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Produkt / Product: Planar Wide Band Lambda Sensor

with pumped O2 reference

Typ / Type: LSU4.9

Bestellnummer / Part Number: 0 281 004 001 ... 0 281 004 200
0 258 0.. ...

Angebotszeichnung / Offer Drawing: A 258 ... ...

Bemerkung / Comment:

Nr. Seite Änderung Datum Author Approved by

Index Page Revision Date
1 - Erstausgabe / First Edition 13.07.07 GS-SI/ENX4-Ham GS-SI/ENX
gez. Hamann gez. Dr. Stanglmeier
GS-SI/ENX2
gez. Bischoff
GS-SI/ENX4
gez. Dr. Diehl
GS-SI/ENX6-Se
gez. Dr. Schenk
DS-SEN/EDS3
gez. Dr. Funk
DS/EEC4
gez. Dr. Buchenau

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Contents

1. Characteristics 3

2. Application conditions 6

3. Test data (functional values) 9

4. Environmental test specification 14

5. Carrying out tests 20

6. Evaluation of field parts 21

7. Design variations 21

8. Installation and operation instructions 22

9. Operating instructions 23

10. Appendix 25

Reference Specifications

Handling instruction Y 258 E00 000

Add. installation and operation instructions Y 258 E00 025

(Gasoline engines)

Application guideline (Gasoline engines) Y 258 E00 018

Application guideline (Diesel engines) 0 281 YE0 028

Temperature measurement sensors Y 258 E00 006

Test method: measurement temperature and Y 258 E00 007

thermo shock (Gasoline engines)
Test method: measurement temperature and 0 281 YE0 029
thermo shock (Diesel engines)

Application of heater power demand

in Bosch Diesel-Systems 0 281 YE0 030
Application of heater power demand
in non-Bosch Diesel-Systems 0 281 YE0 032

Measurement in synthetic gas (PSG) Y 258 E00 004

LSU test bench and test method Y 258 E00 005

Connector module LSU (RB 150, sensor and 1 928 A00 15T-0
wire harness plug)

The validity of this TKU includes also the above mentioned documents.

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General

The wide band lambda sensor LSU is a planar ZrO2 dual cell limiting current
sensor with an integrated heater. It is used to measure the oxygen content
and the λ-value of exhaust gases. Lambda describes the ratio of available
air mass in the combustion chamber and theoretically necessary air mass for
stoichiometric combustion.
This document is valid for application in
- automotive spark-ignition engines using gasoline fuel
- passenger cars with diesel engine using diesel fuel.

The wide band sensor LSU operates only in combination with a special LSU
control unit (e.g. AWS control box or CJ125 IC). The connector module
(RB150) contains a trimming resistor, which defines the characteristics of
the sensor and is necessary for the sensor function. Therefore a removal of
the connector is not allowed.

Note: values signed with [N] in this document are nominal values or guide
values. They depend directly on other values which are specified with tol-
erances elsewhere in this paper.

1. Characteristics

1.1 Electrical connection

Connector 6 pole
Range of trim resistor 30 ... 300Ω [N]

1.2 Sensor element

The heater supply voltage must be controlled, so that the temperature of

the sensor is kept at the operation point. The temperature is determined by
measuring the internal resistance of the sensor’s Nernst cell Ri,N

Nominal internal resistance of λ=1 Nernst cell

for new sensors (operating and calibration point)
(measured with AC f = 3 kHz) Ri,N = 300 Ω [N]

Max. current load of λ=1 Nernst cell

Continuous AC (f = 3 kHz) IN,max ≤ 250 µA
for Ri,N measurement

O2 reference pumping current Ip,Ref (current source with max. 2.5V)

- minimum necessary value for sensor function Ip,Ref,min ≥ 10 µA
- maximum allowed value
- continuous Ip,Ref,max ≤ 25 µA
- short time (max. 25h without interruption) Ip,Ref,max ≤ 75 µA
- recommended value for ref. pumping current
- continuous Ip,Ref = 20 µA
- short time for 10s during heat up Ip,Ref = 60 µA

Max. pumping current Ip into pump cell

- for rich gas signal (λ≥0,65) Ip,max,rich ≥ -9 mA
- for lean gas signal (air) Ip,max,lean ≤ 6 mA

Pumping current Ip must only be activated after the heater has been switched
on and the sensor element reached a sufficient temperature (internal resis-
tance of λ=1 Nernst cell Ri,N ≤ 1kΩ).

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1.3 Isolation resistance

(all measurements in static air, heater off)

- between housing and each heater- and sensor

circuit connector pin, for new sensors at room
temperature, measured with 800V DC ≥ 30 MΩ

- between sensor signal circuit (IPN connected to

virtual ground VM, see section 9.7)
and heater circuit at 600°C hexagon temperature,
new and after aging acc. to section 4.1,
measured with 12V DC: ≥ 1 MΩ

- between sensor signal pin APE and housing

at 600°C hexagon temperature, new and after
aging acc. to section 4.1,
measured with 12V DC: ≥ 100 kΩ

Note: for heavy sooted or wet sensors the isolation resistance

temporary can decrease below this value

Isolation resistance of wire harness see section 8.5 (installation instruc-

tions)

1.4 Signal coupling between heater and sensor signal

Measurement of the sensor signal with sensor operated by control unit.

