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2Y1 Assembly Guide

1. a a k A AL Ww p lt A NI AY Line Drawing of the 2Y controller Copyright 2011 Tech Edge Pty Ltd Australia Page 2 of 28 Tech Edge 2Y1 Assembly Guide Table of Contents Tee Basie COnSty eti i u uuu uu y RE C E EROR NEU OD FERA UC IRA MESE COS SERES CUR aaa KUNA BK E C KKRRE RES 3 Lal TANGAN I MOGE arasan T UU Mte 3 EZ OEr 2yr Models y TIM py aa uu yu a a i ana KAE a ga ene een ee aa een ee aa Aan Qasa 3 Zi RIT CODtentEs ios u ESI BS KEN Kak BAANG NGANG QUIA M CX CREE DEPAN BAG LIU FR EA AGA DE BEA EIUS MES BI edi EVE E paytapas 4 2 1 Electronic PARES aan unu uu daa a a Ba ara a NG EOM end rate u LA OT Bag Ba ae aana BE OR Reena 4 2 2 MISCellatiGoUs Palle u u uyak Sapa Sa aaa ci eee a nan aaa pea gah a a na ata ab aba a Ka a geng E ag a ag anan 5 23 Parts NGLANGUT Gi uu u aa ncs u Qusa ue NGA DP Aor ono bd Que tob uoc ag a GA gaga aaa aaa hea 5 3 Overlays With Values and Numbers sssnwunwanawaanaanana 5 3 1 Overlay With Part Values over page sssseseeseeeeeeee nenne meme me meses 5 5 2 Oyeblay Wich Pare NUMDE S cias uuu l Ruta dun uuu as n rii Pana Sad dat paf s be dede 7 Ase Gemo Sl CC Oras uu 2 ssimum sa Sa a spossassassssessosssosssashssuyspasaaspiasaqasspsussussamasaassupusss 8 2 1 Importance ol ASSEMDIY NOLES uuu tie ws uu l pua vctus a at b a oed e Y a Cc aco C C 8 dq Z BY Easy OLS ate gee E D pruden Tr Cur soam audam ee eer ee Tn
2. j Instdledonend Note7 may be 100uH or 330uH Orange Orange Brown Silver 330 uH multi coloured capacitor X1 16 000 MHzCrystal C Temporarily remove plug with tunnel connectors Temporarily remove plug with tunnel connectors LM358 Op Amp Note 3 MC33204 Op Amp Note 3 with jumper shunt Page 12 of 28 Tech Edge 2Y1 Assembly Guide Descipion Notes with jumper shunt t RJ 45 style socket 5 5 ll ss 5 l l E E RJ45 style socket Tactile switch 90 push button 5 Assembly Notes 5 1 Note 1 Regulators The 5V LM7805 regulators should have their leads bent at 90 and mounted such that the hole in the TO 220 package lines up with the hole in the PCB Later for each regulator a screw will be installed from the solder side of the PCB into a nylon spacer The lambda module mounts on the other side of the spacers 5 2 Note 2 Fuse The two fuse holders each have a small end tab that may prevent the fuse from being inserted if they are the wrong way around Also some longer fuses require that the end tabs are bent out slightly to allow a little more length for the fuse Insert the fuse holders into the PCB holes then insert the fuse into the holders Check to see if the end tabs need to be bent out Bend the tabs as necessary before soldering the fuse holders in 5 3 Note 3 DIP Sockets Be careful to insert the DIP sockets so the n
3. E 4 1kQ 5 1k Ohm Resistor 3 1k5Q _ 5 1 5k Ohm Resistor E o 6 10kQ 16 10k Ohm Resistor A Molex MiniFit two pin PCB connector prn OE power OAE E tote 5 2kQ 1 30kQ _ 1 30kOhmResistor 4 100kQ 1 100k Ohm Resistor 2 180kQ _ 1 180k Ohm Resistor Green connectors are made up of a S aa a End removable and pluggable screw header Tech Edge 2Y1 Assembly Guide Page 5 of 28 Partt Description lt 5 RJ45 socket for SS seriall O Two are used one on the side and the other at the end of the case ST202 16 pin HIN202 ST202 RS232 driver 4052 _ 16 pin MC74HC4052 multiplexer Electrolytic capacitors are 1 6484 14 pinLMC64840p amp polarised Refer to the 1 white markings on the PCB 31 7414 14 pin 74HC14 hex Schmitt trigger _ for the correct orientation THERM 47k 25 C thermistor ABS plastic case with closing screws Black endplate made from PCB laminate has Tech Edge logo Green endplate made from PCB laminate 4 SCREW M3 x 6mm screws 4 WASH M3 spring washers Base of the plastic case with both endplates Detailed assembly notes should be followed for the circular 8 pin socket on the black left endplate 2 3 Parts Not Included Some parts needed for a fully functional wideband controller are not included in this kit e Controller to Sensor cable The Contr
4. Plug in the lambda module Making sure it mates correctly with the 24 pin header plus the 1 position O E N Ra Page 14 of 28 Tech Edge 2Y1 Assembly Guide header for the 25th pin Install the M3 x 6mm screws for the two corners of the lambda module with holes Now the lambda module with the 25th pin is positioned correctly Solder the 25th pin By undoing the top two M3 screws unplug the lambda module It is recommended that you remove the lambda module for now until after initial testing see the Preliminary 5 Volt Testing section below 5 9 Note 9 Molex Power Socket The 2 pin Molex socket for power amp ground lines up with a cutout in the black endplate 5 10 Note 10 C16 Laid Flat Capacitor C16 ends up under the lambda module next to the unused 8 pin U2 C16 if left standing up as usual can be too close to a jumper shunt on the lambda module To avoid this lay C16 flat on the main PCB by bending it over in the direction of U2 6 TheCircular 8 Pin Socket and Transition PCB The circular 8 pin socket is on the black endplate and the Controller to Sensor cable plugs into it The small 20mm x 20mm transition PCB is soldered to the other side of the circular 8 pin socket then eight small copper wires join it to the main PCB The order of assembly noted below is critical for correct and long term reliable operation Take very careful note of the following instructions We have found many people who h
5. Shield aE Sanco Harness End Wires Tech Edge Combined Cable Caniector VW part 1J0 973 733 WB Unit Cable to 6 066 Sensor LSU 0 258 006 066 Sensor Harness End Wires VS Nernst Shield 123456 Bosch part 1 928 404 Sensor Tech Edge Combined Cable Connector WB Unit _ Cable to 17 025 Sensor LSU 0 258 017 025 I C8 Socket m j je TELER EERI anmo Al i x Sensor Harness End Wires C8 Socket I Sensor Tech Edge Combined Cable Connector Bosch part 1 928 404 687 wWBunt Cable to NTK L1H1 Sensor NTK L1H1 Sensor Harness End Wires C8 Socket Tech Edge Combined Cable Connector Page 24 of 28 Tech Edge 2Y1 Assembly Guide 16 2 DIY Controller to Sensor Cable Assembly The DIY cable is supplied with the fibreglass sheath already pulled over the combined cable Heatshrink tubing is used for mechanical strength and insulation Heatshrink size is the internal diameter which the tubing has in the expanded before shrinking state The size is printed on the tubing but you may have such a short piece of tubing that by chance the printed size is not visible Before shrinking the size can be estimated by squashing the tubing flat measuring the flattened width then multiplying by 0 6 So for example 20mm heatshrink will be about 33mm wide Five pieces of heatshrink are included in a DIY cable kit 1 5mm 3mm 6mm 10mm and 20mm Most heatshrink can shrink down to 40 of its original diamete
6. The on line version is here To assemble the 2Y1 you will require the following tools e A good hand held temperature regulated soldering iron or soldering station with a fine tip 1mm chisel tip is suitable and a wetted tip cleaning sponge or curly brass tip cleaner e Good quality fine 1 0 mm or finer flux cored tin lead solder from a reputable electronics supplier we use Crystal 511 0 71mm 60 40 solder from Multicore e A small pair of needle nose pliers e Philips head 2 screwdriver e Good quality diagonal cutters or side cutters so component leads may be cut off close to the PCB after soldering Ensure all soldered component leads are trimmed to 1mm or less on the solder side of the PCB This prevents leads from being squashed and creating a short to adjacent pads e A de soldering suction tool or de soldering copper braid solder wick may be useful e A Digital Multimeter DMM may be useful for checking component values 4 1 I mportance of Assembly Notes Please take note There are important assembly notes spelled out in the component tables below for some of the components Carefully read the relevant notes before installing these components as often it is too late to do it properly after the part has been incorrectly installed copyright 2007 CETT BER W Tech Edge Pty Ltd fe rev 1 0b NOVO7 cer 4 SOURCE TB 2710 ATHEGA168 E T f i C INST 7 TPI 595 SINK d 9 T C es
