Motec PLM User Manual
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Motec PLM User Manual

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MoTeC
Contents
Introduction ...................................................................... 3
Meter Operation ................................................................ 4
PLM Connections ..........................................................................................................4
Connectors .............................................................................. 4
Analog Output.......................................................................... 4
Digital inputs............................................................................ 5
Communications ...................................................................... 6
PLM Display....................................................................................................................6
Sensor Placement.........................................................................................................7
Sensor Warm-up ...........................................................................................................9
Sensor Lifetime..............................................................................................................9
Lambda .........................................................................................................................10
Engine Tuning ..............................................................................................................10
Operating Tips..............................................................................................................11
PLM Setup Software.........................................................12
Computer requirements .............................................................................................12
Connecting to a PLM...................................................................................................12
Installing PLM Setup ...................................................................................................12
Configurations..............................................................................................................12
Managing Configurations ......................................................... 13
Changing Configurations ......................................................... 14
Sensor Calibration ...........................................................19
Introduction ...................................................................................................................19
Calibration Methods ....................................................................................................19
Use Measured Calibration Value.............................................. 19
Enter Calibration Value ........................................................... 19
Calculate from O2 Concentration (Free Air)............................... 20
Enter Calibration Table............................................................ 21
PLM Communications.......................................................22
CAN Messages ............................................................................................................22
Configuring Basic CAN with an ADL......................................... 23
Configuring basic CAN with an M800........................................ 23
CAN Collect Functionality...........................................................................................24
16)........................................................................................ 25
PLM User's Manual

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Summary of Contents for Motec PLM

  • Page 1: Table Of Contents

    CAN Messages ......................22 Configuring Basic CAN with an ADL......... 23 Configuring basic CAN with an M800........23 CAN Collect Functionality...................24 Configuring the CAN collect master unit (PLM 1)....... 24 Configuring the CAN Collect slave units (PLM 2 to PLM 16)..................25...
  • Page 2 Appendix F – PLM to ECU Wiring Details..............40 Analog Output................ 40 CAN..................40 Appendix G – PLM to ADL Wiring Details ..............41 Appendix H – General CAN Bus Wiring..............42 Appendix I – PC Comms Wiring ................43 Appendix J – Analog Output Wiring ................44 Appendix K –...

  • Page 3: Introduction

    Analog Meter or other measurement instrument such as an ECU, Data Logger or dynamometer. The PLM also supports RS232 and CAN data links to devices such as the Motec Dash Logger or M800 ECU for transmission of sensor and diagnostic data.

  • Page 4: Meter Operation

    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.

  • Page 5: Digital Inputs

    CAN and RS232 data streams. Digital Input 2 can be enabled as a switch input, and the PLM can be configured to operate based on the switch state (active high or active low). This input can also be configured to change the display units on the PLM display.

  • Page 6: Communications

    CAN. The CAN communications can be configured to allow one PLM unit to collect CAN data from up to 15 other PLM units, and then retransmit the data on a single CAN address and on the RS232 interface. For detailed information on communications interfaces, see the PLM Communications section.

  • Page 7: Sensor Placement

    MoTeC Meter Operation 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.
  • Page 8 Meter Operation Correct sensor placement Incorrect sensor placement...

  • Page 9: Sensor Warm-Up

    MoTeC Meter Operation 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...

  • Page 10: Lambda

    It is important to ensure that the sensor is not overheated due to incorrect placement in the exhaust as this significantly reduces the sensor life. The sensor impedance (Zp) is measured by the PLM, and this is a reasonable indication of sensor temperature. Zp should be approximately 80 Ohms in normal operation.

  • Page 11: Operating Tips

    MoTeC Meter Operation 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...

  • Page 12: Plm Setup Software

    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.

  • Page 13: Managing Configurations

    PLM (using the serial cable), or created as a new configuration. A loaded configuration can be saved to a file on disk, and then sent to the PLM (using the serial cable). A modified configuration must be sent to the PLM for it to take effect.