Sensor is heater-controlled to operating temperature, heating with VBatt=13V,
heater duty cycle frequency 100 Hz. Signal filter of pumping current with
R = 33 kΩ and C = 100 nF. The temperature of the hexagon is 600°C.

Sensor signal due to signal coupling ∆Ip,meas ≤ 0.19 mA

1.5 Heater supply

Nominal voltage: VH,nom = 7.5 V [N]

Nominal heater power at 7.5 V heater supply

at thermal equilibrium in air: PH,nom = 7.5 W [N]

Heater cold resistance at room

temperature for new sensors,
including cable and connector: RH,cold = 3.2±0.8 Ω

Minimum heater cold resistance at -40°C: RH,cold,min = 1.8 Ω [N]

Note: the influence of the cable length between ECU and lambda sensor in
Diesel systems must be considered by measuring the actual heater power de-
mand according to 0 281 YE0 030/032.

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1.6 Heater strategy

When the heater is ramped up after dew point end, the heater power must be
limited as follows.

Maximum initial value of heater voltage VH,eff during the heat-up phase:
(for gasoline engines dependent on the temperature of the sensor at start)
TSensor [°C] -40 -10 20 50
Operation in gasoline engine: VH,eff,max(t=0)[V] 8.5 9.5 10.5 10.5
Operation in diesel engine: VH,eff,max(t=0)[V] 8.2

- ramp rate ∆VH,eff / ∆t ≤ 0.4 V/s

effective heater voltage

V Heff [V] operating point reached

13 V //
heater power reduced
during condensation
water phase

maximum
ramp rate
= 0.4V/s

application specific
max. initial value
acc. to table
//

← application specific → time after heater start

Fig. 1 Maximum permissible heat up rate with limited heater power to reduce the thermal stress
in the heat-up phase

To rule out thermo shock damage of the sensor ceramic, the sensor must be
operated with a defined heater power during the condensation water phase,
see measuring method Y 258 E00 007 and 0 281 YE0 029.

Caution: the use of fast-light-off conditions from Y 258 E00 007 chapter
1.4 (immediate start of the sensor heater without waiting for dew point end
in close to engine installations) is not allowed for this sensor type!

Heater voltage during condensation water phase VH,eff = 1.5 to 2.0 V

Maximum permissible effective heater voltage

to reach the operating point
- short time ≤ 30sec (200h cumulated time): VH,eff ≤ 13 V
- continuous: VH,eff ≤ 12 V

Maximum system supply voltage Vbatt,max ≤ 16.5 V

- short time voltage peak for 60ms Vbatt,max ≤ 28 V
(10 times over lifetime, ceramic temp. ≥ 20°C)

Minimum system supply voltage Vbatt,min ≥ 10.8 V

at this system supply voltage the function of
the sensor is given in typical applications.
This must still be tested in the respective application.

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Admissible frequency of heater voltage control fH ≥ 100 Hz

- recommended and lifetime tested value: fH = 100 Hz

Notes:
Heater duty cycling of fH > 100 Hz is not tested. Usage must be checked with
Bosch.
The use of the sensor with 24V power systems is not permissible except if a
voltage converter system is used.
1/2
Calculation of VH,eff over duty cycle ED: VH,eff = (ED) * VBatt

2. Application conditions

2.1 Temperature measurements

The sensor temperatures in operation are measured with a special sensor
equipped with NiCrNi thermocouples.
The temperature measurement sensors are available in different combina-
tions. There are measurement points at the upper side of the PTFE formed
hose (“D”), the PTFE cable grommet (“C”), the hexagon of the sensor housing
(“B”) and for the exhaust gas temperature (“A”).

For more information see description of temperature measurement sensors

Y 258 E00 006 and measurement method Y 258 E00 007 and 0 281 YE0 029.

2.2 Storage temperature (passive): -40°C ... +100°C

Storage conditions see handling instruction Y 258 E00 000

2.3 Operating temperatures

Notes:
If the operating temperature is exceeded, the sensor accuracy might be
limited during this time.

If the max. gas temperature exceeds 930°C or hexagon temperature exceeds

600°C, the use of a longer thread boss is recommended.

