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GEN3 User Manual – Feb 2011 – Rev 2.2

1. RPM Fress lt Ctrl gt Enter gt keys together to Update Window Fuel Press 0 psi Gross Inj PW 1 8m5 Act Drv Shaft 5475 RPM Ethanol 0 0 AGIL_AFR 0 0 4 LO Corr 100 0 Vol EF 23 4 ACTAPR 15 9 1 CamCrk Ady 11 0 deg Inj Duty Cycle 3 Boost 4 5psig AFT Corr 0 0 AIR Corr 0 0 RPMI 1900 Des IAC 27 0 Spk Adv 36 0 deg Air Temp 77 2F MAP 70 1kPa JEGOR 86 0 CLT Corr 0 0 O2 Corr J U Scaled Load 0x28 Scaled RPM 0x23 TRS aa Coolant 2314 14F Vbat 13 3 Static Test Timing This feature is not functional with all released firmware The Static Test Timing feature allows for a quick way to lock the entire spark map to a fixed value This feature eliminates the need to enter a fixed spark value into all the cells in the spark map when setting the Crank Reference value A Test Timing value of 40 is recommended The enable check box directly below the calibration value must be checked to invoke this feature Once enabled the user can adjust the Crank Reference value up or down to ensure that the Dash spark advance value Spk_Adv in the Dash equals 40 at the cranksh
2. 77 Configure Replay To configure Replay open the Configure Replay drop down screen as shown above The following screen will open s Replay Configuration Extended Replay Signals WOS Stage Ww Oct Gear Ar Cor ATM Corr k Air Temp Base Puy Ww Boost Engine Acceleration Fuel Flow W Fuel Press Gearl_FRtd Grogs Puy Inj Bank 2 L_AiUhme r l I Mistre Pan Vac Pet DC Fro OS RPM F_UEGO_AF R_AiQhme Ale Corr e W Timer Enable M TISS_ 1pm Toq Ad Stage JOS5_rprn TOT iw TP3_Pet A L UEGO_AF L02 Cor W LPDC OR Eth W MAF iw MPH Misfire Cnt rpm iw Trans LF Seld_ Load Turbo Back Press Scld_ APM Turbo rpm Spark Ady W TwoStep Stage batt CE DE WasteGate DC W Cam Crk Adv CLT Temp CSM Syne Error dMAP_ Cor Desired Boost ECM Walid lt E i Oll Pressure OR Accelerometer ALL OFF ALL ON Sample Fate 20me 0 Records Logged TPS tigger Lewel 89 Acceleration Filtering O 19Hz Acceleration Sensor oe ee lt Update Help Cancel Replay Duration 11 sec Signals Displayed Select the signals you would like logged and displayed by checking the box next to the desired signal Check the ALL OFF or ALL ON toggles the bottom of the table to turn all the signals off or on respectively Any signal checked will be logged and displayed Replay Duration The length of time the GEN3 ECU will log
3. GEN3 PRO SEFI System System Hardware Installation amp BigComm Software User Instruction Manual Revision 2 1 December 2010 BigStuff3 Pro SEFI System Table of Contents CSection Page s Hyperlink O O __ Frequently Asked Questions FAQs __ Key Notes Summary fromthe Manual Key Notes Summary 1 Introduction SSS a2 S O 2 Features 8 S O 3 PackageContents 5S o O 4 Main Wire Harness Installation 6 Main Harness Installation Injector_Harness_Installation 6 Wide Band Oxygen Sensor Installation 21 Wide Band O2 Installation 7 ECUInstallation 22 ECU Installation _ 8 BigComm Software Overview 22 BigComm Software Overview 9 BigComm Software Installation 23 BigComm_ Software_Installation 10 Communication Cable to PC Connection 28 Connecting to the PC l1 Usingthe ToolBar 28 sing The ToolBar Establishing a Connection BigComm_Main_Menu_Screen Inputting_Values_Into_Cells 15_ Closing Windows 34 Closing Windows 16 Configuration 3 Configuration 17 Hardware Configuration 35 Hardware Configuration 18 Operating Configuration 37 Operating Configuration Dwell_Time_Table 20 Loadvs RPM Lody RPM 21 FiringOrder iin Order S O Injector_Opening_Time 23 InjectorPhase Angle 47 Injector Phase Angle 24 AirFuelRatio 5 Air Fuel Ratio Air Fuel_Ratio_Table Positive _O2_Correction Nega
4. Pin C Pin D To Coil Pack Connector D To Coil Pack Connector B To Coil Pack Connector C To Coil Pack Connector B Version 2 1 February 2011 17 BigStuff3 Pro SEFI System GM Northstar Direct Ignition System DIS Pin out Detail BigStuff ESC Harness Connector BigStuff HEI Harness Connector Connector Clip Pin D Pin A Pin B Pin C ESC To Coil Pack C4 F To Coil Pack C4 D To Coil Pack C4 C To Coil Pack C4 E To Coil Pack C4 B GM Opti spark Ignition Pin out Detail Connector Clip BigStuff Harness Connector Pin D Pin C Pin A Pin B To distributor connector pin D Not Used To distributor connector pin A To Coil Driver Module Connector B More GM Opti spark ignition wiring information is available on the Bigstuff3 website via this link http bigstuff3 com pdf OPtS park 20to 20BS3 20HEI 20 Wiring pdf Back_to_Ignitions Version 2 1 February 2011 18 BigStuff3 Pro SEFI System CAM Gray 2 way Packard connector with a separate ground wire 3 8 ring terminal For distributor based applications BigStuff3 recommends using the cam sync input The cam sync input is required for all coil on plug applications The GEN3 system will to operate sequentially without the cam sync hooked up but the point of injection the number of degrees BTDC where the fuel is injected will vary every time the engine is started Individual spark control per
5. view Log From File From this drop down screen the following data Logging events can be configured e Configure Log Instructs the ECU to Start logging when user defined TPS percent 1s reached o How long to Log data for o Whether the display will update while data is being logged o Set the default file name for the series of data to be logged O e Record Log Starts logging data e View Log From File View logged data from a user defined file name The logging options are further explained below 72 Configure Log From the tool bar on Main Menu screen left click on the Logging When the drop down screen opens hold the left mouse button down and slide the mouse until Configure Log is highlighted Release the mouse button The screen below will open 9 BE Offline 8 18 10 Testing big lt lt Logger Configuration B TPS Trigger Level 5 Log For 10Sec O EO i l I at 1 1 1 l Update Display While Logging fe Yes C No Vehicle Type Car C Bike Default Filename BigLog Using the Throttle Position Sensor TPS as a Load input the user can automatically trigger the BigComm software s data logging feature Place the left mouse cursor on the TPS Trigger Level slide bar Depress the left mouse button and slide it to the desired TPS value or threshold The logging feature will automatically start once the selected TPS value is exceeded Before exiting this window th
6. communication has been established between the Big Stuff ECU and an external computer A red sliding ball indicates communication has not been established between the Big Stuff ECU and an external computer A blue sliding ball indicates Off line No communication has been established between the Big Stuff ECU and an external computer BigComm Tool Bar Left mouse click on PC on the main tool bar Select the COM Port associated with the USB cable that was installed Close the BigComm software Version 2 1 February 2011 34 BigStuff3 Pro SEFI System s BigComm lO Eef Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Factory windows Help Z ReSync Refresh Rate Com2 Com3 Com Coms ey If the Com Port selected is not available the following message will appear a o x Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Factory PC Windows Help be BB Big Comm Error Comm port not available Select another Com Port until an available port is identified Once the PC identifies an available Com Port the following screen will appear biglomir AO Sle File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Facto
7. 5s 3 Rear Gear Ratio n 1 w Inductive Delay u5 j5 Tire Diameter in 26 2 Res Limi Static Test Timin Pickup Wheels Rer Limit On APM E Test Timing deag Orveshatt Pulse rev jao Rev Limit Off RPH 6 Enable Test Timing Crankshaft Pulsecrev E 2 Step RPM Hi 3 Input Shatt Pulse rev E 2 Step RPM Lo 1 Crank reference deg 350 00 o0 Turbo Shaft Pulse rew i Override Cam Syre Test Em Fueling Parameters Fan Contro i in 550 Pme tmel po fisas Injector Flowrate A cc min Fan On Temp F Injector Flowrate E eer 0 Second Purp On TPS 36 0 160 8 Fan Off Temp F Engine Size in E A C Anticipate fis EGT ALS Off On Help Close Fuel Purp 45 Warm Up Before the engine reaches normal operating temperature i e 180 additional fuel is required as a function of engine coolant temperature and manifold absolute pressure for speed density applications To calibrate warm up enrichment fuel go to the Main Tool bar and highlight Warm Up Keep the left mouse button depressed and slide the cursor down to select Coolant Correction or Air Temperature Correction depending on the table to be accessed 46 Air Temperature Correction The inputs from this table are used by the ECU if Alpha N was the control algorithm selected during the Main Configuration set up If Speed Density the control algorithm was selected the ECU ignores inputs from this table For Alpha N systems the ECU u
8. Boost Parameters Closed Loop Boost Parameters Minimum AFM Mininurn TPS Minimum Zp Stage 1 Timer TPS RPM Stage 2 Timer ang DE ference Parameters re Stage 3 Timer Spark Retard Mode Boost Mode d Stg Boost C Tet Gear e Staged CO EWM Tet Gear Axis Units fe Time C APM Tat Gear Timer OyverRide oa Sec 1st Gear Closed Loop Parameters Blend Rate o Counts Proportional Gain High Gear Atd Delay oa Sec Derivative Gain High Gear Atd 0 00 Deg Integral Gain E OK Help Close For more information see Boost_ Control in Section 60 Back_to_ Boost Version 2 1 February 2011 23 BigStuff3 Base System Data Log Trigger Timer Enable Wiring Diagram Using the Brake Pedal Switch Es OS Witched 12V from the vehicle Boost Connector from Main Wire Harness Brake Switch 12V applied to this wire when the brake pedal is depressed Required ON OFF Switch to turn the Replay Trigger signal On and Off Timer Enable Wire With all GEN3 base systems the Boost connector location A is used to enable two 2 functions L The internal timer referred to as the Timer Enable No matter how the GEN3 system is configured or what options the system has Pin A of the Boost connector will always act as the internal timer trigger wire used for boost and traction control and other optional features The timer enable wire connector location A must hav
