ALM-CAN manual - v1.8

ALM-CAN is the version that comes with the auto industry standard CAN bus. This is the only wideband controller equipped with the CAN bus available to the after-market. The CAN bus has been widely used in auto industries and especially in engine control systems for a few decades. There are tons of CAN bus based communication protocols published by SAE, ISO, CARB (California Air Resource Board). Multiple oxygen sensor based signals have been defined in those protocols. One specific protocol, SAE J1939 , defines the oxygen concentration in the exhaust gas, which can be broadcasted by the sensor control module, or a wideband controller. By default, our ALM-CAN supports SAE J1939 protocol, and broadcasts O2 concentration. Furthermore it broadcasts lambda, sensor temperature, and sensor fault codes, etc.

specific CAN protocols if needed.

ALM-CAN can also be customized to follow OEM Our ALM-CAN has been used in many specific engine applications or gas analyzing applications, where the main controller has already used the CAN bus to communicate with other control modules.

ALM-CAN is kind of a perfect plug-and-play unit for the CAN bus based application. Any controller on the CAN bus can read the broadcasted O2% or Lambda, or other sensor info without any hardware changed. The protocols can be either standard, or customized. We do provide the customization of the protocols for small manufacturer applications.

Another big advantage of the CAN bus communication to the 0-5V analog voltage output is accuracy.

The CAN bus completely eliminates all the errors created by DAC (Digital to Analog Conversion) and ADC (Analog to Digital Conversion) conversions. The errors created by DAC and ADC alone can be as big as 0.02 lambda, depending on many factors here: your 5V reference voltage, which always has some errors, and your DAC, ADC chips, which are mostly 10 bit length and have rounding errors.

Honestly, all wideband controllers that use the 0-5V analog output cannot be called "professional", because no OEM application uses that.

ALM-CAN comes by default in a sealed and solid case. It can work in very harsh environment, like -40 C to +125 C temperature; and severe vibrations. It is water submersible and meets the IP67 water-proof standard.

You can also request to add a LED display to ALM-CAN and make it lab environment equipment.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Again, ALM-CAN uses the more advanced LSU4.9 sensor instead of a LSU4.2 which is still used by most other wideband controllers. LSU4.9 is the new generation wideband sensor. It is superior to LSU4.2. One obvious proof is: Bosch uses LSU4.9 across the board for their wideband applications.

(See the appendix: LSU4.2 vs. LSU4.9 for a quick comparison) Here is why LSU4.9 is superior to LSU4.2: http://www.ecotrons.com/technology/bosch_lsu_49_is_superior_to_lsu_42_sensors/ Second, Bosch chip CJ125 is the integrated chip (IC) specifically designed for LSU 4.9/4.2 Sensors.

Bosch's own wideband controller, "LambdaTronic", uses CJ125 driver chip. In fact, Bosch uses this chip wherever a LSU sensor is used. The CJ125 and LSU sensor are mated-pair by Bosch. Presumably LSU sensors work the best with CJ125 chips.

See here for Bosch Motorsport’s wideband controller, LT4: http://www.bosch-motorsport.de/media/catalog_resources/Function_Manual_LT4pdf.pdf

List of ALM-CAN parts

        Small ALM controller with CAN bus built-in Large LED display (optional, for lab environment) Harness (1.5 meter default, 3 meter optional) Bosch LSU 4.9 sensor Sensor plug and bung CAN communication cable USB to CAN converter (optional) CD - documents and ALM-CAN GUI software (CAN bus based) www.ecotrons.com

Accurate Lambda Meter-with CAN bus

Chapter 2 ALM-CAN technical specifications

ALM-CAN Manual v1.8

Power supply

   

Sensors

Input voltage range Input current Voltage protection Load Dump Clamp DC9V~15V (12V Typical) 60mA typical plus the heater current Reverse polarity protected, & over voltage protected Maximum Voltage   

