ExTuner v1.

1
AFR & EGT Meter system

User manual
Rev 1.2

ExTuner - User Mnual

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 Description
ExTuner – compact combined device, the main functions of which are the
measurement and monitoring of A/F ratio and exhaust gas temperature (EGT),
as well as additional functions such as input of analog signals to monitor any
parameters on the display, output of measurements to analog outputs for
output readings to external devices, such as ECUs, loggers, etc., emulation of a
narrow-band oxygen sensor signal, emulation of the Innovate ISP2 (LM-1,2 /
LC-1) open protocol for working with third-party tuning software, etc.

General Precautions
1. DO NOT INSTALL / REMOVE THE SENSOR WHILE POWERED ON!
DISCONNECT THE SENSOR AND WAIT TOTALLY COOLED OUT.
2. THE OXYGEN SENSOR (LSU) HAS AN INTEGRATED ELECTRIC HEATER,
THEREFORE THE SURFACE OF THE SENSOR CAN REACH HIGH
TEMPERATURES WHEN OPERATING, WHICH CAN CAUSE A FIRE OR
EXPLOSION!
3. DO NOT USE AN OXYGEN SENSOR (LSU) WITHOUT A POWER SUPPLY
CONNECTED! EVERY TIME WHEN THE SENSOR IS USED (INSTALLED IN THE
EXHAUST PIPE) BUT NOT CONNECTED TO A WORKING APPLIANCE, IT WILL
PERFORM QUICKLY AND BE DONE!
4. DO NOT CONNECT / DISCONNECT THE OXYGEN SENSOR WHILE THE
DEVICE IS TURNED ON (hot-plugging).

ExTuner - User Mnual

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 Connecting and preparing the device
Power supply
For power supply and full operation of the device, a constant voltage of 10
to 16V (12V nominal) with a current of at least 3A is required. In addition, the
device can operate from a USB connector (5V), but with a limitation of the
oxygen sensor (for the operation of LSU sensors, a supply voltage of at least
9.5V is required).
A proprietary cable from the kit is used for connection, which is
connected to the “PWR” connector of the device.

Location of main connectors

Observe polarity when connecting at other cable!

ExTuner - User Mnual

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 Oxygen sensor (LSU) connection
The device currently supports Bosch LSU wideband oxygen sensors
versions 4.2 and 4.9. To connect the sensor, a proprietary cable from the kit is
used, according to a specific version of the sensor (the pinout of different
versions of the sensors is identical, but the form factor of the connectors is
different). The device uses a 6-pin connector “LSU”.

The provided cable from the kit for Bosch LSU 4.2 and 4.9 sensors is of the
most common type, with the original shape and dimensions:

LSU 4.9 LSU 4.2

Some of the compatible sensors (Bosch part numbers):

0258017025 0258007351
0258017178 0258007359
0258017179 0258007057
0258017020
0258017230
0281004107

The sensors can be distinguished by the size of the connector (respectively, LSU
4.2 is larger).

ExTuner - User Mnual

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 Connection to PC (USB)
To connect the device to a PC, use a USB 2.0 mini USB cable (4 pins). For
normal operation of the device when powered from USB, a current of at least
250mA is required.
The USB interface is a virtual serial port (COM) through which the PC
software communicates with ExTuner, as well as for the operation of the
Innovate ISP2 protocol emulation.
For the interface to work, drivers must be installed on the PC.
After connecting, you should have a new device in the task manager. After
that, you need to install the USB drivers.
Drivers can be downloaded on our website:
https://cobrartp.com/en/downloads, by selecting the item for the
corresponding version of Windows.
After downloading the archive with the drivers, you also need to select and
run the appropriate installer, depending on the bitness of your operating
system x86 or x64.
Drivers are tested on Windows XP, Windows 7, Windows 10. Official
website of the driver supplier:
https://www.silabs.com/products/development-tools/software/usb-to-uart-
bridge-vcp-drivers.

ExTuner - User Mnual

The installation process is standard.

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 After successful completion of the driver installation, in the device
manager, if there is a connected emulator, a virtual COM port should appear:

After installing the drivers, you can use the emulator with various software
using the Innovate ISP2 protocol, as well as with ExTuner Utility.

Note: The COM port number in your case may be different from the one
shown above.