9. Google File Folder 12 19 2009 9 02 PM E 4onle Software Update i BigStuFF Hewlett Packard File Folder 5 6 2009 10 11 AM E E Bigcomm Hp File Folder 6 25 2009 8 38 AM B sR Hycam z File Folder 6 1 2009 11 45 AM SR2 File Edit view Favorites Tools Help Back gt S pi Search Ke Folders E Address B C Program Files BigStufF BigComm SR2 Folders J 05 c amp O _AcroTemp O Config Msi Default dsh DSH File Defaulti col Default col COL File FR COL File Un zip the file into the SR2_BigComm folder All your future calibrations replays logs etc must now be saved to the new SR2_BigComm folder If old non extended replay calibrations are loaded into the ECU the extended replay capability will be wiped out and the ECU will need to be sent to back to BigStuff3 to be reconfigured Rename the BigComm icon SR2_BigComm and send it to your desk top New BigComm icon Right click rename and send it to the desktop Program Files 9 98SEaME H Adobe Analog Devices Apple Software Update 3 O BigStuff O BigComm 9 Bie Sn _____ File Edit View Favorites Tools Help ar Back QJ wi P Search E Folders Ei Address I C Program Files BigStufF BigComm SR2 v gt Folders Bll Default1 col A Default col i Default dsh f D Program Files 4 fs File Ep m File A File seseame gt i jia H
10. I your paean repoluhon makes pereen deme lon one coraiodlably pou can increase the DPI to compensate To change lori sizes only chck Cancel and go to the Sppestance tab DPI setting ES a Hiema size 56 dpi Cerrar bebty seed wer le Ero t oae computer alter changang displ set Alter change diplis settings O Restart the computer before apphang the new display settings Ca Apply the ew display setting vh erlat Ask me befor applying the new display settings Some games and other pogana masi be nun in o6 cokor mad Lenin mote Abot PHY process in Z O node e What dwell times should be used with the LS1 coils sold with my system e With a 12V charging system From idle to approximately 4 000 RPM Use about 3 0 milliseconds near idle and no more than about 4 0 milliseconds at approximately 4 000 RPM From approximately 4 100 Max RPM Use no more than about 6 milliseconds of total dwell time at max RPM e With a 16V charging system From idle to approximately 4 000 RPM Use about 2 0 milliseconds near idle and no more than about 3 0 milliseconds at approximately 4 000 RPM From approximately 4 100 Max RPM Use no more than about 4 5 milliseconds of total dwell time at max RPM e For LSx COP engines make sure the cam sync override box in the Operating Configuration drop down is not checked e The Ford Mod Motor COP system must have the Override Cam Sync Test box checked Version 2 1 Februar
11. ATM Corr 0 0 Scaled Load 0x00 Scaled RPM 0x00 TPS 0 0 what 13 54 MAP 8 0kPa WhenUSEARCH Q Search g Specials The WhenUSearch Toolbar Saving You Time and Money Find out s3 Start Screen Prints ia GEN1_BigComm manu BigComm e Fill Choosing Fill will open a secondary drop down screen which allows the selected cells to be changed to the value inputted into the window e Multiply Choosing Multiply will open a secondary drop down screen which allows the values of the selected cells to be changed by the Multiply value inputted into the window For example if the values in the cells selected are 13 and the inputted Multiply value was 80 the new cell values would be 10 4 e Interpolate If a series of cells in the same row are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way to the left and the cell value all the way to the right and interpolate the numbers in between so that the values are linear Version 2 1 February 2011 67 BigStuff3 Pro SEFI System Cell Values Selected in a Row Cell value to the left Cell value to the left Interpolated Result from Cell Values Selected Above 7 73 7 80 If a series of cells in the same column are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way at
12. E85 ethanol flex fuel systems for COP and distributor based GEN3 systems Uses a GM style flex fuel sensor e Sequential fuel control for up to 24 injectors low or high impedance injectors in a staged configuration e Barometric Pressure Compensation e Transmission control for GM 4L60E 80E transmissions e Data Logging Internal DAI 128k of on board RAM for internal data logging 52 user selectable channels twenty two 22 16 bit channels amp thirty 30 8 bit channels 10 bit resolution with a 50Hz acquisition rate e Data Logging External DAE amp DAE 2 Additional data logging capabilities of the following engine vehicle parameters Fuel pressure 150 psi Oil Pressure 150 psi Turbo back Pressure 150 psi Trans Line Press 500 psi Drive shaft RPM Turboshaft RPM STUFF Version 2 1 February 2011 J BigStuff3 Pro SEFI System Pan Vacuum Accelerometer Clutch or trans brake input TCC slip MPH e Auxiliary control of Fuel Pump High amp Low Side drive 2 spare high amp low side outputs Torque converter clutch spare PWM high amp low side output to 3 stage boost control Fan low amp high speed control 3 Package Contents Base System with DAI The BigStuff Engine Management System includes the following components Black powder coated aluminum Engine Control Unit ECU Main Wire Harness Injector Harness Wide band Oxygen Sensor handle wi
13. example why this condition is undesirable is if the GEN3 ECU demands more fuel demanding a larger pulse width and the injector is already static The only way to move more fuel through the injector would be to increase the fuel pressure Increasing the fuel pressure at the 1 8 mile marker is not possible so things go bad quickly Also teetering on and off at the static point is also undesirable Lastly running the injectors drivers static for long periods of time can damage them e How do I set up my ignition system with the GEN3 system O For more information on ignition system setups beyond what is available in this manual go to the How To Help section on the BigStuff3 website and then Ignition System Setup Tutorial The link is http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf There are nine 9 ignition system setups outlined There is also information on the setting up the Ford TFI GM HEI GM Opti spark amp MSD8 ignition systems in the How To Help section of the website e Where can I find wiring harness information on the BS3 power train system and optional systems O Information on most of our wiring harnesses is available on our website at www bigstuff3 com Go to the How To Help section on the website The first fourteen 14 files listed in this section are wiring diagrams The link 1s http bigstuff3 com how to help e My engine will not start What should I check O Make sure the harness
14. other ground location will work e Since my DAI enable wire is also the timer enable wire the Boost connector Pin A pink wire how can I trigger my timing events e g 3 stage timing retard tables and data log Replay at the same time See Data_Trigger_Replay_Relay_ Wiring above o Connect the DAI Timer Enable wire to an inverted signal from the trans brake See an example on how to invert the signal via a relay in the Boost section of this manual e Can Iuse a5 Bar MAP sensor Yes but you will need to know what the transfer function of the sensor is Once determined call BigStuff3 for the final determination Note The 4 BAR MAP sensor sold by BigStuff3 is good to 52 PSI e How to use starting line timing retard See the Start_Line_ Timing section above e Why is the Replay feature better than using my laptop to log data See the section above in this manual titled Data Acquisition then the paragraph titled Logging vs Replay e Why are my Replays all are distorted o Calibrations based on the Original replay firmware cannot be loaded into ECU s with Extend Replay firmware and vice versa If your GEN3 system includes the ETM EGT or NTK WBO2 options it also includes Extended Replay firmware and can only accept calibrations from other ECU s with any one of these optional system If you loaded an Original replay calibration into a GEN3 ECU that has the ETM EGT or NTK WBO options your Replay function will b
15. the cell to be changed Input the desired value and hit Enter to save the change Version 2 1 February 2011 92 BigStuff3 Pro SEFI System 63 Boost Staged When Staged mode is selected the time intervals between the boost stages need to be configured In the Boost Parameters table above these inputs are defined as Stage 1 Stage 2 and Stage 3 Before the staged boost sequence can be enabled 12 Volts needs to be present at the Timer Enable pin which is Pin A of the 4 way Boost connector on the main wire harness Boost_Connector_Pin_ Out A clutch switch or trans brake button should be wired between the timer enable pin and a 12 volt source A toggle switch can be added between the 12V source and the clutch switch or transmission brake button to allow the timer enable pin to be turned on and off see the illustration below In the example table below once 12V is applied to the Timer Enable wire Stage 1 will be activated one half 5 seconds Stage 2 will be activated after two 2 seconds and Stage 3 will be activated three and one half 3 5 seconds Note Once the stages are turned on they stay on until the TPS and or RPM criteria are no longer true or the Timer Enable goes low off Note The Timer sequence will be reactivated every time the throttle is closed and then opened again since the Minimum RPM and Minimum TPS criteria are re satisfied x Boost Parameters BE x Boost Parameters Closed