7. WBlin and GND on the 10 way green connector otherwise disconnected Convert the single ended WBlin to a differential output by taking J2 off and removing any link between WBlin and GND on the unit Hint hang the little jumper off one pin so that you do not lose it Connect the the WBlin input to the GND terminal of the target Connect the WBlin output to the voltage input of the target Then the difference between the ground potentials of the wideband unit and the target is cancelled out by the circuitry inside the wideband unit For complex electronic reasons which will not be explained here this technique only works reasonably well It works a lot better than getting it wrong but a true differential input on the target is the best The wideband unit can only cope with a voltage difference between the grounds of at most two volts at any instant in time Since both the unit and the target are independently earthed then excessive voltage differences between the unit and the target should be impossible However be careful to preserve the independent earthing Pay attention to the loop area enclosed by the independent earthing and take reasonable steps to minimise it 12 6 Incorrectly Setting J 2 It is important to note that incorrectly setting this jumper can result in either e Excessive WBlin noise mostly heater switching transients at 30Hz occurring on WBlin This happens when WBlin is connected to the GND pin but grou
8. ee eee eee eT aita ud S aT d 8 4o CAD ere ETE T D LE 10 4 4 SISTINE OIC GE ONS ise cite dod den Dd e DC Ln ac Ce pe dew tie Dac a e e eoa a a eas Ce eaa dn 11 5 Assembly Not s u u u u uuu a gaga di uu SERERE ERRIRSRRNEURRETURESRIRE KENE ENE ka ENG naa EE AREE 12 5 1 NOE T RECOU ITO orno kuya u EP ELO Ere Ead hua we de Db OTRA n opto bid ME RO sasa 12 2 2 NOLO e IS score idu atak aa agar e tosta DEP ILI Mundi Ma D ME EID M shu asan aa Suyana maaa 12 S S NOLS ota DPA SOCK Cbs caravan tan yu aii aa sapu say Piu ME a BA macto ado SU Db uS a a EE a hap qaqas s pr 12 5A NOtes4 e LEDS iiic op ep p a ERE E Ea OS ERE Ed DR RU RUNE ERE ERR daan ers raa ec Cora d Oe a RA 12 5 5 MOLte 5 PuSnbDUttOll uyu usu ew Q ques ete UN br ronda d REPE Ee 12 5 6 Note 6 gt Polarised COMPONENTS s uu u u uu u 21 a oar ER m a a ss a aaa aal UTR 12 5 7 Note 7e DIOGS uuu e bons besten ua soa apuka nman aqa wasa TA BEA aa m aq asqa dva 13 5 8 Note S Lambda Mod le uyay A en re eh CR EE CER AERE ICE Ne C u y CD Ce DO oed 13 5 9 Note Ye Molex POWOL SOCKET 7 3 a aa add i acta orc ana E d hes a EAQUE rcl edat Fur bd bte pat bar A t 14 S I0 Note 10 I6 Eald PIat scutis Dye muhu SSS uma Ea beni t GG KG RE ME Rc 14 6 The Circular 8 Pin Socket and Transition PCB 14 7 Correction of Board Faults sssswuswanwanwanaanaanaanaanaaannana 15 8 Power
9. relative to GND on the wideband unit For more detail on WBlin considerations please see http wbo2 com sw wblinout htm The first thing to do is to decide whether you have a differential or a single ended target If the target has no separate earth connection of its own then it must be differential It is using the GND pin on the unit as its ground reference point For example an ordinary battery operated digital multimeter is differential A mains operated target with a double insulated power supply is also differential However if the target does have its own separate earth connection then you need to look harder at the target to see whether it has a differential input or not The sign of something being a single ended input is one of the input terminals is a ground pin connected to the case You can check that with a multimeter For example a conventional oscilloscope with an earthed case and a BNC input would be a single ended input Conversely some oscilloscopes have differential plug ins with a true differential input However such oscilloscopes are rather rare It can be difficult to Page 20 of 28 Tech Edge 2Y1 Assembly Guide decide whether your target is differential or single ended Seek help from an electronics expert if you are not sure 12 4 Differential Target Suppose you conclude that your target is differential The target must be differential sensitive only to the voltage difference between its input termin
10. supplied from a current limited bench power supply which must be capable of a sustained delivery of 3 Amps while maintaining a 12 Volt terminal voltage An alternative source is a fully charged automotive battery in good condition but as these are not current limited be aware of the hazards of high currents causing local heating and injury Do NOT use a battery charger for testing A proper bench power supply or real fully charged battery should be found Battery chargers usually have no current smoothing and produce an unfiltered AC waveform that will cause improper operation and at worst may damage the wideband unit An old PC power supply is a good source of regulated 12V DC 12V is on the yellow wires GND on the black Page 18 of 28 Tech Edge 2Y1 Assembly Guide 5 Volts 5 Volts 29 Y 4 v AM Au With power applied but with no sensor connected yet the wideband unit should have the green power LED brightly illuminated but the other LEDs should not be illuminated Using a good quality voltmeter or digital multimeter check both of the 5 Volt rails using the tab of one of the 5 Volt regulators as a Ground reference Refer to the diagram above in this section for where to place your probes If the voltage measured is not between 4 9 and 5 1 Volts then there is a problem that must be corrected before going on any further 11 Inserting the Integrated Circuits Insert the integrated circuits paying attention to
11. wire you can find where the wires emerge from the jacket of the cable You could perform other electrical testing at this point if you wished See the section Final Electrical Test below for details The silicone seals should end up in the correct place inside their holes For any that did not push them forward with long nose pliers or some other suitable tool The heater wires can be difficult If the seals do not go forward as you would like then give up It is no great problem Pull the 6mm heatshrink forward as far as it will go and shrink it Pull the fibreglass sheath forward so that it is almost touching the connector The 20mm heatshrink is then pulled over the lip at the rear of the harness connector and shrunk Now you have the 20mm heatshrink attached to the harness connector but it will not shrink down far enough to properly grip the fibreglass sheath underneath Slide the 10mm heatshrink over the end of the 20mm heatshrink Put the end of the 20mm heatshrink about half way along the 10mm heatshrink then shrink Put a cable tie on the 10mm heatshrink next to where the 20mm heatshrink ends This end of the cable is now finished 16 5 Final Electrical Test This is very important Do a final electrical test of the finished cable Use a multimeter set to ohms or continuity test It is not a good idea to poke multimeter probes into the circular 8 pin plug Use a straightened paper clip and a small jumper lead to make the con
12. 202 ST202 100nF 104 104 105 C1 100uF 25V Electrolytic Capacitor 4 100uF25v Note 6 C4 100uF 100uF25v Note 6 m e e e m UJ w Re O O O O O OO O O O IO UJ UI O U1 UT L N NsN N C13 C25 C32 C33 C34 C37 M C30 DOO C2 les C8 C9 C11 C14 c loot a 104 C18 C19 C20 feat C23 C24 C26 C27 C28 C35 C17 C13 C25 C32 C33 C34 C37 C29 C30 C31 C2 C3 C8 C9 C11 C14 C15 C16 C18 C19 C20 C21 C22 C23 C24 C26 C27 C28 C35 C17 C1 C4 4 4 Semiconductors Next the semiconductor components and miscellaneous parts are installed These include diodes the inductor looks like a large resistor the crystal LEDs etc Tech Edge 2Y1 Assembly Guide Page 11 of 28 Notice that when you are finished there will be a few places on the PCB where there will be blank holes These are for components which are part of options not covered in this document or relate to design changes SEM m d a PA je AN E W S v in Section 7 Correction of Board Faults Part Description Notes D6 1N07 J Note7 D4 1N4148 Signal Diode Installed on side Note7 D8 1N4148 JInstdledonend Note7 D9 1N4148 X 9
13. C21 leave the appropriate leg of C21 long and unsoldered and bend it over close to U5 pin 13 Solder them both later on when installing the socket for U5 The capacitor leg and pin 15 are already connected by a PCB trace Once this fix is made both the capacitor leg and pin 15 should be at GND potential You can check that both pins Page 16 of 28 Tech Edge 2Y1 Assembly Guide 13 and 15 of U5 are grounded by using an ohmmeter The mounting holes at each corner of the PCB are handy ground reference points to use for this test t ZUM LEZL 2 ase miog YB logger module T FT iso 4 ki T m UU uni The main PCB is now complete ready for preliminary 5 Volt testing see picture above Note that the ICs have not been inserted at this stage Note that capacitor C16 has been laid over flat 8 Power Cable Construction Figure 8 Cable with white flash The heavy duty figure 8 power cable is assembled as shown The terminals are crimped onto the figure 8 cable with a pair of long nose pliers and soldered securely To maintain compatibility with the way we make production cables ensure the white stripe flash on the figure 8 cable is inserted into the bottom of the plug that is away from the Molex plug s lock tab The cable without the stripe flash is the positive connection and should be marked at the other end of the cable with some red heat shrink red alligator clip or other method of ensuring it o