Accuracy

  Compatible Number of Sensors Free air calibration Lambda range Lambda accuracy LSU4.9 ( LSU 4.2 capable but not recommended ) One No need (it measures the free air O2%) λ = 0.5 ~ ∞ (Gasoline AFR: 7.35 to free air) ±0.008 @ ±0.01 @ λ =1.00

λ =0.80

±0.05 @ λ =1.70

Fuel dependent (see lambda range and accuracy) 

Heater

Air/Fuel Ratio    Control Current Heater return (H-) Built-in PID control with CJ125 Typical 1A; Max 1.7A

Standalone Heater return wire

Response time

 

Output

Lambda 5ms updating rate (everything finished in 5ms) 250k, 500k, 1M CAN bus baud rate configurable       CAN bus signals, default SAE J1939 protocols Broadcasted signalsO2 concentration, lambda, sensor temperature, and sensor fault codes Signal accuracy All 16 bit values Lambda analog output 0~5V user programmable (optional, not included) Data logging Compatible to any CAN bus based data logger User-friendly PC software for configurations and customer settings

Main-Processor

 CPU Freescale MC9S12P128 16-bit micro-processor (auto industry www.ecotrons.com

Accurate Lambda Meter-with CAN bus   rated) Speed Memory 32MHz 128k Flash, 6k RAM, 4k Data

Special features of ALM wideband sensor

   On-Board-Diagnosis and error report Self-learning of part-to-part variations, aging effect Working with different types of fuels (gasoline, diesel, E85, etc)

General

  Temperature range Dimensions -40 o C ~ 125 o C 4.0 " x 2.6" x 1.0" ALM-CAN Manual v1.8

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Accurate Lambda Meter-with CAN bus

Chapter 3 Appearance and dimension

ALM-CAN Manual v1.8

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Chapter 4 Protect your oxygen sensor

Installation

Correct installation of the oxygen sensors is a must to avoid sensor damage. It protects the oxygen sensor from condensations and gives the sensor longer life. It also can make the measurement more accurate. The sensor body should be perpendicular to the exhaust gas flow, and it should also be tilted in the range of 10 o ~75 o from the horizontal line (see below figure). The typical tilt-angle is 30 o . The sensor head should be close to the center of the exhaust pipe.

After finding the right location on the exhaust pipe, drill a hole of 18 mm in diameter. Weld the sensor bung on it.

Note: do not weld the bung with the sensor in it.

Note, if you vehicle has a Bosch narrow band oxygen sensor (LSF) already you can just un-plug the LSF, and plug-in the wideband LSU sensor into the hole. Bosch LSU and LSF have the same size of the thread.

More User Notes

LSU sensors are not designed to work with leaded gasoline. Using LSU sensor with leaded gasoline will reduce the sensor life.

With the LSU sensor installed in the exhaust pipe, whenever the engine is running, please also run ALM-CAN, which controls the LSU heater. Otherwise, long-time-running engine with LSU sensor not heated can cause damage of the sensor.

LSU sensor is preferred to run within the temperature range of 500~900 o C, the best temperature is 780 o C. Too high temperature (>1030 o C) will cause damage of the sensor. Refer to Bosch LSU4.9 data for more details about the variant temperature requirements.

http://www.etas.com/en/downloadcenter/5858.php

Avoid heating the LSU sensor before the engine is running. At the engine start, there may be www.ecotrons.com

Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

condensations in the exhaust gas, which can cause damage of the sensor. The preferred order: start the engine first, then immediately turn on the ALM-CAN, which will ramp up the heating power smoothly.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Chapter 5 ALM-CAN hardware connections

5.1 ALM-CAN main connector pin-out

ALM-CAN is a weatherproof design. There are 3 cables coming out of ALM-CAN:  LSU 4.9 sensor cable with Bosch standard sensor connector   CAN bus which are CAN-H and CAN-L twisted wire pair 12V+ Power and Ground wires (standalone Heater return)

5.2 CAN bus connection overview

Multiple ALM-CAN units can be connected on the same CAN bus; their ALM IDs should be different, and can be configured via a PC GUI interface.