16. 10 before the crankshaft pulse To determine what the crank shaft timing relationship is between the cam and crank sensors add the CamCrkAdv signal to the Dash Make sure a value greater than 1 exists a minimum of 6 but ideally a 10 window is needed Additionally you can view past Replays DAI to check if a Cam Synch Error occurred and what the CamCrkAdv relationship was during the pass If the Replay indicates Cam Synch Error ON the cam pulse is occurring at the same time as the crank pulse For more information on how to resolve this issue go to the How To Help section on the BS3 website then to Ignition System Setup Tutorial or contact BigStuff3 o Make sure your pulses per rev in the Operating Configuration table is correct for your application For example a four 4 magnet MSD crank trigger setup should have a value of 4 An LSI engine should have 24 a Ford Mod Motor should have 36 and LS2 7 should have 60 o For LSx COP engines make sure the cam synch override box is not checked The Ford Mod Motor COP system must have the Override Cam Sync Test box checked e How can I check if my cam sensor input is setup correctly o From the main BigComm tool bar go to the Individual Cylinder them Individual Spark table In the cell for cylinder 1 type in the number 10 this represents 10 of spark retard for cylinder number 1 With a timing light check cylinder 1 timing It should be 10 less than the other cylinders at
17. 2011 52 BigStuff3 Pro SEFI System At a given voltage the minimum pulse width required to open an injector will vary based on injector size injector type and manufacturer This input screen allows the user the ability to fine tune flow rates injector opening time based on battery voltage 23 Injector Phase Angle Injector Phase Angle setting allows the ECU to time the fuel delivery relative to the intake valve opening Note The main wire harness cam connector cam sync must be hooked up for the injector Phase Angle and Individual cylinder spark control functions to work To calculate the actual Start of Injection SOD use the following formula SOI Injector Phase Table Value from Injector Phase Table below Crank Reference Value Crank _Trigger_Configuration Injection Point point where injector will begin introducing fuel The major benefit of this feature is realized when using high flow injectors with a smaller duty cycle Note The RPM values at the bottom of the table are from the Load vs RPM Axis drop down accessible from the Configuration tab from the Main Menu screen x BigComm Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Logging Replay wie Ea Dealer Factory PC Windows Help hee Opaning eee i TA Iffline C Program Files BigStuff BigComm Leo s C167Vette bi Firing Order IO Status Load vs RPM Axis Hardware Config
18. 5 OK Cancel e Why does the following file error screen appear error eee xi file error occurred efault dsh File is missing or corrupt Would you like to save a new default dash File now to Fix this Each default dash created must be saved in the same BigComm folder or BigComm sub folder that the calibration being used is saved in Version 2 1 February 2011 128 BigStuff3 Pro SEFI System 2 2 Save ire So Biglorri d E EE i GJ My Documents 4 My Computer z IBM_PRELOAD C After changing a 3 Prograrn Files Dash s BigStutt omen configuration ua DVD CD RW Drive ID make sure to 9 Shared Documents immediately save a A a i it The Dash must be saved in the BigComm folder or a sub folder that the calibration is saved in Subfolders inside the TC _Bigcomm BigComm Ej Default dsh folder File name Default dsh Save as type Dash File Cancel a e I cannot see 100 of the BigComm tables What should I do e Make sure the screen is set to 96 dpi as shown below Go to Windows Control Panel Version 2 1 February 2011 129 BigStuff3 Pro SEFI System E Control Panel gt O p Esh Foes Fi Address F Corral Paral 7 ie Control Pane 5 j Dis Properties See Also ip i 3 Aa Weds f L Color Management EN IrtetA Graphacs Media Accelerator Diver Genet Adapter Montor Troubleshoot 3 Dhiaplay
19. 500 1 800 2 000 2 400 2 800 L 3 600 4 000 5 000 6 000 7 000 RPM nm nm N S gt gt N N N e 0 0 27 8 27 8 Sefeti Nef The BigComm software allows the user to configure the Load MAP and RPM axes allowing for a larger number of cells map area to be used for the fuel and spark tables 32 FUEL F3 Quick Key There are several ways to access the base Fuel table The quickest methods are to hit the F3 key or left mouse click on the Fuel Table icon accessible from the main BigComm Screen Version 2 1 February 2011 65 BigStuff3 Pro SEFI System The Main Tool Bar can also be used to access the Fuel table From the Main BigComm software screen tool bar left click on Fuel and the drop down screen will open BigComm j ca 5 x File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting MAGE WarmUp Dash Logging Configuration PC Windows Help e Ctrl F Fuel table drop down screen accessed from the Main Tool Bar Fuel Table Icon Using the PC s mouse keep the left mouse button depressed and slide the mouse pointer down until Fuel Table is highlighted Release the left mouse button The screen below will open 33 Fuel Table BO BBS tnt MAP KPa 106 The ellipse will move throughout the Fuel table relative to the current RPM amp Load operating point 600 800 1000 1111 1200 1500 1800 2000 2400 2800
20. 8 18 10_Replay002 File name Files of type Replay Files Replay CS Cancel EXTENED REPLAY FIRMWARE IMPORTANT NOTICE Please read carefully if your GEN3 system is being upgraded to the any of the following optional systems This section does not apply if the GEN3 system was originally purchased with any of these optional systems SR2 SR2 with ETM NTK WBO2 for methanol CAN EGT Prior to the above mentioned upgrades the GEN3 ECU was configured with Original Replay internal data logging capability it recorded for up to eighteen seconds The system upgrades mentioned above include the Extended Replay functionality which increases the number signals that can be recorded and increases the record time up to five 5 minutes based on the sample rate selected The Extended Replay firmware requires that a new folder be created inside of the BigComm folder so that the internal data logging or Replay functionality is not affected First create a new folder inside of the BigComm folder and name it SR2_BigComm so that the file hierarchy is C ProgramFiles BigStuff BigComm SR2_BigComm Next save and then unzip the latest BigComm software from the BigStuff3 website into the new SR2_BigComm file folder Lastly and most importantly connect your PC to the GEN3 ECU and immediately save the calibration from the BS3 GEN3 ECU into the new SR2_BigComm folder This calibration must be used as your
21. BigComm folder If the PC does not automatically take you to the BigComm folder navigate to C Program STUFF Version 2 1 February 2011 36 BigStuff3 Pro SEFI System Files BigStuff BigComm Double left click on the calibration to be used for off line modifications and the calibration will be loaded After the calibration is loaded the Main BigComm window will open lt Bigcomm aag Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Windows Help saii IKIE EESE owt Open Calibration File Look in BigComm v c Eg 3 TK_SC_383 big File name Files of ype big Cancel G 12 Establishing a Connection The sequence for connecting the GEN3 ECU to the Main Wire Harness is as follows e First connect battery terminals e With the ignition switched off connect the 30 way header connector with terminals A K to the ECU e After terminals A K are connected to the ECU connect the header connector with terminals L Y This assembly sequence should preserve the firmware and initial calibration that was loaded in at the factory Assuming that the system wire harnesses ECU and software are all installed and connected correctly the next step is to establish communication between the PC and BigStuff3 GEN3 ECU Double check to make sure the communication cable connections between the PC and to the GEN3 ECU is
22. Fuel Map pulse width is re enabled It is used to calibrate deceleration drivability Typically the DCFO Off value is set to 5 kPa above the DCFO On value For example if the DCFO On value is set to 30 kPa the DCEO Off value should be set to 35 kPa Once the MAP value exceeds 35 kPa the Base Fuel Map pulse width is turned back on The third and final entry of the MAP Parameter Configuration table is Acceleration Enrichment AE Temperature It is used to disable the affect of the Run Time Correction multiplicative scalar value has on the Positive MAP Correction and dTPS Transient fuel values relative to an engine coolant temperature deg F Below is a brief description of the AE Temperature Run Temperature setting Run Temperature Establishes the engine coolant temperature in deg F at which the Run Time Correction multiplicative scalar term no longer influences the Positive MAP Correction or TPS Transient fuel values Therefore if the Run Temperature value is set to 120 F the Run Time Correction multiplicative scalar term will no longer influence the Positive MAP Correction or TPS Transient fuel values at engine coolant temperatures above 120 F To change a value in these tables move the cursor using the PC s mouse or arrow keys to the cell to be changed and input the desired value Then click on OK to save the changes TPS Transient Fuel The TPS transient fuel control is comprised of 2 primary tables Each of the table s