14. Cable Constructions isa EAR UT S uu s KERNEL RUD UA ER FERRE 16 Qs RS232 CAD le cis uyum kau E SOUS AMA assaka paui uqaqa GERE UVERME EUM M aa s UNE 16 9 1 8952322 DB9 RIA5 Gabple Schenmiable5 u uten dh antur mace E XR EN RAO ADS V ei era ER Pri dra 17 92 RS232 Cable ASSemDIly nete orator Xd ac deo Metu ea umasa cto a a atte ttn 17 I0 Prenminary 5 Volt Testilhig suiit ioco mutas Na asa aa a aa a kaq a EE a saqsa sua M APIS 17 11 Inserting the Integrated Circuits ssssswanwwawaanannan 18 T2 Jumper Snulits cens uu uy ag KEN a aaa CES ES FUENTE DI ERREUR ELE U ELE ERES 18 12 1 J1 Thermocouple Gain x1 or X101 ccc eee HH Rhen 18 12 2 2 WBlIri t GND rmper Snunt ido uu eter et ence ever aec Susa nad o p 19 12 3 WBlin Measurement General Considerations sss nnn 19 12 4 Differential Target sssssssssssssssssseeee nennen nnn aa aaa aaa aaa eaa rn nne 20 12 5 Smmglese nded Tar geb ssec bo Tan pq ccce doa oid oa acia a a CD EE ERG DR ORE LUPO 20 IZO Incortectly SebEEIHg 2 ceti hlc an ama uma etate duet echan di tu ukuka des cpm saa an totg t d 20 12 4 Avold Large EoODS asuossensasaddaat n tesa ac E TAa wor DRE dS u eU NL PLN C D ULM Del Sand Nd ihn 20 1278 Danger of Arc Welder uu uuu xr eid dac teda Kao cicer ed vd VE d UR EUER RUBER OPES Ce P PR REN 21 TS Fi alrASS mblyu uuu uu yu uu E IER EE CI D RR KE WT NM VE E a UU NUM aoaaa 21 I3 Ll Green En
15. Gold Brown Black Orange Silver Brown Black Black Red Silver R4 5 22kQ PRedRedOrangeGold RedRedBlackRedGoli RG 5 22kQ RedRedOrengeGold Red Red Black Red Gold R8 5 22kQ RedRed Orange Gold Red Red Black Red Gold Orange Black Orange Silver Orange Black Black Red Silver Brown Black Yellow Silver Brown Black Black Orange Silver Silvet Brown Black Black Orange Silver Brown Black Yellow Silver Brown Black Black Orange Silver Brown Black Yellow Silver Brown Black Black Orange Silver Brown Grey Yellow Silve Brown Grey Black Orange Silver Brown Grey Yellow Silver Brown Grey Black Orange Silver Red Red Yellow Silver Red Red Black Orange Silver Red Red Yellow Silver Red Red Black Orange Silver Ze fs D un lt s rev 1 0b NOVO7 es dp D OURCE TB62710 6 2611 C240 j 3 C4 Das pein LI Fi NES s PTT 4 9 7889 Fes JE E mA TEES r 1 NS Note the larger 1 W resistors Don t confuse these with the inductor L1 Page 10 of 28 Tech Edge 2Y1 Assembly Guide 4 3 Capacitors CM The capacitors are now added The largest two electrolytics go last Part Marked As 15pF Ceramic Disc Capacitor l5pF lnF Ceramic Disc Capacitor lnF lnF 3 3nF Ceramic Disc Capacitor 3 3nF EF C 563 104 104 104 104 100nF C22 is not marked on the PCB it is to the left of U5 104 HI N
16. Tech Edge DI Y Wideband Kit 2Yl Assembly Guide Note 2Y1 model no onboard logger no inbuilt display Rev 0 3 April 2011 The 2Y1 DIY unit is a high accuracy wideband oxygen sensor controller The 2Y range is the successor to the original 2A DIY range that Tech Edge released in July 2003 Thousands of 2A0 and its updated model the 2A1 have been sold worldwide We designed the 2Y range based on 2A customer feedback We also incorporated technology from other controllers we have developed The 2Y1 wideband kit was introduced in March 2008 The 2Y1 is Tech Edge s first DIY controller where we don t offer a factory built version We offer other models that are factory built and backed with full warranty However third parties may offer the 2Y units in pre built and tested forms The 2Y is named from the Y in DIY Do It Yourself The 2 refers to the Tech Edge model range that has a maximum 5 Volt output the 3 models have an 8 192 maximum output voltage 2Y1 uses a combination of through hole components and pre built and tested modules The basic 2Y1 kit includes the lambda module which is an SMT surface mount technology board containing the major circuitry to implement the sensor interface An Atmel 8 bit microprocessor with a 10 million instructions per second throughput drives the lambda module and other functions on the main board 8 Way Connector Black Endplate Green Endplate V a LN JP wa EN Se
17. Y1 Assembly Guide Overlay With Part Numbers 3 2 e O O O O O O O 2 Qoooo 00530 a o 2238 92895 Bros Q or 1822022 o 8202 OOOO ao NEO ee t 590 667000009 656600 Xo OL O6 o 00056 s 00000 9 6 6 n pd bed a 3 PTY O09 oo0o0o0000a O Mo LM gt 2 ooooN5m 00000oo E CO Q O O O O O O IJ T O s o Ol zeu ah o009009Bf o 9 OTA Lm 3 5506000 s rr into o9 O0000000000000000000000909 Jo O5 Ewe 060 ol SBP u o OAC viser 110 5 gb s AIC o BT g ol 1o Q 2 edi O O O O O O O O O A Oll 9 for Z aodanv Z 13420S N33M138 duo uui 3ava1 O roro qo Nad L002 1uBuKdoo 9 o m eo lt 2 891V93WIV LN 9t d11 O eo yg ez cd11 1d11 O O O O O 1 im 00000000 E 9 ng ng ING o s o x 902096 sa O u 00 su o t OO tea O x9 20000000 2 Q3TIVISNI LON 6 921d1 ZN o o 20000000 o 2 Bo att O a Lad Go Orno ne 02 P gt 00 Q9 ve 200900 z zad OF 20 gt oO O Ons Rolis O r oC DO LTD n SO OOI ei OO oc O LL OO 2 ZA o 19 lo lo lO 9 Page 8 of 28 Tech Edge 2Y1 Assembly Guide 4 Getting Started The PCB overlay and parts locator diagrams on the previous pages may be printed out and used as a reference while installing the through hole components
18. agram below on the pins Then solder one pin Pull out the copper wire Check that there is a nice even small gap Solder the remainder of the pins The transition PCB should have 8 short lengths 1cm of copper wire soldered on so they protrude from the transition PCB side with the text opposite the socket The easiest way to do this is to bend some copper wire into four hairpins about 20mm by 5mm Then insert each hairpin into two adjacent holes in the transition PCB then solder Cut the protruding wires to length thereby discarding the bent part of the hairpin On the socket side of the transition PCB cut the wire off nearly flush You end up with eight short wires protruding out Bend the wire as shown and insert into the main PCB the endplate should fit nicely over the RJ 45 socket which is already soldered to the main PCB Carefully filing the bottom right corner of the endplate so that it is no longer sharp will help the fitting of the main PCB The face of the RJ 45 socket should be flush with the face of the endplate This positioning is essential so that later on the case can be assembled correctly Check Tech Edge 2Y1 Assembly Guide Page 15 of 28 by doing a trial fit of the main PCB into the bottom half of the case You wish to line up the mounting holes in the main PCB with their associated screw holes in the bottom of the case Careful bending of the 8 short copper wires will achieve the desired result Do not allow the 8 cop
19. als and ignore any common mode voltages Nor must the target inject any differential currents into either of its input terminals A well designed target will do all that The unit stays as standard with a single ended output J2 stays on or an external link is provided between the WBlin and GND terminals Both WBlin and GND are connected to the two input terminals of the target For example on a multimeter connect WBlin to the multimeter s VDC terminal and connect GND to the multimeter s COM common terminal Two wires are to be connected it is that simple If you have a true differential target which is also independently earthed then watch out for excessive common mode voltages which could overload your target s common mode rejection circuitry For example suppose the unit was installed in a car with the WBlin signal going to an external earthed oscilloscope or logger There is nothing to stop the body of the car floating at some high voltage Provide an earthing wire for the car body to prevent this problem Then common mode voltages will be a small fraction of a volt and will not cause trouble 12 5 Single ended Target Suppose you decide that your target is single ended Now things get a little bit tricky Joining the GND pin on the unit to the GND terminal on the target would be a mistake because they have both been earthed by separate means You can test for that by checking for continuity between the two GND points with WBlin
