DL-32 Multi-sensor Universal Data Logger User Manual
Contents
1. Sometimes even the edges of a large retaining nut can be used to detect rotational speed with these kinds of sensors Hall sensors without built in magnets are also often used for crank triggers In that case the magnets are attached to the measured shaft This is often the case in crank triggers for crank trigged ignition systems Hall effect sensors typically have 3 wires Supply voltage output and ground Some hall sensors including the one indicated have what s called a open collector output OC output This means they don t output a voltage but instead switch the output to ground when a magnetic field is detected Example hookups for Hall sensors to the SSI 4 LMA 3 or DL 32 Hall Sensor w regular Output Hall Sensor with open collector Output Hall Hall 5 4 7 kOhm 114Watt A Hall sensor with an open collector output needs a load resistor example 4 7k Ohm between it s output and 5V The advantages of hall effect sensors compared to VR sensors are a No special amplifier or signal conditioning required b Work with many irregular ferromagnetic shafts c No minimum speed operate down to zero speed The disadvantages of Hall sensors are Cost Angular precision is not high enough for trigger wheel sensing High temperature sensitive Maximum detection frequency is typically less than 20kHz 290 47 6 4 4 Reed Switches A reed switch is just a relay contact made of thin ferromagnetic material enclo2. DL 32 Multi sensor Universal Data Logger User Manual DL32 Manual_1 1 doc 1 IVONI W O RN TORE aCe ROIS ORL OR Oe ree ee eT ee 4 2 The Innovate Log Chain Conce Ol rancu n ea eee eee 4 2 1 Log Chain of 5 channels consisting of DL 32 alone cccccccccccooonnnnnnncconoonnccnnnnnonononaso 5 2 2 7 channel Log Chain example with 2 AFR Chanmnels oooccccnccccccccnnnccnnnnccconononcconnncnnnnnnnos 5 23 1 7 Channel Lod Chain example aia A n 5 3 GONMECING the DL S2 nit cee tale E E E E 6 3 1 Connecting a Record button and Indicator LED ooccccccccccocnncnnnnccnonononncnnnnconononnnnnns 6 9 2 Connecting power 10 ine DL 32 ii cias 7 3 3 Connecting external sensor signals eiconau a NE a N e ate ai 7 34 P wenngexternalsSensolSacsnan a e NE a 7 29 Connecting an RPM SIONAL scvsucan sess cerns A A A 8 3 6 Connecting Type K Thermocouples ccccccccscccesssseeceeeeeeeseeseeeeeeeeesseeeseeeeesessaaaaeeeeeeees 8 4 FACCONGING WIR MSDS aii A A E EA A 9 Al MIME ama Dali A AE A 9 A2 ODC omen ee Re PR re ete EE REN ee Reh eee N RR eT Oe ere ee eee 9 43 ilOGS ANG Sessions arer eee eter aces A AE AA AE AI A 10 AA Olan Stp RECON ist iio 10 4o FOFCINO anew log onenn a N a a es tecvestaveds 11 AG Recording Audio NOS cui a a 11 4 7 Importing DL 32 1095 into LOGWOKS uan a ade 12 4 8 Deleting log files from the SD card osian E 12 5 Mounting and calibrating the DE 32 42 25 2562 eerie N 12 5 1 Calibrating the A
3. a LC 1 a LMA 3 a DL 32 s and 2 XD 16 s In this case the chain has 17 channels 6 from LM 1 1 from LC 1 and 5 each from the LMA 3 and DL 32 To Computer gonty for realtime recording Devices attached to the LM 1 s analog input count as being part of the LM 1 s 6 channels They don t count extra XD 16 s do not contribute any channels so you can add as many as needed 3 Connecting the DL 32 The DL 32 looks like this Accelerometer Calibration and Channel APM Cylinder Function Select Select Select Solenoid Control Outputs Inductive A o Llamp Input 1 Power gt eral a Ports External A de Expansion sensor Ports E L Comm Port Thermocouple Input exb Sensor Power Record Microphone Port Button Port optional MAP Sensor SO memory card slot SO memon card 3 1 Connecting a Record button and Indicator LED As part of the DL 32 package you will have received a LED a push button switch and a stereo 3 5mm cable with three stripped ends The cable can be extended with shielded stereo wire up to 30 feet This kit is the record button and indicator The installation of this is required if you do NOT have an XD 16 connected in the log chain after chained to SERIAL OUT of the DL 32 1 The drill size recommended for mounting the included momentary switch is a 25 64 drill 2 Optionally any momentary Normally Open push button switch may be used 3 The included LED
4. 5 see chapter 12 5 When selecting one of the acceleration measurement modes for Input 5 the center of the window changes to this Acceleration sensor Travel Direction Build in direction relative to travel direction cl Select the travel direction of the car Please note that changing this setting will effect the travel direction setting for side force measurements on Input 2 as well 39 15 Kit Contents DL 32 Kit P N 3782 DL 32 TTS N5OR uerve RSAL DATA OGGER DL 32 QUICK START GUIDE The complete instruction manual is on the CD To gain aceese Po the complete OL 37 manual pioase irra ali Eha software provided on e CO which wis included as part of your ee Tha manual sell cantin impartari imi armaan BUE ds H programming and ailfsar Mp A tricks jac ma me 40 Appendix A Limited Warranty LIMITED WARRANTY Innovate stands behind the quality of its products Innovate makes the following warranty to purchasers of its products All new Innovate products carry a six month warranty from the date of purchase If proof of purchase cannot be provided warranty will be determined by date of manufacture When Warranty Void This warranty shall terminate and Innovate shall have no obligation pursuant to it if 1 your Innovate product has been modified or repaired in a manner not previously authorized by Innovate in writing ii the identification markings on your Innovate product h
5. ATDC The time the mixture takes to burn is dependent on many variables AFR mixture density temperature and so on are some of the variables The point of ignition advance is to time the spark such that the peak pressure point is reached at the ideal position Earlier or later looses power An engine typically does not have a crank degree sensor output of sufficient resolution Therefore ignition advance must be measured as a time measurement An engine crankshaft rotates at 360 degrees per revolution So by measuring the time between the spark pulse and a reference pulse the ignition advance time can be calculated For example if the reference pulse is at a 90 degree crank angle and the spark happens at 20 degrees BTDC at 6000 RPM the engine rotates at 36000 degrees per second So the time difference between spark pulse and reference pulse is 0 003055 seconds Most modern EFI systems have trigger wheels that create reference pulses through a hall effect or variable reluctance sensor These trigger wheels look like toothed gears with one or two teeth missing some instead have extra teeth Some systems also have only a single magnetic trigger reference from the flywheel or balancer and use the starter ring gear to provide extra pulses The extra pulses are needed by the ECU to determine the exact crank angle when to fire the sparks for the different cylinders The DL 32 is not concerned with firing multiple cylinders but only with
6. channel number is still displayed eee The DL 32 will either display a lower case c to indicate the Calibration has occurred for the selected channel or an upper case E to indicate that the calibration could not occur Normally an E indicates that the voltage being input is 1V or more off from 5V 12 1 3 Restoring a channel to factory calibration In order to restore an external input back to the factory default calibration the following steps must be taken e Connect a jumper wire from the input of the channel to be restored to the GND connection on the DL 32 e Press the Channel button until the channel number to be calibrated is displayed e Press and hold the Calibrate button while the channel number is still displayed The DL 32 will either display a lower case d to indicate the defaults have been restored for the selected channel or an upper case E to indicate that the restoration could not occur Normally an E indicates that more than 1V is being detected on the selected input 13 External Solenoid Drivers This feature is not supported in the initial firmware release of the DL 32 It will be supported in future firmware releases 14 Programming the DL 32 with LM Programmer To connect the DL 32 for programming follow these steps 1 Disconnect any devices plugged into the DL 32 s Serial IN port and restart the DL 32 by switching it s power off and back on eee ee 2 Connect the 2 5m
7. device on a flat horizontal surface and press and hold all three buttons together until the display shows the letter A A After this re try the above calibration procedure You can now mount the DL 32 6 Setting up the input channels The DL 32 can be programmed directly through the setup buttons on the DL 32 Alternatively the LM Programmer software version 3 09 or later allows you to program the DL 32 via the LM Programmer software This is necessary for some of the more advanced functionality of the DL 32 Some of these advanced functions like speed sensing frequency sensing custom RPM ignition advance and so on require more user input data that cannot be supplied by the simple 3 button interface of the DL 32 The DL 32 must be programmed before it is introduced in the serial chain the serial IN port is empty and the serial OUT is connected directly to the PC 6 1 Programming the DL 32 with the setup buttons To program an input channel repeatedly press the Channel button until the channel number to program appears on the DL 32 digit display Then repeatedly press the Function button until the digit display shows the intended function The digit display will switch rapidly between indicating the input channel number and the set function The LEDs next to the channel and function buttons will indicate which value is being displayed If the function selected is External input the digit display shows a sign