23. Loop Boost Parameters Minimum RP 2000 RPM Mininum TPS 50 0 A StageiTime 5 sec Sisee 2 Tma o A Pw Boost Reference 3 5 pe Stage 3 Timer sec Spark Retard Mode Boost Mode f 3 Stg Boost f st Gear fe Staged C Put 1st Gear Axis Units Time C RPM Ist Gear Timer OverFide oo Sec 1st Gear Closed Loop Parameters Blend Rate Counts Proportional Gain oO High Gear Atd Delay oo eC Derivative Gain oO High Gear Rtd 0 00 Deg Integral Gain bt OF Help Close Version 2 1 February 2011 93 BigStuff3 3 Stage Boost Solenoid Wiring Timer Enable Wire from Relay Boost Connector from Main N Wire Harness 12V Switched kai es ae Battery Ground Ground plousjos soog SNOJUN OM piou jos Ss0O0g SNOJUN OM plousjos soog SNOJUN OM BigStuff3 Pro SEFI System Boost Spark Tables 1 2 amp 3 The Boost spark tables allow the user to set the spark retard degrees timing as a function of RPM for each stage The retard timing for each stage is not additive In other words when the second stage comes on it replaces the timing values of the first stage and when the third stage comes on it replaces the timing values of the first and second stage wi as a Offline 8 18 10 Testing big lt 1st Stage Boost Spark Table Retard deg 600 800 1000 1111 1200 1500 1800 2000 2600 3200 3750 4200 4800 5400 6000 6500 Time sec To change a value in the Stage 1 Boo
24. Personalization Personalization Window Color and Appearance What do I need to do to make sure my 3 step works correctly assumes your system 1s configured with the optional 2 Step and 3 Step o 12V must be applied to the DAE wire Hdr 2 wire Y2 o Apply 12V to the 2 step wire Hdr 1 wire B2 via a line lock manual trans foot brake or trans brake switch o With your foot still on the brake assuming the foot brake switch is used to invoke the 2 step Apply 12V to the 3 step wire Hdr 2 wire W1 turbo speed wire in the DAE harness 12V is must be applied to this wire the moment the trans brake is activated o Lastly if you are planning to activate a traction control staged timing retard or turn on boost or nitrous solenoids in a timed sequence 12V must be applied to the Timer enable the instant the trans brake is released See Three_Step_Relay_Wiring above Version 2 1 February 2011 126 BigStuff3 Pro SEFI System e Ido not think my injectors are pulsing What can I check o Make sure the BS3 and MSD systems are grounded directly to the battery o Plug a noid light into each injector position in the injector wire harness Turn the engine over and see if the light pulses for each injector location e Ido not think my COP coils are firing What can I check o Make sure the BS3 main wire harness ground is wired directly to the battery o Make sure the coil ground wire is grounded to the engine block or cylinder head No
25. Shift key Depress the Page Up key to increase the cell values and the Page Down key to decrease the cell values The cell values will increase or decrease by a value of one 1 for every keystroke To exit this mode depress any one of the arrow keys Once complete the new calibration can be saved and then loaded into the ECU Note See Save_Calibration to ensure calibration changes made On Line are properly saved Version 2 1 February 2011 115 BigStuff3 Pro SEFI System 81 Loading and Saving Calibration Files Calibration files can be saved to a file folder or loaded from an existing file in one of two ways In off line mode a calibration file can be saved to the PC so changes can be made off line and saved to a disc the hard drive or flopping disc In on line mode calibration changes are made and sent directly to the GEN3 ECU while the ECU is live 82 Save Calibration F12 Quick Key To save a calibration file go to File on the Tool Bar Left click on File The following drop down will appear While holding the left mouse button down drag the mouse down until Save Calibration is highlighted Release the mouse button Alternatively hit the F12 Quick Key x BigComm mie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Load Calibration pip m 22 erento EE The following scree
26. Starting Fuel WarmUp Dash Logging Configuration PC Windows Help E S Iffine C Program Files BigStuff BigComm Leo s C167Vette bi Enter a filename Save in BigComm ek g Help feo Default dsh E dtps dt dsh E Learn Dash dsh E Log Window dsh fj MAP AE Decay dsh File name ID efault Save as type D ash File Cancel 88 ECU Header Connector Pin outs Specific header connector pin out detail for the various GEN3 Systems and available options can be found on the BigStuff3 website at www BigStuff3 com Under the How To Help section e Base System Main Wire Harness http bigstuff3 com pdf JMI 006 014 CC_REV_F_GEN3_PRO_SEFI BASE_MWH pdf Version 2 1 February 2011 122 BigStuff3 Pro SEFI System GM LS1 24x crank wheel System Main Wire Harness http bigstuff3 com pdt JMI 006 016 CC_REV_B_GEN3_ PRO _SEFI_LS1_ MWH pdf Ford Modular Motor Main Wire Harness http bigstuff3 com pdf JMI 006 03 CC_REV_C_GEN3_PRO_SEFI_MOD MWH pdf GM LS7 58x crank wheel Main Wire Harness http bigstuff3 com pdtf JMI 006 034 CC_REV_B_GEN3_PRO_SEFI_LS7_MWH pdf The following additional system wire harnesses are also available in How To Help section DAE System Wire Harness 16 Injector System Wire Harness 24 Injector System Wire Harness NTK WBO2 for Methanol System Wire Harness GM Transmission System Wire Harness Injector Wire Harnesses for GM Chrysler Ford Buick applicatio
27. and top right corners of the entire range and interpolate the numbers in between so that the values are linear Range of Cell Values Selected e Cancel Hit cancel to disregard making any changes The illustration below shows the areas of the Spark map that the ECU accesses under different driving conditions j E oe Version 2 1 February 2011 64 BigStuff3 Pro SEFI System Cell Changes using the Page Up amp Page Down Keys Fuel and Spark Tables Multiple cell values can also be changed simultaneously using the Page Up and Page Down keys This approach offers a quick alternative to using the mouse Use the keyboard arrow keys up down left right to maneuver to area of the map where the desired cell changes will be made Next depress and hold the keyboard Shift key Now use the arrow keys to maneuver through the cells to be changed As the cells are being selected they will become highlighted Once the desired cell range has been highlighted release the Shift key Depress the Page Up key to increase the cell values and the Page Down key to decrease the cell values The cell values will increase or decrease by a value of one 1 for every keystroke To exit this mode depress any one of the arrow keys MAP Kpa Engine Load 7 FIRE 150 N 125 111 100 90 81 70 64 60 56 50 3 35 39 40 40 fo Pe 28 rs Ls e fa AEON o 800 1 000 1 150 1 200 1
28. bar and left click on File as shown below A drop down screen will open Left click on Set Default Calibration i BigComm mi Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Logging Load Calibration sip Save Calibration S as Offline C Program Files BigS tuff BigComm NewdMAP_O1 big Set Default Calibratio Exit Set Default Calibration The following screen will open Select Yes to save the default E Set Default Calibration x WARNING THE MOTOR MUST NOT BE RUNNING DURING THIS UPDATE Please turn Ignition OFF 4nd then back ON now Would you Like to Set the Default Calibration No fm Base Gen3 Manual tay GEN3 manual_Ver BigComm Lb Bry Dye tM 9 34PM The following screen will open indicating that a delay worst case 30 seconds typically less than 2 seconds is required to set the default calibration i E oe Version 2 1 February 2011 117 BigStuff3 Pro SEFI System wx File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Logging Configuration PC Windows Help b 9 Bm SE Jffline C Program Files BigStuff BiglommsMB_ST_383_65 5 28 04 bi Calibration Will be Updated Please Wait 30 Seconds Before Restarting 83 Load a Calibration To load a calibration file previously saved to the PC s hard drive or ex
29. baseline moving forward Previously created calibrations must not be used or the Replay functionality will be affected If old non Extended Replay calibrations are loaded into the ECU the new extended replay capability will be wiped out The ECU may need to be sent to back to BigStuff3 to be reconfigured Call BigStuff3 if this situation occurs See the screen prints below for the file setup details Version 2 1 February 2011 111 BigStuff3 Pro SEFI System Program Files File Edit View Favorites Tools Help pack T pi a Search B Folders ddress B C Program Files HEE Folde x Mame Size Type Date Modified El Se 05 C a 985E8ME File Folder 9 1 2009 8 51 AM _AcroTemp E Adobe File Folder 6 30 2009 a40 OM E Config Msi D Analog Devices File Folder 3 25 2009 2 10 AM E DELL E da Folder 6 9 2009 8 43 AM 5 Documents and Settings First at the C Program Files per 1 15 2010 9 25 AM O drivers BigStuff BigComm create a new folder ay Renn een ed326860720d63da6cd904f74105 inside the BisComm folder and name it ler 5 1 2009 7 23 AM i 1386 8 Her 4 24 2009 10 49 AM SR2_BigComm Save the zip file from BS3 Website or email attachment into the jer s 21 2009 9 51 AM jer 4 25 2008 4 27 PM E MsaCache program Files SS Syvssesr SR2_BigComm folder ee eA oem E Adobe gt dder 5 1 2009 5 17 PM E Ge analog Devices QD IFX File Folder 5 19 2009 9 40 AM gt