Exhaust gas TExhaustgas ≤ 930°C

Hexagon of the sensor housing THexagon ≤ 600°C

Cable grommet (PTFE formed hose)

- sensor side (grommet) TGrommet ≤ 250°C
- cable side (upperhose crimp) TUpperhose ≤ 200°C

Cable and protective sleeve: Tcable ≤ 250°C

(additional assembled parts such as clips or cable ties according to
supplier spec or offer drawing)

Connector RB150: Tconnector ≤ 140°C

(s. TKU-RB150, 1 928 A00 15T-0)

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2.4 Maximum temperatures

2.4.1 (max. 250 h accumulated over lifetime)

Exhaust gas TExhaustgas ≤ 1030°C

Hexagon of the sensor housing THexagon ≤ 680°C

2.4.2 (max. 40 h accumulated over lifetime)

Cable grommet (PTFE formed hose)

- sensor side (grommet) TGrommet ≤ 280°C
- cable side (upperhose crimp) TUpperhose ≤ 230°C

Cable and protective sleeve: Tcable ≤ 280°C

(additional assembled parts such as clips or cable ties according to
supplier spec or offer drawing)

Connector RB150: Tconnector ≤ 150°C

(s. TKU-RB150, 1 928 A00 15T-0)

2.5 Fluids in the exhaust gas system

When fluids (especially condensation water) are present at exhaust side,
the heater power of the sensor must be limited, see 1.6.

2.6 Exhaust gas pressure

Absolute pressure at continuous operation Pgas ≤ 250 kPa

2.7 Permissible vibrations

(measured at the sensor housing)
Stochastic vibrations: (peak level) ≤ 1000 m/s2
Sinusoidal vibrations: ≤ 300 m/s2
- vibration amplitude ≤ 0.3 mm

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2.8 Permissible fuel additives

Gasoline: in accordance with DIN EN228 for commercially available unleaded

fuel.

Diesel: the sensor LSU4.9 is designed for use with all commercially avail-
able diesel fuels.
The testing was done with gasoline and diesel fuel acc. to DIN EN 228 resp.
DIN EN 590. All other fuels can only be tested and released project spe-
cific in accordance with Bosch.

2.9 Oil consumption and oil brand

Permissible figures and data must be determined by the
customer by the way of adequate large-scale tests.

2.10 Lifetime
The technical development of the sensor is aligned to a service life of
250.000 km and a maximum life time of 15 years.

The following conditions must be fulfilled in order to reach this service

life:
- Application conditions acc. to section 1 and 2.
- Installation conditions acc. to section 8.
- Checking of each application/installation location according to applica-
tion guideline Y 258 E00 018 resp. 0 281 YE0 028.
- For the electrical connection of the lambda sensor the RB approved sen-
sor connector module acc. to TKU-RB150, 1 928 A00 15T-0 with gold plated
sensor signal contacts for the sensor signal circuit must be used.

The commercial warranty and liability is regulated in the conditions of

delivery, independent of the above figures. The aforesaid information on
lifetime for which the product has been construed shall in no case be a
guarantee regarding the condition or quality of the product.

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3. Test data (functional values)

Special hints for carrying out test bench measurements:

The measurement is done with the sensor operated with an AWS control unit.
The given tolerances are only for the lambda sensor. The heater power is
closed-loop controlled while the measurement is done, so that the nominal
sensor internal resistance is reached. The reference pumping current is
continuous 20µA for all measurements. The signal Ip,meas is the current
through a measuring resistance of 61.9Ω.
Due to the technical design of the gas test benches these measurement data
cannot be used for capability calculations.

3.1 Nominal characteristic line [N]

For a synthetic gas (measurement in LSU test bench acc. to Y 258 E00 005)
the following nominal characteristic line is reached:
IP meas / mA
3,000

2,500

2,000

1,500

1,000

calibration point XO2 = 8,29%

0,500

0,000
0 5 10 15 20 25

-0,500 O2-concentration xO2 / %

IP meas / mA

1,500

x O2
1,000 1+
for H / C = 2 : λ = 3
1 − 4,77 ⋅ xO 2
0,500

0,000
0,70 0,80 0,90 1,00 1,1 1,20 1,30 1,40 1,50 1,60 1,70 1,80 1,90 2,00 2,10 2,20 2,30 2,40 2,50

λ
-0,500

-1,000 Lean test gas: O2 in N2

Rich gas composition of synthetic test gas:

-1,500
9 % CO, 7 % H2, 7 % CO2 in N2

-2,000

Fig. 2 Nominal characteristic line

O2-conc. xO2 [%] 3.0 6.0 8.29 12.0 20.95

λ-value 0.65 0.70 0.80 0.90 1.00 1.18 1.43 1.70 2.42 air
Ip,meas [mA] -2.45 -1.99 -1.13 -0.49 -0.010 0.33 0.67 0.94 1.38 2.53

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(*) All data “after test bench run” are references for endurance and
environmental tests in chapter 4.

3.2 Light-off time

Measurement of the light-off time of the sensor in synthetic gas test bench
at 20°C gas temperature acc. to test method Y 258 E00 004:
New After test
bench run (*)
light-off time [s] ≤ 10 ≤ 10

Note: these light-off times are reached using the defined maximum heat up
ramp for gasoline (s. chapter 1.6). In the engine the time to reach sensor
readiness might differ, depending on installation and gas temperature con-
ditions, especially by delay times due to condensation water in the exhaust
gas system.