To connect via USB, the device must be in working mode, i.e. in

parameter display mode (AFR, EGT, etc.). When switching on for the first
time, you need to wait until the LSU sensor preheats (Warming up) or only
connect from USB (for firmware v1.35 +, preheating will be automatically
skipped), you can also skip preheating by long pressing the joystick.
To connect to ExTuner Utility, the Innovate ISP2 protocol emulation
mode must be disabled (LC-1 Mode - Disable) or vice versa, respectively -
for connecting to third-party software using the Innovate ISP2 protocol
(LC-1 Mode - Enable).

Note: data transmission may be interrupted when entering a menu or in

other circumstances when the device is taken out of operation (parameter
display).

ExTuner - User Mnual

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 Exhaust gas temperature sensor connection (EGT)
Any K-type thermocouple can be used as EGT sensor (0-1100°С).

Typical EGT sensor

To connect the sensor to the device, there is a universal connector “screw

clamp” (EGT):

Note: polarity must be observed for the thermocouple to function

properly. An error in polarity does not lead to damage to the device or sensor,
so if you think that you have made a mistake in polarity, just reconnect the
conductors.
To check it is enough to use USB power and any EGT indication menu on
the display.
ExTuner - User Mnual

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 Auxiliary inputs/outputs (AUX)
This connector is located on the side panel of the device, and serves to
connect to external devices for output and (or) input of analog signals with the
ability to convert and display any parameters on the display, create feedback
from the ECU control system, etc.

Signal contacts are used for connection and to common point contacts
(GND): analog outputs AFR, EGT and analog input AI.
Pinout of AUX:
1. AFR - analog output signal of A/F ratio readings.
2. EGT - analogue output for exhaust gas temperature reading.
3. AI – general purpose analog input.
4, 5. GND – common (-).
Common conductors of external devices must be connected to the
common point of the device (GND). For better signal transmission without
distortion, it is recommended to use a separate common (GND) conductor,
bypassing the body of the vehicle's.
Examples of connecting external devices to AUX
1. 1. Connecting analog outputs to an ECU or other device:

ExTuner - User Mnual

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 Connecting analog sensors and outputs:

Note: names of the device outputs are presented conditionally.

Параметры сигналов AUX порта:
Pin Purpose Range and ratio
AFR output Voltage Used sensor
LSU 4.9 LSU 4.2
0V 0.523 0.56
5V 1.36 1.36 λ
EGT output 0V 0 °С
5V 1024
AI input 0V Customizable via ExTuner Utility
5V

AFR reading range for different fuels

Selected fuel type λ=1 λ => ∞
λ = 0.523 (stoichiometry) λ = 1.36 (Air)
Gasoline 7.7 14.7 20.0
LPG (propane) 8.1 15.5 21.1
ExTuner - User Mnual

Methanol 3.35 6.4 8.7

Ethanol 4.71 9.0 12.24 20.9%
CNG 9.0 17.2 23.4
Diesel 7.63 14.6 19.86

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 Signal (voltage) levels at the AFR output in the mode of emulation of a
narrow-band oxygen sensor oxygen (0-1V):

0V : ƛ>1.02 (Lean)
0.5V: stoichiometry ƛ=1.0
1V : ƛ<0.952 (Rich)

Analog Input Setting (AUX)

The analog input (hereinafter - AI) is configured in ExTuner Utility, and

consists in achieving the readings of its own required parameter on the display,
depending on the signal voltage level at the analog input.
Here is an example of setting AI for pressure readings from a MAP sensor.

1. Connect the device to a PC via USB

2. Open the utility and connect to the device (after making sure that the
device is in working mode and LC-1 Mode is off):

ExTuner - User Mnual

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 3. Next: Device - Configurations (AUX) - Analog Input:

4. Adjust conversion values.

For example, let's take a standard sensor with the following
parameters:
Output signal at atmospheric pressure ~100kPа or 0 Bar (excess):
1.25V
Output signal at 200kPa or 1 Bar (excess): 2.5V
Based on this, in order to obtain unknown linear functions, at least two
known points are needed.
Enter the known parameters in the appropriate fields, as well as the
units of measurement (the text that will be displayed on the display after the
number):

5. After filling in all the fields, click Apply and the calculated parameters
will be saved to the device. Also, the dependency will be visualized as a
graph for convenience.
ExTuner - User Mnual

Then you can connect the corresponding signal to AI (AUX) and view the
parameters on the display (Analog in).