30. control the engine idle speed The amount of air needed to maintain a desired engine speed varies depending on engine coolant temperature camshaft overlap etc The Idle Airspeed Control IAC motor and plunger control the amount of air allowed to be bypassed around the throttle blades The Throttle Follower table allows the user to set a relationship between throttle blade angle and the position of the IAC metering valve plunger This is required to keep the engine from stalling when the throttle position changes from some percent open to fully closed very quickly The fixed values along the bottom of the table below represent the percent throttle position which increase in increments of eight 8 percent The input values above the fixed numbers are used by the ECU to position the IAC metering valve plunger inside the bypass channel The position of the metering valve plunger will vary depending on throttle position The default values configured with the system as shipped will work with a majority of engine applications While the engine is running a real time Ellipse will move within the Throttle Follower Table relative to the current TPS operating point Use it as a point of reference to help calibrate the Throttle Follower table To change a value in the Throttle Follower table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to
31. cylinder will also not function without the cam sync hooked up The 3 8 ring terminal must be fastened to a secure ground location preferably on the engine block near the Cam sensor The main wire harness side Packard connector must be connected to the sensor The system is supplied with the sensor side mating connector terminal and seals which needs to be configured per the table below BS3 2 Way Gray Cam Connector MSD Synch Pulse A Red A Green B Black B Purple Back to Cam H20 Black 2 way Packard connector This connector mates with a GM only coolant temperature sensor Back_to_Coolant_Temperature Air Gray 2 way Packard connector This connector mates with a GM only air temperature sensor Back _to_Air Temp F IAC Idle Air Control Black 4 way Packard connector The base main harness IAC connector was designed to work with a GM style IAC motor and valve assembly with a 2 by 2 connector If a GM style IAC motor and valve assembly with a 1 by 4 in line connector is the factory installed IAC the 2 by 2 connector can be removed and replaced with a 4 by 1 in line connector per the pin out table below The 1 by 4 connector is available from BigStuff3 The LS1 LS7 Ford Mod Motor systems main harness AC connector is a 1x4 GM style IAC motor connector Version 2 1 February 2011 19 BigStuff3 Pro SEFI System BS3 2 by 2 IAC Connector Pin ou
32. engine is cranking so that when the engine starts the idle speed can be quickly reached and maintained The position values shown in the table below can be used as a baseline for most applications You can see from the large values in the table that when the coolant temperature is cold the IAC seeks a position in the direction of the fully open position position number 180 As the engine reaches normal operating temperature the IAC finds the position that allows the engine to idle at the user prescribed Desired idle speed While the engine is running a real time Ellipse will move within the IAC Start Position table relative to the current engine Coolant Temperature operating point Use it as a point of reference to help calibrate the IAC Start Position table To change a value in the IAC Start Position table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change Version 2 1 February 2011 75 BigStuff3 Pro SEFI System lt IAC Start Position Table IAC Position 170 1165 160 100 75 40 30 55 4 779 102 125 169 230 Coolant F 44 IAC Gain Terms This input table allows the user to set how quickly the AC motor moves in or out in a given period of time Use the default settings that come with the ECU unless it becomes necessary to control the IAC motor speed The Proportional Gain setting should be from 4
33. interpolate the numbers in between so that the values are linear Range of Cell Values Selected e Cancel Hit cancel to disregard making any changes Example Air Fuel Ratio Tables Example air fuel ratio tables for a normally aspirated street engine a super charged engine and a turbocharged engine are shown below The air fuel ratio values in these cells can be used as base lines for each of the engine configurations The Example Maps below are segmented into engine operating areas Cruise Idle Wide Open Throttle etc to help the user understand what part of the map 1s active under different driving conditions engine speed and load combinations Version 2 1 February 2011 57 BigStuff3 Pro SEFI System Normally Aspirated Street Engine ioa prea prer pea ea er i y M 35 as ies 13s es Ea e se FES RE oro or ore LOAD gg fs sr er er erie er sr er er La mpo paalia a oslas ae a s fres as res rer er vr rer ar er or er or oe rs es fs er or sil er or er vr er oe Per or 800 1 000 1 100 1 200 1 500 1 800 2 400 2 800 3 000 3 500 4 000 4 500 5 200 5 500 6 000 RPM Super Charged Engine 15 PSD wwe e pe pe oe Dos Died ag ne va va ve vw i 744 75 11 75 11 75 11 75 11 75 11 75 Wills Open joe 11 75 11 75 11 75 11 75 ME pEE0O00OCCOCCLLA A e e e e e e e e e e e e e ale tS ad CN CCRC ThE ee Se wer oar er var er ve Peal oer ver Per ver ver
34. into the set up table For example Idle Spark control will not function if the Max TPS for Idle value inputted into the OPerating Configuration table is set to 4 and the actual TPS is 5 with the throttle blade completely closed Idle Spark control will function if the actual throttle position TPS is 2 and the Max TPS for Idle value is set at 4 In this case Idle Spark control would function until the throttle blade was opened above 4 Back to TPS Configuration The fixed values below the table are the ECU s reference points for how many RPM the engine is operating at above or below the Desired RPM The fixed values define the active control RPM range The active range is from 256 RPM below the Desired RPM to 224 RPM above the Desired RPM The bi directional input table allows the user to quickly advance the timing left side of the input table when the RPM begins falling below the Desired RPM setting Once the timing 1s advanced it needs to be retarded right side of the input table as the engine RPM begins increasing The zero point in the table is equal to the user defined Desired RPM STUFF Version 2 1 February 2011 74 BigStuff3 Pro SEFI System While the engine is running a real time Ellipse will move within the Idle Spark table relative to the current RPM Delta operating point Use the ellipse as a point of reference to help calibrate th
35. is AE Position Correction It can be compared to a carburetor s accelerator pump cam profile The ECU uses the AE Position Correction table value to modify the size of the Asynchronous Pulse Width APW relative to the throttle position at which the dTPSdt event occurred For example if a 10 second dTPSdt event occurred resulting in a look up of STUFF Version 2 1 February 2011 87 BigStuff3 Pro SEFI System 2 0 ms at a 24 throttle position the ECU would immediately look up the corresponding AE Position correction value of let s say 13 The ECU will then decrease the 2 0 ms pulse by 13 and output a 1 74 ms pulse If the same 10 second dTPSdt event occurred at a 48 throttle position and the corresponding AE Position Correction value was 31 the APW would then be 2 0 ms 31 or 1 38 ms While the engine is running a real time Ellipse will move within the AE Position Correction table relative to the current TPS operating point Use it as a point of reference to help calibrate the AE Position Correction table To change a value in the AE Position Correction table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The greater the TPS the larger the AE Position Correction table value needs to be The inputs shown in the table below can be used as a baseline c AE Position Correction Table AE Position Co
36. milliseconds ms as long as the throttle is moving The ECU will increase or decrease the base pulse width relative to the MAP Correction table s correction value 1 e 100 Changes in MAP need to be compensated for by increasing or decreasing fuel synchronously to the base fuel pulse width Each cell in the input table represents eight 8 kPa increments While the engine is running a real time Ellipse will move within the Power Valve Fuel table relative to the current Correction operating point Use it as a point of reference to help calibrate the Power Valve Fuel table To change a value in the Power Valve Fuel table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change s_s lt Power Valve Fuel Table dMAP Correction EOR 44 34 25 16 9 3 0 75 141 162 162 172 172 i 8 6 4 2 0 2 4 6 8 10 12 14 14 12 10 16 kPa 50 MAP RPM Modifier F10 Quick Key The second table used to calibrate the MAP Transient Fuel is the MAP RPM Modifier table Inputs to the table are used to increase or decrease the MAP correction as a function of engine RPM The positive or negative value inputted into the table is the percent applied to the MAP Correction table relative to the RPM see below While the engine is running a real time Ellipse will move within the MAP RPM Modifier table rel
