operation Communications RS232 Interface The RS232 interface is used for configuring the PLM from a PC, and for transmitting data to third party equipment. For configuration from a PC, the PLM can be directly connected using a standard (straight through) 9 pin serial cable. See Appendix I – PC Comms Wiring for details on wiring to a PC.
MoTeC Meter Operation 7 If the PLM loses control of the sensor at any point, then the sensor warm-up process is repeated and these codes are displayed again. Sensor Readings The displayed format of sensor readings can be configured to select the display units, decimal places, update rates and filtering. For more information, see Setup | Display in the PLM Setup Software section. If the reading is too large to be displayed using the configured settings, the display will only show ‘- -‘.
Meter Operation Correct sensor placement Incorrect sensor placement
MoTeC Meter Operation 9 Exhaust slip joints should be avoided near sensor placement as some designs allow air to enter. Slip joints can be reversed to make them better for use near sensors. Introduced air No air introduced Exhaust flow Exhaust slip joint design to avoid incorrect lambda readings Sensor Warm-up The internal heater in the LSU or NTK sensor is powerful enough to allow accurate measurement when gas temperature is at room temperature.
Meter Operation At the end of its life the sensor becomes slow to respond and does not read rich properly. The NTK and LSU are designed to be accurate for 50,000km of operation in a road car, so the above figures are a conservative estimate. Sensor lifetime will be reduced by contaminants such as lead, silicon, oil, etc. Thermal cycling will also age the sensor more rapidly, along with exposure to exhaust fumes without any heating control active (ie: not connected to the PLM).
MoTeC Meter Operation 11 maximum power and at light loads the engine is tuned for emissions or economy. The following table gives a guide to the required Lambda values for different tuning objectives. Objective Lambda Power 0.84 to 0.90 Economy 1.05 Emissions 1.00 Note: The exact requirements for a specific engine and fuel must be found by experimentation. Note: On Turbo Engines extra fuel may be desirable to reduce exhaust temperatures and help avoid knock.
PLM Setup Software PLM Setup Software The PLM Setup Software allows a PLM unit to be configured from a PC for a particular target application. A new PLM unit must be configured before its initial use in order to specify sensor type, display units etc. This section covers the basic configuration of the PLM. Advanced functions are also covered in the PLM Communications and Sensor Calibration sections.
MoTeC PLM Setup Software 13 Standard configuration templates for most common preferences are included with the software. Managing Configurations When the PLM Setup software is started, a configuration file needs to loaded before changes can be made, or before a configuration can be sent to the PLM. This configuration can either be loaded from a file on disk, retrieved from the PLM (using the serial cable), or created as a new configuration.
PLM Setup Software select Options | Communications Port from the main menu. The PC must be connected to the powered PLM using the serial port specified. When a configuration file is sent to the PLM, any changes are automatically saved to the current configuration file on the PC. Changing Configurations Once an existing configuration file has been opened or retrieved, or a new configuration has been created, the configuration may be modified by choosing the options under the Setup menu.
MoTeC PLM Setup Software 15 heater at a sustained voltage above 10.5 volts will reduce the sensor lifetime. Sensor Timeout: The option to ignore sensor errors is only recommended for very specialised applications where extreme changes in lambda may cause a short loss of sensor control. Enabling this option will disable the default PLM behaviour of shutting down the sensor for a timeout period when control is lost. This timeout is to protect the sensor as loss of control can indicate a wiring fault.
PLM Setup Software Display Update Rate: The update rate of the displayed value can be from 1 to 10 times per second. Filter Time: The display data can be filtered so that it is more stable and easier to read. This filtering is independent of the update rate. The filter time can be specified in 0.1second units from 0 to 25 seconds.
MoTeC PLM Setup Software 17 Input 2 Mode: ‘Off’ – digital input 2 is disabled ‘Active High’ – digital input 2 is active when the input voltage is high ‘Active Low’ – digital input 2 is active when the input voltage is low ‘Display Other Output Table When Low’ – the other output table is used for the display value while digital input 2 is low. For example, if Output to Display (in the Setup | Display menu) is table 2, then table 1 will be displayed while digital input 2 is low.