8. differential This means that each input channel has 2 input terminals A terminal and a terminal This is to eliminate ground offsets in the signal Many times the ground point of a sensor is at a different ground than the DL 32 Because each electronic device can only measure a voltage referenced to it s own ground differences in grounding can introduce measurement errors The DL 32 measures the sensor signal s ground FAS with the input and them measures the difference between the and the input This way it recreates the sensor signal s own ground reference as if this input were referenced directly to that sensor s ground The input is NOT a ground itself It is a ground reference input 6 3 Input signal requirements The DL 32 can record either analog signals or pulsed signals Analog signals are measurements where the information for example a pressure is converted by a sensor to a voltage output between 0 and 5V With pulsed signals the measured information is contained either in the frequency of a pulse train or the duty cycle of a pulse trains Examples for frequency type signals are RPM speed and some MAF sensors Duty cycle signal examples are contact dwell of a contact type ignition system or the duty cycle of fuel injectors For all pulse type signals the actual voltage of a pulse must rise ON phase above 2 5V the pulse must fall OFF phase below 2 5V to be measurable by the DL 32 An example of
9. for every cylinder The number of ignition pulses per crank rotation in this case is the number of cylinders divided by 2 Some engines have one coil for every 2 cylinders instead of a distributor The coil fires two spark plugs at the same time One spark is wasted because it fires one cylinder at the end of its exhaust stroke Therefore this system is called a Waste Spark System Each coil of a Waste Spark System fires once for every crank revolution Other distributor less 4 stroke engines use one ignition coil for every spark plug This ignition system fires each coil once for every 2 crank revolutions Coil on Plug ignition systems actually incorporate the ignition coil in a module that plugs directly onto a spark plug and do not have a spark plug wire 7 1 2 Two Stroke Engines On a 2 stroke engine there is a spark for every crank rotation so the spark frequency doubles compared to a 4 stroke Very few multi cylinder 2 strokes have distributors For those that do the number of ignition pulses per crank rotation is equal to the number of cylinders Most two stroke engines have one coil for every cylinder The coil fires once for every crank revolution the same as on a 4 Stroke Waste Spark system 7 1 3 Rotary Engines Wankel Engine A rotary engine consists of a roughly triangle shaped rotor rotating in a roughly elliptical chamber The three spaces left between the chamber and the rotor go through the four cycles of a four stroke eng
10. for external sensors when no 5V supply is available The 5V supply can power sensors with a total power consumption of up to 300mA 3 5 Connecting an RPM signal For RPM measurement you can either connect a tach signal to the CH1 input or plug an inductive clamp into the 3 5 mm stereo socket marked RPM See chapter 6 for RPM measurement details 3 6 Connecting Type K Thermocouples Thermocouples are used to measure temperatures by relying on the phenomena where a junction of any two different metals Copper and Iron for example will generate a small voltage This voltage is dependant upon which two metal are used and the temperature of the junction This phenomena is known formally as the Seebeck Effect Because every junction of different metals contributes its own voltage into the measurement it is important to have as few junctions between dissimilar metals as possible in order to record an accurate measurement This is why thermocouple wire is made completely of two different metals The Type K thermocouple included in the DL 32 kit is composed of Cromel and Alumel one lead being made of each the red and yellow leads Do not look in the box for a thermocouple sensor to put onto the end of the thermocouple wire You can use the wire AS the sensor or use the wires to attach to a Type K thermocouple To make a thermocouple strip approximately 3 4 of insulation form one end of the thermocouple wire Twist the two exposed metal
11. like this Each of the five inputs of the DL 32 can be user configured for different functionalities The 7 segment display of the DL 32 Function indicator will show which functionality is selected The following tables show the functionality of each of the 5 inputs of the DL 32 Input 1 Functions Indicator 2 Functionality RPM External 0 5V 0 10230 0 20460 sensors 12 Input 2 Functions Indicator Functionality Thermocouple Thermocouple i i i External 0 5V EGT range CHT range sensors 0 1093 degC 0 300 degC 32 1999 degF 32 572 degF Input 3 Functions re Indicator Functionality Duty Cycle Ignition Timing Frequency External 0 5V straight sensors frequency Speed sensor Custom RPM range Input 4 Functions EM O O O O O Indicator Functionality MAP Vacuum Boostt Frequency External 14 7PSI straight 0 5V 29 4 PSI frequency sensors Speed sensor Custom RPM range Input 5 Functions Indicator Functionality Acceleration Acceleration Acceleration Frequency Duty Cycle External 29 19 0 259 straight 0 5V frequency sensors Speed sensor Custom RPM range The DL 32 also can act as a power supply for user supplied external sensors The 5V output of the DL 32 can supply up to 300mA of current For this functionality the DL 32 converts the 12V to 5V to power the sensors 6 2 Differential Inputs The DL 32 s external connections are
12. lot of ignition systems Fortunately many multi spark ignition systems output a tach signal with only one pulse per engine cycle But some notably Ford EDIS systems output all pulses and therefore require a special tach adapter 3 Odd fire engines like V Twin motorcycle engines and odd fire V6 engines have ignition pulses that are not evenly spaced For example a 60 degree V Twin running at 10 degrees ignition advance will fire cyl 1 at 10 degrees BTDC Then fire cyl Two 420 degrees later at 410 degrees Then fire cyl 1 300 degrees later at 710 degrees This means the ignition pulses sent to the DL 32 are alternating between 420 and 300 degrees apart and therefore the time between pulses alternates The DL 32 therefore measures the times between ALL pulses for a complete engine cycle 2 rotations and averages the times between them 7 3 Programming the RPM input Determine the number of ignition pulses per crank rotation Refer to Table 2 or 3 for guidance Press the Channel button until it shows channel 1 Press the Function button until it shows 1 or 2 Use 1 if your engine s redline is below 10000 RPM Otherwise use 2 Press the Calibrate button until the selected Cyl Number appears Table 2 Cylinder number and RPM calibrate number 4 Cyl engine Number 4 Stroke Calibrate Comment of pulses Crank Number Cylinders Rotation IE AA he also when using inductive so dare dama on spark wire or power wir
13. once per revolution The reference tooth is either the tooth after the missing tooth or teeth on a missing tooth trigger wheel the extra tooth on a extra tooth trigger wheel or simply the mark tooth if only one tooth wheel or mark is used called the Redneck Trigger because it has only one tooth For this to work the RPM signal on Input 1 MUST have either a negative edge or positive edge when a spark happens A RPM signal on Input 1 that is derived from a trigger wheel without spark offset can t be used This is often the case if an RPM signal generated by an ECU is used In that case the RPM signal needs to be tapped of the coil negative or the ignition drive signal In the case of getting the RPM signal from coil negative typically a positive edge happens when the coil fires This assumes a regular inductive not a CD ignition system CD ignition systems typically do have an RPM output but the polarity of the pulse which edge coincides with the spark event is depending on the manufacturer and device model On some dwell controlled ignition systems like GM HEI very often a potentiometer needs to be used to attenuate the RPM signal so only the TRUE spark event is measured not other edges in the waveform Below is an example on how to connect such a potentiometer to Coll negative Potentiometer 0k0 hm to 50 k0 hm CH1 CH1 The importance of programming the correct pulse edge for both the TDC reference signal and spark sig
14. reflectivity between a reflective mark on the measured shaft and the rest of the shaft See chapter 5 2 for an example of a DIY optical sensor The advantage of optical sensors are Simple and inexpensive Light weight Very high maximum frequency up to 1 MHz No minimum frequency apop Their disadvantages are a Sensitive to contamination dirt on the reflective surface b Lower temperature range only up to 80 degC typical compared to VR sensors The description on how to connect and calibrate an optical sensor is described in chapter 9 2 6 4 3 Hall Effect sensors Hall effect sensors rely on the property of some special semiconductors to output a voltage when they are in a magnetic field Hall sensors come in many different varieties Some have an analog output voltage others have trigger electronic built in that outputs the hall sensors supply voltage when the magnetic field strength is above a built in threshhold and low when not Some hall sensors have built in magnets and can detect the change in the magnetic field when brought in proximity to a ferromagnetic material steel or iron but not some stainless steels These sensors are often very convenient to use One example is to sense the bolts on a driveshaft CV joint to measure wheel speed 16 CW Joint Cv Bokt Hall Sensor 65100701 The hall sensor used in this case is a Cherry GS100701 with built in magnet lt can be found at www digikey com as P N CH398 ND