37. pulses per rev e Crankshaft Pulse rev Input options o 2 pulses per rev 4 cylinder engine Assumes either a two 2 magnet crank trigger wheel or four 4 reluctor distributor o 3 pulses per rev 6 cylinder engine Assumes either a two 3 magnet crank trigger wheel or four 6 reluctor distributor o 4 pulses per rev 8 cylinder engine Assumes either a two 4 magnet crank trigger wheel or four 8 reluctor distributor o 24 pulses per rev 8 cylinder GM LSI and HEMI COP engines o 36 36 1 crank wheel pulses per rev 8 cylinder Ford Modular Motor COP engine o 60 60 2 crank wheel pulses per rev 8 cylinder GM LS1 engine For more information on ignition system setups go to the BigStuff3 website and then Ignition System Setup Tutorial The link is http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf STUFF Version 2 1 February 2011 47 BigStuff3 Pro SEFI System e Input Shaft Pulse rev Assumes GENS system is equipped with the DAE option Input options 1 2 4 or 31 pulses per rev No input required unless the GEN3 system is equipped with the DAE option Call BigStuff3 for more details e Turbo Shaft Pulse rev Assumes GEN3 system is equipped with the DAE option Input options pulse per rev The turbo must have a tooth provisioned into the turbine shaft for this to work Return_to_Pickup_Wheels 19 Dwell Time Table for coil on plug systems only The dwell time affects th
38. s internal data logging eliminates the need for a PC in the car Logging files and Replay files are automatically saved to the BigComm folder Logging files are saved with a csv suffix Replay files are saved with a csv replay suffix When you look at the BigComm folder using Windows Explorer you can see both file types When using the Replay function and want to view a Replay file the only files shown will be Replay csv replay files When using the Logging function and want to view a Log file the only files shown will be Log csv files Logging vs Replay Logging A very basic data acquisition system that requires all data to be recorded to an external source thus requiring a PC in the car Only base system engine operating parameters can be recorded The more parameters selected to be recorded the slower the sample transfer rate Also only the parameters selected to be recorded are saved for future reference The Logging feature is often used and very useful for dyno tuning Replay The GEN3 Replay system 200 upgrade is an advanced data acquisition system that records all engine and vehicle operating parameters internal into the GEN3 ECU No PC 1s required in the car All base system operating parameters and any engine vehicle operating parameters that are part of GEN3 system upgrades are also recorded The GEN3 ECU has 128k of on board RAM for internal data logging up to 52 user selectable channels twenty two 2
39. save the change Version 2 1 February 2011 73 BigStuff3 Pro SEFI System 41 Desired Idle RPM The Desired Idle Rpm table allows the user to set the desired engine RPM as a function of coolant temperature To configure the table input the desired engine RPM for the each temperature shown at the bottom of the table The ECU controls the idle speed so transitions between temperature ranges are not noticeable Note The TPS needs to be set properly for this input to function properly See TPS Configuration for further assistance While the engine is running a real time Ellipse will move within the Desired Idle Rpm Table relative to the current engine coolant temperature operating point Use it as a point of reference to help calibrate the Desired Idle Rpm table To change a value in the Desired Idle Rpm table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change lt Desired Idle RPM Table Desired RPM 1200 1000 850 720 Coolant F 0x00 Coolant 14 8F RPM 0 42 Idle Spark The Idle Spark control function helps maintain idle quality by introducing bi directional spark timing as an additional control variable This is a very useful idle control function Note Idle spark control is only active when the actual throttle position the TPS value shown in the dash is below the Max TPS for Idle value inputted
40. sensor on after the engine is started e What caused my O2 sensor to fail e Being dropped e Running leaded fuel STUFF Version 2 1 February 2011 127 BigStuff3 Pro SEFI System e Running rich at idle e A combination of the above items e Is there anything special about using the BigStuff3 GEN3 system with the three 3 valve Ford Modular Motor o Yes these engines have three 3 cam interrupt ribs You must find the rib that lines up with cylinder 1 TDC and then modify remove the other two ribs so that they do not send cam pulses to the ECU e I already have DAE and want to add the ETM with 3 step option What wire in my DAE harness do I use for the 3 step enable o The Turbo Shaft Speed wire becomes the 3 step enable wire e Can BS3 activate a transmission air shifter o Yes BigStuff3 offers an optional transmission auto shift feature The system will shift up to five 5 speeds with independent shift RPM and Hysteresis points see screen print below Once the system is configured for the auto shift feature a wire from ECU Header 2 location M2 must be run to the ground side of the shift solenoid The shift solenoid coil must be 70 Ohms amp Auto Shifter Configuration Auto Shifter WOT 1 gt 2 Shift 12750 RPM Hysteresis 12750 RPM WOT 2 gt 3 Shift 12750 RPM Hysteresis 112750 RPM WOT 3 gt 4 Shift 112750 RPM Hysteresis 112750 RPM WOT 4 gt 5 Shift 12750 APM 12750 RPH Hysteresis Gears
41. test 1s complete although the Test Timing value becomes invalid once the TPS exceeds the Clear Flood TPS for safety reasons in case it is accidentally not disabled Note The RPM values at the bottom of the dwell time input table are established when the Load vs RPM Axis table is configured Note If the fuel map VE values around peak torque are above 125 there is a good chance the injector flow rates inputted into the Operating Configuration Fueling Parameters table are too low The opposite can also be true If the VE values near peak torque are below 80 there is a good chance the injector flow rates inputted into the Operating Configuration Fueling Parameters table are too high Note Be sure the ECU is properly configured and the Base Fuel and Spark Tables are calibrated before configuring and calibrating any of the following engine operating parameters Note If the throttle is opened to position greater than what was set in the Clear Flood TPS setting the ECU will not add fuel Note Idle spark control is only active when the actual throttle position the TPS value shown in the dash is below the Max TPS for Idle value inputted into TPS the set up cell Note A cam input cam sync Is required for individual spark control and injector phasing to be operational Without a cam sync the GEN3 system still injects fuel sequentially and allows for individual fuel control per cylinder All coil on plug systems must have the c
42. that RPM e What are the steps I need to take to make sure three 3 stage timing retard boost control functions correctly o There must be a value in each of the three timer cells o Each value for the three boost stages must be higher than the prior stage o The DAE trigger wire must have 12V applied to it Abate Version 2 1 February 2011 125 BigStuff3 Pro SEFI System o The Timer Enable wire must be used o If there is a zero 0 timing retard value in any of the cells in the 3 timing retard tables the ECU will automatically revert to the base timing map Can I use my three 3 stage Boost control feature to just retard the timing o Yes but the criteria directly above must be met I can t get my LSx engine started I m using an LS2 sensor in the front of the engine o Swap pins A amp Cin the cam input connector around o Inthe Operating Configuration table make sure you have correct pulses rev value inputted for your engine LS1 engines have 24 LS2 7 engine have 60 Check with your engine builder to be sure My TPS sensor reads 100 when the throttle is closed and 0 when the throttle is fully opened o Swap the wires A amp C in the TPS connector The engine may not start since the ECU senses that the Clear flood Mode has been invoked When I look at my replay it shows timing values different from what is in my spark map How can this be o There may be values in the Boost timing retard tables If th
43. the Crank Reference for Coil on Plug Engines not distributor based engines Crank Reference deg A good Crank Reference starting point value by engine type is as follows e GM LSx and Chrysler Hemi engines 350 e Ford Mod Motors 329 Start by inputting the Crank Reference starting point value from above into the COP Crank Reference cell see screen print below With the engine RPM above 2 500 RPM use a timing light to confirm that the spark advance value displayed in the Dash window see below exactly matches the value shown on the crank dampener If they do not match change the value move the number up or down in the Crank Reference cell until the value in the Dash window exactly matches the crank value on the dampener you see with the timing light Me Operating Parameter Configuration Ox TFS May TRS for Idle a o Clear Flood TPS feo Drivetrain Rear Gear Ratio rr1 3 44 Tire Diameter iri 25 0 Crank Trigge Crank reference deg 48 0 Inductive Delay uS fi a Crankshaft Pulses rev for COP Engines For the LSI COP engine the value must be 24 For the LS2 and LS7 COP engines Rev Limi Static Test Timing Pickup Wheel h be 60 Th ae P the value must be OU e Rev Limit On RPM 2300 Test Timing deg 20 00 Driveshaft Pulse rev fao o Ford Mod Motor COP Rev Limit Off RPM far un Enable Test Liming f engine the value must be 36 2 step A