3.3 Tolerances for λ=1 and frequency

Measurement in synthetic gas test bench at 350°C gas temperature acc. to

test method Y 258 E00 004:
New After test
bench run (*)
3.3.1 λ static 1.016 ± 0.006 1.016 ± 0.008
(pump current IP,meas=0)
3.3.2 λ dynamic 1.013 ± 0.006 1.013 ± 0.008

3.3.3 Frequency [Hz] 2.2 ± 0.8 2.2 ± 1.0

Note: the parameter λstatic is replaced by the pumping current at λ=1.0 (see
chapter 3.4.2) for the application in Diesel engines.

3.4 Tolerances for rich and lean gas and for λ=1

Measurement in LSU test bench at 20°C gas temp. acc. to Y 258 E00 005:
New After test
bench run (*)
3.4.1 λ signal at λ=1.7: 1.70 ± 0.05 1.70 ± 0.15

3.4.2 Pumping current [µA] -10 ± 12 -10 ± 14

Ip,meas at λ = 1.0
3.4.3 λ signal at λ=0.8: 0.80 ± 0.01 0.80 ± 0.04

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For other λ values and operating conditions the λ tolerances can be calcu-
lated.
∆I p ,meas
For λ>1 and small values of ∆IP,meas/IP,meas: ∆λ = λ(λ − 1) ⋅
I p ,meas
x O2
1+
For a H/C-ratio of H/C=2: 3 λ=
1 − 4.77 ⋅ xO2
(with Ip,meas = measuring current, xO2 = oxygen concentration)

Note: changes in the test gas composition, especially of the H2-

concentration, will have an influence on the characteristics of the sensor.
These influences are stronger in rich gas then under lean gas conditions.

3.5 Tolerance of the sensor signal in air (r-value)

The r-value is the relative deviation of the sensor signal from the nominal
value on air as in 3.1 (O2–content = 20.95%)

⎡ Ip measured − Ip nominal ⎤
Relative deviation r = ⎢ ⎥
⎣ Ip nominal ⎦ in air

with Ip,nominal = Ip,meas value from the nominal characteristic curve in 3.1

Measurement in LSU test bench at 20°C gas temp. acc. to Y 258 E00 005:
New After test
bench run (*)
Relative deviation r [%] 0 ± 7 0 ± 12

3.6 Relative deviation of the characteristic curve camber from the nominal
characteristic curve (t-value)

In lean gas, the signal is not completely linear in relation to O2. To have
the possibility of calibrating the characteristic of a sensor by measuring
the signal in air (calibration during fuel cut-off), the relative deviation
“t” of the characteristic curve camber at the calibration point of λ=1.7
from the nominal curve is defined as:

⎡ Ip measured − Ip nominal ⎤ ⎡ Ip measured − Ip nominal ⎤

Relative deviation t = ⎢ ⎥ − ⎢ ⎥
⎣ Ip nominal ⎦ at λ =1.7 ⎣ Ip nominal ⎦ in air

with Ip,nominal = Ip,meas value from the nominal characteristic curve in 3.1

Specification:
Measurement in LSU test bench at 20°C gas temp. acc. to Y 258 E00 005:
New After test
bench run (*)
Relative deviation t [%] 0 ± 2 0 ± 2

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3.7 Pressure dependency of the sensor signal (k-value)

A change of the exhaust gas pressure leads to a deviation of the sensor

signal (see diagram), which can be approximately described in lean gas as
follows:

p k + p0
I p ,meas ( p ) = I p ,meas ( p0 ) ⋅ ⋅
k+p p0
with p0 = 1013 hPa (reference pressure)

In rich gas the equation is only valid for p≤160 kPa. Above p>160 kPa the
nominal values can be taken from the diagram.

25,0%
∆Ip/Ip(1013 hPa)
20,0%

15,0%

10,0%

5,0%

0,0%

-5,0%
lambda > 1
-10,0%

-15,0% lambda < 1

-20,0%

-25,0%
0,5 0,7 0,9 1,1 1,3 1,5 1,7 1,9 2,1 2,3 2,5
absolute pressure
Absolut-Druck in [bar]

Fig. 3 Pressure dependence of the pumping current

The factor k is depending on operating mode „rich“ or „lean“ and is

approx.: krich gas = 61 kPa (at p=150 kPa) [N]

Specification:
Measurement in LSU test bench at 20°C gas temp. acc. to Y 258 E00 005:

New After test

bench run (*)
klean gas [kPa] 53 ± 10 55 ± 12
(measured at λ=1.7,p=400 kPa)

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3.8 Temperature dependency of the sensor signal and the internal resistance of
the Nernst-cell Ri,N

A temperature change of the sensor ceramic gives a deviation of the sensor

output signal of approx. ∆IP,meas/IP,meas = 4%/100°C [N]

The temperature is known by measuring the internal resistance of the Nernst

cell Ri,N and the following curve:

1000

operating point
Nernst cell resistance RIN / Ohm

Ri,N = 300Ω,
Tceramic = 780°C

100

10
600 700 800 900 1000 1100 1200
Tceramic / °C

Fig. 4: Temperature dependency of the inner resistance of the nernst cell for a new sensor

Guide value [N] for operating point:

- new sensor: Ri,N = 300Ω, Tceramic = 780°C
- after 3000h endurance run: Ri,N = 300Ω, Tceramic = 880°C

Note: these values are guide values. The specification of tolerances is

covered by section 3.4 (Tolerances in rich and lean gas), because the sen-
sor is power-controlled to reach the operating point Ri,N in these measure-
ments. So all tolerances of the Ri,N and IP,meas temperature dependency are
included in the total sensor tolerance.