20. ave not paid attention have soldered parts that are difficult or impossible to remove without their destruction Tech Edge uses the convention that a connector which is part of a panel is called a socket The circular 8 pin metal bodied socket is first inserted through the hole in the black endplate made from PCB material The keyway on the circular socket must be aligned as shown below The lock washer and nut should be attached and tightened so that the socket does not rotate Don t over tighten and destroy the thread Tech Edge Refer to the images below Note that the finished picture is of the main PCB in an upside down position compared to the line diagrams The transition PCB should be soldered to the sensor socket but it s very important that a small gap around 1mm is left between the housing of the sensor socket and the surface of the transition PCB As there is sometimes a little play in the end of the Socket any movement against the PCB can cause the thin solder resist to be abraded away and in time cause a short circuit and possibly damage the unit or the sensor The easiest way to ensure the necessary small gap is as follows Put the socket assembled onto the black endplate with the solder side pins facing straight up Get some bare copper wire supplied in the kit and bend it into a hairpin shape like a tall U then lay it flat between the pins of the socket Then lay the transition PCB in the correct orientation see di
21. degrees low This error was corrected in March 2008 and should no longer occur No action is required 17 2 HIN202 ST202 Ground Error Rev 1 0b PCB Pin 15 of U5 HIN202 or ST202 is not connected to the ground plane of the PCB This can cause erratic or non existent serial communications All Revision 1 0b PCBs require a simple addition of a wire link on the underside of the PCB Provided this modification described above in the section Board Correction has been done then no further action is required vv 9 a Bp3 u e1 TTOZTO LL0c d93 GC bad LACASM r H3TIOH LNODOSHODIN 89TV543WlV JdST ETI TX CO ZHWOT Adgt ZTO Sv sivas SLNN QNnOSS amp r ezsu z sxs 5 lt lt InOAS_ 3u00T Tech Edge 2Y1 Assembly Guide AJAYA CECSH cu LLVSA 819 ay T L1V8A 3u001I vTO kd AS AUOOT 612 U AS SANA Ant L O AS1X3 IC PCB Schemat LNOAS e CD cD D D e D D D D Page 28 of 28 Main 18 SMT YOST stu 6T e LLVSA ASt QN5A ta LOOPNT py JAS T VEE ZZSSNT VA d 9va WMd T JOT AT aed eeu AE T HOOT NIV95 OL JUT Jur EED ZED UOLSINWNYJHL 2 S7TOALY
22. dplate Modea O y ter a a x ura aor dna asta eaaet u a Ra XC VR REA ie tana RASTA Cl aka eas 21 13 2 FENO The Caseros dis uuu RE RETI a SER rads unuy tetra dod uid au dad aaa du a ed rade 21 13 3 8 Way Green Connector Modificato crise eE E E awuha ua nnn n 21 14 Advanced Teskting u u u u aaa Tu agan aa Nan Waaa aa SE Naga a En Na MNERC UN FU REUS aga 22 15 changing The Sensor TYPE asia a Naane EEE EPI RU u samai asss 22 16 Coritroller to Sensor GCabl6eS uu RIO RR ORC OLD NGANAN KAGEN SS GR Ev a a eR ow EN ER RA ONE a ERKR E MER ERE 23 16 1 Controller to Sensor Cable Schematics sssssssssseseee nme 23 16 2 DIY Controller to Sensor Cable Assembly r r nnn 24 16 3 Circular 8 Pin Plug ASSEMDIY 0 cece cece cece eee eee eee ee ee eee nennen nnns 24 16 4 Harness Connector Assembly u u u u eurn aids es su tuor e Vp a bari tnde ius EE Aa aaa KE aaa 25 16 5 Final Electrieali esbuu T EN aa a a Ka Ega E aa BE a Ba a a a a A N bag ag DA aaa ENEG KK 26 EY m a f Eel Cale pee EE Ee 26 17 1 Lambda Module LOK Thermistor EEPPOL vss aac dac a Kc i dca ed Ra a R0 d A AR RR XS Ra 27 17 2 HIN202 ST202 Ground Error Rev 1 0b PCB oce eoe opc ec 9 v Gr a c e pc ccena 27 18 Main PCB ScHematiC u uyu u u uuu usu u SENEC REI EN u uu uuu isuu FREI IUE EIN apaa NUUS 28 Tech Edge 2Y1 Assembly Guide Page 3 of 28 1 Basic Construction The 2Y1 was de
23. duce a nice neat connection which does not project above the top of the square section of the terminal The insulation retention tabs should then be crimped closed afterwards otherwise the heat from soldering will melt the insulation Check that those tabs fit nicely within the circle defined by the wire end of the terminal Push the silicone seals forward so that they touch the terminals Consult the correct diagram for your cable then orient the heater terminals with the heavy wire such that they will go into the appropriate holes in the back of the harness connector Notice that the pin numbers of the harness connector are moulded into the lip at the rear of the connector Note carefully the rotational orientation of the terminals is critical If you look at the end of the terminal you will see two pieces of metal meeting at a tiny black line When the harness connector is oriented as shown in the section Controller to Sensor Cable Schematics the black line must be horizontal If all goes well the heater terminals go in together they go snick snick and there are the heater terminals done Now the lighter wires can be pushed into their correct holes one by one Each one goes snick as the locking tabs operate The terminal retention clip purple is pushed closed with a screwdriver Now is your last chance to do an electrical test on the shield Check for continuity between the correct pin on the circular 8 pin plug and any stray shield
24. e terminal is now marked with a black rectangle Remember that the black rectangle terminal is a GND terminal 13 2 Fitting The Case Now the PCB is assembled into the plastic case Make sure the green endplate is slid over the 8 way green connector before the PCB is inserted The PCB should be inserted at an angle initially to allow the LEDs and logger button to fit into the holes in the bottom of the case The mounting holes in the PCB should line up nicely with the screw holes in the case If that does not occur then difficulties will be experienced operating the logger button Correct any such problems before continuing Fix the PCB to the case using four M3 x 6mm screws At this point the unit should look like the illustration on page 1 The 4 rubber feet included are optional but recommended if the unit is to be placed on a dashboard or other hard surface to stop the unit sliding off Each rubber foot has a circular die cut around it By carefully bending the rubber backing sheet the foot with adhesive on the bottom will detach The case lid is placed on and the 4 x 20mm countersunk case screws are installed Finally the sticker should be carefully applied to the top of the case Make sure that the descriptions of each pin on the label line up properly with the terminals on the 10 way green connector Assembly of your 2Y1 wideband unit is now complete If you are going to do advanced electronic testing it will be necessary to t
25. emporarily remove the case lid again so as to give you access to internal points of the circuit 13 3 8 Way Green Connector Modification When plugging in the 8 way green connector it will be found that there are two little plastic nibs which hit the endplate when attempting to plug in the connector Cut them off with side cutters The connector will then plug in normally Page 22 of 28 Tech Edge 2Y1 Assembly Guide 14 Advanced Testing It is preferable on first powering up your unit to connect the serial cable to a PC running the WButil program available from Tech Edge Please see http wbo2 com sw util htm Check that the latest firmware has been installed Tech Edge updates the firmware from time to time and it is worth checking to see if new firmware has been released There is another document 2Y1 Test Procedure which should be consulted for more advanced testing 15 Changing The Sensor Type The unit must be correctly set to drive different types of sensor As standard the 2Y1 unit is set to drive a Bosch LSU 4 2 sensor In 2010 the LSU 4 2 was Tech Edge s most popular sensor by sales volume However the unit can be set to drive a variety of sensors including the recommended Bosch LSU 4 9 sensor The LSU 4 9 is a later design has somewhat better performance and its price is falling due to increasing popularity driving volume Older sensors tend to have a higher price because as manufacturing technology imp
