ACCEL DFI Engine Analyzer Series Quick guide

INSTR 77062 2007-10-25
Engine Analyzer Series
Wideband Oxygen Sensor
Installation and
Instruction Manual
For DFI part numbers: 77062, 77062N, 77062S, 77063

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Table of Contents
Introduction ................................................................................................. 2
Installation and configuration...................................................................... 3
Wiring arness Connections ........................................................................ 4
Configuring the controller with the DFI Gen 7+ system ............................... 7
Installing and Connecting the Air/Fuel Ratio Gauge .................................... 8
arness Schematic and Pinout Chart – 1 Channel ........................................ 9
arness Schematic and Pinout Chart – 2 Channel ...................................... 10
Populating Additional Wires in the arness eader ................................... 11
Wire List..................................................................................................... 13
PCB-Mounted DIP Switch Chart and Function List ...................................... 16
Connecting an Older NTK-Only System to a Bosch LSU 4.2 Sensor ............. 17
The Engine Analyzer Integrated Data Logger ............................................. 18
DataMap Software Installation ......................................................................1
Engine Analyzer Monitoring...........................................................................19
Data Logger Operation .................................................................................21
Data Logger and Single Channel I/O Configuration.................................... 23
Auxiliary Output Configuration Examples ........................................................2
Dual Channel Engine Analyzer I/O Configuration....................................... 30
Editing the Voltage Output vs. Air:Fuel Ratio Curve ................................... 31
Data Analysis Using the DataMap software ................................................ 32
Frequently Asked Questions....................................................................... 35
Recommended Air/Fuel Ratio Chart ........................................................... 38

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Engine Analyzer Series
Wideband Oxygen Sensor
Introduction
Congratulations on the purchase of your new Accel DFI “Engine Analyzer Series”
wideband oxygen sensor kit! This system uses the latest available technology to
offer unparalleled accuracy, repeatability, and reliability. The durable water resistant
enclosure and harness assembly make it an ideal choice for installation under the
hood or under the chassis.
All Engine Analyzer Series kits include integrated Data Logging functions, and are
available with a host of options and configurations to suit virtually any application.
The following is a list of available part numbers in the Engine Analyzer Series along
with the associated parts and configurations for each number:
77062 – includes electronic control module, wiring harness, and sensor.
77062N - includes electronic control module and wiring harness. This kit does
not contain a sensor.
Optional sensors are available under part number 77065 (Lab grade) O2
sensor or a 77061 (Standard grade) sensor. The unit is configurable for both
types.
77062S - includes electronic control module, wiring harness, and sensor
described above along with a single 2 1/16” digital air/fuel ratio gauge.
77063 - includes electronic control module, wiring harness, and (2) sensors
can be connected simultaneously for monitoring air/fuel ratio information in
dual exhaust applications.
77063S – includes one 2 1/16” digital air/fuel ratio gauge. This gauge
features an easy-to-read digital display and multi-color LED sweep gauge for
readability at a glance.
This manual contains instructions and wiring schematics for each part number listed
above.

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Installation and configuration
Read over this entire document before beginning installation!
Securely mount the controller to a location within 36 inches of the oxygen sensor
location. The controller may be located inside the car or in the engine compartment.
The controller unit is water-resistant, but it is not waterproof. If you are mounting
the controller in the engine compartment, select a location with minimal exposure to
water as a safeguard.
Route the wiring well away from any moving parts or extreme heat sources like
header pipes, etc. Connect the harness as per the diagrams in this manual.
If your exhaust system doesn’t already have a fitting in place for an oxygen sensor,
one must be welded in place. A fitting has been included with the kit. If you need to
weld this fitting in place, be certain to weld all the way around the outside of the
fitting to prevent any air leaks. The optimum location for the oxygen sensor is in the
collector of a header or exhaust manifold. Put anti-seize on threads and be careful
not to get any on the element of the sensor. Note: For 77063 users, 2 oxygen
sensors and 2 oxygen sensor fittings are included in the kit. Each fitting
should be properly welded into each side of the exhaust system.
In turbocharged applications, the sensor must be in the downpipe, not in the
collector. The high heat and pressure found in the collector of a turbocharged car
will impact the accuracy of the sensor and will drastically reduce the life expectancy
of the sensor.
In any application, avoid installing the sensor in the short-side radius of a bend in
the exhaust tubing. Also, try to mount the sensor in a location that offers some
protection from damage caused by debris or other objects in the roadway.