The dependency of the sensor output from the sensor internal resistance
results from these values. It is measured and specified as follows:

The sensor output IP,meas is measured (in air at room temperature) in the
points Ri,N = 450Ω and Ri,N = 200Ω (by variation of heater power). For new
sensors the deviation is

∆I p ,meas I p ,meas , 200Ω − I p ,meas ., 450Ω

= 0.0506 ± 0.0316
I p ,meas I p ,meas , 200Ω

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4. Environmental test specification

Each test must be carried out with new sensors. After the tests the sensors
must meet the functional values in 3.3 and 3.4 (“after test bench run”), if
not otherwise specified. The tests are carried out operated with a control
unit, if not otherwise specified.

4.1 Engine endurance runs

4.1.1 Endurance run in gasoline engine

For measurements of functional values after endurance test the sensors have
to be fitted into the exhaust system of a λ=1 controlled gasoline engine.
The sensors are operated with a control unit in this test (closed loop con-
trol of heater power).
Speed and load are changed in a 6-cycle program so that a temperature curve
is reached in the sensor tip as per sketch.
- Fuel: according to DIN EN228 for commercially available unleaded fuel.
- Oil consumption ≤ 0.01 l/h.
- Oil brand: multi-range oil viscosity 10 W 40, API specification SF.
Compliance with the temperature limits as per section 2.3 must be ensured
by adequate cooling. The exhaust gas temperature is set by varying engine
speed and load. The temperature at the hexagon is limited by additional air
cooling.
After the test the functional values in section 3.2 to 3.7 (“after test
bench run”) must be fulfilled.

Test time: up to 3000h

T1 = exhaust gas

T2 = housing hexagon

Fig. 5: Profile of the endurance run in gasoline engine

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4.1.2 Endurance run in diesel engine

For measurements of functional values after endurance test the sensors have
to be fitted into the exhaust system of adiesel engine. The sensors are op-
erated with a control unit in this test (closed loop control of heater
power).
Speed and load are changed in a 5-cycle program so that a temperature curve
is reached in the sensor tip as per sketch.
- Fuel: according to DIN EN 590 for commercially available diesel fuel.
- Oil brand: commercially available multi-range oil.
- The exhaust gas temperature is set by varying engine speed and load.

After the test the functional values in section 3.2, 3.3.3, 3.4 to 3.7
(“after test bench run”) must be fulfilled.

Test time: up to 3000h

5000

Engine Speed/ 1/min

600 Exhaustgas Temperature Range
4500
Torque
Engine Speed 4000
TExhaustgas/ °C

500
Torque/ Nm

3500
400 3000

2500
300
2000

200 1500

1000
100
500

0 0
0 5 10 15 20 25 30
t / min

Fig. 6: Profile of the endurance run in diesel engine

4.1.3 Aging by operation in air

For measurement of the characteristic shift under continuous lean condi-

tions, the sensors are operated in calm air (room temperature). The sensors
are operated with a control unit in this test (closed loop control of
heater power). The signal output is monitored during the test.

Test duration: 100 h

Test evaluation: Signal drift ≤ 7%

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4.2 Poisoning endurance runs

4.2.1 Test of sensitivity to silicon in gasoline fuel

Engine test run with additional silicon (Octamethylcyclotetrasiloxane)

content in fuel.
The sensors are fitted in the exhaust pipe of a λ=1 controlled gasoline
engine as in 4.1.1, but operated under the following conditions:

exhaust gas temperature: 400°C

test time: 6 h
Added silicon amount during runtime: 0.79 g

After the test the sensors must meet the functional values in 3.3 to 3.5
(values “after test bench run”).

4.2.2 Test of sensitivity to sulfur in fuel

Engine test run with high sulfur content in fuel.

The sensors are fitted in the exhaust pipe of a λ=1 controlled gasoline
engine as in 4.1.1, but operated under the following conditions:

exhaust gas temperature: 200°C (idle operation)

test time: 500 h
Added sulfur amount during runtime: 188 g

After the test the sensors must meet the functional values in 3.3 to 3.5
(values “after test bench run”).

4.2.3 Test to oil component sensitivity

Engine test run with additional oil components in fuel.