PLM Setup Software Setup | Analog Output Output Table: The Output Table Setup dialog is displayed when the Output Tables button is clicked. Note that the two tables setup in this dialog are the same tables used for displayed values, transmitted values and analog outputs, but each function can use either table 1 or table 2. Output Function: This parameter specifies input to the analog output Calibration Table.
MoTeC Sensor Calibration 19 Sensor Calibration Introduction The NTK and Bosch lambda sensors are factory calibrated with a trimming resistor embedded in the sensor connector. This resistor value can be read by the PLM and used to calibrate the sensor readings for a new sensor. As sensors age their calibration changes. To maintain accurate readings, the PLM allows comparison of the measured O2 concentration in air against that of the pure O2 reference in the sensor itself to calculate a new calibration.
Sensor Calibration Calculate from O2 Concentration (Free Air) This calibration method uses the known oxygen concentration of free air to calibrate a sensor. Re-calibration using this method allows a sensor to maintain accuracy as it ages. To perform the free air calibration, the PLM must be powered up and connected to a PC (with a serial cable) running the PLM Setup software. The configuration in the PLM must match the sensor type being used for the calibration.
MoTeC Sensor Calibration 21 To apply the new calibration, the PLM configuration must be saved and sent to the PLM. Enter Calibration Table For advanced applications, a calibration table can be specified to calculate Ipn (normalized sensor pump cell current) from Ip (sensor pump cell current). At least two pairs of values must be specified in the table, and linear interpolation is used between the points. Calibration tables may be saved and reloaded for use in other calibrations.
PLM Communications PLM Communications CAN Messages The PLM can transmit up to four CAN messages containing readings and diagnostics. The format of these four messages is fixed (see Appendix M – CAN Messages Format), but the following parameters can be configured by the user for each message under the Setup | CAN Messages menu. Address Format: Standard address formatting is recommended for most applications.
MoTeC PLM Communications 23 For use with MoTeC equipment (ADL or M800), the selected table must be setup for Lambda with 3 decimal places. Other table setups should only be used for interfacing with third party equipment. Configuring Basic CAN with an ADL To connect a small number of PLM units (maximum of six) to an ADL, the ADL must use one CAN template (PLM#1 to PLM#6) for each PLM. The PLM units must be configured as follows to match the ADL templates.
PLM Communications Compound Id Message 1 = 0 Message Rate Message 1 = User defined Message 2 = Off Message 3 = Off Message 4 = Off Collect Master = Off CAN Collect Functionality For applications involving multiple PLM units, a single PLM can be configured to collect calibrated lambda readings from up to 15 other PLMs on the CAN bus, and to retransmit the 16 readings on a single CAN address. This functionality is available in PLM firmware V1.1 and later.
MoTeC PLM Communications 25 The base address is the address on which the collected Lambda values will be retransmitted. This address must lie on a 16 message boundary (i.e. the address, in hex, must end in 0). The base address also defined the addresses of the Collect slave units that the master will monitor. The recommended address is Hex 460. The message rate is the rate at which the Lambda values are retransmitted on the CAN bus to the measuring device (usually an ADL or ECU).
PLM Communications Messages 2 to 4 are not required and should be “OFF” on the slave units. The Collect Master message rate must be set to OFF on the slave units. A PLM configured as a slave unit will briefly display the PLM unit number (eg “U 4” for PLM 4) on start-up after displaying the firmware version. Appendix O – Recommended CAN Collect Configuration describes the recommended configuration for connecting multiple PLM units to an ADL.
MoTeC PLM Communications CU1 PLM 1 Collect Master enabled U1 PLM 1 Collect Master disabled 27 Message 1 address = xx0 U2 PLM 2 Collect Master disabled Message 1 address = xx1 … … … U16 PLM 16 Collect Master disabled Message 1 address = xxF A correctly configured network of PLMs using the CAN collect functionality should have the unit numbers CU1, U2, U3, U4 etc.