  • Page 14: Changing Configurations

    The sensor type used with the PLM (NTK, Bosch LSU 4 or Bosch LSU 4.2) must be specified before a configuration can be sent to a PLM. It is important to select the correct sensor type to prevent damage to the sensor and ensure correct lambda measurements.
  • Page 15 These user calibrations can be saved for re-use by clicking the ‘Save As’ button. Output to Display: The default PLM display value can be selected as the result from one of the two tables that are specified under the Output Tables setup. Display Decimals Table 1 / Table 2: This is the number of decimals used to display the values from Table 1 and Table 2 in the Output Tables setup.
  • Page 16 Setup | Digital Inputs Device Activation: If digital inputs are not used for PLM activation, the ‘Run always’ option should be selected. The remaining four options allow the PLM to be activated either while a digital input (1 or 2) remains active, or after a digital input (1 or 2) first becomes active.
  • Page 17 The addresses chosen must match those of the PLM CAN communication templates provided with Dash Manager. For example, the ADL template ‘PLM #1 (CAN ID 460)’ requires that the Message 1 Address be 460. Note that “CAN Collect” functionality is the preferred method for communications from more than one PLM to an ADL.
  • Page 18 Once created, calibration tables can be saved (using the Save As button), and reloaded (using the Load button) for use in other configurations. Default Output: The analog output voltage is set to the Default Output voltage if the PLM is not active or if the analog output is disabled.

  • Page 19: Sensor Calibration

    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.

  • Page 20: Calculate From O2 Concentration (Free Air)

    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. Free air calibration must be done in the open air – not in a workshop or dyno room where there will be large amounts of hydrocarbons in the atmosphere.

  • Page 21: Enter Calibration Table

    MoTeC Sensor Calibration 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).

  • Page 22: Plm Communications

    CAN message is transmitted. Scaling The scaling of the actual reading for the PLM is determined by the Output to Transmit parameter which specifies the output table to be used for transmitted values (eg. Lambda, O2 concentration etc.).

  • Page 23: Configuring Basic Can With An Adl

    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.

  • Page 24: Can Collect Functionality

    PLMs. Configuring the CAN collect master unit (PLM 1) Only one PLM on the CAN bus should be configured as a Collect Master. To enable the CAN collect functionality, a base address and a message rate...

  • Page 25: Configuring The Can Collect Slave Units (Plm 2 To Plm 16)

    Messages 1 to 4 do not need to be configured on the master unit. Output to Transmit must be LA V1, with 3 decimal places in the table setup. The master PLM unit will briefly display “CU 1” (Collect Unit 1) on start-up after displaying the firmware version.

  • Page 26: Can Unit Number Display

    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.

  • Page 27: Rs232 Messages

    U0. RS232 Messages The PLM transmits RS232 status messages at a rate of 20 times a second. If the PLM is configured as a CAN Collect Master then the transmitted message contains the Lambda values for the master PLM and up to 15 slave PLMs.

  • Page 28: Specifications

    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 Compatible Types Bosch LSU 4/ Bosch LSU 4.2/ NTK UEGO Calibration Methods...
  • Page 29 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...
  • Page 30 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 1Mbit RS232 9600 baud, 8 data bits, no parity, 1 stop bit (9600, 8N1)

  • Page 31: Appendices

    MoTeC Appendices Appendices Appendix A – Lambda to Air Fuel Ratio Table Lambda Air Fuel Ratio Petrol Alcohol Diesel 0.70 10.3 10.9 10.2 0.75 11.0 11.6 10.9 0.80 11.8 12.4 11.6 0.85 12.5 13.2 12.3 0.90 13.2 14.0 13.1 0.95 14.0...

  • Page 32: Appendix B - Plm Display Codes

    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.

  • Page 33: Appendix C - Plm Can Diagnostic Codes

    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.

  • Page 34: Appendix D - Plm Connector Details

    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. Longer looms are available from MoTeC by request. It is not recommended that the loom is extended by using a standard serial cable.
  • Page 35 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...

  • Page 36: Appendix E - Sensor Wiring Details

    Appendices Appendix E – Sensor Wiring Details Bosch LSU 4 Sensor Wiring Details BAT+ BAT+ Heater + BAT- Bosch Common LSU 4 BAT- Heater - Heater + Heater - Common...
  • Page 37 MoTeC Appendices Bosch LSU 4.2 Sensor Wiring Details BAT+ BAT+ Heater + BAT- Bosch Common LSU 4.2 BAT- Heater - Common Heater - Heater +...