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 Navigation and interface
Navigation
As a control (input), ExTuner has an incremental encoder (hereinafter
referred to as a joystick) with a button.
Control coordinates:
1. Clockwise rotation:
- selection of menu items (scrolling down)
- increasing a numeric parameter
2. Counterclockwise rotation:
- selection of menu items (scrolling up)
- decreasing a numeric parameter
3. Push:
- short: confirmation (selection), scrolling through screens
- long (more than 2 seconds): entering the main menu, ending the
process (heating), exiting the menu.

Turning on the device

After power is applied to the device, the welcome screen appears and
then the process of preheating to the operating temperature of the oxygen
sensor (LSU). At the same time, information is displayed about the selected type
of sensor, heating progress, firmware version, the presence of the enabled LC-
1 protocol, etc.:

Main menu
The device menu has a standard and intuitive interface. Control is
ExTuner - User Mnual

performed with a joystick.

To enter the main menu, press and hold the joystick for about 2 seconds
from any parameter display screen.

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 The main menu items contain sections for setting and configuring
individual subsystems of the device:

1. AFR config – settings of the subsystem for measuring, displaying

and outputting signals of the AFR.
2. Alarms – warning system settings.
3. AUX config – General purpose I/O settings and other settings using
a PC.
4. Exit – exit from the main menu. Alternative - holding the joystick
button.
AFR config menu

1. LSU Type – select of LSU sensor type

2. Calibration – start calibration of LSU sensor
3. LC1 mode –Innovate ISP2 emulation mode
4. Fuel type - selection of the type of fuel used for correct AFR
readings (v1.42+).
Alarms menu

1. EGT – setting the alarm threshold for overtemperature

2. Errors – error processing
AUX config menu

1. AFR – analog output settings AFR

2. Other – additional settings.
ExTuner - User Mnual

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 Oxygen sensor calibration

ExTuner has a function of individual calibration of oxygen sensors in the

open air (free air calibration), which allows you to achieve the maximum
accuracy of readings taking into account the individual properties of the sensor,
including the wear (aging) of the sensor, which is inevitable during long-term
operation.

THIS PROCEDURE IS NECESSARY AFTER THE FIRST CONNECTION

OF EACH SENSOR FOR FURTHER USE WITH THE DEVICE!

It is also recommended to calibrate a constantly used sensor after every

30,000 km of run, especially for new sensors, as well as before each sensor
installation.
Calibration process:
1. Connect sensor to device
2. Turn on the device (12V power)
3. Wait for the sensor to warm up (Warming up), before displaying the
mixture reading (AFR). When doing so, make sure that the correct
sensor version (4.2-4.9) is selected (information about the current
sensor version is shown on the display during the warming up process)
4. Place the sensor outdoors (street, room)
5. Enter the main menu (long press on the joystick), and select: LSU config
-> Calibration
6. Wait for the calibration process.
Indication oxygen readings should be approximately O2% = 20.9

During operation, the sensor body may heat up to 80-90 °C, so

be careful!

Notes:
ExTuner - User Mnual

1. The calibration process takes on average 10-20 seconds, during

which the sensor should be at rest and should not be exposed to
moving air masses (wind).

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 Selection of LSU sensor type

The choice of the oxygen sensor (LSU) is to programmatically switch the

sensor version (4.2 <-> 4.9), which is necessary for the correct operation of the
system, because parameters of sensors of different versions are different.

To switch it is necessary to complete the heating process (long press on

the joystick), enter the main menu, then: AFR Config -> LSU type and select the
corresponding version of the used sensor:

After selection, the data is saved in the device memory.

Note: after changing the sensor version, the changes take effect after the
device is rebooted.

ExTuner - User Mnual

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 Identifying faults and solving them

This device has a diagnostic system for the LSU sensor as well as the main
systems of the device.
In the event of malfunctions or abnormal operating modes, the device
notifies about this on the display in the form of an error code or text
notification.

Text warnings:

Message Description Resolve

Power low! Critically low supply voltage (less If the message occurs
than 9.5V). briefly (for example, when
the starter is running), then
no action is required.
If the message appears
frequently during normal
operation, check the supply
voltage and the reliability of
all power contacts.
LSU is not calibrated, Diagnostic has determined that Calibration procedure
Calibration required! LSU sensor is not calibrated or required.
needs to be calibrated.
Not Air! Sensor not in open air warning to Free the oxygen sensor, and
continue calibration process. place outdoors.
LSU Type The system has determined that Select the appropriate LSU
Not correct LSU the connected sensor is not sensor type or confirm the
appropriate for the selected. suggested type.