Specifications Specifications Meter Power Supply Input Voltage Range 7 to 16Volts Input current 60mA typical, backlight off 110mA typical, backlight on Plus sensor heater current Protection Reverse polarity protected Load Dump Clamp Max 40V at 100 Amp 100msec Sensors Sensors 1 Compatible Types Bosch LSU 4/ Bosch LSU 4.
MoTeC Specifications 29 Sensor Heater Outputs 1 Current Max 8 Amp Control Bosch - Digital PID NTK - Constant Voltage Voltage supply to the PLM should be at least 11V for proper operation of the sensor heater when using an NTK UEGO sensor. Output Output Type Differential Calibration User Programmable Max Output Current 10mA (Short circuit protected) Output Voltage Swing 0 to 4.5V relative to the negative output (when the negative output is less than 0V and greater than negative 4.
Specifications Max Positive Pin Output Voltage 4.5V (relative to Battery-) for current less than 1mA Inputs Digital 2 x User Programmable as RPM or PLM Operate Communications CAN 1Mbit RS232 9600 baud, 8 data bits, no parity, 1 stop bit (9600, 8N1) Display Type LCD 3.5 Digit Digit Height 12.
MoTeC Appendices 31 Appendices Appendix A – Lambda to Air Fuel Ratio Table Lambda 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 Air Fuel Ratio Petrol 10.3 11.0 11.8 12.5 13.2 14.0 14.7 15.4 16.2 16.9 17.6 18.4 19.1 19.8 20.6 21.3 22.1 22.8 23.5 Alcohol 4.5 4.8 5.1 5.4 5.8 6.1 6.4 6.7 7.0 7.4 7.7 8.0 8.3 8.6 9.0 9.3 9.6 9.9 10.2 LPG 10.9 11.6 12.4 13.2 14.0 14.7 15.5 16.3 17.1 17.8 18.6 19.4 20.2 20.9 21.7 22.5 23.3 24.0 24.8 Diesel 10.2 10.9 11.6 12.
Appendices Appendix B – PLM Display Codes Warm-up Codes C-6 Sensor Protection Shutdown. The C-6 state is entered when the PLM can not pump enough current into the pump cell to balance the sense cell. When C-6 is entered pump current is turned off. The PLM will try to gain control of the sensor (the C-1 state) every 10 seconds. If it is then unable to regain control after 2 seconds then it will re-enter the C-6 state. C-5 User Stop.
MoTeC Appendices 33 Appendix C – PLM CAN Diagnostic Codes These are the bit field descriptions for the diagnostic error groups that are sent to the ADL via the CAN link. Diagnostic Group 1 1: No Sensor 2: Sensor Hot 4: Sensor Cold 8: Sensor Faulty 32: Warm Up 64: Ref voltage out of range Diagnostic Group 2 These codes correspond to those displayed by the PLM. 1 (C-1) - Checking Operation. 2 (C-2) - Control Initialization. 4 (C-3) - Warm Up. 8 (C-4) - No heater detected.
Appendices Appendix D – PLM Connector Details Sensor Connector - Male D9 1 2 3 4 5 6 7 8 9 Battery +12 Power (Note 2) Heater + Rc Ip Sensor Common Battery 0V Power Heater – Vs Ipr Auxiliary Connector – Female D9 1 2 3 4 5 6 7 8 9 CAN Hi (Note 3) RS232 Tx RS232 Rx Digital Input 1 Comms 0V CAN Lo (Note 3) Digital Input 2 Analog out + (Note 4) Analog out – (Note 4) Note1: Extension of Standard Sensor Loom The length of the standard loom supplied for connection of the PLM to a sensor is 2.5m.
MoTeC Appendices 35 Note 3: Wiring See Appendix G – PLM to ADL Wiring Details for CAN wiring to an ADL See Appendix F – PLM to ECU Wiring Details for CAN wiring to an M800 ECU See Appendix H – General CAN Bus Wiring for recommended CAN wiring practices Note 4: Analog Output Connect the “Analog out +” to the input on the measuring device. Connect the “Analog out –“ to the 0V reference point on the measuring device. “Analog out –“ must be connected for the measuring device to make a correct reading.