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Wiring arness Connections
Connect the pin connector in the main harness to the female end of each
O2 sensor harness.
If you purchased kit number 77062S, your kit includes a 2 1/16” digital
air/fuel ratio gauge. Locate the 2-pin gray connector in the gauge harness,
and connect it to the supplied connector and wiring for the main harness. If
your kit did not include this gauge, it is available separately through your
Accel DFI dealer. The part number for this kit is 77063S.
If you are connecting the control module to an Accel DFI Generation 7+
system, the 4 pin square male connector in the main harness will have a
corresponding female connector in the Generation 7 system harness labeled
as “HEGO”. These connectors should be joined as per diagram A.
If you are using the system as a standalone air/fuel ratio meter, refer to
diagram B.
If you are using the system with another manufacturer’s engine management
system, refer to diagram C.
If you have a dual exhaust system and are using the 77063 dual wideband
controller, please refer to diagram A1.

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Diagram A – EA series module used with Accel DFI Gen 7+ Engine Management System
Diagram A1 – EA series module shown with optional dual wide and sensors

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Diagram B –EA series module used as a standalone air/fuel ratio meter
Diagram C – EA series module used with engine management system other than Accel DFI

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Configuring the controller with the DFI Gen 7+ system
Once the Engine Analyzer Series controller is properly connected to your Gen 7+
system per the above diagram, you must make a few quick changes to the
configuration of your Gen 7+ ECM for it to operate properly. Refer to Diagram D and
perform the following steps:
Run the CalMap software program and go online with your ECM.
Once online, go to the Controls Configuration Editor. This can be accessed
through the pulldown menus by selecting Configuration and then Controls.
The keyboard shortcut to access this screen is Ctrl-C.
Once in the Controls screen, set the Exhaust Feedback Sensor to UEGO.
Set the Wideband O2 Sensor Type to DFI Type 2 – All Applications.
(DFI Type 2 and Type 3 UEGO kits use the Type 2 Setting in software)
If you wish to run your engine in closed loop mode, set the Closed Loop
Fueling setting to Enabled.
It is recommended to initially set the Strategy Adjustment switch to Auto.
Please refer to the Gen 7+ operation manual for additional information on this
setting.
It is recommended to initially set the O2 Feedback Processing Delay
switch to Off. Please refer to the Gen 7+ operation manual for additional
information on this setting.
Diagram D – Wide and Oxygen Sensor Settings are located at the ottom portion of this screen in
CalMap.

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Installing and Connecting the Air/Fuel Ratio Gauge
Locate the three wires on the back side of the air/fuel ratio gauge. The following
table outlines each of the connections necessary to operate the DFI air/fuel ratio
gauge with the Engine Analyzer series wideband controller.
Wire color Function Connect to
Red Gauge power Switched +12V source
Black Gauge ground Main ground source for wideband controller
Gray Signal input Gauge output wire on wideband controller
The gauge can be mounted in a 2 1/16” hole or gauge pod. Mounting
hardware is included for panel-mount installations.
It is important to connect the black gauge ground wire to the same grounding
point as the main ground wire for the controller. This is necessary to prevent
ground loops that could cause the gauge reading to be incorrect. The main
ground for the controller is on pin C of the 4-pin connector labeled “0-5V
output” in the wideband controller harness.
Connect the gray wire on the gauge to the gray wire coming from pin 9 on
the wideband controller.
The red power wire should be connected to a switched +12V source.
The Accel DFI air/fuel ratio gauge is designed specifically to operate with this
controller. The multi-color LED sweep display around the perimeter of the gauge
face is specially calibrated to provide instant feedback to the driver by changing
colors as the air/fuel ratio range varies. Even if the driver’s attention can’t be
focused on the numbers in the gauge, the color of the LED on the sweep display will
immediately alert the driver if the air/fuel ratio is out of the intended range.
The gauge output from the wideband controller produces a voltage that is equal to
the air/fuel ratio being measured. For example, a 12. volt signal means that the
air/fuel ratio is 12. :1.
If you choose to use a different gauge, you may only use a self-powered digital
voltmeter. Analog voltmeters or gauges will not operate correctly with this
controller.