26. en used in professional audio and telephony for many years cancel out the ground voltage difference and thereby extract the wanted signal WBlin in our case The ideal situation is to have a differential input target being driven by the unit s WBlin and GND operating as a single ended output The interference is cancelled out in the target since the target measures only the voltage difference between the two output pins WBlin and GND It is not acceptable to have a single ended output driving a single ended input because then there is then no rejection of the ground voltage differences However it sometimes happens that someone has an existing piece of equipment the target which happens to have a single ended input What to do then Answer cancel out the ground voltage differences in the wideband unit That is the purpose of the WBlin input That gives the unit a differential output The general rule is Single ended output to differential input OK recommended Single ended output to single ended input Not OK Differential output to single ended input OK sort of Differential output to differential input Not OK 2Y1 s 10 way green connector has two pins that carry the name WBlin one is WBlin the WBlin output voltage representing lambda AFR and the other is WBlin which is a ground reference input for WBlin The output voltage on WBlin is the sum of WBlin and the input voltage on Wblin The voltage on WBlin is measured
27. ewer and is built fundamentally differently from the older 4 0 4 2 sensors Because it s different it needs three things l Additional bias current implemented with a resistor which is enabled disabled by moving a jumper which is on the underside of the lambda module 2 Different firmware this firmware handles the LSU 4 9 slightly differently and these differences were too great to be handled with just the one firmware 3 Different Controller to Sensor cable the LSU 4 9 connector is different from that of both the LSU 4 0 and the LSU 4 2 It is vitally important to note that the above items must always be changed when changing to or from an LSU 4 9 sensor If you have multiple wideband units set for different sensors and they might get mixed up label each unit carefully with its correct sensor type WARNING Trying to use an LSU 4 0 or 4 2 sensor with the jumper shunt in the LSU 4 9 position and or with LSU 4 9 firmware will result in damage to the sensor Similarly using the LSU 4 9 with the 2Y1 set for the LSU 4 0 4 2 may also damage the sensor Tech Edge 2Y1 Assembly Guide Page 23 of 28 The jumpers for sensor type are on the underside of the lambda module but the markings for jumper position are on the top in tiny white lettering Rather than describe here how to change the jumper settings and the firmware you should go to the on line 2Y User Manual page at http wbo2 com 2y userman htm sensor where ful
28. from touching the body Pull the clear insulator up over the soldered pins Reinsert the plug into the body and refit the locking screw Pull the fibreglass sheath down so that it almost touches the body Then pull the 10mm heatshrink up into the saddle cavity making sure the fibreglass sheath remains under the heatshrink and shrink with a heat gun A cable tie should be clamped around the heatshrink to help retain the fibreglass sheath Reinstall the saddle and lightly tighten the screws Compress the saddle down onto the cable with long nose pliers or similar Tighten the saddle screws This end of the cable is now finished 16 4 Harness Connector Assembly fibreglass cable 10mm expanded 6mm tinned silicone crimp harness sheath tie heatshrink heatshrink heat wires seals terminals connector shrink 10mm 20mm LETTER jin heat heat Mg shrink shrink UE iy 30mm 20mm 30mm dE 25mm 55mm At the harness connector sensor end place a 20mm length of 10mm heatshrink over the cable and fibreglass sheath Get a 30mm length of 20mm heatshrink and see if it will fit over the lip at the rear of the harness connector This will be the cable boot for the connector If it does not fit expand the heatshrink mechanically using pliers until it does Heatshrink is tough when it is cold Once i
29. her that shows the part number on Page 7 3 1 Overlay With Part Values over page There is an on line version of this image which includes additional embedded information that pops up when the mouse is moved across the part See http wbo2 com 2y 2yloverlay htm Tech Edge 2Y1 Assembly Guide Page 6 of 28 ls 8d SV LYNL LG u318WV N1349 MM e e9 O 6 0m ou lOO vost OOI sm eoo d m gt OQ voor lo O4001 6 O4001 6 O xz 0010 lo m uo iO O xz Oln OOo m COD en eY Nt 4001 9 Ox001 0 oO EN 9wi 0 C m m ltt NOOL 00000000 2 p AAA mg o e o n io S 0066064 0000000 OTA b ae i O 0000000 D O ao O xo o O wz 00 m lo wor lo na GA 00000000 s JINGOW 33990108 2 vy K o ool m e s cil o0 u901 6 Owoo1 6 O O O O O ago o xO Somes oe Oe 2 s 49 9 9 OO Ds 8 9 S y Z I G3TIVLSNI Salsi 019 JO OOO OC e LON ZN 200006 00000000 15 a Ox001 6 es Oro 6 T K ro el O wv avin O S o lo 26 JO s OJE DAS QU T d 10 Szol amp lo Qo oo xol o AIG LOOPNL 10001 ol lo 0016 Cf u O BJ of 1o ol lo olo 5zi 50 09 m o loooos it ome 9 0 0 53 90 2O OI t ol JORR g o o0 9 T9907 lw wa O OO s LOAON GO L Ae 00Z iubudoo 3 O m La B i gj Page 7 of 28 Tech Edge 2
30. ill not also go through Pull some cable out that is move the body and sheath back out of the way Put a 25mm long piece of 6mm heatshrink on the cable Next strip 15mm of the cable and separate the wires Consult the diagrams in the section Controller to Sensor Cable Schematics and carefully identify which is the correct diagram for your cable You may like to use a highlighter to identify the correct diagram It is easy to accidentally use the wrong diagram otherwise Put the shield twisted to make it manageable in the centre with the other wires arranged in the correct order around the shield Strip and tin the individual wires A good quality wire stripper will be useful Tin the terminals of the plug Place the clear insulator over the cable then a 6mm length of 3mm heatshrink over each large wire and a 6mm length of 1 5mm heatshrink over each of the smaller wires Put around 12mm of 1 5mm heatshrink over the shield Solder the shield on to the correct terminal pin That is usually pin 8 the centre pin except in the case of the NTK L1H1 sensor then use pin 2 Solder the other wires each to the correct pin Once the wires are soldered pull the heatshrink up over the soldered joints then shrink them with a heat gun Pull the 6mm heatshrink so that it covers the visible parts of the wires and butts up to the 6mm pieces of heatshrink Shrink the 6mm heatshrink with a heat gun The purpose of the 6mm heatshrink is to prevent the shield
31. l details are presented The firmware can be found at http wbo2 com sw hxf htm In accordance with the 2Y user manual the NTK L1H1 UEGO sensor is not supported There is no HXF file that is there is no firmware available for the 2Y series to drive this NTK sensor Make sure the NTK LSU jumper is in the correct LSU position 16 Controller to Sensor Cables The 6 core Controller to Sensor cable goes between the wideband unit and the sensor plug which is provided as part of the sensor The cable has two ends The circular 8 pin plug end plugs into the unit or controller The harness connector end plugs into the connector attached to the sensor The Controller to Sensor cable has a fibreglass sheath to protect it from mechanical damage and damage by hot objects Please Note These cables are available pre built or as DIY cables from Tech Edge Correctly assembling a DIY Controller to Sensor cable is reasonably difficult and should only be attempted by experienced constructors Read the assembly instructions given in this document most carefully before you begin Consider the possibility of buying a pre built cable 16 1 Controller to Sensor Cable Schematics WB Unit Cable to 7 057 Sensor LSU 0 258 007 057 l Sensor I Shield ser i I 1 Vs Grey 2 Vs Ip Yellow X 3 Ip R r Red 3 4 Ip CalR P Green Bani Red Gj co Heater e Om O 7 Heater kBlue j i 8
32. lar function e Socketed CPU and other parts for easy testing and replacement e Thermocouple inputs re configurable as 0 5v user inputs making up to 6 user channels 1 2 Other 2Y Models 2Y1M 2Y2 2Y1M An optional 1MB SMD module and some other parts may be purchased to upgrade the 2Y1 to the 2Y1M This provides on board logging memory 2Y2 The 2Y2 model will have an on board 4 digit display The 2Y1 was originally designed for this option but unavailability of one key component prevents us from offering this option Page 4 of 28 Tech Edge 2Y1 Assembly Guide 2 Kit Contents Upon receiving your kit please check that the following parts have been included Unpack all parts Some parts can be wrapped with other parts Note that 196 resistors may be substituted for 5 parts but 596 should not be used where 1 is specified 2 1 Electronic Parts Ooty Pat Description The PCB as it comes from the fabricator showing the lambda module transition PCB optional on MOLEX MiniFit 2 pin power socket board logging module and main 2Y PCB 10 way green pluggable header with plug already connected 8 way green pluggable header with olug already connected L HR Red oe eo Pre built lambda module with SMT s T a a Sis rcunb Sese CS mounts to the transition PCB and the 90 mount tactile push button transition PCB mounts to the main PCB 3 100R 56 100 Ohm Resistor EN 1 150R 5 150 ohm Resistor