Appendices Appendix E – Sensor Wiring Details Bosch LSU 4 Sensor Wiring Details PLM BAT+ BAT- N/C Bosch LSU 4 Ip Heater + Heater Common Vs Ipr 6 5 4 3 2 1 M1 BAT+ M2 Heater + M3 Rc M4 Ip M5 Common M6 BATM7 Heater M8 Vs M9 Ipr
MoTeC Appendices Bosch LSU 4.2 Sensor Wiring Details PLM BAT+ BAT- N/C Bosch LSU 4.
Appendices NTK – UEGO Sensor
MoTeC Appendices Wiring Details PLM M1 M2 M3 M4 M5 BAT+ BAT- NTK UEGO Heater + Heater Rc Common 1 2 6 3 4 5 N/C 6 Vs 7 Ip 8 Common N/C BAT+ Heater + Rc Ip Common M6 BATM7 Heater M8 Vs M9 Ipr 39
Appendices Appendix F – PLM to ECU Wiring Details Analog Output PLM wiring using the Analog Output to M4/M48/M8/M800 ECUs: PLM A out A out - M4/M48 F8 Red 31 La+ F9 Black 32 La - (Previously La- was shown connected to ECU 0V, this is now optional) PLM A out A out - M8 F8 Red 24A La+ F9 Black 36A La - 10A 0V PLM A out + A out - M800/M880 F8 F9 Red Black B25, B12 / 60, 61 B16 / 27 La1S or La2S Sensor 0V CAN One or more PLMs may be connected to the M800 ECU via the CAN bus.
MoTeC Appendices Appendix G – PLM to ADL Wiring Details One or more PLMs may be connected to the MoTeC ADL via the CAN bus. See Appendix H – General CAN Bus Wiring for details on correct wiring and termination for CAN devices.
Appendices Appendix H – General CAN Bus Wiring The CAN bus should consist of a twisted pair trunk with 100R (0.25Watt) terminating resistors at each end of the trunk. The preferred cable for the trunk is 100R Data Cable but twisted 22# Tefzel is usually OK. The maximum length of the bus is 16m (50ft) including the MoTeC CAN Cable (PC to CAN Bus Communications Cable) CAN Devices (such as MoTeC PLM, ADL, etc) may be connected to the trunk with up to 500mm (20in) of twisted wire.
MoTeC Appendices 43 Appendix I – PC Comms Wiring A PC may be connected to the PLM by connecting to the 9 pin female connector as shown below. This allows the PLM to be configured using the PLM Configuration software. It is also acceptable to use a standard 1:1 male to female communications cable which connects all 9 pins. Note that during configuration the PLM must also have power connected to it via the PLM 9 pin male connector.
Appendices Appendix J – Analog Output Wiring Floating Measuring Device When connected to a floating measuring device such as a multimeter, Aout– should be connected to Battery– as shown to ensure that the full output voltage swing is available.
MoTeC Appendices 45 Note: Aout+ and Aout– must be within the within the input common mode range of the measuring device. This limits the voltage difference that can be between Battery– and Ground.
Appendices Appendix K – Digital Input Wiring Typical wiring for switches PLM Digital Input 1/2 0V Typical wiring for RPM measurement PLM RPM Sensor: Must be Hall Effect type Digital Input 1 0V Signal Sensor 0V 8V sensor supply
MoTeC Appendices Appendix L – Glossary CAN – Controller Area Network.
Appendices Appendix M – CAN Messages Format Messages 1 to 4 can be optionally transmitted from any PLM unit. Messages 5 to 10 are only transmitted from a PLM unit configured as a CAN Collect Master. Message 1 Byte 0 3 4 5 6 Name Compound ID – user defined, default 0 Calibrated Sensor Output Value – user defined, default Lambda Heater duty cycle Device Internal Temperature Zp (Pump cell impedance) Diagnostic Field 1 7 Sensor state 1:2 Scaling N/A Hi:lo*1 = x.