15. same as for a 1 cyl 2 stroke motor Note On any distributor less ignition system you can alternately clamp the inductive clamp around one of the power wires on the primary side of the ignition coil or coil on plug module 7 5 Using the RPM Converter with pulsed RPM input Tach signals Unplug the inductive clamp from the DL 32 if connected Connect the RPM signal to the CH1 input screw terminal The decimal point of the digit display of the DL 32 should light up steadily This indicates when a valid rom signal is detected If it does not light up check your connections DO NOT CONNECT A PULSED RPM SIGNAL TO THE INDUCTIVE CLAMP INPUT THIS MIGHT DAMAGE THE DL 32 OR LM 1 Again this should just result in an error code not mechanical damage 8 Measuring Pressures The DL 32 has a built in MAP sensor To use it connect a small 4 hose between a vacuum boost connection AFTER the throttle body and the DL 32 MAP input port It should be connected after the throttle body because the lowest pressure that can be measured before the throttle body is atmospheric pressure discounting some pressure losses from the intake tract before the throttle body MAP stands for Manifold Absolute Pressure This means that the sensor measures pressure referenced to absolute vacuum not atmospheric pressure like many vacuum and boost gauges Engine parameters like fueling ignition timing compressor efficiency and so on are dependent on the MASS o
16. the timing of one cylinder typically cylinder 1 Therefore it does not need the additional pulses but can identify the reference trigger from each Another concern is the phase of the pulses The timing can be measured either from the rising or falling edges of the spark pulse to the rising or falling edges of the reference pulse Which pulse edge for each has to be known to allow accurate measurement Very often this can be only determined by trial and error This means you have to go through all four possible combinations until you measure the correct advance verified with a timing light For this reason the use of the inductive clamp as RPM source is NOT recommended for spark advance measurement because its phase is undetermined can changes depending on which way around you use the clamp For example if the source for the spark pulse is the negative side of the ignition coil inductive ignition the negative side of the coil goes to ground negative edge of pulse to charge the coil When the coil discharges spark happens the voltage rises to several hundred volts and then returns to 12V In this case the spark pulse would use the rising edge The same is true for the trigger pulse from the trigger wheel Depending on the sensor used the output pulses can be negative or positive This can either be found out with an oscilloscope or by programming the DL 32 for one way or the other and finding out which is the correct one The tryo
17. will show up in LogWorks as Audio note icon To play them in LogWorks 2 click on the Note Icon Audio notes require 0 5 Mbyte of SD card capacity for every minute of audio recorded The DL 32 can record audio notes only if it is currently recording a session 11 4 7 Importing DL 32 logs into LogWorks This requires LogWorks Version 2 02 or later Earlier versions of LogWorks will not be able to import d32 files created by the DL 32 The SD card must be inserted into an SD card reader connected to your computer Open the LogWorks application but do not connect when LogWorks asks you Select Import DL 32 Log from the File Menu in the main window of LogWorks Browse and find the SD card in the list of mass storage devices For that you will most likely need to go up the file and folder hierarchy on your computer to the my Computer level Open the SD card and then open a d32 file a log file A log window will be opened Sessions are named Session 1 Session 2 etc If a DL 32 session is too long for LogWorks longer than 1 1 2 hours it is broken up and a letter is used ex Session 2a Session 2b etc 4 8 Deleting log files from the SD card The SD card must be inserted into an SD card reader connected to your computer The SD card looks to your computer just like any other mass storage device like a CD Floppy or hard drive Open the SD card and drag the log files to be deleted to
18. Measuring DOOST Vaca A NE 23 9 Measurnno lonon AV ANCONS 23 9 1 Using a GM HEI Module as VR amplifier ooooocconccccccconoccconnncnnnononacnnncnnnonnnnos 25 9 2 Making your own optical reference pulse Sensor ccoooocccnccnnnnccncconnaccnncnnnnanconcnonacinnonnnnns 26 9 3 How the DL 32 measures ignition advance cccccoooccncccocnncoconcnnnonannnnonannnnnnnnonennanonconanons 28 9 3 1 Measurement Dell arar E 28 10 Measuring Frequencies custom RPM or speed coocccccnoncnncccnccnccnononcnoncnnnonanoncnnancnnonanenonnas 30 Ty Measuring QUISO iii n 30 12 AVIGASUMNG external SV Sensors daa A N 31 12 1 Calibrating extennal OV MPUIS l 31 12 1 1 Calibrate using built in Sensor DOWEL occccncccccnconnccnnnnccnonononccnnnnnonononnnonnnnnnononanecnnns 31 12 1 2 Calibrate using external sensor DOWEL occccccccccoonoccononcnnnonnnancnnnnnnnnononanonnnnnnonanancnnnss 32 12 1 3 Restoring a channel to factory calibration ooonccncconcncononinnnnonnnnonnnnnnonnnrnnononess 33 1393 EXxemalSolenola DINE Sanae a vada cece avoasa avons 33 14 Programming the DL 32 with LM ProgrammMet cccccccseseeeseeeeeeeeeeeeeeeeeeesseeeeessaseesaaes 33 14 1 Ghanging ihe dec NAMES ster ee Gest ears ede Ree ede eee 34 14 2 Updating me OWAE suce 34 14 3 Mpu T GOninG Ur atlO Mas A eee eee ee 35 1A Sek Measuring TURIN aa A A a 35 14 4 Mpu GOnNGUNAON rr ees eee eee ee eee 35 14 5 MOUS COMMNGUT ATOM ar a A uated tusn
19. Units f US Units Max Speed fi O mph T b kmh Pulses per mile Calculate pulses per mile With the radio buttons you can select to use metric km h or US mph units In the left drop down list you select the max speed to be measured The DL 32 measures the speed with a resolution of 0 1 of the selected max speed In the right edit box you enter the pulses per mile the speed sensor produces Speed sensors are typically pulse sensors mounted either on the drive shaft or wheel To calculate the pulses per mile or km h click on the calculate button 97 Speed Sensor Calculation x Speed enor setup Wheel sensor C Driveshaft sensor Pulses per rotation 1 140 f Tire diameter 25 00 Inch Final drive ratio Select if you use a drive shaft sensor or a wheel sensor Enter the pulses per rotation created by the sensor either as driveshaft rotation or wheel rotation You also need to enter the wheel diameter and in case of a drive shaft sensor the final drive differential ratio The LM Programmer will calculate the pulses per mile km for you This functionality is also available for Inputs 4 and 5 14 5 4 Measuring Ignition Timing When selecting ignition timing See chapter 9 for details for input 3 the center of the window changes to this TOC sensor Trigger wheel setup Positive pulse edge used ae 36 incl missing teeth Teeth in trigger wheel Extra tooth does not count Nu
20. an DL 32 If higher precision is required the DL 32 can be field calibrated The following calibration instructions all assume that the input being calibrated has already been configured for external input Either using LM Programmer or the front panel interface 12 1 1 Calibrate using built in sensor power In order to calibrate using the built in sensor power the following steps must be taken e Connect the DL 32 to external 12V power e Connect a jumper wire between the 5V sensor output and the terminal for the input to be calibrated 384 2 ye e Press the Channel button until the channel number to be calibrated is displayed e Press and hold the Calibrate button while the channel number is still displayed The DL 32 will either display a lower case c to indicate the Calibration has occurred for the selected channel or an upper case E to indicate that the calibration could not occur Normally an E indicates that the voltage being input is 1V or more off from 5V 12 1 2 Calibrate using external sensor power In order to calibrate using external sensor power the following steps must be taken e Connect the ground from the external sensor supply to the GND connection on the DL 32 e Connect the 5V from the external sensor supply to the input of the channel to be calibrated e Press the Channel button until the channel number to be calibrated is displayed e Press and hold the Calibrate button while the
21. are file this new firmware will be downloaded in the DL 32 device 34 14 3 Input 1 Configuration Click on the Input 1 tab in the top of the window 14 3 1 Measuring RPM cm LM Programmer Version 3 05 E i mi x Ifo input 1 input 2 Input 3 input 4 Input 5 RFM sensing Positive pulse edge Negative pulse edge Cylinder Count fi Cyl 4 Stroke Also for inductive clamp on 1 spark plug Non waste spark or Coil on plug The drop down list at the top of the window allows you to select the different functionality for that input If RPM is selected the area below the functionality selection shows as above The positive edge negative edge selection is ONLY important if this input is also used as spark reference signal for ignition advance measurement Select the cylinder count in the appropriate drop down list 14 4 Input 2 Configuration Function 1 and 2 of Input 2 use the TK and TK inputs The CH2 and CH2 inputs are used ONLY of this input is set for external 0 5V sensor When selecting one of the side force modes for Input 2 the center window looks like this 35 Side Force Sensor Travel Direction Build in direction Cs r relative to travel direction Select the travel direction of the car Please note that changing this setting will effect the travel direction setting for acceleration measurements on Input 5 as well 14 5 Input 3 configuration Input 3 has by default
