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Summary of Contents for ECM AFRecorder 4800
- Page 1 ™ AFRecorder 4800 Dual-Channel Fast Air-Fuel Ratio Analyzer Instruction Manual 6/03 Part Number 4800-11...
- 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 4800 AFRecorder Components List Important Operation Notes Air-to-Fuel Ratio Sensors Physical Features and Hook-up Front Panel Rear Panel and Power Hook-up Air-to-Fuel Ratio Hook-up Analog Outputs and Simulated EGO Sensor Outputs RS-232 Communication Hook-up Stand-Alone Operation Measurement and the "SYS"... - Page 4 Remote Operation (using AFRemote Software) Software Operation Measurement Measurement with Direct Storage to Disk Recording Results and Plot Configuration Setup AFR Measurement Offsets 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
The AFRecorder 4800 is a dual-channel, UEGO (universal exhaust gas oxygen) sensor- based, air-to-fuel ratio (AFR) analyzer. The AFRecorder 4800 comes in two forms: a Model R (rack mount) and a Model P (portable). Both AFRecorders report an engine's AFR in four ways: •... -
Page 6: Afrecorder Components List
AFRecorder Components List The following items are included with the AFRecorder 4800R (rack mount) package. For pictures, visit www.ecm-co.com. Item No. Description Part Number AFRecorder 4800R 4800R 2a. (standard) Air-to-Fuel Ratio (AFR) Sensors (Quantity 2) 2400E-1 2b. (optional) Air-to-Fuel Ratio (AFR) Sensors (Quantity 2) - Page 7 Notes: The AFR cabling can be modified to suit customer needs. When the Severe Duty Panel-Mount Cable Kit (Part No. 4800R-21) is supplied, the AFR sensors are equipped with matching severe duty connectors. An AFR sensor with a severe duty connector is Part No. 2400E-1S. AFRecorder to back-of-panel AFR cabling is not supplied as part of kit unless requested.
- Page 8 The following items are included with the AFRecorder 4800P (portable) package. For pictures, visit www.ecm-co.com. Item No. Description Part Number AFRecorder 4800P 4800P Air-to-Fuel Ratio (AFR) Sensors (Quantity 2) 2400E-1 AFR Sensor Cable, 20 ft. (Quantity 2) 2400E-2 120 VAC U.S. Power Cable, 6 ft.
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Page 9: Important Operation Notes
Important Operation Notes Please read and follow all of the cautions contained in the Safety Warnings section on page 45 of this manual. Air-to-Fuel Ratio Sensors Read the AFR Measurement Calibration (“AIR CAL”) section on page 22. Do not use the air-to-fuel ratio (AFR) sensors with leaded fuel or in a heavily sooting or crankcase oil burning engine because these conditions can shorten the life of the sensors. -
Page 11: Physical Features And Hook-Up
Physical Features and Hook-up Front Panel Once the power, sensors, 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 LCD displays. -
Page 12: Air-To-Fuel Ratio Hook-Up
DC power enters the AFRecorder Model 4800P through the smaller of the three keyed circular plastic connectors (CPCs) on the rear panel. The input voltage must be between 11 VDC and 16 VDC. A 10 A Slow Blow fuse for the DC power is located below the connector. -
Page 13: Analog Outputs And Simulated Ego Sensor Outputs
exhaust pipe. After the boss is attached to the exhaust, tap the threads to clean them and file the top of the boss to provide a flat surface for sealing. Install the sensors by lightly coating their threads with a non-lead containing antiseize compound and tightening to 30 ±3 ft-lbf (40 ±4 Nm). -
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 performed. The displays show "Initializing" and the internal buzzer is tested. If the AFR measurement function is enabled (see AFR Measurement Enable/Disable on page 23), the left display begins a 40 second countdown to allow the AFR sensors to reach operating temperature. - Page 16 When the %O in the exhaust surrounding a sensor exceeds 19.5%, the AFRecorder will automatically change from displaying that sensor's 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.
- Page 17 Main Menu Level 1 Level 2 Function MEASURE Measure & display RESULTS 1 REPLAY Slow motion playback 2 STATISTICS Recorded data statistics 1 AFR_L Left AFR sensor 2 AFR_R Right AFR sensor 3 L-R Left minus Right AFR 4 AVG Average AFR 3 POINT Display one recorded point...
