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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. 
      
    						
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