22. ark Mount the device so that its front edge is about 0 15 3 8 4 mm from the flywheel balancer The LED shines infrared light on the flywheel balancer but the light is absorbed by the black surface So the photo detector in the device is off and the CH3 connection should be between 3 and 5V If the voltage is lower replace the 3 3 kOhm resistor with a lower value but don t go below 1 kOhm When the LED shines on the white stripe light is reflected and the photo detector is on drawing current through the 3 3 kOhm resistor The voltage at the CH3 connection should be less than 1 Volt If the voltage is higher replace the 3 3 kOhm resistor with a higher value 97 9 3 How the DL 32 measures ignition advance Ignition Advance is how many crank degrees before or after TDC the ignition fires This means the measurement system must know where TDC is and when the spark fires There s no sensor on a car that directly measure crankshaft degrees Therefore the DL 32 needs to measure RPM and the time difference between the TDC mark and the ignition firing Example At 6000 RPM an engine rotates 100 times second This means the crankshaft rotates 36000 degrees per second So if the spark fires 1 millisecond before TDC the ignition advance is 36000 degrees sec times 1 1000 second or 36 degrees 9 3 1 Measurement Details To determine advance the DL 32 uses RPM and the time it takes the reference tooth to pass by lt passes by
23. ave been removed defaced or altered iii your Innovate product was subjected to accident abuse shipping damage or improper use iv your Innovate product was not used or configured as specified in the product manual or v your Innovate product was subjected to operating conditions more severe than those specified in the product manual Exclusions From This Warranty Oxygen Sensors are excluded from this warranty Repairs Under This Warranty In the unlikely event that your Innovate hardware product should prove defective during the warranty period contact Innovate Customer Support for a return material authorization RMA at 949 502 8400 Products returned for service must be securely packed to prevent damage and shipped charges pre paid along with proof of purchase and the return material authorization number to the Innovate repair location as instructed by Customer Service Innovate within a reasonable amount of time from its receipt of your product so shipped will ship to you at its option the repaired product or a new or reconditioned product of comparable or greater specified functionality All repaired or replacement products shall be warranted for the remainder of the Original product warranty Disclaimer INNOVATE MAKES NO OTHER EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO YOUR INNOVATE PRODUCT OTHER THAN THE LIMITED WARRANTY SET FORTH ABOVE No Innovate dealer agent or employee is authorized to make any modification extensio
24. blink twice a second If the DL 32 cannot start a recording when it is commanded to do so it will blink the LED in a different sequence as indicated in the following table LED blinking codes DL 32 in standby mode not recording Blink 2 times second Recording actively Blink fast 4 times second No SD card detected or SD card damaged Slow once second with short SD card full or write locked dark periods Using XD 1 XD 16 to start stop recording Press the button on the XD 16 briefly to start or stop a recording The XD 16 record indicator light will start blinking when the DL 32 actively records If it does not the DL 32 could not start a recoding for whatever reason Check for missing SD card card full or card write locked 4 5 Forcing a new log To force a new log file press and hold the record push button for three seconds while the DL 32 is NOT recording With the XD 1 XD 16 press and hold the XD 16 button until it shows rES on the XD 16 The time date of a new log file name does not reflect when it was forced to be new but is the time and date when the first new session was recorded in the log file Forcing a new log does not automatically start recording 4 6 Recording Audio Notes Note This feature is not supported in the initial firmware To record audio notes the optional microphone must be connected to the MIC port of the DL 32 The DL 32 will record audio notes in to the current session These audio notes
25. bove this is NOT the preferred way of measuring pressures but it is possible The DL 32 will measure the current atmospheric pressure in the intake tract when it starts up and stores this value internally until it is started the next time In vacuum boost measurement mode the DL 32 will then subtract the measured value from the MAP value internally For this to work the DL 32 MUST be powered by a switched 12V source that switches on before the engine is started like the ignition power This 12V source MUST stay active during cranking To give the DL 32 a chance to measure atmospheric pressure you must change the way you start the engine First switch ignition on powering the DL 32 wait for 0 5 seconds THEN crank the engine starter Function 3 of input 4 of the DL 32 measures vacuum with a range of 0 30 inHg gauge This is the range intended for normally aspirated engines where the maximum intake pressure can be atmospheric pressure Function 4 of input 4 of the DL 32 measures vacuum and boost pressure with a range 14 7 to 29 4 PSlg This is the range intended for boosted engines where the maximum intake pressure can be up to 29 4 PSI above atmospheric pressure Vacuum is typically measured here as negative PSI But you can set up any metric you want with LogWorks 2 9 Measuring Ignition Advance Warning Measuring ignition advance is NOT a simple plug and play process The variables are many and you need to know what you are doing t
26. cceleration Sensor to the MOUNTING POSITION ccccooonccnncccncnncnnnnnnno 12 6 Setting up he MpUt chales eel ue eres ee earnest ee eee 13 6 1 Programming the DL 32 with the Setup buttons oooccccoonnnnncccncccncnnnnccnnnccnnnnannnccnnnnnnnnnno 13 62 DINCSENUAl INPUTS caridad terre eea ate nene ar 14 63 Input Signal FEGUIRGMENIS hi vceisetsiccteaveraviteduivens N AA ta 15 6 4 Types of Speed RPM and Frequency sensors occcccccccccccccccnncnnnnnnannnnncnnnnnnnnncconnnnnnnannnnos 15 6 4 1 VR Variable Reluctance Sensors orense e a rE E A E ETNE 15 64 2 Opica Sens sinnn ta Ghd lee N E os 16 BES MHalElteciSens Sin A AL a a A 16 GAA A tee Sic ie eee eae aes 18 rie PP WEIMeCA SUN CMC IN sess at ate rcecteeasoriaayetaan ii O Sak 18 Fl APM Measurement Dasics sra eed ees eases 18 7 1 1 FOU STOKO ENGINE rapsen e a larder ace sla E 19 Pelee TWO STOKE ENOINGOS us S ar ETE EEE N E 19 7 1 3 Rotary Engines Wankel Engine ooccccccccnococcnconcconcnnconnnnnonononnonannncononnnnnnnaneness 19 fee How ihe Di 32 determines APM ccc eee Geers eee 20 Zo Programming ine RPM NPU enrete Goeeter a aa 20 7 4 Using the DL 32 with the Inductive ClaMp oocccccccccccccconnconncccononnncnnnnnonononannnnnnnnnnonan 21 7 4 1 inductive Clamp US ages E E E 21 7 5 Using the RPM Converter with pulsed RPM input Tach signals oooccccooccnnoc 22 8 Measuring Pressure cui Acta 22 Sol jJMOCASUPING MAPS a ea abel 23 8 2
27. ce if received on it s OUT port If the sending device immediately receives that command on its IN port again because the terminator is plugged in it assumes it Is the first and special device in the chain The LM 1 having only one serial port is ALWAYS a special device and MUST be connected to the beginning of the chain NOTE 1 The DL 32 does NOT need a terminator plug on its IN port It automatically detects if another device is plugged into it s IN port and terminates the IN port if nothing is plugged in NOTE 2 The DL 32 can only record data from devices chained to its IN port Data from devices chained after its OUT port can t be recorded The following are some examples of Log Chains using the DL 32 and other MTS devices 2 1 Log Chain of 5 channels consisting of DL 32 alone To Ser Ser Computer IN OUT conky for realtime DL 32 recording Notice the DL 32 s input port does not need a terminator plug like some other MTS devices It can auto detect if something is plugged into its input port 2 2 7 channel Log Chain example with 2 AFR channels To A Computer ana IM OOUT IN OUT IM a OUT IN OUT IM OUT only for erminator 4 Wt ER j T T realtime Plug a os a Arnold recording a LC 1 LC 1 DL 32 XD 1 AD 7 Notice that the LC 1 s are connected BEFORE the first DL 32 LC 1 s should always be connected before the first DL 32 2 3 17 Channel Log Chain example The example chain consists of a LM 1 LMA 2
28. dependent on the ignition system and engine type a universal RPM measurement method must be adaptable to the different environments encountered The typical ignition system consists of an ignition coil a coil driver that switches current to the coil on and off and a distributor When current is switched on to the coil the coil stores energy in its magnetic field When the current is switched off that energy gets discharged at a very high voltage pulse on the coil s secondary winding creating a spark A capacitive discharge ignition system CDI uses a capacitor to store the spark energy The capacitor is charged to about 400V and then rapidly discharged over the ignition coil s primary winding The coil thus only acts as transformer and does not store energy and can therefore be smaller The advantage of a CDI system is a very high and fast rising spark voltage less susceptible to spark fouling The weakness of the CDI system is the very short duration spark which might not be long enough to ignite the mixture Multispark ignition systems try to overcome the inherent weakness by creating multiple spark pulses over some degrees of crank rotation to increase the likelihood of igniting the mixture The distributor switches the spark voltage to the appropriate spark plug 7 1 1 Four Stroke Engines On a typical 4 stroke engine each spark plug fires once for every two crank rotations The coil on a distributor equipped 4 stroke has to create sparks