ExTuner - User Mnual

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 Errors:

Code Description Resolve

E1 Overheating of the LSU sensor. Not a critical error. Install the sensor at a greater
May occur if the sensor is too close to the exhaust distance from the engine (1-
manifold. 1.5m recommended).
E2 LSU sensor underheating. It occurs when the 1. Check the supply voltage of
operating temperature of the sensor is insufficient, the device during operation.
at the maximum signal strength of the heater. May 2. Check the LSU cable.
occur when the device supply voltage is low (close 3. Replace the sensor.
to the minimum allowable).
Е3 Invalid Nurnst cell resistance value. 1. Check the LSU cable.
2. Replace LSU sensor if
reoccurring.
E4 LSU sensor preheating error. 1. Make sure the sensor type
matches
2. Check the LSU cable.
3. Replace the LSU sensor.
Е5 Suspicious parameters of the Pump cell. 1. Make sure the correct sensor
Occurs with sensor defects associated with type is selected
deviations in sensor properties. It can manifest 2. In case of a frequent error,
itself when the sensor is physically or thermally replace the LSU sensor.
damaged, as well as when it is significantly worn
out.
Е6 Overestimated signal parameters of the Nernst cell. 1. Check the LSU cable.
Normally, the signal of the narrowband sensor cell 2. Replace the LSU sensor
is within 0-1V, and if these values are exceeded, this (sensor poisoning).
error appears.
Е7 Understated signal parameters of the Nernst cell. 1. Check the LSU cable.
Failure to achieve normal cell signal Nernst. 2. Replace the LSU sensor.
Е8-E11 LSU sensor calibration errors. 1. Check if the sensor is exposed
Occurs when it is impossible to achieve the required to air currents or
parameters to complete the calibration. electromagnetic interference
and fix it.
2. Check the LSU cable.
3. Replace LSU sensor
ED1 Internal device circuit error - incorrect LSU sensor 1. Disconnect the sensor and
reference voltage or device analog circuit reference check if an error appears. If not,
voltage. check the sensor cable for LSU
shorts.
2. If the problem persists with a
disconnected LSU sensor,
replace the device
ExTuner - User Mnual

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 Other issues:

Issue Resolve
The device does not turn on -Check if the device is connected correctly.
from the on-board supply -Check the reliability of the contacts.
(12V) -Check the integrity of the fuse in the plug for the on-board power
socket (12V).
-Check the power supply in the vehicle electrical socket.
The device does not turn on -Replace USB cable.
from USB -Check the reliability of the power supply (should be 5V and
current at least 250mA).
EGT readings fluctuate within -Check the sensor wires for a short circuit.
the ambient temperature -Replace EGT sensor.
range (~ 5 ... 35 ° C) when the
sensor's working area is
heated above this temperature
Device does not connect to -Check for installed drivers (drivers must be installed correctly).
ExTuner Utility -Check if there is a device in the device manager.
-Check if the device is in the LC-1 Mode protocol emulation mode
(this mode must be turned off to work with the utility).
-Put the device into operating mode (monitoring readings), if not
done.
- Disconnect the device from USB and try again following the
instructions in the utility.
-Replace USB cable
The device is not recognized in -Uninstall and reinstall the drivers
Windows or does not work -Replace USB cable
properly when connecting

ExTuner - User Mnual

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 SPECIFICATIONS

Supply voltage [1] 10…16 V

Supply current (from 12V) 3А
Supply current from USB 180 mA
LSU sensor reference voltage 1.91 V
Analog input impedance 16.8 kOhm
Maximum allowable analog input voltage [2] 60 V
AFR output voltage range 0-5 V
EGT output voltage range 0-5 V
AFR readings error in static mode, no more, in
calibrated state 0,1
EGT Reading uncertainty [3] 2 °C
AFR output resolution 500 digits
EGT indication range 0…1024 °C
AFR indication range λ [4] LSU 4.2 LSU4.9
0.56-Air 0.523-Air
Data rate of proprietary protocol 250 kBps
Innovate ISP2 protocol emulation baud rate 19,2 kBps
Heater PWM signal frequency 31 Hz
[1] voltage across PWR contacts, voltage drop across wires is not taken into account
[2] exceeding this value may damage the device!
[3] in the range from 0 to 800 ° C
[4] may be slightly limited by the permissible cell current Pump

For more information, contact us through the official website

(cobrartp.com/en) or mail ([email protected]).

ExTuner - User Mnual

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