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Page 18: Recording
Pressing "SYS" at any time will suspend the current operation and present the user with the main menu. Recording Recording is started by pressing the "REC" (Record) key while the AFRecorder is displaying its measured AFRs. During recording, the displays will appear as shown in Figure 4. RECORD 30/1250 RECORD... - Page 19 RESULTS 1 REPLAY 3 POINT 2 STATISTICS 4 EXIT Figure 5: The Results Menu Results - Replay If "REPLAY" is selected from the results menu, the display replays the recorded data in slow-motion (see Figure 6). "AFR_L" is the AFR of the left sensor, "AFR_R" is the AFR of the right sensor, "L-R"...
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Page 20: Setup Menu
∑ − using data from the entire recording. As with the Average Deviation of AFR (DEV), the greater Sd gets, the "rougher" the recorded AFR is. Sd is different from the real-time parameter DEV. DEV is calculated from a computationally simpler formula more suited for real-time calculation and display. -
Page 21: Display Menu
SETUP 1 DISPLAY 4 OPTIONS 2 RECORD 5 CONSTS 3 OUTPUTS 6 EXIT Figure 9: The Setup Menu Setup - Display Menu The selection of "DISPLAY" from the setup menu allows the configuration of the manner in which the measured parameters are displayed (see Figure 10). "EXIT"... -
Page 22: Record Menu
Setup - Display - Rate ● "RATE" determines how often the measurement information on the display is updated. Each choice (SLOW, MEDIUM, and FAST) has a specific update interval associated with it as shown in Table 1. The table also shows the number of measurements which are recursively averaged to generate the information displayed for a given update interval. -
Page 23: Options Menu
Setup - Outputs - Analog ● The choice of "ANALOG" from the setup - outputs menu allows the setting of the analog voltages output by the AFRecorder for the values of air-to-fuel ratio (including the offset, see AFR Measurement Offsets on page 22) measured. The analog outputs are a linear function of the measurements in their displayed units between the values entered for 0 V and 5 V. -
Page 24: Constants Menu
Setup - Options - ICC ● "ICC" stands for "Incomplete Combustion Compensation". The activation of this option takes into account engine characteristics which, if ignored, would reduce the accuracy of the AFR measurement. The degree of ICC can be programmed (see Setup - Constants - ICC_L, ICC_R on page 21). - Page 25 Setup - Constants - Fuel & Air ● Information about the chemical composition (atom ratios) of the fuel is required to determine the AFR. This information is entered into the AFRecorder after selecting "FUEL & AIR" in the setup - constants menu. The information requested is "H:C RATIO"...
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Page 26: Afr Measurement Offsets
AFR Measurement Offsets The main menu selection of "OFFSETS" allows the user to bias the displayed, recorded, and output AFRs for each AFR sensor by an entered amount. The entered offset acts across the entire range of measured AFRs. Separate offset values are maintained for each of the AFR units choices (AFR, φ, λ... -
Page 27: Afr Measurement Enable/Disable
The AFRecorder will abort the "AIR CAL" if the AFR sensor's output in air is unreasonable or if its output is not steady. An aborted "AIR CAL" can be caused by a faulty sensor or an improper calibration environment (i.e. not pure air). AFR Measurement Enable/Disable Selecting "ENABLE"... -
Page 29: 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 30 Figure 14 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 31 Make the hardware connection between the AFRecorder and the PC by connecting the RS-232 communication cable between the AFRecorder and any one of two serial ports (Com1, Com2) on the back of the PC (see the section entitled RS-232 Communication Hook-up on page 9). Turn on the AFRecorder and the PC.