29. duty cycle measurement as function 1 See chapter 10 for details Duty Cycle measurement is also available on Inputs 4 and 5 14 5 1 Measuring Custom RPM When using the custom RPM feature the center area looks like this RPM sensing f Positive pulse edge C Negative pulse edge Custom Max RPM Cylinder Count EN fi Cyl 4 Stroke Alzo for nducte clamp on 1 spark plug Non waste spark or Col on plug On the left edit box you can specify the max RPM for this measurement channel In the example case the max RPM is 6000 This means that in LogWorks 6000 RPM is equivalent to 5Volt This allows LogWorks to have a higher RPM resolution 6 RPM per step instead of 10 RPM when the range is 0 10230 RPM This functionality is also available for Inputs 4 and 5 14 5 2 Measuring Frequency The center section of the window changes to this 36 Frequency measurement Full Scale Frequency must be between 10Hz and 15kHz Full Scale Frequency ll You can enter any frequency between 10 Hz and 15000 Hz as full scale frequency DL 32 measures the frequency with a resolution of 0 1 of the full scale frequency specified So in LogWorks O Hz is always O Volt and the full scale frequency is equivalent to 5 Volt This functionality is also available for Inputs 4 and 5 14 5 3 Measuring Speed Select the Speed sensing function in the topmost drop down list The center section of the window changes to Speed sensor setup Metric
30. e of COP system of 1 cylinder only for all cylinder numbers Use also when using inductive clamp on spark wire or power wire of Waste spark coil of 1 cylinder only Waste spark system 1 coil for every 2 cylinders Table 3 Cylinder number and RPM calibrate number 2 Cycle and Rotary Engine Number 2 Stroke Calibrate Comment of pulses Crank Number Cylinders Rotation re z he also when using inductive nn on spark wire or power wire of COP system of 1 cylinder only for all cylinder numbers Also use for rotary engine Use also when using inductive clamp on spark wire or power wire of Waste spark coil of 1 cylinder only Waste spark system 1 coil for every 2 cylinders 7 4 Using the DL 32 with the Inductive Clamp The inductive clamp measures the magnetic field created around a spark plug wire when spark current flows If a metallic shield covers the spark plug wire the inductive clamp may not work because the shield would short out the magnetic field Like all inductive clamp rom pickup devices some ignition systems like Capacitive Discharge Ignition CDI or multi spark ignition systems may not work properly with the inductive clamp pickup because the pulses created may be too short in duration Multi spark systems confuse the ignition timing measurement because the RPM converter cannot distinguish which ignition pulse belongs to which crank rotation The LAM 3 will work only on the tach output of the ignition syst
31. em in this case The inductive clamp must be clamped around ONE lead only Clamping it for example around all wires of a coil on plug pack does not allow it to work because the magnetic fields of the wires most likely cancel each other out 7 4 1 Inductive Clamp Usage Plug the inductive clamp s 3 5mm audio plug into the RPM socket of the DL 32 Clamp the Inductive Clamp on the spark plug wire of one cylinder so the wire is completely surrounded by the clamp Make sure the clamp is completely closed Start the engine Switch on the LM 1 unit The decimal point of the digit display of the DL 32 should light up steadily This indicates when a valid RPM signal is detected If it does not light up or lights up intermittently reposition or reverse the clamp try clamping it upside down If the decimal point out only occasionally that is OK The RPM converter will still convert though its output might be noisy A noisy output has spikes 91 or lengthy flat areas in the data log Note to work properly with the inductive clamp pickup the DL 32 must be set up for the appropriate number of pulses per crank rotation e Fora 4 stroke engine without waste spark ignition this would be 1 pulse per 2 crank rotations This is the factory setting e Fora 4 stroke engine with waste spark ignition or a 2 stroke engine this would be 1 pulse per crank rotation e For a rotary engine this would be 1 pulse per rotation This is the
32. ends together You may optionally solder them also But twist them first Do not solder them in parallel This will form what is called the Hot junction This Hot junction is what you will connect to the surface that you want to measure This is usually either a under the copper gasket of a sparkplug for cylinder head temperature CHT or b clamped to a primary header tube for exhaust gas temperature EGT There is also the Cold junction This is where the 2 leads of the thermocouple come together again at the DL 32 terminals The DL 32 has an internal temperature sensor at the T C input terminals It uses this sensor to offset the effect of the Cold junction in the measurement This is called Cold junction compensation Once the effects of the cold junction are neutralized the DL 32 can accurately read the temperature of the Hot junction which is the twisted lead pair at the opposite end of the thermocouple wire One thing that is counter intuitive for many people is that the negative side of a thermocouple wire is always red There are many different types of thermocouple wire types K J and T being the most popular All have a red negative lead and a yellow black or blue positive lead respectively When connection the thermocouple to the TC terminals on the DL 32 be sure to connect the yellow lead to the TC and red lead to the TC terminals Several manufacturers offer EGT thermocouple probes which are actually inserted in
33. f air in pounds per cubic foot or kg per cubic meter entering the engine As air is a gas it s mass is dependent on its ABSOLUTE pressure referenced to absolute vacuum and it s temperature Most vacuum and boost gauges are gauge pressure sensors A gauge pressure sensor measures the difference to atmospheric pressure not the absolute pressure So without knowing atmospheric pressure at the point where the sensor gets it from the actual air mass entering the engine can t be measured Because the atmospheric pressure changes with altitude and weather the gauge pressures are not a precise metric This is specially problematic for boost pressure sensors because their atmospheric reference source comes typically from inside the cabin or engine compartment The atmospheric pressure there can change with speed from aerodynamic effects ram pressure _99 6 1 Measuring MAP Function 1 of input 4 of the DL 32 measures absolute pressure with a range of 0 1 bar 0 14 7 PSla This is the range intended for normally aspirated engines where the maximum intake pressure can be atmospheric pressure Function 2 of input 4 of the DL 32 measures absolute pressure with a range of 0 3 bar 0 44 1 PSla This is the range intended for boosted engines where the maximum intake pressure can be up to 29 4 PSI above atmospheric pressure 8 2 Measuring boost vacuum The DL 32 can use it s MAP sensor also as gauge pressure sensor if so desired As stated a
34. g display and analyze up to 32 engine parameters Most users will use less though Each of the MTS components reads between 1 and 6 engine parameters To interface a multitude of MTS components to LogWorks with a single connection the Innovate LogChain concept was introduced The DL 32 can be used as a MTS component in a Log Chain Each of the MTS components has two serial ports except the LM 1 which has only one One serial port is designated as IN port the other as OUT port The OUT port of one device is connected to the IN port of the next device and so on This way devices can be daisy chained to build a log chain for up to 32 channels total The OUT port of the last device is connected to the computer for logging or downloading of logged data The device that s first in the chain is special It determines the logging sample rate The first device in the chain sends a data packet containing its channel data a sample to the next device downstream left to right in the diagram every 81 92 milliseconds The next device appends its data to that packet and hands that packet to the next device downstream and so on At each device the packet grows in length The devices in the chain synchronize their sampling of the engine parameters to the packets so that all the channels in a packet together represent the same instance in time At the downstream end of the log chain OUT port of the last device a computer or external logger can be connec
35. ieci da 36 14S Measuring Custom RPM ca 36 14 52 Measuring FIEQUGNGCY aria E N a 36 145 3 Measuring Specs caca a N N 37 1454 Measuring lomituon ANUN acid 38 14 6 Mouras cOn IQUTa MON arre N 39 14 7 HUE O GONtIQUra ON as AI 39 Os IUCOMIEN Sar TOS 40 Appendix A Eimited Warrants 41 REVISION HIS TOV ors n a a Aaa 42 1 Overview The DL 32 is a data logger with 5 general purpose inputs lt can record these inputs on a SD memory card In addition to its own native 5 inputs the DL 32 can record data from other Innovate MTS Modular Tuning System devices up to a total of 32 recorded channels A 32 channel recording requires a memory space of 1Mbyte in the SD card every 17 minutes A 16Mbyte card therefore can record 272 minutes or about 4 1 2 hours If less channels are recorded the recording time is proportionally larger So for 16 channels on a 16Mbyte card the recording capacity would be 9 hrs Each recording is organized in logs and sessions The DL 32 contains a real time clock that allows it to time stamp each log and session it recorded Most of the functionality of the DL 32 regarding its internal channels is identical to the LMA 3 product from Innovate Motorsports This manual is primarily organized into 3 parts 1 Description of the capability and setup of the internal channels 2 Programming the DL 32 with a computer 3 Recording data to the SD card 2 The Innovate Log Chain concept LogWorks 2 0 has the capability to lo
