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AEM Flex Fuel Wideband Failsafe Gauge Includes FF Sensor 304911 User Manual
AEM Flex Fuel Wideband Failsafe Gauge Includes FF Sensor 304911 User Manual
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AEM Performance Electronics 2205 126th Street Unit A, Hawthorne, CA. 90250 Phone: (310) 484-2322 Fax: (310) 484-0152 http://www.aemelectronics.com Instruction Part Number: 10-4910 Rev B 2016 AEM Performance Electronics Instruction Manual P/N 30-4910 Wideband Ethanol Boost Gauge P/N 30-4911 Wideband Ethanol Boost Gauge This product is legal in California for racing vehicles only and should never be used on public highways. Wideband Ethanol Boost Gauge Parts List WARNING: ! This installation is not for the electronic novice or the PC illiterate! Use this system with EXTREME caution! If you are not well versed in electronics and vehicle instrumentation or are not PC literate, please do not attempt the installation. Refer the installation to an AEM trained tuning shop. A list of AEM trained tuning shops is available at www.aemelectronics.com or by calling 800-423-0046. You should also visit the AEM Performance Electronics Forum at http://www.aemelectronics.com. NOTE: AEM holds no responsibility for any engine damage that results from the misuse of this product! Qty Description Qty Description 1 Wideband Ethanol Boost Gauge 1 Faceplate, Lambda Black 1 LSU4.2 UEGO Sensor 1 Faceplate, Vacuum Black 1 UEGO Harness 1 Harness, Input / Output 1 Install Kit w/ Bung 1 Rubber Band 1 Power/IO Harness 1 Wideband Ethanol Boost Instructions 1 USB Cable 1 Gauge Box 1 Faceplate, AFR White 1 Boost Hose Adapter 1 Faceplate, Boost Black 1 Vacuum Hose, 7/64” ID x 36” L 1 Faceplate, Boost White 1 Silver Bezel 1 Flex Fuel Sensor (30-4911 Only) 2 3/8” - SAE Barb Fittings (30-4911 Only)
Page 3 GETTING STARTED THIS PRODUCT DOES NOT INCLUDE SOFTWARE IN THE PACKAGING. PLEASE DOWNLOAD AND INSTALL THE WIDEBAND ETHANOL BOOST CONFIGURATION SOFTWARE FROM THE AEM WEBSITE AT: www.aemelectronics.com/downloads Software Installation Instructions Follow the Installation Instructions as outlined in the forum post described above. After the software installation is complete, double-click on the AEM W ideband Ethanol Boost icon (shown below) to launch the application. Connect the USB cable to the PC. The Wideband Ethanol Boost will turn ON with ignition key-on power. Alternatively, the Wideband Ethanol Boost can be bench-programmed outside of the vehicle without powering it by connecting just the USB cable. However, the UEGO sensor, MAP sensor, Flex Fuel sensor, analog outputs, and CAN outputs will not function. Overview AEM W ideband Ethanol Boost is an advanced safety device that allows the end user to closely monitor the performance of their engine. As a tuning tool, this device provides the ability to accurately monitor AFR, while actively protecting the engine by constantly recording AFR curves and activating a user-defined failsafe strategy if it runs dangerously lean or excessively rich. The Wideband Ethanol Boost Gauge is a UEGO (Universal Exhaust Gas Oxygen) controller with an internal boost sensor, an internal data logger and a full color Organic Light Emitting Diode (OLED) display. It includes technology to activate a failsafe strategy in the event AFR falls outside of a user-defined operating window. If the AFR falls outside of the set operating window, the Wideband Ethanol Boost Gauge triggers a user defined output function that can save an engine from catastrophic damage. This product allows the user to view and log the output of a flex fuel ethanol content sensor. P/N 30-4911 is supplied with an AEM Flex Fuel Sensor; however, 30-4900 is not. It is recommended to use one of the following AEM sensors: Part Number Description 30-2200 Ethanol Content Flex Fuel Sensor Kit (Barbed) 30-2201 Ethanol Content Flex Fuel Sensor Kit (-6 AN) *Most “Continental” or “GM” style sensors are compatible with the 30-4910/4911 Wideband Ethanol Boost Gauge. Sensors that ouput a 12V square wave using the following calibration are compatible. Description Calibration Conversion Formula Ethanol Content (%) 50 Hertz = 0% ethanol 150 Hertz = 100% ethanol ethanol % = [ Frequency (Hz) - 50 ] Fuel Temperature (degC) 1 millisecond pulsewidth = -40 degC 5 milliseconds pulsewidth = 125 degC degC = [ 41.25 * Pulsewidth (ms) ] - 81.25
Page 4 ECU / Datalogger Installation Diagram Installation 1. Disconnect the negative battery cable. 2. Temporarily install gauge without bracket into desired mounting location. Gauge mounts into a 2-1/16” (52MM) hole. The supplied rubber band can be used as a spacer around the gauge if it fits loosely in mounting hole. 3. Locate a suitable place in the exhaust system to install the included oxygen sensor weld bung. On non-turbocharged engines, mount the oxygen sensor in the exhaust system at least 18 inches downstream from the exhaust port. On turbocharged engines the oxygen sensor must be installed after the turbocharger, ideally 18” downstream from the turbocharger exhaust housing. NOTE: If the sensor is mounted before the turbocharger the pressure differential will affect the accuracy of the unit. For accurate readings, the sensor must be mounted upstream of the catalytic converters and/or auxiliary air pumps. To prevent collection of liquids between the sensor housing and sensor element during the cold start phase, the installation angle should be inclined at least 10° from horizontal with the electrical connection upwards, see image below.