The sensors are fitted in the exhaust pipe of a λ=1 controlled gasoline
engine as in 4.1.1, but operated under the following conditions:

exhaust gas temperature (cycle): 30 min at 400°C

30 min at 700°C

test time: 100 h

Engine oil with high additives is mixed into the fuel. The whole amount of
added oil additives is for the complete test (the P/Ca ratio is constant
over the test):

P [g] Ca [g]
40 51

After the test the sensors must meet the functional values in 3.3 to 3.5
(values “after test bench run”).

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4.2.4 Test of sensitivity to silicon additives in diesel fuel

Engine test run with additional silicon content in fuel.

The test is carried out as in the diesel endurance run (4.1.2), except:

Test duration: 750 h

Added silicon amount during runtime: 20 g
Si amount is determined from fuel analysis in the inflow of injector.

After the test the sensors must meet the functional values in 3.3.3, 3.4,
3.5 (values “after test bench run”).

4.2.5 Test to sensitivity to Cer and iron additives in diesel fuel

Engine test run with additional iron additives in fuel (diesel additive for
soot filter regeneration).
The test is carried out as in the diesel endurance run (4.1.2), except:

Test duration: 750 h

Added Fe amount during runtime: 227.5 g
Added Cer amount during runtime: 530.0 g
Fe and Cer amount is determined from fuel analysis in the inflow of injec-
tor.

After the test the sensors must meet the functional values in 3.3.3, 3.4,
3.5 (values “after test bench run”).

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4.3 Environmental tests

4.3.1 Sinusoidal vibration test acc to IEC 68-2-6 test Fc

Test equipment: electrodynamic vibrator

Test:
50 to 160 Hz with amplitude ≤ 0.3 mm
160 to 2000 Hz at constant acceleration of ± 300 m/s2.
Frequency change velocity: 1 octave/min.
Test duration: 24 h to be performed in all 3
perpendicular planes.
Ambient temperature: 25 ± 3 °C.

4.3.2 Random vibration test

Test equipment: Random vibration test bench

as per Bosch standard N42 AP 411.
Acceleration: 1000 m/s2 (peak level)
Test duration: 24 h
Ambient temperature: 25 ± 3°C

4.3.3 Test with damp heat, cyclic (12+12-hour cycle)

acc. to IEC 68-2-30, test Db

No. of cycles: 21
max. air temperature: 40°C

The heater has to be switched off during this test.

4.3.4 Salt mist test acc. to IEC 68-2-11, test Ka

Testing time: 288 h

The sensor heating is switched on 5 minutes before and during testing. In

order to prevent water from reaching the exhaust side sensor ceramic, a
stainless steel sleeve is screwed onto the sensor thread for proper seal-
ing.

4.3.5 Change of temperature acc. to IEC 68-2-14, test Na

Minimum temperature: -40 °C

Maximum temperature: 130 °C
Exposure duration at each temp.: 30 min.
No. of temperature cycles: 250

The heater has to be switched off during this test.

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4.3.6 Sulfur dioxide test with general condensation of moisture acc. to DIN EN
ISO 6988
(Corrosion in humid SO2 atmosphere)

No. of cycles: 6 (24 h for each cycle)

The heater has to be switched off during this test.

In order to protect the exhaust side sensor ceramic, a stainless steel
sleeve is screwed onto the sensor thread for proper sealing.

4.3.7 Submergence test acc. IEC 529, IPx7

Water level 150 mm above sensor cable outlet. Test duration is 30 min. The
connection system must be out of the water during the test. The sensor is
operated with a LSU control unit in this test, the sensor signal is moni-
tored.

Test evaluation: the sensor signal must be Ip,meas ≤ 2.95mA

4.3.8 Wire pull test

The mounted sensor has to withstand an axial force of 100 N applied to the
wire harness for 1 min.

4.3.9 Fuel resistance test (FVP-test)

The exhaust gas side of the sensor is exposed to Pentan vapor in a test
chamber (pressure 100hPa). The soak time is 2 h. After this the sensor is
removed and then operated with a control unit. The sensor signal in ambient
air is monitored for 120 min.

Test evaluation: the sensor signal must be Ip,meas ≤ 2.95mA

4.3.10 Fine leak test

The gas leakage is measured from exhaust gas side with an air pressure of
400kPa (sensor not heated). The leakage rate must be ≤ 0.1 ml/min.

4.3.11 Drop test acc. to IEC 68-2-32 test Ed proc. 1

The sensor is dropped onto a concrete floor from a height of 1m, one time.