36. ill need an SD card reader Those are available in most computer stores They typically connect to a USB port on your computer A SD card inserted into an SD card reader on your computer will appear on your computer as a removable mass storage device To find it open on your computer the my Computer Icon It will be listed there 4 3 Logs and Sessions Different to other data logging products the DL 32 organizes the acquired data in logs and sessions A session is a contiguous data set This means there is no interruption in the data stream and all data points are spaced equally in time 81 92ms apart Each time you start logging a new session is created and the session ends when the logging stream is stopped A log is a collection of sessions In a typical qualifying race or tuning session multiple runs are made and each run is data logged The DL 32 conveniently organizes these runs into a common log The sessions in a log are numbered from 1 through x Typically they are sequential in time starting with the oldest session as session 1 and so on Each log is stored in a separate file on the SD card Each session can later be renamed with LogWorks 2 so it does reflect something more meaningful than just a numbered sequence In addition each SD card log contains information about the settings of all devices connected to the log chain connected to the DL 32 serial IN port Log Files are named by the DL 32 with the date at which the firs
37. ine for each rotation of the rotor A single or dual spark plug at a fixed position in the chamber ignites the mixture of each space in sequence Therefore a rotary engine requires 3 sparks for every rotation of the rotor The mechanical power from the rotor is coupled to an eccentric gear to the output shaft This gear has a 3 1 gear ratio and the output shaft therefore rotates 3 times faster than the rotor The output shaft is the equivalent of the crankshaft on a piston engine Because RPMs are measured conventionally as the rotations of the crankshaft the rotary engine requires one spark for every crankshaft rotation the same as a two stroke engine 19 7 2 How the DL 32 determines RPM The DL 32 measures RPM not by measuring the number of pulses over a time period as a tachometer does That measurement would be too slow to provide adequate correlation between input channels Instead the DL 32 measures the time between input pulses and from that calculates RPM for each pulse measurement This measurement method has a few caveats though 2 Ifthe RPM pulse signal is derived from the ignition signal a multi spark ignition system will trigger the measurement multiple times for each pulse This throws the measurement off because the DL 32 does not know if the pulses are for each ignition event one per cylinder cycle or because of multi spark This is specially problematic because the number of multi spark pulses also varies with RPM in a
38. ly a cylindrical magnet with a coil of thin copper wire wound around it As a ferromagnetic material steel or iron gear tooth approaches the magnetic field of the magnet strengthens and when the gear tooth departs it weakens Any changing magnetic field crossing a conductor will induce a voltage in that inductor The coil serves as such a conductor The resulting voltage when a gear tooth passes under a VR sensor looks like this 15 VR sensor output voltage waveform mid tooth tooth approaches tooth departs as T positive negative Voltage Voltage When the gear tooth approaches the magnetic field strengthens and a positive voltage gets created by convention the voltage direction is positive for an approaching tooth The coil by that convention has a positive and a negative end In mid tooth the field is constant not changing and the induced voltage is zero crosses the OV line As the tooth departs the field weakens and a negative voltage is created The VR sensor amplifier arms itself when it sees a positive voltage When the voltage crosses OV it outputs a pulse to the measurement system and disarms itself again Therefore a VR sensor with amplifier mounted on a gear with 6 teeth would output 6 pulses per rotation The frequency is number of teeth times the rotations per second Or RPMs would be frequency 60 divided by the number of teeth 6 4 2 Optical sensors These sensors react to the difference in
39. m to DB 9 computer interface cable into the Serial OUT port Your computer needs a serial port If it does not have one you will need a USB to serial adapter 3 Power the DL 32 either from 12V or a 9V 4 Start the LM Programmer application The following screen will show up LM Programmer Version 3 09 ee o x Info Input 1 input 2 input 3 input 4 Input 5 2003 2004 Innovate Technology Inc MOTORAS PORTES Device Type DL 32 Fimware Version 1 10e Connected to port COM 1 Processor Version ATM162 16 Please give this device a unique name Max 8 characters DL 32 The LM Programmer software then shows in its first page the type and version number of the firmware of the device 14 1 Changing the device name If multiple DL 32 s are used in a Log Chain each MUST be given a unique name so that LogWorks can identify each DL 32 Just enter a name in the edit box in this page 14 2 Updating the firmware Click on the Update Firmware button You will be presented with a file dialog box that allows you to select a firmware file Firmware files end with the file extension dld DL 32 firmware file names start with DL32 The first part is followed by a dash then a V then the version number without dots Example DL 32 firmware version 1 00 alpha release would have the file name DL32 V100A dld DL 23 firmware version 1 00 would have the file name DL32 V100 dld After you opened the firmw
40. mber of mission teeth i gt E Extra teeth before TOC trigger tooth Mot missing Offset degrees of T Use negative number Trigger tooth after real TOC when before TOC Select the trigger wheel characteristics The trigger tooth is the tooth after the last missing tooth if missing teeth or the extra tooth when the wheel has extra teeth If only one pulse is used the missing teeth extra teeth input is ignored To enter the offset in degrees measure the offset in degrees after TDC after the last missing tooth Also measure the offset of the sensor from TDC Subtract the sensor offset from the tooth offset to get the real offset of the Trigger tooth to be entered The following picture shows an example 38 Sensor Offset Te m 45 degrees Sensor Rotatio oe as Direction ee ere offset 100 degrees In this case the offset of the Trigger Tooth is 100 degrees after TDC in rotation direction The sensor is mounted at 45 degrees after TDC So the complete real offset from TDC is 55 100 45 degrees after TDC To measure ignition advance Input 1 MUST be configured for RPM measurement 14 6 Input 4 configuration Function 1 2 3 and 4 on this input are used for pressure measurement See chapter 7 for details For Custom Frequency Custom RPM speed sensing and duty cycle inputs on Input 4 see chapter 12 5 14 7 Input 5 Configuration For Custom Frequency Custom RPM speed sensing and duty cycle inputs on Input
41. n or addition to this warranty unless enforceable or unlawful under applicable law INNOVATE DISCLAIMS ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY NONINFRINGEMENT AND FITNESS FOR A PARTICULAR PURPOSE AND THE LIABILITY OF INNOVATE IF ANY FOR DAMAGES RELATING TO ANY ALLEGEDLY DEFECTIVE PRODUCT SHALL UNDER ANY TORT CONTRACT OR OTHER LEGAL THEORY BE LIMITED TO THE ACTUAL PRICE PAID FOR SUCH PRODUCT AND SHALL IN NO EVENT INCLUDE INCIDENTAL CONSEQUENTIAL SPECIAL OR INDIRECT DAMAGES OF ANY KIND EVEN IF INNOVATE IS AWARE OF THE POSSIBILITY OF SUCH DAMAGES Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you s i Revision History 1 0 3 31 06 Initial Release 1 1 9 14 07 Added Kit Contents 49
42. nal is illustrated below We assume a 8 tooth trigger wheel teeth 45 degrees apart with one tooth missing The wheel is installed with the missing tooth at 180 degrees from TDC the VR sensor is mounted at 90 degrees after TDC as in this illustration 28 f opening tooth From this we know that the missing tooth number 8 passes by the VR sensor at 90 degrees BTDC The missing tooth is 180 degrees before TDC The VR sensor is offset from that in counter rotating direction by 90 degrees so 180 90 90 Tooth number 1 can t be used as opening tooth because it passes by 45 degrees BTDC Tooth number 8 can t be used because it s not there So tooth number 7 is used It passes by 135 degrees BTDC Now let s look at the pulses that the DL 32 would see at 6000 RPM We assume a tach pulse width of 1 msec spark at TDC Tooth reference pulse edge is positive rising edge and tach reference pulse has a positive edge at the spark event The example shows a 2 cylinder engine with one spark at every spark event The measurement window range is shown in gray Spark E E I Tach Signal on CH1 MILLI LILI LJ LILI LILI l Trigger wheel Signal 123453678 1234567 8 One can clearly see that the falling edge of the tach signal is outside the measurement window If for example the tach signal contains the spark signal of all sparks of an 8 cylinder engine the spark event of cyl 8 instead of cyl 1 could fall in