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Page 32: Measurement
Figure 17: PC Screen During Software Connection After the software connection has been completed, operation of the AFRecorder can be controlled from the PC. To leave remote mode: ● Remote mode is terminated by selecting "Commands" followed by "Disconnect AFRecorder" on the PC, or by pressing the "SYS" key twice on the AFRecorder. Measurement Measured parameters can be viewed on the PC's screen in two forms: real-time display or real-time plotting. -
Page 33: Measurement With Direct Storage To Disk
Figure 18: Real-Time Text Display Real-time display is started by selecting "Commands" followed by "Real-Time Display On". The command "Real-Time Display Off" ends the display. "%O2", "xxxx", "V LO", "OFF", and the large character display are not available with AFRemote. Real-Time Plotting Real-time plotting turns the PC into an oscilloscope showing the values of the measured parameters as a function of time. - Page 34 On selection of this option, AFRemote requests the sample interval (allowable values: 0.1 to 60 sec.), the sample size (allowable values: 100 to 100000), and the filename. It is recommended that the filename extension .AFR be used. During real-time to disk operation, the PC's display is updated with every fifth data point for 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.
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Page 35: Recording
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 29) except that the data is plotted while being stored to disk. -
Page 36: Results And Plot Configuration
Results and Plot Configuration Analysis of Data AFRemote allows real-time to disk data, real-time plot to disk data, recorded data (via "Upload Recorded Data"), or loaded data (via "Load PC File Data") to be analyzed by statistics or static plotting. Statistics are accessed by selecting "Analysis" followed by the measured parameter. -
Page 37: 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 (stoichiometric) ±0.008 (0.8<φ<1.2) ±0.009 (elsewhere) λ... -
Page 38: Real-Time To Disk And Real-Time Plot To Disk Specifications
Real-Time to Disk and Real-Time Plot to Disk Specifications Sample Selection: Both AFRs are stored. If an AFR sensor is not used, its limit value is stored. Sample Size: 100 to 100,000 measurements for each AFR sensor. Sample Interval: 0.1 to 60 seconds. Input Specifications and Limits Air-to-Fuel Ratio: •... - Page 39 • Exhaust Gas Pressure Range: 0.8 - 1.3 atm. • Installation: Thread Size: M18X1.5 mm. Lightly coat with antiseize compound. Hex Size: 22 mm. Tightening Torque: 30 ±3 ft-lbf, 40 ±4 Nm. The AFR sensors' thread size is identical to that of the exhaust oxygen (EGO) sensors used in current production automobiles with 3-way exhaust catalysts.
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Page 40: Output Specifications And Limits
Output Specifications and Limits Analog Outputs: • Programmable Ranges for: Air-to-Fuel Ratio (in AFR, φ, λ) or %Ο of each AFR sensor. • Output Range (linearized in displayed units): 0 - 5 VDC. 20 mA max. • Bits Resolution: 12 bits. •... - Page 41 To compensate for differences in voltage references and ground potentials between the AFRecorder and a data acquisition system receiving its outputs, use Equation A: [Equation A] − × where: AFR is the compensated AFR value. is the programmed AFR for 0 Volts. is the programmed AFR for 5 Volts.
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Page 42: General Information
RS-232 Communication: • Data Format: Bi-directional. 4800,8,N,1 • Connector: Female DB25 (Model 4800R only). Pin 1: Shield ground Pin 2: Rx to AFRecorder Pin 3: Tx from AFRecorder Pin 7: Signal ground All other pins: Not connected • Connector: Male DB9 (Model 4800P only). Pin 2: Tx from AFRecorder Pin 3: Rx to AFRecorder Pin 5: Shield ground and Signal ground... - Page 43 • Fuse: 10 A, Slow Blow, 250 VAC, Type 3AG Case Ground: Electrically connecting the AFRecorder's case to the vehicle's chassis, the engine block, the negative terminal of the battery, or a “ground mecca” may provide improved noise rejection in some environments. A braided cable should be used for this purpose.
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Page 45: 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 20. - Page 46 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". The ICC factors are factory-set for typical production engines and can be modified (see Setup - Constants - ICC_L, ICC_R on page 21.
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Page 47: Maintenance
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. "EEPROM Errors Found ..." indicates that one or more of the setup parameters stored in the EEPROM has been corrupted. -
Page 48: 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 49: 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 51: Warranty And Disclaimers
Warranty and Disclaimers WARRANTY The products described in this manual, with the exception of the AFR sensors, 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 55 Los Altos, CA 94023-0040 • USA • (408) 734-3433 • Fax: (408) 734-3432 www.ecm-co.com...
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