44. the boost timing sequence Minimum Throttle Position Sensor TPS This input establishes the minimum throttle position the TPS sensor must reach to initiate the boost timing sequence Both the Minimum RPM and Minimum Throttle Position inputs must be satisfied before the boost timing is initiated 62 Boost PWM Before this table becomes active PWM needs to be selected in the Boost mode window of the boost configuration table The values inputted into the PWM window below represent the percent duty cycle of the boost valve The PWM boost function will run continuously when this mode is enabled The solenoid valve used must be a Normally Closed NC valve The valve is T d into the line from the turbo compressor to the bottom of the waste gate diaphragm The solenoid valve resistance must not be lower than 14 ohms w 14 volt supply 1 A One end of the solenoid valve is connected to Switched Ignition and the other to the Boost Connector Pin B See Boost_Connector_Pin_Out b 9 ns w Boost PWM Table Duty Cycle Offline 7 8 18 10 Testing big 2 g 38 44 50 56 600 00 1000 1111 1200 1500 1600 2000 2600 3200 370 4200 4600 5400 6000 6500 RPM Same as screen above with window maximized 22 SE cr Altres a 1 rae Duty Cycle 600 800 1000171111120015001800200024002800320036004000500055006000 To change a value in the Boost PWM table move the cursor using the PC s mouse or arrow keys to
45. to 16 The Derivative Gain should be 4 to of the Proportional Gain Enter the desired value in the table and left mouse click OK to save the information X IAC Gain Term Configurati Oj x IAC Proportional Gain 16 Derivative Gain 8 Close See Throttle Follower amp Idle Spark Table Setup Tips section directly below for more information on how to use the Idle Spark control in combination with the IAC Start Position to improve overall idle control Throttle Follower amp Idle Spark Table Setup Tips This brief tutorial will outline how to set the IAC Throttle Follower and Idle Spark tables to ensure engine idle stability under various engine operating conditions Setup Steps 1 Run the engine until it reaches its normal operating temperature 2 Hook up the PC to the GEN3 ECU and make sure communication is established 3 Zero out the Idle spark calibration From the main BigComm tool bar go to Idle then Idle Spark in the drop down menu 4 The following process steps are iterative The goal is to decrease the ignition timing in the spark map while opening the throttle blade to maintain the desired engine rpm When the timing in the spark map is decreased the engine RPM will also decrease below the desired level To offset the drop in engine speed the throttle blade set screw will need to be adjusted to increase the engine RPM back to the desired level The task is to get the spark timin
46. 1 February 2011 31 BigStuff3 Pro SEFI System To create a link on your desktop and in the short cut tool bar in the lower right hand corner of the PC s desktop put a check box next to both the Create a desktop icon and Create a Quick Launch icon as shown in the screen print below then double click Next ie Setup BigComm Select Additional Tasks Which additional tasks should be performed Select the additional tasks you would like Setup to perform while installing BigComm then click Next Additional icons Create a desktop icon Create a Quick Launch icon Next double click Install Eat Yew poet Format Jos Taie Window Help Adete POF Acrobat Comments ie Setup BigComm Ready to Install Setup is now ready to begin installing BigComm on your computer Click Install to continue with the installation or click Back if pou want to review or change any settings Destination location C Program Files BigS tuff Biglomm Start Menu folder BigComm Additional tasks Additional icons Create a desktop icon Create a Quick Launch icon The software will self install on your PC as shown below Version 2 1 February 2011 32 BigStuff3 Pro SEFI System ie Setup BigComm Installing Please wait while Setup installs BigComm on your computer Extracting files C Program Files BigStuff BigComm BigComm exe Cancel Lastly if you want to open software
47. 11 12 Primary Fuel Pump LS Relay Wiring Diagram Standard 40 Amp relay i o je lt Switched 12 Volt Battery 3 Em a 8 a LO Vehicle Chassis so 5 Ground oD Black White wire z from BS3 harness labeled Primary Fuel Pump LS Battery or Vehicle Chassis Fuel Pump Ground Secondary Fuel Pump HS Relay Wiring Diagram Standard 40 Amp relay Red White wire from BS3 harness labeled Secondary Fuel Pump HS B O Battery or Vehicle Chassis Ground Battery or Vehicle Chassis Ground Battery Vehicle Fuel Pump Chassis Ground BigStuff3 Pro SEFI System Fan Control engine cooling fan Single lead Packard connector with a single black with red stripe wire sy i S gh This termination must go to the negative side of a fan relay not directly to the fan Terminating this connection directly to a fan will damage the BigStuff controller and will void the warranty The fan connector is identical to the fuel pump connectors so make sure to read the label to ensure the connector is terminated correctly Wire the fan relay per the diagram below This diagram 1s also available on the Bigstuf
48. 2 16 bit channels amp thirty 30 8 bit channels with 10 bit resolution The system operated at a 50Hz acquisition rate or 20 times per second Understanding that it takes about 150 milliseconds to slam the throttle to the flow a 50Hz acquisition rate is pretty good All of the data recorded is available for future reference 71 Logging External This section titled Logging describes the external data logging feature The internal data logging feature titled Replay is described in the following chapter The BigComm software allows the user to log data while the engine is running The data is captured by an external PC during the logging event and can be subsequently reviewed On Line connected to the ECU or Off Line PC only Note The Dash for the Log Window needs to be configured so that all of the logged data is captured and displayed in the Dash at the bottom of the Log window Refer to the Dash Logging procedure outlined at end of the Logging section Also see Dashboard for information on how to configure other Dashes From the tool bar on Main Menu screen left click on Logging The drop down screen below will open STUFF Version 2 1 February 2011 101 BigStuff3 Pro SEFI System lt BigComm eo Cm F x File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Configuration PC Windows Help e Ee Perehi Configure Log RecordLog Ctri L
49. 2 1 February 2011 116 BigStuff3 Pro SEFI System to the On position The ECU cannot be programmed and changes will not be saved with the ignition switch is in the Off position The best way to detect that the calibration changes have been saved from RAM to the GEN3 s Flash memory is to watch the green communication ball in the upper right corner of the BigComm software screen After the ignition switch is turned off the green sliding ball will continue to move back and forth for approximately fifteen 15 seconds After approximately fifteen 15 seconds the green ball will momentarily stop indicating that the ECU s calibration RAM has been permanently saved to the ECU s Flash memory DO NOT TURN THE IGNITION SWITCH ON OR CRANK THE ENGINE WHILE THE CALIBRATION IS BEING SAVED Notes o The ECU stays alive for thirty 30 minutes after vehicle ignition is off to allow for DAI uploads from the GEN3 ECU to a PC o The ECU cannot be programmed when the vehicle ignition is off o The Flash memory is only updated when calibrations changes are made Saving a Default Calibration Once the ECU s calibration RAM changes have been saved to the ECU s Flash memory and you are satisfied with the calibration BigStuff strongly recommends that a Default calibration be saved to the ECU to safeguard against system crashes With the engine off no engine rpm and the vehicle ignition in the On position go to the main tool
50. 20Injector 20Harness pdf Buick V6 http bigstuff3 com pdf Visio Buick 20Injector 20Harness pdf Back_to_Injector_Harness 6 Wide Band Oxygen Sensor Installation Once the main and injector harnesses are installed the Wide Band Oxygen WBOZ2 sensor needs to be installed and connected to the main harness First install the wide band sensor eee WIDE Gran een BANOO2 aaa This connector mates with Main Harness Wide Band O2 connector Main Wire Harness side connector for O2 Sensor The WBO2 sensor threads into the sensor mounting bung optional see picture below which needs to be drilled and welded into the exhaust pipe Before drilling and welding read the design guidelines below e Install mounting bung approximately 8 12 from where the primary pipes enter the exhaust collector e Make sure the mounting location selected does not allow condensation to collect directly in front of the sensor Make sure there are no depressions projections edges etc in the exhaust pipe near the sensor tip Version 2 1 February 2011 26 BigStuff3 Pro SEFI System e The mounting angle of the sensor should be tilted a minimum of 10 to the horizontal tip of the sensor The tip of the sensor must be tilted down See the diagram below The optimum sensor angle is 90 The optimal Oxygen sensor mounting Oxygen Sensor angle is bung entire circumference completely needs to be we