33. lding bench was earthed by having a small grinder bolted to it The work clamp of the welder was attached to the bench The welder being reasonably large had its own heavy earth wire One day the welding bench was found to be no longer earthed Inspection revealed that the grinder s earth wire was blown How did that happen Answer Someone had left the electrode holder on the top of the welder which was metal The welding rod had touched the metal case The current flow was as follows welder electrode terminal electrode holder welding rod welder case welder earth wire switchboard earth link grinder earth wire grinder welding bench work clamp welder work terminal The grinder earth wire being the weakest link then blew Notice that the grinder and the welder kept right on working and nothing was obviously wrong The solution was 1 Replace the grinder power cable 2 provide an insulating platform on the top of the welder where the electrode holder could go 3 give the welding bench its own heavy earth wire back to the switchboard 4 educate staff 13 Final Assembly 13 1 Green Endplate Modification The green endplate with the 8 way green connector labelled Logger Inputs has a terminal on it which is incorrectly marked RPM That terminal is actually a GND terminal the same as its neighbouring terminal which is marked with the international ground symbol Using a black permanent marker obliterate the RPM marking Th
34. nd on the wideband unit is different to ground on the target then using a single ended target This problem can be caused by the jumper being ON when it should be OFF e Floating WBlin which then causes the WBlin output to exceed 5 Volts or go below 0 Volts The Wblin input should always be connected to some ground either GND on the unit or ground on the target This problem can be caused when the jumper is OFF when it should be ON As standard the J2 jumper is ON but you know what kind of target you have so you make the decision 12 7 Avoid Large Loops Make sure your two wires joining the unit to the target do not include any significant area between them This would create a loop of wire capable of picking up interference It is best to have both wires together and shielded Conventional shielded microphone audio cable will do the job very nicely If the target has its own earth connect the shield to a GND point on the target Otherwise connect it to GND on the unit Tech Edge 2Y1 Assembly Guide Page 21 of 28 12 8 Danger of Arc Welders Arc welders are a particular danger to earth wires It is easy to accidentally get a very large current from an arc welder going through some earth wire thereby causing it to blow like a fuse Then your earth wire is no longer doing its job Then all sorts of safety hazards and electronic malfunctions can happen Example An arc welder was set up next to a heavy metal welding bench The we
35. nection to your probe It is advisable to hold the harness connector sensor end still with a small vice or some other third hand arrangement That allows you to conveniently touch the terminals of the harness connector with your probe Do not be rough with the terminals Make sure that there is continuity between every connected pin on the circular 8 pin connector and the correct terminal pin on the harness connector All wires should be under 1 Ohm Check pin numbers carefully verify that you have not accidentally swapped over two pins Then check that there is good insulation between every connected pin and every other pin Anything under 100 MOhms is suspect Resolve all cable problems before attempting to use it with the unit and a sensor 17 2Y1 Errata This is a comprehensive list of all known problems and the solutions and modifications offered for the Tech Edge 2Y1 DIY kit Tech Edge 2Y1 Assembly Guide Page 27 of 28 17 1 Lambda Module 10k Thermistor Error Some early lambda modules shipped before July 2008 included a 10K SMT resistor marked 103 installed in position R31 note on the lambda module not the main PCB which should have been 47K marked 473 If the incorrect resistor is fitted the thermistor field in the WINLOG software will display a low or negative value at room temperature typically 20 degrees For details please see http wbo2 com sw log htm Thermocouple measured values will also be up to 50
36. nly goes to a positive terminal Circuitry prevents the 2Y1 being damaged if connected in the reverse polarity but do not rely on this in case there is another fault that could damage the unit when it s reverse connected Note carefully the rotational orientation of the terminals when they go into the plug is critical so that the small locking tangs will work 9 RS232 Cable 2Y1 can communicate via a standard RS232 serial connection Most PCs and many laptops have a standard RS232 port typically referred to as the COMI or COM2 port Newer computers laptops in particular may not have an RS232 port in which case a USB RS232 converter or dongle should be used these are available from Tech Edge or general PC suppliers Tech Edge 2Y1 Assembly Guide Page 17 of 28 9 1 GROUND Pin 5 shield cover with heatshrink PC Tx Pin 3 w OY ul IS U IN a 9 2 te DB9 Serial 5 GND te RJ45 Serial shield PC Rx WHITE WBo2 Rx RED PC Tx RED WBo2 Tx WHITE GROUND SHIELD GROUND SHIELD 1 2 3 4 5 6 7 8 9 A partially constructed RS232 cable is supplied it has just the RJ45 plug crimped on one end The supplied DB9 S female DB9 connector must be soldered according to the diagram above The lower diagram shows the DB9 connector viewed from the solder side The white wire goes to pin 2 on the DB9 connector Red goes to pin 3 Twist the shield tin it and put a small piece of 1 5mm heatsh
37. o Ero fene d s PASTU PIC6C595 i 5 10 10 11 12 ji J 6 9 2 I p eU A rmm 9 g pen ges Joca RS Os dsl Ra L R5 fec2s TY 32 lo ol meee ee R26 mm Pa at I x101 30 4t R v MJ a Qui Wus R27 N l Jus M 2 pa LM358 a alis M Oui in oS ee o k r 0 eo e v 7 y MES o LUC 74HC4052 x sx 4 r7 Vnd i st F IEE S ow MS ears RZ RIS i tN ve S i sq z mr 10000 o ERNY w e 25 x aaa 2 Lee Ji RIIS d I y MX V AME INE ZEE ee e m 2 nu Bare main Beard before construction has commenced Note that y your board revision may be newer than and different from the one shown 4 2 Resistors It is recommended the watt that is smallest through hole resistors be installed first as taller components can get in the way when the PCB is component side down for soldering Although most part values are written on the component use a DMM to double check each resistor s value before installation Don t rely on resistor colour bands alone Your board will look like this once the resistors are installed Tech Edge 2Y1 Assembly Guide Page 9 of 28 Part Resistor description 4 Band Colour Code 5 Band Colour Code Orange Orange Black Silver Gold R9 5961000 Brown BlaekBrownGola Brown Black Black Black
38. oller to Sensor cable goes between the unit and the connector attached to the sensor Tech Edge has a DIY cable kit optional 2 6m or 4 0m length that is normally purchased with the controller Some constructors may wish to buy a pre built Tech Edge cable or make their own from scratch e Harness connector The harness connector is at the sensor end of the Controller to Sensor cable Tech Edge sells harness connector kits for use with different sensor types Bosch LSU 4 0 LSU 4 2 amp LSU 4 9 and NTK L1H1 L2H2 sensors e Sensor A lambda sensor is needed for the unit to be useful Bosch s latest and greatest the Bosch LSU 4 9 is recommended Note carefully the unit is set as standard for the Bosch LSU 4 2 sensor Always use the correct sensor type The unit can be set to suit different sensor types see Section 15 Changing The Sensor Type e On board logging module option Allows logging information to be recorded inside the unit for later playback to a computer This option is covered in another construction manual e External display displays are available from Tech Edge in both fully built forms for example LX1 or DIY kits LDO2 DIY A Tech Edge external display is recommended 3 Overlays With Values and Numbers The overlays on the following two pages show the location of parts installed on the rev 1 0b PCB Two versions are provided one that shows the actual component value at each part location on Page 6 and anot