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arness Schematic and Pinout Chart – 1 Channel

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arness Schematic and Pinout Chart – 2 Channel

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Populating Additional Wires in the arness eader
1.) Release the two tabs on the sides of the connector retainer.
2.) Slide the wire retainer away from the connector. It does not need to be removed.

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3.) Insert the wire into the proper location on the connecter. The wire pin locations are marked
on the back and sides of the connector.
4.) Push the wire retainer back down in order to lock the wires into place.

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Wire List
Ion Pump – Connection to internal component of wideband oxygen sensor. Must be
properly connected for sensor to operate.
Sense Cell (-) - Connection to internal component of wideband oxygen sensor.
Must be properly connected for sensor to operate.
eater (-) – Controls the internal heating element inside the wideband oxygen
sensor. Must be properly connected for sensor to operate.
Aux. Input 1 – Auxiliary input used for triggering data log function record session.
Triggered by applying an electrical ground to the wire.
Aux. Input 2 – Programmable Input for Single and Dual Channel models with
firmware versions 2.0 and higher. Triggered by applying an electrical ground to the
wire.
Aux. Input 3 – Programmable Input for Dual Channel models. Triggered by
applying an electrical ground to the wire.
Gauge Output – Connects to signal input of 77063S gauge kit. Provides a voltage
from to 1 volts, with the voltage being equal to the measured air/fuel ratio (12.
volts = 12. :1 a/f ratio). This output must be connected to a self-powered digital
gauge or voltmeter only – it is not compatible with analog gauges.
0-5V Out – This is the main voltage output from the controller. A 0 volt output
represents the richest possible reading from the controller, and 5 volts represents
the leanest possible reading. The output can be configured to represent an average
of two sensor readings in dual sensor applications, or it can be configured to
represent the reading from a single sensor. Refer to the DIP switch chart in this
manual for information on configuring this option.
Sense Cell (+) - Connection to internal component of wideband oxygen sensor.
Must be properly connected for sensor to operate.
Calibration Resistor (+) – Connects to one side of the built-in calibration resistor
inside the wideband oxygen sensor connector.
It is critical that the original calibration resistor included with the sensor remains with
its associated sensor. This component is installed in the sensor by the sensor
manufacturer to calibrate the sensor and ensure accuracy. It is not installed by
Accel DFI. Tampering with this calibration resistor may result in sensor inaccuracy,
poor engine performance, or engine damage!
RPM Input – Receives information on engine speed for recording and reviewing
air/fuel ratio information as a function of engine speed. Input signal specifies 5V or
12V square wave form. Typical connections are from a CD spark enhancer module
or Distributorless ignition module with Tachometer output. Otherwise connect to a
distributor with either a 5V or 12V ignition module. Consult your owner’s manual for
more information. NOTE: DO NOT connect the RPM Input to the Coil (-) negative
lead when using a Capacitive Discharge or CD Ignition system. Severe damage will
occur to the electronic control unit.