43. nsor The device to be used is a Fairchild reflective optical sensor type QRC1133 This device contains a infrared LED to shine an infrared light beam on a mark on the balancer or flywheel and also contains a photodiode to detect the reflected light The device can be ordered from www digikey com Part Number QRC 1133 ND This device looks like this 0 420 10 67 24 0 609 60 0 328 8 33 RHE AWG AS 0 150 3 81 A x NOM Fl a ie 0 226 5 74 gt 0 373 9 47 pe i 0 703 17 86 0 150 3 81 J L 0 210 5 33 MIM 0 603 15 32 REFLECTIVE SURFACE 0 020 0 51 Ax 0 300 7 62 FUNCTION WIRE COLOR C COLLECTOR WHITE EV EMITTER BLUE Ki CATHODE GREEN A ANODE ORANGE 96 To use it you also need two resistors 1 4W One resistor is 330 Ohm the other 3 3 kOhm The hookup schematic to be used is this EN To 5W from LMA 3 CH3 on LMA 3 CH3 on LMA 3 a k0hm Reflective eae D Surface ii LMA 3 Paint the balancer or flywheel surface flat black so as not to reflect any light Then paint a 4 to 1 3 6 9 mm white stripe on the balancer or flywheel at 90 degrees after TDC The edge of the stripe in rotation direction should be at the 90 degree mark The sensor should be mounted at TDC where the TDC mark is when the engine is at TDC TOC Mark 4 3 White Stripe The device will output a pulse with the NEGATIVE edge at the 90 degree m
44. o do it right Read this chapter multiple times before attempting this and try to understand what you are measuring The DL 32 expects the spark reference pulse on input 1 and the crank reference pulse on input 3 Input 1 is simultaneously still used to measure RPM but MUST be set to measure RPM The DL 32 can measure ignition advance between 10 degrees ATDC to 50 degrees BTDC ADTC numbers will be negative BTDC numbers will be positive The LogWorks equivalents are OV 50 degrees 5V 10 degrees Ignition advance is typically measured in degrees This is the number of degrees before Top dead center of a piston where the spark fires DG ee When the spark in an engine fires the mixture in the combustion chamber starts the burn process Because it takes time for the fire to consume the mixture it has to be lighted before the piston hits top dead center During that burning process the pressure and temperature rises The pressure and temperature rise results not only from the energy released by the burning mixture but also the piston is still moving up compressing the burning gas At some point in this process the pressure in the cylinder peaks and then falls off The position of this pressure peak in crank angles depends on the engine geometry bore stroke ratio stroke rod length ratio and so on but NOT on engine load or RPM For many engines the ideal peak pressure position to extract the maximum energy is between 14 and 20 degrees
45. pulse type sensor is given in the next sub chapter 6 4 Types of Speed RPM and Frequency sensors Many times in measuring a vehicle rotational soeeds need to be measured Vehicle speed itself is also typically measured by wheel or driveshaft rotational soeed This chapter discusses the different kinds of sensors to detect rotational speed and how to connect them to an SSI 4 DL 32 or LMA 3 Some of these sensors use the magnetic properties of gear or bolt heads to detect rotational speeds With those sensors it s important that the gear or protrusion sensed is magnetic Some stainless steels are not Easy test is if a magnet sticks it s magnetic 6 4 1 VR Variable Reluctance sensors These are the most commonly used rotational soeed sensors used in Automobiles today Their advantage is their mechanical robustness and simple and inexpensive construction Also they allow high precision in detection of rotation angles and are very impervious to tolerances or dirt in the measurement apparatus That s why they are used as crank or cam angle reference sensors Their disadvantages are a They have a low speed limit depending on their construction Rotational soeed MUST be above a certain minimum speed before they can sense b They require special electronics VR sensor amplifier to condition their output signal before it can be used by more typical electronics devices c Maximum gear tooth frequency is about 15 kHz A VR sensor is basical
46. put of the DL 32 and the ground terminal of the DL 32 4 Recording with the DL 32 4 1 Time and Date The DL 32 has an internal real time clock device that will continue to run even when power is off This clock device DOES NOT automatically set the correct time and date during changes from daylight savings time and back To set the real time clock device the DL 32 must be connected to a computer as if it were prepared to be programmed see chapter 13 When the LM Programmer software connects to the DL 32 it will automatically synchronize the DL 32 s clock to the current time and date setting of the computer Therefore it is very important that your computer s time and date is set correctly 4 2 SD Cards The DL 32 accepts standard secure digital SD cards with a capacity of up to 2 Gbyte The cards have to be formatted in the FAT16 file system as most SD cards are SD cards are graded in speed grades like 1x 2x 4x and so on The minimum speed required for an acceptable SD card Is 4x The DL 32 ships with a 128 Mbyte SD card d Front Unlocked Write Lock _ sie Locked A2Bwe Ss Back To be able to record to an SD card the Write Lock Slider on the left side of the SD card must be in the Unlocked position O To insert an SD card into the DL 32 push it into the SD card slot until it clicks in To remove the SD card push on it to unclick it It will pop out To read an SD card with a computer you w
47. rammed by with LM Programmer The DL 32 can be set to any frequency range between 0 and 30 Hz for the full 0 5V range to 0 15 kHz for the full 0 5V output logging range Also LM Programmer has convenient conversions built in so you dont have to calculate the resulting frequency ranges for speed sensing or RPM sensing yourself See chapter 10 x for details A frequency input signal must have an amplitude voltage range of pulse between 0 5V at the low pulse point to minimum of 3V and maximum of 40 V at the high pulse range NOTE The custom RPM feature will work only for even fire tach signals not for tach signals that vary their time between pulses during an engine cycle Use the input 1 RPM functions instead Please refer also to appendix A for details on different speed or rotational sensors 11 Measuring duty cycle To measure the duty cycle of a signal in channels 3 4 and 5 the input signal must cover the same voltage range as for a frequency signal Duty cycle is defined as the ratio between the time a signal is active and the total time of the active and inactive time A signal can be either active high the event like injector open happens when there is a high voltage or active low the event happes when the measured signal is at ground or close to it 30 Very often the injector duty cycle is to be measured by the DL 32 A typical fuel injector is connected to 12V on one side while the other side is connected
48. sed in a glass case The contacts have a very small distance from each other so normally they don t make contact When in a magnetic field the contacts get magnetized and attract each other If the magnetic field is strong enough they touch and the switch is closed This means they can only be used when magnets are attached to the shaft to be measured Their advantages are a No minimum rotational speed b Very inexpensive c Large temperature range Their disadvantages are Limited lifespan of the contacts few million on off cycles Contact bounce can cause false measurements Requires attached magnets on measured shaft Vibration sensitive Maximum detection frequency is less than 100 Hz to a few hundred Hz depending on switch Highr frequency capability makes switch more vibration sensitive DND Because reed switches do not output voltage pulses they require a load resistor An example hookup for a reed switch is shown below E Ground 4 7 kOhm 1 4VVatt 7 RPM measurement 7 1 RPM Measurement basics Most RPM measurement methods use the ignition system of the car as a convenient source of RPM dependent pulses Other methods use a TDC sensor one pulse per rotation cam sensor or fuel injection pulses number of pulses rotation is dependent on the fuel injection system Some actually measure the AC frequency created by the car s alternator 18 Because the number of pulses per crank rotation is
49. t session of a log was recorded and in addition a log sequence number Up to 100 log files can thus be created in a single day The file name of a DL 32 recorded log file looks like this MMDDYYCC d32 Where MM is the month DD is the day of the month YY is the year and CC is the log count of that day For example the first log recorded on March 15 2006 is named 03150600 dI32 There is no limit other than memory size on the number of sessions in a log All Sessions are tagged individually with the time and date when recording was started in the session Normally the DL 32 will add a new session to the existing log file every time you start recording Unless 1 The channel settings of the DL 32 changed from the last recorded log 2 Achannel setting of another device that the DL 32 records on the log chain changed 3 Devices have been added or removed from the log chain 4 The user forces a new log file see next chapter 4 4 Start Stop Recording You can start stop recording with a pushbutton connected to the REC port of the DL 32 connected as described in chapter 4 1 10 Alternatively you can start stop recording with an XD 1 XD 16 chained to the serial OUT port of the DL 32 Pushbutton and Indicator LED operation Press the push button briefly to start or stop a recording When the DL 32 is NOT recording the LED will be steadily lit When the button is pressed the LED will go out When actively recording it will