Keep in mind, ALM-CAN does NOT come with a CAN bus termination resistor (120 Ω ) internally. It is assumed the user CAN bus has that already.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

1) Connect the 6-pin LSU4.9 mating connector to the O2 sensor.

2) Connect ALM-CAN to the CAN bus. Yellow wire is CAN-L; Dark Green wire is CAN-H.

3) 4) Connect the 12V+ to 12V battery plus or the DC power supply +; Connect the GND (and heater return ground) to 12V battery minus or the DC power supply negative ; Note: 1) 2) 3) User’s CAN bus must have 120 ohm terminal resistors; The default CAN bus baud rate is 250K; this can be configured to 500k and 1M via PC GUI.

If you want to communicate with your computer, you can use ECOTRONS USB to CAN module.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Chapter 6 Software instructions

6.1 Install ALM-CAN GUI

1) Setup Find the software installation folder on the CD, or you can download the latest software installation package from our website: http://www.ecotrons.com/support/ 2) Run the "setup.exe" file, here is the welcome Window 3) Installation destination Directory Note: do NOT install it into Windows "Program Files" folder. Windows does not allow unknown software to change the content below the "Program Files" folder.

You can change the destination directory if you don't want to install it into the default directory. Or click the installation button to continue.

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Accurate Lambda Meter-with CAN bus 4) Setup Successful ALM-CAN Manual v1.8

When you see "ALM-CAN Setup was completed successfully", it is done.

6.2 Using ALM-CAN GUI

To open the software GUI, go to Windows desktop, and find the ALM-CAN GUI icon, double click it.

ALM-CAN GUI running state will be like this:      The signals that can be displayed in the ALM-CAN GUI window include:  Lambda Oxygen concentration (O2%) Duty Cycle of Heater, form 0% to 100%.

Temp (LSU 4.9 sensor temperature, unit: degrees C) ID ( Current ALM ID : This is the Source Address byte in J1939 protocols) DTC (Diagnostic Trouble Code, bit wise) www.ecotrons.com

Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

6.2.1

Ecotrons CAN protocols Ecotrons CAN protocols are subset SAE J1939 protocols or the customized subsets.

The default CAN bus baud rate is 250kbs.

J1939 standard CAN protocol message format:

Here, 29-Bit identifier is the CAN ID.

(Note, 11 bit CAN ID is possible, as customer specific required) ALM ID is stored in the Source Address byte, the range is 1 to 254, and the default is 1.

Standard CAN data bytes: 8-Bytes of data includes: Lambda, O2%, Duty Cycle of Heater, Sensor Temp, and DTC.

Below are 8 data bytes defined in ALM-CAN: Byte 1 Byte 2 Byte 3 Byte 4 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 %O2 Lambda value Byte 5 Byte 6 Byte 7 Byte 8 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Sensor temperature PWM duty cycle (High 4 bits) Sensor faults PWM duty cycle (Low 8 bits) For SAE J1939 specific terminology, please contact SAE.

http://www.sae.org/standardsdev/groundvehicle/j1939a.htm

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PGN 65280 Ecotrons Specified Information

The purpose of this PGN is to group the wide band oxygen sensor data. including below signals: www.ecotrons.com

Accurate Lambda Meter-with CAN bus      %O2 (2 bytes), Lambda value (2 bytes), Sensor temperature (2 bytes), PWM duty cycle of heater (12 bits), Sensor faults (4 bits).