  • Page 38: Ntk - Uego Sensor

    Appendices NTK – UEGO Sensor...
  • Page 39 MoTeC Appendices Wiring Details BAT+ BAT+ Heater + BAT- Common BAT- NTK UEGO Heater - Heater + Heater - Common Common...

  • Page 40: Appendix F - Plm To Ecu Wiring Details

    Appendices Appendix F – PLM to ECU Wiring Details Analog Output PLM wiring using the Analog Output to M4/M48/M8/M800 ECUs: M4/M48 A out Black La - A out - (Previously La- was shown connected to ECU 0V, this is now optional)

  • Page 41: Appendix G - Plm To Adl Wiring Details

    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.

  • Page 42: Appendix H - General Can Bus Wiring

    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.

  • Page 43: Appendix I - Pc Comms Wiring

    MoTeC Appendices 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.

  • Page 44: Appendix J - Analog Output Wiring

    Note: The Ground voltage must not be more than 4.5 volts below Battery–. Note: If the Ground voltage is greater than the Battery – voltage then the PLM output voltage swing will be reduced. (See the specifications for details)
  • Page 45 MoTeC Appendices 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. Differential Input Measuring Device Input + A out + Input –...

  • Page 46: Appendix K - Digital Input Wiring

    Appendices Appendix K – Digital Input Wiring Typical wiring for switches Digital Input 1/2 Typical wiring for RPM measurement RPM Sensor: Must be Hall Effect type 8V sensor Digital Input 1 Signal supply Sensor 0V...

  • Page 47: Appendix L - Glossary

    MoTeC Appendices Appendix L – Glossary CAN – Controller Area Network. High speed serial data bus common in automotive applications Ip – Sensor pump cell current Ipn – Normalised Ip Vs – Sense voltage...

  • Page 48: Appendix M - Can Messages Format

    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 Name Scaling Compound ID –...
  • Page 49 MoTeC Appendices Message 2 Byte Name Scaling Compound ID – user defined, default 1 Ipn (Normalised pump cell Hi:Lo * 1 = X µA current) Vs (Sense voltage) Byte*5 = X mV Vp (Pump cell voltage) Byte * 10000 / 255 – 5000 = X...
  • Page 50 RPM Message 5 Byte Name Scaling Compound ID = 4 Reserved PLM 1 (Master PLM) Calibrated Sensor Output Hi:Lo*1 = x.xxxLa Value (Note 1) PLM 2 Calibrated Sensor Output Value Hi:Lo*1 = x.xxxLa (Note 1) PLM 3 Calibrated Sensor Output Value Hi:Lo*1 = x.xxxLa...
  • Page 51 Appendices Message 7 Byte Name Scaling Compound ID = 6 Reserved PLM 7 Calibrated Sensor Output Value Hi:Lo*1 = x.xxxLa (Note 1) PLM 8 Calibrated Sensor Output Value Hi:Lo*1 = x.xxxLa (Note 1) PLM 9 Calibrated Sensor Output Value Hi:Lo*1 = x.xxxLa...
  • Page 52 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. Note 2 Low Voltage reset: this is the only reset code that should be seen in normal...

  • Page 53: Appendix N - Rs232 Message Format

    Header 0 = 0x80 0x80 Header 1 = 0x81 0x81 Header 2 = 0x82 0x82 Data Length PLM 1 (Master) Calibrated sensor reading Hi:Lo = x.xxxLa PLM 2 Calibrated sensor reading Hi:Lo = x.xxxLa PLM 3 Calibrated sensor reading Hi:Lo = x.xxxLa 32:33 PLM 15 Calibrated sensor reading Hi:Lo = x.xxxLa...

  • Page 54: Appendix O - Recommended Can Collect Configuration

    Appendices Appendix O – Recommended CAN Collect Configuration The following configuration is recommended for connecting multiple PLM units to an ADL. Master Unit (PLM 1) CAN Message 1 Message Rate CAN Message 2 Message Rate CAN Message 3 Message Rate...
  • Page 55 Message Rate CAN Collect Message Rate 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. This template places PLM values in the following channels:...
  • Page 56 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...

  • Page 57: Appendix P - Dimensions

    MoTeC Appendices Appendix P – Dimensions...
  • Page 58 Notes...
  • Page 59 MoTeC Notes...

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