39. ons This document is about the 2Y1 model which does not include on board logging nor an inbuilt display Features include e Pre built lambda module for quick troubleshooting and reliable operation e 2x RJ45 communications connectors Tech Edge standard for simultaneous display and PC logging Suitable remote displays are available from Tech Edge for example LD02 rectangular available built or as a DIY kit LX1 LCD display or LA1 round suits gauge mounting e 3x K Type thermocouple 0 50mV inputs intended for coarse Exhaust Gas Temperature EGT measurements e K Type cold junction compensation CJ C and PCB temperature via an on board thermistor e 3x 0 5V User inputs intended for analog voltage measurements such as Manifold Absolute Pressure MAP Throttle Position Sensor TPS and Cylinder Head Temperature CHT sensors e RPM measurement 0 5 Volt input on the RPM input possibly from an Engine Control Unit or direct connection to a Kettering coil ignition via the COIL input e 0 5 Volt 12 bit optional differential WBlin re programmable output for wideband aware ECUs etc e Two additional 0 5 Volt 9 5 bit single ended independently fully re programmable outputs NBsim and SVout for narrowband simulation driving analog displays etc e External logging button input used with the on board logging option which is useful when the unit is hard to reach Tech Edge displays also have a button to perform a simi
40. otched end matches the legend on the PCB This will help prevent you or someone else inserting the matching IC the wrong way around 5 4 Note 4 LEDs LEDs are polarised Make sure they are mounted the right way around They have a ridge running around the circumference of the main body and there is a flat section on this ridge which indicates the Cathode Match the flat to the PCB legend Mount LED m The three LEDs are mounted with correct polarity then bent The base of each LED should be 6mm from the PCB Then they are bent over by 90 so as to Then BEND 90 ultimately protrude slightly from the holes in the lower casing Refer to images The tips of the LEDs should project about 2mm further than the face of the adjacent green 10 way connector 5 5 Note 5 Pushbutton 7mm The 90 PCB mounted tactile switch autocal and logging button must have its legs straightened slightly so that it will sit flat on the PCB The push button should protrude very slightly through the hole in the case when the PCB is eventually assembled into the case We suggest you test assemble the case with the button lightly soldered in before final soldering The button must operate freely when the case is finally assembled 5 6 Note 6 Polarised Components Some components are polarised and must be installed in the correct orientation to work correctly and to avoid hazards e g exploding electrolytic capacitors It is absolutel
41. per wires to project too far away from the main PCB because then they might touch the bottom of the case Be careful and patient When you have the endplate in the right position then solder the 8 wires to the main PCB Leave 1mm gap Transition PCB 1 mnm TH w ie Notice that the transition PCB isa very tight fit against the bottom of the case You may have to carefully file the transition PCB so that it fits properly If for some reason the transition PCB is damaged it is still possible to build the unit we suggest you remove the transition PCB and simply wire the 8 pin circular connector directly by using insulated wires going to the main PCB The pin numbers of the circular 9 pin socket are marked on the main PCB This technique is not recommended as normal practice because the transition PCB actually makes the unit more rigid robust and better able to withstand the demands of everyday use 7 Correction of Board Faults There is a board fault on the Rev 1 0b PCB Pin 15 of the RS232 chip U5 either an HIN202 or ST202 is floating rather than grounded This error will cause poor or no RS232 communication and any attached Tech Edge display may show show nd no data To correct this on the solder under side of the PCB connect a short wire link between U5 pin 13 a GND point and the nearest capacitor leg solder pad of C21 as shown in the images below A neat way to achieve this result is when installing
42. r 16 3 Circular 8 Pin Plug Assembly Threaded Collar 1 Vs Grey 2 Vs Ip Yellow 3 Ip Thin Red 4 CalR Green 5 Not Connected 6 Heater Red 7 Heater Blue 8 Ground Shield sensor clear 3mm heat body T plug insulation shrink Los Uy Ee fibreglass sheath 10mm heatshrink Tech Edge 6 core shielded cable harness 10mm connector heatshrink terminated wires Using a number 0 Phillips screwdriver undo the locking screw in the plug body twist the plug slightly anticlockwise relative to the body then pull the plug from the body Ensure you retain the screw and the clear insulator from inside the body It is a good idea to keep small parts you are not actively working on in a small plastic container that avoids things getting accidentally lost Remove the two screws securing the cable retaining saddle of the body Put those tiny parts into your plastic container sensor 3mm soldered 6mm clear saddle 10mm cable fibreglass plug heatshrink wires heat insulator body clamp T heatshrink tie sheath shrink heat shrink WWW 12mm 25mm 20mm Tech Edge 2Y1 Assembly Guide Page 25 of 28 Take the end of the Controller to Sensor cable where a small piece of cable is projecting clear of the fibreglass sheath Thread a 20mm length of 10mm heatshrink over the fibreglass sheath and then put the cable through the body Notice that the sheath w
43. rink over it to prevent any stray strands of wire touching any other terminal The shield Ground goes to pin 5 Notice that the red wire PC Tx DB9 3 goes to WBo2 Rx RJ 45 2 and the white wire WBo2 Tx RJ 45 3 goes to PC Rx DB9 2 This is because Tx an output must go to an input Rx Both cable ends PC and WBo2 have a Tx and Rx circuit so that data can flow in both directions at the same time The GND Ground is a common return path for both of these Tx Rx circuits The backshell supplied as parts in a small plastic bag includes a cable strain relief clamp You do not want any tension placed on the cable causing tension on the soldered joints The cable is a little too small in diameter so wrap it with adhesive tape where the strain relief clamp will go to build up the diameter Install the strain relief clamp Assemble the backshell halves with the screws and nuts supplied The RS232 cable is now finished 10 Preliminary 5 Volt Testing Once all the components have been installed as described above some tests should be carried out before installing the CPU and other integrated circuits This ensures the 5 volt regulators and other components are working correctly and should not damage any ICs inserted later Remove the lambda module if it is already installed No I Cs apart from the regulators should be installed and no sensor should be connected Power is now applied to the unit via the Molex power cable Power is preferably
44. roves the same or a better product can usually be manufactured at a lower cost Also manufacturers persuade their customers to use the latest manufacturing technology by raising the price of older sensors as they become a legacy part Bosch oxygen sensors follow this rule with older 1 2 3 and 4 wire narrowband sensors often costing more than the latest LSU 5 wire sensors Within the LSU range Tech Edge prices for the newest sensor LSU 4 9 is now also the lowest cost and the oldest LSU 4 0 is the most expensive Of course the newer sensors are also better and with the correct controller setting will give more accurate and faster results and may even last longer in harsh environments The 2Y1 unit currently supports several Bosch LSU sensor types Type Models Notes LSU 4 9 17123 17025 currently the best sensor to use LSU 4 2 7200 7057 used by us and others for the last 8 years LSU 4 0 6066 was one of Bosch s first LSU sensors The LSU 4 0 and LSU 4 2 are similar internally and only differ in their free air pump current specifications the older LSU 4 0 requires about 2096 more pump current compared to the LSU 4 2 The 2Y circuitry has been designed so that proper free air calibration will adequately account for the differences between the LSU 4 0 and LSU 4 2 sensors However the LSU 4 0 and 4 2 sensors have different connectors so a different Controller to Sensor cable is needed The LSU 4 9 sensor is n