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Driveshaft Speed (VSS) Input – Receives information from a speed sensor located
on the driveshaft. Multiple tooth sensors can be used to increase resolution and
accuracy by adjusting the Number of Pulses/Revolution setting located in the
configuration page of the DataMap software. A Hall Effect type (3-wire), or Variable
Reluctance-IPU type (2-wire) sensor can be used with this controller by setting
Dipswitch #5 on the Printed Circuit Board to the appropriate position. See Driveshaft
Signal type on Page 16 of this manual to properly configure this feature.
EGO Output – Mimics the output of a conventional narrow-band oxygen sensor. A
0.1 volt output is the leanest possible reading, and a 0.9 volt output is the richest
possible reading.
Main +12V – Voltage source for the controller. This wire should be connected to a
switched +12V source for the controller to operate. If you are NOT connecting this
controller to an Accel DFI Gen 7+ Engine Management system, it is recommended to
install a 30-amp fuse on this line for short circuit protection. Note that on some
models, this input must remain powered until data is read from the integrated
internal data logger or else the stored data will be lost.
eater +12V – Power source for the heater element inside the oxygen sensor,
must be properly connected for sensor to operate. For units with Firmware versions
2.0.0 and higher, this wire is replaced by the Keep-Alive Voltage Input, and heater
voltage is drawn from the Main +12 Volt input.
Keep-Alive Voltage Input – Connect this wire to an auxiliary voltage source to
retain the contents of the Data Logger memory after the Main +12 Volt input is
switched off. Any logged data will be preserved as long as at least 9 volts are
supplied to this input, regardless of the state of the Main +12 Volt input line.
Dual Channel models are also equipped with a memory backup that allows the Data
Logger to retain the contents of its memory after the device is disconnected from
any main or auxiliary voltage supply. Data can be retained for approximately 4
hours before power must be reapplied to the Keep-Alive input wire.
Single Channel units with Firmware versions less than 2.0.0 cannot fully use the
Keep-Alive Voltage input wire. In those units, the keep-alive wire is internally tied to
the Main +12 Volt input. You must keep those units fully powered until the logged
data can be downloaded to your computer. Connection of this wire to a +12 volt
supply may require a 1N4007 (or equivalent) Diode to be placed inline with the Main
+12 Volt supply wire to prevent back feeding of voltage to the switched source.
Place the Diode with the negative side pointing toward the Engine Analyzer module.
Data Ground – Ground source for the communication circuit between the controller
and the laptop PC being used to configure it.
Main Ground – Ground source for the controller’s main power supply.
If not connecting this controller to an Accel DFI Generation 7+ Engine Controller
harness, make sure to connect this wire to an adequate ground source. As with any
electronic equipment in your car, the negative battery terminal is the recommended
grounding point. Inadequate grounding of electronic equipment such as this can
result in equipment malfunction or damage!

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Note: All input and output drivers are active low. For
example, in order to trigger data logging, the input
wire (AuxIn1, Pin 7, Color: Green with Yellow trace)
will be activated by switching the input wire to a
ground source. Similarly, any output wire should be
connected to the ground trigger of a relay for proper
operation.

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PCB-Mounted DIP Switch Chart and Function List
There is a Dipswitch mounted on the circuit board of the Engine Analyzer that can be
used to quickly configure the sensor for customized operation. The Dipswitch is
located at the back of the circuit board, and can be easily accessed by removing the
rear endplate of the enclosure. The function of each switch is defined in the
following table.
Switch Function Description
1 Sensor Type Select On = NTK
Off = Bosch
2, 3, 4 NOT USED
5 Driveshaft Signal Type On = 2-wire Magnetic Pickup
Off = 3-wire Hall-Effect/Square Wave
6 Not Used MUST BE OFF FOR PROPER OPERATION
7, Not Used
Switch 1 – Sensor Type Select
For Engine Analyzer models with firmware version(s) 2.0.0 and higher, put this
switch in the ON position if you are using an NTK wideband sensor. Put this switch in
the OFF position if you are using a Bosch wideband sensor.
For Engine Analyzer models with firmware version 1.0.2 and higher, but less than
2.0.0, the sensor type selection is done on the configuration screen of the DataMap
software, and the dipswitch setting has no meaning.
Switches 2, 3, 4, – Not Used
The Functions of these switches will be determined in the future.
Switch 5 – Driveshaft Signal Type
In the ON position, the wideband controller will accept a magnetic pickup signal input
from a driveshaft speed sensor. This type of sensor is generally identifiable by its 2-
wire pickup. In the OFF position, the wideband controller will accept a hall-effect or
square wave signal input from a driveshaft speed sensor. This type of sensor is
generally identifiable by its 3-wire pickup.
Switches 6, 7 & 8 – Not Used
To be determined. These switches must be in the OFF position for the Engine
Analyzer to function properly.