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5. Carrying out tests

Test procedure Section 100% Lot Product Design

test release audit verifica-
test test tion test
(DV-Test)
Isolation resistance at room 1.3 x
temperature (heater, sensor
signal circuit and housing)
Isolation resistance hot 1.3 x
(heater to sensor circuit and
APE and housing)
Signal coupling betw. heater and 1.4 x
sensor signal
Functional test in rich gas x
λ=0.8
Functional test in lean gas x
λ=1.7 (sensor calibration)
Tolerances at λ=1 (PSG) 3.3 x
Tolerances in rich and lean gas 3.4 x
(LSU test bench)
Light-off time 3.2 x
Tolerances of the signal in air 3.5 x
Relative deviation 3.6 x
Pressure dependency 3.7 x
Engine endurance run 4.1.1 x
gasoline, t=500h)
Engine endurance run 4.1.1 x
(gasoline, t=3000h)
Engine endurance run 4.1.2 x
(diesel, t=3000h)
Operation in air 4.1.3 x
Sinusoidal vibration test 4.3.1 x
Random vibration test 4.3.2 x
Test with damp heat 4.3.3 x
Salt mist test 4.3.4 x
Change of temperature 4.3.5 x
Sulfur dioxide test 4.3.6 x
Submergence test 4.3.7 x
Wire pull test 4.3.8 x
Fuel resistance test (FVP) 4.3.9 x
Fine leak test 4.3.10 x
Drop test 4.3.11 x
Silicon sens. test (gasoline) 4.2.1 x
Sulfur sensitivity test 4.2.2 x
Oil component sens. test 4.2.3 x
Silicon sens. test (diesel) 4.2.4 x
Cer + Fe sens. test (diesel) 4.2.5 x

Note:
Product audit tests are carried out for monitoring the product quality on a
regular basis.
DV tests are only carried out with new sensor types in the design verifica-
tion phase.

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6. Evaluation of field parts

In case of complaints about the products they are effectively free of fault
through attainment of the following characteristic data:

- functional values from section 3.4.1 and 3.4.3 (tolerances for rich and
lean gas, values “after test bench run”).

7. Design variations

The following variations are available:

7.1 PTFE formed hose

• Longer PTFE hose at cable grommet for installations with critical tem-
perature conditions in the sensor area.
• Shortened PTFE hose at cable grommet.

Note: the temperature resistance is the same for both types at the defined
measuring points.

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8. Installation and operation instructions

The sensor installation point and the sensor functionality in the full
system must be assured sufficiently by the customer through appropriate
vehicle tests under realistic conditions of use.

8.1 Installation in the exhaust system must be at a point guaranteeing repre-

sentative exhaust gas composition whilst also satisfying the specified tem-
perature limits.

8.1.1 Tested installation positions:

- passenger car automotive spark ignition engine using gasoline fuel: af-
ter turbocharger, in front of catalyst
- passenger car diesel engine using diesel fuel: after turbocharger, in
front of catalyst, after oxidation-catalyst
All other installation positions must be assured sufficiently in the
respective application, in agreement with Bosch.

8.2 The lambda sensor must only be used with a appropriate control unit, e.g.
vehicle ECU or AWS control box). It must be activated only after engine
start. The heater power must always be switched on power controlled, e.g.
duty cycled heater power.

In the heat-up phase at start the sensor is heated with reduced heater
power acc. to diagram in chapter 1.6 to reduce thermal stress of the sensor
element due to high peak power in the first seconds. The heater power must
only be increased after all occurrence of condensation water, which could
damage the hot ceramic, can be ruled out.

8.3 To allow early heating of the sensor to reach a fast sensor activity, the
sensor installation location design must be selected in a way to minimize
exhaust-side stressing of the sensor with condensation water.
If this is not possible by design measures, the start of the sensor heater
must be delayed until demonstrably no more condensation water appears.

Note: The test method for evaluation is described in Y 258 E00 007 (for
gasoline applications) and Y 281 YE0 029 (for diesel applications).

8.4 Detailed instructions and hints for

- design of the sensor installation point to avoid build up of condensa-
tion water, cooling of sensor element etc.
- positioning of the sensor in the exhaust gas stream
- design of the sensor boss
- assembly notes

are given in the following documents

For application in gasoline engines:

Y 258 E00 018 Application guideline
Y 258 E00 007 Method for temperature- and thermo shock measurement
Y 258 E00 025 Add. installation and operation instructions

For application in diesel engines:

0 281 YE0 028 DS Application guideline
0 281 YE0 029 DS Method for temperature- and thermo shock measurement
0 281 YE0 030 Application of heater power demand in Bosch Diesel-Systems
0 281 YE0 032 Application of heater power demand in non-Bosch Diesel-
Systems

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8.5 To ensure the necessary minimum reference pumping current, the isolation of
the vehicle wire harness including all connections must be guaranteed. The
minimum isolation resistance under all ambient conditions (temperature, hu-
midity) over the whole vehicle life time must be ≥ 2MΩ between all sensor
signal pins.

9. Operating instructions

9.1 Conditions for connection and electrical operation of the sensor

It must be assured, that when the sensor is operated, the connection to the
control unit is not disconnected during operation, or that the control unit
diagnosis recognizes a failing connection.
It is also not allowed, to disconnect or to connect the sensor to the
control unit or ECU while the sensor or control unit is being operated.

Background: if the signal of the λ=1 Nernst cell is missing (e.g. connec-
tion failure), the internal control circuit can not operate correctly, so
that
- an excessive pumping voltage with wrong polarization can destroy the
pumping cell of the sensor

- the sensor element can be destroyed by overheating, when the closed loop
heater control is not able to measure the ceramic temperature

The control unit may only be switched on after the sensor is connected
completely.