45. se to access J2 but make sure J2 is off when you need it off The jumper and the short do exactly the same thing to avoid confusion do not use both 12 3 WBlin Measurement General Considerations WBlin is the main output voltage of the wideband unit derived from the sensor WBlin is a voltage level representing lambda AFR WBlin may be used by an ECU analog data logger or other device we call it the target in the following paragraphs The WBlin output voltage is a single ended output as standard J2 jumper ON but it may also be set up as a differential output Most devices produce single ended outputs for example the 2Y1 s NBsim and SVout are single ended WBlin may be converted to a differential output and this is described below along with the reasons why it should be used as a differential output The problem facing the user of the wideband unit is how to get the WBlin output accurately from the wideband unit to the target without having the signal corrupted by noise hum or interference which would destroy its hard won accuracy The target could be a device with its own GND connection such as a logger Now we have two different pieces of equipment with different ground voltages Ground voltage differences can be caused by induced voltages or currents in ground wires Both of these are unavoidable so any two different pieces of equipment will always have some difference in ground voltage What to do Answer the same as has be
46. signed to be easily assembled by someone with prior knowledge of and success with the assembly of electronics If you have no experience with electronics then we suggest you don t try building this device as the cost of fixing things that are badly assembled can be more than buying a pre assembled unit from us or someone else If there is any question about your ability then don t tempt fate If you need to ask us about your competency our answer will be in the negative if you need to ask then you shouldn t be building it Note If you build it then you fix it Only in exceptional circumstances will Tech Edge accept DIY units for repair If we do accept your unit for repair we will charge you a repair cost that is commensurate with the amount of effort you have expended in building the unit and solving any problems yourself If you built it carelessly or badly then we may not accept it and you are stuck with an expensive paperweight If we decide to repair your DIY kit then will not charge you an unreasonable repair cost We have had several constructors over the years who had an unrealistic expectation we would fix for free the mess they created through inexperience carelessness or by using poor tools 11 The 2Y1 Model We suggest you read all of this document before beginning assembly to avoid missing important Instructions Note that some images can be zoomed in to show more detail The 2Y series is available in several configurati
47. static prevention Refer to the illustration Overlay With Part Numbers in Section 3 2 for guidance Pay particular attention to which way around the ICs are plugged in Notice that there is a notch drawn on the PCB at the end where pin 1 of the IC will be There is also a notch on the IC sockets There is another notch on the ICs All these notches should line up The lambda module should be re installed by plugging it in and securing it with the screws 12 Jumper Shunts J1 Thermocouple Gain J2 WBlin GND MN Ere v LE X101 for thermocouple W1 W2 W3 Not installed X1 for 5 Volt input 12 1 J1 Thermocouple Gain x1 or x101 This jumper sets the gain of an amplifier and thereby switches whether the three inputs T1 T2 amp T3 on the 8 way green connector are used for thermocouples or 0 5 Volt inputs Set the jumper in the x101 position for thermocouple operation or in the x1 position for 0 5 Volt inputs Standard is the x101 position Tech Edge 2Y1 Assembly Guide Page 19 of 28 12 2 J2 WBlin to GND Jumper Shunt The J2 jumper simply joins the WBlin input to its adjacent GND pin on the unit As standard it is on Alas deciding whether J2 should be on or off is somewhat technical Please see the following few sections for details Note that the effect of the J2 jumper can be reproduced by wiring WBlin and GND together with a short piece of wire on the 10 way green connector This obviates opening the ca
48. t fits slide the 20mm heatshrink over the fibreglass sheath and back past the 10mm heatshrink Push the heatshrink and sheath back to keep the sheath clear of the wire ends Push 25mm of 6mm heatshrink over the cable The harness connector is quite deep Strip 55mm of the cable Crop the fine bare shield wires short The shield does not continue through the sensor plug Push the silicone seals over the wires so the harness connector remains watertight The larger diameter wires are cut a little shorter to help absorb cable strain if the harness connector is pulled Strip the wire ends and crimp them to the terminals In normal production an expensive roll in crimp tool is used You may not have a suitable roll in crimp tool so the job can be done using ordinary hand tools with care Orient the wire connection tabs so that they form a tiny U with the wire lying in the middle When bending the tabs in to hold the wire they tend to form a small triangle instead of holding the wire tight That then causes severe problems later on when inserting the terminals into the harness connector Using a small sharp pair of sidecutters cut off about 1mm of one of the wire connection tabs Then bend that tab in first over the wire end using long nose pliers Then bend the other tab over that one Check that the insulation is not touching the terminal Page 26 of 28 Tech Edge 2Y1 Assembly Guide then solder the wire to the terminal The object is to pro
49. the 25th pin An image of the top of a lambda module is shown at below left Note that the electrolytic capacitors silver cans on the bottom of the module are on the face of the PCB opposite the surface mount components and the male header pins also protrude from this face Assemble the 24 pin female header on the main PCB first Make sure that the header is at a right angle to the main PCB not leaning over to the left or right The 25th pin plugs into a 1 pin 2 54mm black header Female which is located next to pin 1 of the unused U2 Look at the underside of the lambda module for a better idea of where the 25th pin is The 1 pin header was made by cutting it off a long header strip Getting this header in the right position is easy provided you go about it correctly 24 pin header 25th pin goes here NM C Y spacer regulator 2 x M3 star washers After the 24 pin header is soldered in assemble the plastic spacers on to regulators U10 and U12 see the diagram above in this note There are two M3 x 6mm screws installed from underneath the main PCB which go through holes in the regulator tabs At each screw put the screw through the PCB and the regulator tab which should be nicely aligned in accordance with Note 1 Then put two star washers on then tighten the screw into the plastic spacer Make sure that C16 is laid flat see Note 10 Put the 1 pin header in position next to pin 1 of U2 but do not solder it yet
50. y essential to be able to recognise directional markings on the casings of all polarised components Electrolytic capacitors are marked with a negative stripe which should be matched with the stripe on the PCB legend Bend the legs on the electrolytic capacitors at 90 and test fit and check before soldering The PCB legend also has a positive symbol to mark the opposite pin to the stripe Electrolytic capacitor A blob of epoxy or hot melt glue may be applied to the bent over electrolytic capacitors to prevent movement and vibrations causing solder mounting points to fracture Tech Edge 2Y1 Assembly Guide Page 13 of 28 5 7 Note 7 Diodes Diodes are marked with a stripe on the PCB legend which should be matched to the end with the black or white stripe on the diode body cathode Some small diodes are mounted on end with a ring marking on the PCB denoting the cathode and a bar pointing toward the other pad The diode should be installed with the black or white stripe cathode closest to the ringed pad 5 8 Note 8 Lambda Module The lambda module has 25 pins in total The module has a 24 pin male header to connect it to the 2Y1 main board This male header plugs into Y6 and Y7 using the 24 pin 2 54mm black header Female which is soldered to the main PCB There is also a 1 pin male header fitted next to the leftmost pin on the lambda module when looking at it as shown on the image on the right below This header is

2Y1 Assembly Guide

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