Page 5 4. Next, the UEGO sensor 8-pin wiring harness should be routed to the oxygen sensor bung. Pin Color Description 1 N/C N/C 2 White Heat - 3 Orange VM 4 Green IA 5 Red IP 6 Black UN 7 N/C N/C 8 Brown 12V 5. Next the main 16-pin connector will be manually wired into the vehicle. Pin Color Description 1 Black Ground; connect to good chassis ground or directly to battery negative (−) terminal 2 Red Ignition power; connect to a fused key on +12V power source 3 Black USB - Dedicated 4 N/C Reserved 5 Red USB - Dedicated 6 Green USB - Dedicated 7 Blue *OPTIONAL* Ground output; connect to an external auxiliary device (1.5A max current) 8 White USB - Dedicated 9 Green *OPTIONAL* Flex Fuel Ethanol Content Sensor Signal Input 10 Gray *OPTIONAL* Gauge backlighting; connect to instrument lighting dimmer wire 11 N/C Reserved 12 N/C** *OPTIONAL* AEMnet - 13 N/C** *OPTIONAL* AEMnet + 14 Brown *OPTIONAL* Analog ground for AFR and MAP; connect to sensor ground of data logger or EMS 15 White *OPTIONAL* 0-5V analog output for AFR; connect to + analog input of data logger or EMS 16 Yellow *OPTIONAL* 0-5V analog output for MAP; connect + analog input of data logger or EMS NOTES: Pins 14/15 are differential analog outputs. The brown wire should be connected to an analog ground input for best results. If the EMS, logger or similar device does not have an analog ground input, the brown wire should be connected to a sensor ground. If no sensor ground is available, the brown wire should be connected to a power ground. The brown wire must be connected in order to obtain correct AFR and MAP readings from the analog output(s). ** Pins 12/13 are un-populated as delivered. Please order the optional 30-3439 wiring harness to connect the WBFS gauge to other AEMnet products.
Page 6 6. Connect the pre-terminated brown three pin connector to the flex fuel ethanol content sensor, if present. Pin Color Description 1 Red Vcc – Battery 12V 2 Black GND – Battery Ground 3 Green Vout – Sensor Output (10k pullup to pin 1) 7. Connect all cables and wiring harnesses to gauge. Fully install gauge into hole using mounting bracket and nuts. 8. Install USB cable so the PC end of the cable is easily accessible and route the gauge end of cable to the gauge mounting location. USB cable is meant to be permanently installed to gauge and left in vehicle. Stow PC end of cable in location such as glove box or center console, etc. Flex Fuel Ethanol Content Sensor Installation The sensor must be installed in the fuel return line between the fuel pressure regulator and the fuel tank, reference the diagram below. The sensor may be installed in any orientation; the direction of flow through the sensor does not matter. It should be noted that the entirety of the fuel flow returning from the fuel rail is not required to travel through the sensor. This may be useful on very high flow systems with a larger than typical return line. In these cases, the sensor can be run in a smaller parallel circuit to measure just a portion of the return flow so that the sensor does not become a restriction for the entirety of the return fuel flow. Please ensure that the barbed fittings are installed securely and verify the system is completely leak free before proceeding.
Page 7 Wideband Ethanol Boost Configuration In this tab, the AFR monitoring and alarm output functionality of the W ideband Ethanol Boost can be configured. Air to Fuel Ratio vs. Pressure Description Displays AFR vs. Pressure data points. AFR points will be populated live whenever the PC is connected to the Wideband Ethanol Boost and the UEGO sensor is registering an input. The current AFR and Pressure values are shown live on the right side of the graph. The graph area is where the high and low AFR limit lines are established. Configure the pressure scale and AFR scale before setting the boundary lines as they will reset each time a different scale is selected. Graph Button Description Auto Set Limits Automatically sets the upper and lower AFR lines based on an average of the collected AFR data points Reset Limits Resets the upper AFR limit line to maximum and the lower AFR limit line to minimum Clear Graph Clears all the displayed AFR data points from the graph; does not clear stored AFR data from logger Logger Button Description Log Percentage Displays current amount of data recorded Download Log Downloads all the collected AFR data that is stored in the logger; will prompt to save log to disk; log files saved as .daq for direct viewing in AEMdata program Clear Log Clears all stored AFR data from the logger Flex Fuel Sensor Parameter Description Ethanol (%) Displays the current flex fuel sensor ethanol content percentage. Fuel Temp (degC) Displays the flex fuel sensor fuel temperature in degrees Celsius.