The sensor cables may never be connected in the wrong way or wrong polar-
ity, otherwise the sensor might be destroyed.

The sensor might not stay in the exhaust gas stream without the control
unit connected and activated.

9.2 Use of LSU outside of the exhaust gas system

The sensor can also be used outside an exhaust gas system, e.g. in air.

When used in a stoichiometric (λ = 1) or rich gas (λ < 1), e.g. measurement

gas in the test bench, it must be assured, that enough O2 donators are
available in the gas to allow the pumping cell to work. Otherwise the ZrO2
ceramic of the sensor can be reduced and the sensor destroyed.
The O2 donator may be free oxygen (non-equilibrium measurement gas), H2O or
CO2.

Guide values: H2O: ≥ 2 vol %

CO2: ≥ 2 vol %

9.3 Electrical heating of the sensor

The sensor heater may never be connected directly to battery voltage. It

must always be controlled by the LSU control unit or the vehicle ECU.
Heating of the sensor before the engine is started is exclusively possible
with a heater voltage VH,eff from 1.5 to 2.0 V (see chapter 1.6 heater strat-
egy, heater voltage during condensation water phase).

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9.4 General function test (at vehicles, in workshops)

The following tests can be done as a rough check of the sensor function
(operation with control unit):

Plausibility check in rich exhaust gas:

- sensor signal: rich (output voltage of AWS < 2.5V)

Plausibility check on air:

- sensor signal: air signal (output voltage of AWS ≥ 5.6V)

Heater cold resistance at room temperature:

- resistance measurement with multimeter between grey and white cable,
sensor not connected to control unit, connector pinout see offer draw-
ing:
RH,cold = 2 ... < 5 Ω (sensor at room temperature)

Visual inspection for mechanical damage

9.5 Sensor characteristic at high exhaust gas temperatures

Hot exhaust gas with a temperature above the operation temperature of the
ceramic can lead to an increasing ceramic temperature and a deviation of
the sensor output signal.

For data see section 3 (functional values).

9.6 Note for calculation of the sensor signal IP,meas when using a control unit
AWS or CJ125:

Output voltage AWS : VAWS [V] = 2.5 + 1.648 * IP,meas [mA]

Output voltage CJ125 : VCJ125 [V] = 1.5 + (61.9/1000*v) * IP,meas [mA]

with v=17 (standard measuring range λ=0.8...air) or v=8 (measuring range

λ=0.65...air). The amplification factor v can be switched between v=8 and
v=17 in the CJ125.

9.7 Connection of LSU and control unit

Sensor Cell AWS

O2, CO, HC, H2 APE ← Ip red IP ← Ip meas

Trimming Resistor −
Measuring
O2− 30-300 Ohm
Resistance 61.9 Ohm
O2− green IA +

IPN yellow VM=2,5V +

Reference
Voltage −
450 mV VCC
RE RV
UN
black
20 µA Reference Pump Current

Ri-control

H- white −
H+ grey +

Fig. 7: Connection and control unit

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10. Appendix

Symbols

Ri,N Inner resistance of the nernst cell

IN,max Max. current load of nernst cell
Ip,Ref,min Min. necessary reference pumping current
Ip,Ref Recommended reference pumping current
Ip,Ref,max Max. permissible reference pumping current
Ip,max,rich Max. pumping current for rich gas
Ip,max,lean Max. pumping current for lean gas
UBatt,min Min. battery voltage
UBatt Battery voltage
UBatt,max Max. permissible battery voltage
fH Heater duty cycle frequency
UH,nom Nominal heater voltage
PH,nom Nominal heater power
RH,cold Heater cold resistance at room temperature
RH,cold,min Min. heater cold resistance (at -40°C)
UH,eff Effective heater voltage
UH,eff,max Max. permissible effective heater voltage
TSensor Sensor temperature
ED Heater duty cycle
TExhaustgas Exhaust gas temperature
THexagon Temperature at hexagon of the sensor housing
TGrommet Temperature at cable grommet (PTFE formed hose), sensor side
TUpperhose Temperature at cable grommet (PTFE formed hose), cable side
TCable Temperature at the cables
TSleeve Temperature at the cable sleeve
TConnector Temperature at the connector RB150
Ip,meas Pumping current, measured over a measuring resistance of 61.9Ω
pgas Gas pressure
p0 Reference pressure, ambient pressure=1013hPa
xO2 Oxygen concentration
Ip Pumping current
r Relative deviation of Ip,meas to nominal value in air
t Relative deviation of characteristic curve cambering
to nominal curve at the measuring point λ=1.7
krich gas Factor describing the pressure dependence of Ip in rich gas
klean gas Factor describing the pressure dependence of Ip in lean gas
TCeramic Ceramic temperature
VAWS Output voltage of AWS control box
VCJxxx Output voltage of IC CJxxx in ECU

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