ALM-CAN Manual v1.8

Message Transmission Rate: Data Length: Extended Data Page: Data Page: PDU Format: PDU Specific: Default Priority: Parameter Group Number:

Start Position

1-2 3-4 5-6 7.1

7.5,8

Length

2 bytes 2 bytes 2 bytes 4 bits 12 bits 10 ms 8 byte 0 0 255 0 3 65280 (0xFF00)

Parameter Name

%O2 Lambda value Sensor temperature Sensor faults PWM duty cycle of heater

SPN

3217 520193 520194 520196 520195

SPN 3217 (R)

Data Length: Resolution: Data Range:

after treatment bank1 O2%

2 bytes 0.000514 %/bit, -12 % offset -12% to 21% Operational Range: same as data range Type: Measured Supporting information: PGN 65280

SPN 520193

Data Length: Resolution:

after treatment bank1 Lambda

2 bytes 0.000244 / bit, 0 offset Operational Range: same as data range Data range: Type: 0.5 - 16 Measured Supporting information: PGN: 65280

SPN 520194

Data Length: Resolution:

Sensor Temperature

2 bytes 0.023438 deg K/bit, 0 offset www.ecotrons.com

Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Data range: PGN: 840 - 1303 deg K Type: Measured Supporting information: 65280 Operational Range: same as data range

SPN 520195

Data Length: Resolution:

PWM duty cycle of heater

12 bits 0.08 %/bit, 0 offset Data range: Type: 0 - 100% Measured Supporting information: PGN: 65280 Operational Range: same as data range

SPN 520196

LSU

Sensor Faults

ALM has on-board-diagnostics capability to detect most common errors. The first thing user should do when ALM is not working is to read DTCs.

0000 -- No faults 0001 -- Internal communication error 0010 -- Internal register error 0011 -- LSU yellow wire (VM) short to power 0100 -- LSU yellow wire (VM) short to GND 0101 -- LSU black wire (UN) short to power 0110 -- LSU black wire (UN) short to GND 0111 -- LSU green wire (IA) short to power 1000 -- LSU green wire (IA) short to GND 1001 -- Operating voltage too low 1010 -- Heater circuit damaged 1011 -- Heater circuit short to power 1100 -- Heater circuit short to GND Data Length: Resolution: Data range: Type: 0 - 12 Status Supporting information: PGN: 4 bits 1 / bit, 0 offset 65280

For example:

O2% = (Byte2 * 256 + Byte1) * 0.000514 + (-12) Operational Range: same as data range www.ecotrons.com

Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Lambda = (Byte4 * 256 + Byte3) * 0.000244

Sensor temperature = (Byte6 * 256 + Byte5) * 0.023438-273 ( deg C ) PWM duty cycle of heater = (Byte7 / 16 * 256 + byte8) * 0.08 + 0 ( Byte7 / 16 * 256 : Get high 4 bits of PWM duty cycle of heater) Sensor faults = Byte7 bitwise & 0x0F 6.2.2

Set the new ALM ID for ALM-CAN ALM-CAN module comes with a default CAN ID, which is the 29 bit identifier. Of which the PGN is pre-defined by SAE J1939; the only customer part the "Source Address" byte. This "Source Address" byte by default is 0x01. You can define your own ALM ID by changing this byte. ALM-CAN supports 0x01-0xFE number of IDs.

ALM-CAN GUI software provides an interface to change this byte (ALM ID). This means you have as many as 254 ALM-CAN modules on the same CAN bus.

Before setting the ALM-CAN ID, make sure the ALM-CAN has been connected to the CAN bus. If there are multiple ALM-CAN modules on the CAN bus, which all have the same default ALM ID, then you can only power on one ALM-CAN at a time. After one ALM-CAN module setup is done, power it off, then you can power on another ALM-CAN and set it with a different ID, and so on.

Device index, channel number, baud rate setting.

If there are multiple CAN devices connected to your PC, for example 2 CAN-USB adapters, the Device Index are used to distinguish the different CAN devices. If only one CAN device on your PC, Device Index should be set to 0, otherwise, increment it in the order of: 0,1,2……7.

Channel Number is used to select the channel of the USB-CAN device. Most USB-CAN adapters have two CAN channels. You can use different channels to connect the ALM-CAN, by selecting the correct channel number.