Page 8 Gauge Configuration In this tab, the gauge lighting and display features can be configured. Alarm Configuration Option Description Alarm Delay Period of time that measured AFR can be outside the upper and lower AFR limit lines before an alarm condition is triggered; 100-1000 milliseconds Alarm Reset Period of time AFR must be within the acceptable range before the alarm will automatically reset and turn OFF; 1-10 seconds Disable Auto Reset Select to require power cycle to reset alarm; overrides the automatic alarm reset period. GND Output Select to turn the ground output ON or turn the ground output OFF when an alarm is triggered; 1.5 amps max Alarm Status Parameter Description Status Indicator Color indicates status; green is system ready, red is alarm triggered Source Indicates the source of the alarm condition; possible alarm conditions are high AFR, low AFR, auxiliary input, and alarm test Alarm Press Pressure when alarm was triggered; Units determined by Pressure Scale selection Alarm AFR AFR when alarm was triggered; Units determined by AFR Scale selection Option Description Alarm Test Simulates the alarm to test output configuration; test duration set by Alarm Delay value Display Option Option Description Upper Display Upper display reading configuration; use to select either pressure (InHg / PSIg or Bar) or O2 sensor (AFR or Lambda) Lower Display Lower Display reading configuration; use to select either flex fuel ethanol content percentage or off. If off then only the upper display reading will be visible. Installed Faceplate Faceplate configuration; use to match 24 outer LEDs to faceplate with either Pressure (InHg / PSIg or Bar) or O2 sensor (AFR or Lambda) [See Appendix II – Changing Faceplate / Bezel]
Page 9 Wideband Ethanol Boost Failsafe Tuning The following is a basic guideline strategy for configuring the Wideband Failsafe for the first time. The ideal time to configure the Wideband Ethanol Boost is while the vehicle is being dyno tuned. Ensure your engine is fully functional mechanically before starting to configure the Wideband Failsafe! 1. In the W ideband Ethanol Boost Configuration tab, click Clear Graph and Reset Limits to zero all settings. 2. If a boosted pressure scale is selected, there will be a pink triangular cursor on the left side of the graph when the engine is in high vacuum, as shown below. The upper and lower limits for this high vacuum area will use the lowest pressure (furthest left) breakpoint for alarm triggering. Alarm Flash Option Description Flash Speed Select speed of flashing while alarm is triggered; flash slow or fast Dimmer Max Brightness Option Description Dimmer Max Brightness Select whether +12V or ground indicates maximum backlighting brightness Bar-Graph LED Color Option Description RED LED (1) Can be disabled; use slider to configure multiple LEDs. Reference gauge display at bottom right. ORG LED (2) Can be disabled; use slider to configure multiple LEDs. Reference gauge display at bottom right. GRN LED (3) Cannot be disabled; use slider to configure multiple LEDs. Reference gauge display at bottom right. ORG LED (4) Can be disabled; use slider to configure multiple LEDs. Reference gauge display at bottom right. RED LED (5) Can be disabled; use slider to configure multiple LEDs. Reference gauge display at bottom right.
Page 10 3. Run the engine as you would normally drive the vehicle then complete a series of long sweeping high load 3rd and 4th gear pulls going from low to high RPM each time to populate the graph with AFR data. Avoid making quick hard pulls as this may skew the AFR data points. Repeat this procedure until a baseline AFR curve is established. Note: You may notice that a few random AFR data points are plotted well outside of the normal AFR curve. This is caused by dynamic tip-in wall wetting in transient pressure situations. This is normal behavior and false triggers can be ignored in the configuration setup process below. 4. With a baseline AFR curve now established, click on Auto Set Limits and the software will produce its best suggested high and low AFR limit lines based on the populated AFR data shown on the graph. Review and adjust the high and low AFR limit lines as needed to contour the lines around the baseline AFR curve (shown below). This can be done by clicking on a breakpoint and either dragging up or down with the mouse or by clicking the up and down arrows on the keyboard. To move to the next breakpoint, click on it with the mouse or use the right and left arrows. Pressing the Tab key will toggle back and forth between the high and low limit lines.
Page 11 5. Test the configuration using your anticipated normal operating conditions with varying engine speed and engine load situations to account for starting, stopping, accelerating, high boost, low boost, tip in, fast shifts, slow shifts, etc. If false triggers occur, either adjust the high or low AFR curve up or down at the pressure breakpoint where the alarm occurred or adjust the Alarm Delay setting. NOTE: There are two general configuration strategies to follow when using the W ideband Ethanol Boost. The high and low AFR limit lines can be set very tightly to the baseline AFR curve and a longer Alarm Delay can be used. Conversely, the high and low AFR limit lines can be set further way from the baseline AFR curve and a shorter Alarm Delay can be used. Furthermore, many tuners may conclude that a rich AFR is more acceptable for, safety measures, than a lean AFR. If true, a looser tolerance can be put into the lower limit line as depicted in the graph above. Only thorough configuration testing will reveal which strategy is best for your application.