50. ted to store or display the stream data The XD 16 or XD 1 display is such a device This also means that the complete channel data set is ONLY available at the end of the log chain A datalogger capable of recording the log chain data stream therefore MUST be placed at the end of the log chain This includes lap top computers or other loggers Commands for individual devices are sent upstream A device incl a computer or an XD 16 can send commands to the devices upstream of itself but not downstream Commands can include start stop recording calibration configuration commands and so on Only the device directly upstream of the command originator of course will receive the command This device then decides depending on the command whether to execute the command and whether to Ae pass it on An example of a case where the command is executed but not passed on is the start stop record command The first upstream device capable of logging internally will execute the command but not pass it on As said before the first device is special because it is the synchronization source for the entire chain By plugging its IN port with the supplied terminator connector a device can detect that requirement when it powers up The terminator connector just connects the transmit and receive line of the IN port together Each device sends a special command out on it s IN port when it powers up This command is ignored and not passed on by any devi
51. the trash icon on your computer 5 Mounting and calibrating the DL 32 In order to use the acceleration sensor of the DL 32 care must be taken to mount the DL 32 correctly on a horizontal surface in the car The DL 32 MUST be aligned with the direction of travel The following pictures show the four possible mounting positions Direction of Travel Direction of Travel Direction of Travel Direction of Travel t Tf 7 external Connector ELlaJRa EENE 10433UU0 JOyISUUO 7 external Connector The mounting position should not deviate more than 3 degrees from horizontal 5 1 Calibrating the Acceleration Sensor to the mounting position 12 Lay the DL 32 down on the mounting surface but don t mount it yet Switch the 12V supply to the DL 32 on ie Press the Calibrate button until the digit display shows a blinking C S If the mounting surface is not within the 3 degrees of horizontal the acceleration sensor can t be calibrated for zero g and the DL 32 shows a blinking E for Error After the zero g acceleration calibration is performed hold the DL 32 such that the side of the DL 32 pointing in the intended direction of travel points vertically up Then press the Calibrate button again until the blinking C shows up If the DL 32 shows the blinking E even when the device is calibrated on a flat horizontal surface the device may need to be reset To reset the DL 32 s accelerometers place the
52. to ground when the ECU opens the injector Because the pulse is therefore active when the voltage on the pin is at ground negative duty cycle is measured So called peak hold injectors as opposed to saturated injectors work differently Their drive signal first goes to ground for a high current opening pulse then rises to 8 10 Volts for the hold period Because the DL 32 sees everything above 2 5V as high it will be able to see only the peak period On some peak hold systems it is possible to connect the CHx input of the DL 32 to 12V at the injector and connect the CHx input to the injector signal to still measure correctly But that is not always the case The LogWorks 2 0 Manual shows an alternative method If the above method works it actually measures positive duty cycle 12 Measuring external 5V sensors Each of the 5 channels on the DL 32 can be configured to accept input from an external 0 5V sensor Hookup is very straight forward with ground going to the input for the channel and the positive sensor signal going to the input for the channel Raw sensor data can be converted into meaningful units and values using the input configuration features of LogWorks on a PC 12 1 Calibrating external 5V inputs DL 32 external inputs are factory calibrated However depending on a number of factors it is not unusual to see a small discrepancy between values read on an external voltmeter and those read by LogWorks from
53. to the exhaust gas stream through a hole in the headers or exhaust manifold These provide a more accurate measurement of exhaust gas temperature They are commonly available in types K and J Only type K will currently work with the DL 32 To use a thermocouple probe connect the red and yellow leads of the thermocouple wire to the yellow and red leads of the thermocouple probe The junction is inside the probe You can not use normal copper wire to connect the thermocouple probe to the DL 32 You must use thermocouple wire to connect the probe If you do not there will be an extra two metal junction where the Copper wire meets the 8 Constantan wire of the probe This extra junction will cause a large error in the temperature readings Most Thermocouple probes are of the grounded junction type This means that the hot junction is also connected to the probe s body As this body is connected for example to the exhaust manifold the sensor wires are essentially grounded through that The same is true if a home made thermocouple junction is used as described above by twisting the wires and if that wire twist is connected to some grounded engine part You can check if you have a grounded junction type by measuring between the probe body and one of the Thermocouple wires If you have continuity you have a grounded junction The DL 32 NEEDs a grounded junction If you don t have a grounded junction connect a wire between the TK in
54. to the measurement window and the measurements would be off The following example shows what would happen if the wrong edge of the trigger wheel signal is used Spark E IO Tach Signal on CH1 SUB BL Trigger wheel Signal 1234567bBE12345678B 1 2 99 One can see that the measurement window is shifted by the width or time duration of the Trigger wheel pulse Because in most cases that pulse width is fixed the error translates to varying number of degrees depending on RPM To set up the ignition measurement system of the DL 32 with unknown edge trigger signals all four possible cases should be examined and verified with a timing light at at least 2 different RPMs Trigger pulse positive edge Spark reference positive edge Trigger pulse positive edge Spark reference negative edge Trigger pulse negative edge Spark reference positive edge Trigger pulse negative edge Spark reference negative edge 10 Measuring Frequencies custom RPM or speed The DL 32 has the capability to measure frequencies on channels 3 4 and 5 It converts a frequency signal pulses per second into a voltage 0 5V to be logged in the LM 1 or a number between 0 and 1023 to be logged directly by LogWorks This is useful for measuring custom RPM ranges signals from speed sensors or the frequency of MAF sensors with frequency output as opposed to voltage output MAF sensors The range of frequencies that the DL 32 can measure can be prog
55. ut should be done at different RPMs because under some circumstances you could get a correct reading at idle but a shift at a different RPM NOTE 24 Variable reluctance sensors cannot be read by the DL 32 VR sensors do not output a clean pulse but a short wave whose 0 Volt crossover is measured The wave amplitude is dependent on RPM and sensor For these applications a special VR amplifier like the LM1815 needs to be used Example voltage trace of a VR sensor output NOISEY INPUT SIGNAL f As one can see the reference pulse created would have a positive edge 9 1 Using a GM HEI Module as VR amplifier Switched 12 390 Ohm 1 2 Watt To LMA 3 WR Sensor You can also use a simple 4 wire GM HEI module to pick up the pulses from an existing VR sensor Those were used on many non computerized GM cars from 1975 to the mid 1980s The VR sensor s wire needs to be connected to the W terminal of the HEI module the side to the G terminal Connect a switched 12V power supply to the B terminal and connect a 390 Ohm 1 2W resistor between B and C terminal 95 The C Terminal goes also to the DL 32s CH3 Ground the DL 32s CH3 terminal NOTE The metallic bottom of the GM HEI module needs to be connected to a solid ground The HEI module will create a positive pulse edge rising when a tooth from the tooth when passes center of tooth 9 2 Making your own optical reference pulse se
56. will fit the following hole size and panel thickness a 5 32 0 155 0 158 hole size and a panel thickness of 28 16gauge 0 031 0 062 4 Optionally any 1 2V 2 2V 1mA 30mA LED may be used A typical LED has 2 wires called Anode and Cathode The Cathode side is typically the shorter of the 2 wires or the black wire The following diagram shows how to hook the supplied switch and LED to the cable To REC Port ie of DL 32 metallic Indicator LED Record Pushbutton Electrically the schematic looks like this INDIC red Typical LED RECS A LED white a Switch Na pop E A GNE metallic 3 2 Connecting power to the DL 32 The DL 32 needs to be powered from the car a switched 12V supply switched on when the cars ignition system is on to the connection marked 12V on the left side Connect the connection marked GND to the cars engine block as ground 3 3 Connecting external sensor signals For each external connection you can connect the external sensor s output to the CHx connection Connect the CHx connection to the ground of the sensor Make sure the sensor output signal does not exceed 5V The DL 32 is protected if sensor signals exceed that up to 40V for most inputs but it cannot measure beyond a 5V signal 3 4 Powering external sensors At the connection marked 5V you can connect external sensors External sensors don t HAVE to be powered by the DL 32 The 5V output is a convenience
Download Pdf Manuals
Related Search