Click "Open device" to open the USB-CAN adapter channel. If successful, you will see at the bottom of the ALM-CAN GUI the message:" Open the device successfully!" and the indicator bar turns green.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

In the ALM ID text box, type in the new ALM ID, and then click "Burn To ALM". The ALM ID range is 1 to 254, it's included in the 29-Bit identifier. This ID byte is the last byte (source address) of the 29 bit identifier. You only need to enter decimal ALM ID; the ALM-CAN GUI will automatically convert it to a hex number. For example, enter ALM ID 100 (decimal), ALM-CAN GUI will automatically burn it as 0x64 (hex).

Setting is completed.

Power off the ALM and then power on, ALM will begin transmitting data.

6.2.3

Select which ALM you want to display You can choose which ALM on the CAN bus you want to display: 1) 2) Click "Open device" to open the USB-CAN channel.

In the "Expect ID" box, enter the Desired ALM ID to display; the range is 1 to 254 .

3) ALM-CAN GUI will only display data corresponding to the selected ALM ID.

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

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Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Chapter 7 DTC table

Below is the Diagnostic Trouble Code table. ALM-S has on-board-diagnostics capability to detect most common errors. The first thing user should do when ALM-S is not working appropriately is to read DTCs.

Trouble Code E1 E2 E3 Description Internal communication error Internal register error LSU yellow wire (VM) short to power E4 E5 E6 E7 E8 E9 E10 E11 E12 LSU yellow wire (VM) short to GND LSU black wire (UN) short to power LSU black wire (UN) short to GND LSU green wire (IA) short to power LSU green wire (IA) short to GND Operating voltage too low Heater circuit damaged Heater circuit short to power Heater circuit short to GND Solutions Contact the manufacturer Contact the manufacturer 1. Check the harness for short-to-power 2. Change the LSU 1. Check the harness for short-to-ground 2. Change the LSU 1. Check the harness for short-to-power 2. Change the LSU 1. Check the harness for short-to-ground 2. Change the LSU 1. Check the harness for short-to-power 2. Change the LSU 1. Check the harness for short-to-ground 2. Change the LSU Check the power supply to the ALM-S spec.

Contact the manufacturer Contact the manufacturer 1. Check the harness for short-to-ground 2. change LSU 3. Contact the manufacturer www.ecotrons.com

Accurate Lambda Meter-with CAN bus ALM-CAN Manual v1.8

Chapter 8 Appendix: LSU4.9 vs. LSU4.2

Characteristics lambda range Accuracy Response time Heating power Free air calibrations Nerst cell resistance vs.

temperature Light off time Reliability Check with Bosch LSU4.2

lambda = 0.65 ~ ∞ only good at lambda = 1 or moderate rich Slower 10W needed 80 Ω  750 C long Still selling it LSU4.9

lambda = 0.65

~ ∞ accurate at both rich and lean, wider range Faster 7.5W

not needed 300 Ω  790 C short Improved reliability Recommended Notes LSU4.2 is only accuracy at lambda =1 and moderate rich, between 0.8~1.0 lambda; LSU4.9 has better accuracy in both rich and lean conditions, suitable for gasoline, diesel, CNG, etc.

Thinner sensing element of LSU4.9 makes it more responsive to the AFR change, dynamically more accurate, and easier to light off, less heating power needed.

LSU4.2 has the off-centered-heater vs. LSU 4.9 has the centered-heater in the laminate; LSU4.9 has better heating efficiency, less heating power needed.

LSU4.2 is susceptible to reference air contaminations, which is called CSD (characteristic shift down), requires frequent free-air calibration.

LSU4.9 uses reference pump current instead of reference air. No more CSD. No requirement of free-air calibrations LSU4.9 has higher resolution of internal resistance vs. temperature characteristics, which makes the temperature measurement more accurate, and better heater control, therefore higher accuracy of lambda.

LSU4.9 lights off faster. Lambda controls can be active much faster during warm up phase.

LSU4.9 is superior to LSU4.2 with regard to reliability and life.

Bosch recommends LSU4.9 to all OEMs.

Bosch uses LSU4.9 for it's own wideband controller http://www.bosch-motorsport.de/media/catalog_resources/Lambdatronic_LT4_Data sheet_51_en_2785631627pdf.pdf