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Connecting an Older NTK-Only System to a Bosch LSU
4.2 Sensor
THIS PROCEDURE ONLY APPLIES TO REVISION A ENGINE ANALYZER MODELS WITH
FIRMWARE VERSION 1.0.2, AND REVISION ‘A’ WIRING HARNESSES HAVING
BLACK/WHITE WIRES CONNECTED TO HEADER PIN #24. DATAMAP SOFTWARE
VERSION 1.0.3 OR HIGHER IS REQUIRED TO SELECT OXYGEN SENSOR TYPE(S).
1.) Measure the electrical resistance of the Bosch Calibration Resistor between
Pins 2 and 6 of the LSU 4.2 Oxygen Sensor. Write this value down and don’t
lose it.
2.) Cut the -Position NTK Connector off of the Single Channel Harness.
3.) Make the following wiring connections between the Single Channel Harness
and the Bosch sensor. Tape off, or otherwise secure the unused wires.
4.) From the DataMap Software, switch the O2 Sensor Type to Bosch, and enter
the calibration resistor value into the Calibration Resistance field on the
Configuration screen.
5.) Briefly power down the unit to allow the new configuration to be recognized.
eader Pin Number Wire Color
Connect To Bosch Pin
13 Red Bosch Pin 1 (Black)
15 Green < NO CONNECTION to Bosch Sensor >
33 Orange Bosch Pin 3 (Gray)
5 Yellow Bosch Pin 4 (White)
3 Blue Bosch Pin 5 (Yellow)
1 White Bosch Pin 6 (Red)
24 Black/White < NO CONNECTION to Bosch Sensor >

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The Engine Analyzer Integrated Data Logger
The Engine Analyzer has an integrated Data Logging System that can store
information gathered internally through the Engine Analyzer controller as well as
information from external devices that may be connected to it – like an ACCEL/DFI
Generation 7+ ECM. The DataMap software CD included with your kit provides a
Graphical User Interface to your Engine Analyzer.
DataMap Software Installation
The DataMap Engine Analyzer Interface has the following Minimum Requirements:
1.) IBM PC-Compatible computer with Microsoft Windows 2000 or higher.
2.) Pentium III Processor or equivalent, 300 MHz or faster.
3.) 64 MB Free RAM.
4.) 25 MB Hard Disk space.
To install the DataMap software, insert the DataMap CD into your computer, and run
the SETUP.EXE program from the DataMap Installer directory on your computer’s CD
drive.
The latest version of DataMap software is always available to download from the
following Internet location: http://go.mrgasket.com/calmap/calmapdownload.asp

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Engine Analyzer Monitoring
The DataMap software’s main screen provides a monitoring and control interface to
your Engine Analyzer. Air:Fuel Ratio, Engine Speed, Vehicle Speed, Ignition Voltage,
and several other parameters are easily read from the real-time readouts. The
following is a quick description of the way data values are displayed on the screen.
Stripchart:
This is an electrical simulation of a paper stripchart recorder commonly used
for data analysis. Air:Fuel Ratio(s), Engine Speed, and Vehicle speed are
shown on the chart in real time, and remain on the screen for several seconds
to make analysis of their data as easy as possible. The switch in the center of
the screen can be used to pause and restart the display.
Engine RPM:
The large gauge on the left side of the screen displays the engine speed
measured on the Engine Analyzer’s RPM Input wire. Values are displayed
with a resolution of 1 RPM.
Vehicle Speed:
The large gauge on the right side of the screen displays the vehicle speed as
measured by the Engine Analyzer’s VSS Input wire. Values are displayed with
a resolution of 1 MPH.
Ignition Voltage:
The ignition voltage measured across the heating element of the Channel 1
Oxygen Sensor is displayed numerically in the center of the screen. Note that
this display may only be accurate when an oxygen sensor is connected to the
Engine Analyzer.
Oxygen Sensor Status:
Two LED indicators on the lower left side of the screen, SNSR1 and SNSR2,
represent the current states of the 2 Oxygen sensors that can be connected
to your engine analyzer. The colors are defined as follows:
Black: Sensor is not enabled.
Red: Sensor is beginning the warm up procedure.
Orange: Sensor voltage is as expected. Sensor is continuing to
warm up, and the Calibration Resistance is being
measured.
Green: Sensor is warmed up, calibrated, and operating
properly.
If one or more of your sensors fails to operate properly, the color of the LED
may provide some clues as to what is happening. For example, a sensor with
a damaged sense cell won’t get past the initial warm up procedure and should
keep the status LED Red.