MoTeC Appendices 49 Message 2 Byte 0 3 4 Name Compound ID – user defined, default 1 Ipn (Normalised pump cell current) Vs (Sense voltage) Vp (Pump cell voltage) 5 6:7 Reserved Ip (Raw pump cell current) 1:2 Scaling N/A Hi:Lo * 1 = X µA Byte*5 = X mV Byte * 10000 / 255 – 5000 = X mV N/A Hi:Lo * 1 = X µA Message 3 Byte 0 1 3 4 5 6 7 Name Compound ID – user defined, default 2 Bosch calibration resistor NTK calibration resistor Reserved Reserved Battery Voltage Sensor in control Scaling N/A Byte*1 =
Appendices Message 4 Byte 0 3 Name Compound ID – user defined, default 3 Positive Analog output pin voltage Negative Analog output pin voltage Sensor type 4 Reset source (Note 2) 5 6:7 Firmware Version RPM HI:LO 1 2 Scaling N/A Byte*1000/255–500 = x.xx V Byte*1000/255–500 = x.xx V NONE NTK BOSCH LSU4 BOSHC LSU4.2 Low Voltage reset Illegal Address reset Illegal operation reset Watchdog timer reset External reset x.
MoTeC Appendices 51 Message 7 Byte 0 1 2:3 Name Compound ID = 6 Reserved PLM 7 Calibrated Sensor Output Value 4:5 PLM 8 Calibrated Sensor Output Value 6:7 PLM 9 Calibrated Sensor Output Value Scaling N/A N/A Hi:Lo*1 = x.xxxLa (Note 1) Hi:Lo*1 = x.xxxLa (Note 1) Hi:Lo*1 = x.xxxLa (Note 1) Message 8 Byte 0 1 2:3 Name Compound ID = 7 Reserved PLM 10 Calibrated Sensor Output Value 4:5 PLM 11 Calibrated Sensor Output Value 6:7 PLM 12 Calibrated Sensor Output Value Scaling N/A N/A Hi:Lo*1 = x.
Appendices Note 1 Calibrated Sensor Output Value is x.xxxLa when the PLM is setup to transmit Lambda with 3 decimal places as recommended for connection to MoTeC equipment.
MoTeC Appendices 53 Appendix N – RS232 Message Format Master PLM Message Byte 0 1 2 3 4:5 6:7 8:9 . . 32:33 34:35 36:37 Description Header 0 = 0x80 Header 1 = 0x81 Header 2 = 0x82 Data Length PLM 1 (Master) Calibrated sensor reading PLM 2 Calibrated sensor reading PLM 3 Calibrated sensor reading . . PLM 15 Calibrated sensor reading PLM 16 Calibrated sensor reading Checksum Value 0x80 0x81 0x82 32 Hi:Lo = x.xxxLa Hi:Lo = x.xxxLa Hi:Lo = x.xxxLa Hi:Lo = x.xxxLa Hi:Lo = x.
Appendices Appendix O – Recommended CAN Collect Configuration The following configuration is recommended for connecting multiple PLM units to an ADL.
MoTeC Appendices PLM 11 = Hex 46A PLM 12 = Hex 46B PLM 13 = Hex 46C PLM 14 = Hex 46D PLM 15 = Hex 46E PLM 16 = Hex 46F CAN Message 2 Message Rate OFF CAN Message 3 Message Rate OFF CAN Message 4 Message Rate OFF CAN Collect Message Rate OFF ADL Use the CAN template “PLM Collect 16 Channel”, and enable (ie. tick) the channels required. By default the template has the first 8 channels enabled.
Appendices Lambda – Cyl 10 PLM 10 Reading Lambda – Cyl 11 PLM 11 Reading Lambda – Cyl 12 PLM 12 Reading Lambda 1 PLM 13 Reading Lambda 2 PLM 14 Reading Lambda – Left Bank PLM 15 Reading Lambda – Right Bank PLM 16 Reading
MoTeC Appendix P – Dimensions Appendices 57
Notes
MoTeC Notes 59