51. 3200 3600 4000 5000 6000 7000 RPM Inj Fuel Flow 0 lb hr Gross Inj PW 0 0mS Base Inj PW 13 6mS RPM 0 Vol Eff 100 0 Act AFR 0 0 1 BLM Corr 0 0 CLT Corr 0 0 02 Corr 0 0 AFT Corr 0 0 AIR Corr 0 0 ATM Corr 0 0 Scaled Load 0x00 Scaled RPM 0x00 TPS 0 0 Vbat 13 5V MAP 14 3kPa Note In some cases the ECU shipped with your system will come pre configured with a table that will closely match your engine configuration The Fuel table uses Volumetric Efficiency VE values in each of the 256 cells in the table Volumetric Efficiency is the measure for how efficient the engine is operating at a given engine speed and load combination The efficiency of the engine is nearly perfect at a value of 100 Volumetric Efficiency VE is highest at peak torque Note If the fuel map VE values around peak torque are above 125 there is a good chance the injector flow rates inputted into the Operating Configuration Fueling Parameters table are too low The opposite can also be true If the VE values near peak torque are below 80 there is a good chance the injector flow rates inputted into the Operating Configuration Fueling Parameters table are too high j Version 2 1 February 2011 66 BigStuff3 Pro SEFI System The Fuel table allows the user to input desired VE values for sixteen 16 engine speed RPM and sixteen 16 load MAP or TPS combinations The X axis represents engine RPM and allows
52. 5 Adobe 5 Analog Devices O Apple Software Update O BigStuff O BigComm om SR2_Milan big a BIG File 2 KB Next immediately save the calibration the file ending in big from the GEN3 ECU into the new SR2_BigComm folder DAE Data Acquisition of External BigStuff3 s Data Acquisition External DAE system is a very popular upgrade The DAE system user s manual is available on the BigStuff3 website The link to the manual is http bigstuff3 com pdt DAE 20Users 20Manual pdf Examples of key DAE parameters that can be logged via the Replay feature are as follows Version 2 1 February 2011 112 BigStuff3 Pro SEFI System e Pan Vacuum The oil pan vacuum or pressure can be logged using a GM 2 Bar MAP which will read and record the pan vacuum pressure in inches of mercury A negative number represents vacuum and a positive number represents positive pressure in the crank case e Fuel Oil and Turbo Back Pressure Using a 1 8 pipe thread 0 150 psi pressure transducer available as an option from BigStuff3 the fuel oil and turbo back pressure can be independently logged Logging the fuel the rail pressure is particularly import in boosted applications where rail pressure needs to increase with boost pressure The logged fuel pressure data provides the user important insight into whether the fuel pump s is capable of maintaining a constant fuel pressure differential during cri
53. A data logging event can be initiated by simultaneously depressing and holding the Control Ctrl and L keys on the PC s keyboard Left mouse clicking on the Take Log icon from the BigComm Main Menu screen will also start a logging event Take Log icon located on the BigComm main menu screen The ECU will log data for the time period defined in the Logger Configuration screen outlined above Once the logging event is complete the ECU automatically stores the logged event as a file using the default file name which was set up The file should be saved in the Program Files BigStuff BigComm folder If not navigate to this folder location The next time the BigComm will automatically save the logged file to this location 74 View Log from File To view a logged file go the BigComm main menu and click on the View Logged File icon View Logged File icon The following window will open Choose the desired file to view by double clicking the left mouse button on the file The logged file will open STUFF Version 2 1 February 2011 103 BigStuff3 Pro SEFI System File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help bo BB a Choose a Log File Look in BigComm 3 My Documents rz My Computer Local Disk C Program Files gt BigStuff G Shared Documents E My Documents
54. AE Decay rate table s fixed values x axis represent coolant temperature which increase from left to right The MAP AE Decay rate input values need to increase as coolant temperature increases The larger the value in the table the quicker the fuel is taken out or decayed While the engine is running a real time Ellipse will move within the MAP AE Decay rate table relative to the current engine Coolant Temperature operating point Use it as a point of reference to help calibrate the MAP AE Decay rate table Version 2 1 February 2011 83 BigStuff3 Pro SEFI System To change a value in the MAP AE Decay rate table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The inputs shown in the table below can be used as a baseline w MAP AE Decay Table MAP AE Decay Rate 8 Fi 6 J 4 14 8 33 8 55 4 77 9 102 Coolant F 52 MAP AE Inc Rate The fourth table is MAP AE Inc Rate It is used to determine how quickly to increase the Negative dMAP correction value after decelerating throttle tip out the engine at a given coolant temperature A MAP AE Inc Rate of 3 represents 3 crank interrupts per 1 step increase of the MAP Correction until it reaches zero In other words if you input the number 3 into the table after 3 crank interrupts the MAP Correction will increase 1 step This 3 interrupt for 1 step process continues until th
55. BigComm_Setup exe Publisher Unknown Publisher should only run software From publishers you trust How can I decide what software to run threats Report an unsafe download Double click on Next Version 2 1 February 2011 30 fe Setup BigComm Welcome to the BigComm Setup 2 Wizard This will install BigComm Jul 01 2010 on your computer It is recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup BigStuff3 Pro SEFI System The software will automatically install using the correct file hierarchy which is C Program Files BigStuff BigComm This file structure is required for the software to work correctly Do not change the file location or file hierarchy Click Next fe Setup BigComm Select Destination Location bay Where should BigComm be installed Setup will install BigComm into the following folder To continue click Next If you would like to select a different folder click Browse C Program Files BigStuff Bigbomm At least 14 5 MB of free disk space is required Click Next again fe Setup BigComm Select Start Menu Folder Where should Setup place the program s shortcuts al f A f Setup will create the program s shortcuts in the following Start Menu folder To continue click Next If you would like to select a different folder click Browse Version 2
56. BigStuff3 Pro SEFI System operating temperature and preferred idle speed adjust the TPS so that the TPS value shown in the Dash see screen print directly below reads between 1 to 2 The dashboard can be configured to appear at the bottom of most of the BigComm software screens An example of a dashboard is shown below See Dashboard for more details described later in this manual Inj Fuel Flow 0 lb hr Gross Inj PW 0 0mS Base Inj PW 13 6mS RPM 0 Vol Ef 100 0 Act AFR 0 0 1 BLM Corr 0 0 CLT Corr 0 0 02 Corr 0 0 AFT Corr 0 0 AR Corr 0 0 ATM Corr 0 0 Scaled Load 0x00 Scaled RPM 0x00 TPS 0 0 Vat 13 5V MAP 14 3kPa How to Set Clear Flood TPS TPS Signal in the Dash Set the Clear Flood TPS value to 80 This setting tells the ECU not to add fuel when the following conditions exist o The engine is cranking between 75 and 400 RPM o The throttle position is at 80 or greater user specified If these conditions are met the ECU does not add fuel during cranking This function is especially useful when attempting to start a flooded engine Once the fuel is cleared from the engine release the throttle to restart the engine Return_to_TPS Setup Rev Limit The Rev Limit On RPM and Rev Limit Off RPM section of the Rev Limiter Configuration table refers is focused at Engine Saver RPM control The 2 Step RPM Lo and 2 Step RPM Hi section of the Rev Limiter Configuration tabl
57. F Version 2 1 February 2011 69 BigStuff3 Pro SEFI System To configure engine starting fuel go to Starting on the Tool Bar Left click on Starting and a drop down screen will open Keep the left mouse button depressed and slide the mouse pointer down until the desired Starting fuel drop down is highlighted S Bigcomm E Mo x Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Etid Fuel WarmUp Dash Logging Configuration PC Windows Help B 9 SS EnO ee After Start Correction After Start Delay After Start Decay The sequence of events the ECU steps through during an engine start are defined in order in the next four sections as follows Cranking After Start Delay After Start Correction adding fuel After Start Decay 35 Cranking F1 Quick Key The inputs in this table are only used by the ECU when the engine is in the cranking mode lt 400 RPM The Cranking table allows the user to input the actual pulse width the injectors will operate at during engine cranking The pulse width required is a function of the engine coolant temperature The colder the engine the larger the pulse width required If the throttle needs to be opened to start the engine during Cranking the ECU is adding too much fuel Therefore a smaller injector pulse width needs to be entered into the input cell relative to the engine coolant temperature Make sure pulse width mod
58. Firing Order Table Firing Order 2 3 4 5 6 t D 1 Setting the Firing Order To set the firing order simply work from left to right and input the firing order of the engine the system is installed on The LS1 firing order 1 8 7 2 6 5 4 3 is shown in the example above There are specific injector wire harnesses for Chevy Chrysler Ford and Buick V6 engines Make sure you have correct injector wire harness type for your engine For More information on injector wire harness pin outs go to Injector_Harness 22 Injector Opening Time Next go back to Configuration on the Tool Bar Left click on the Configuration and the drop down screen will open Keep the left mouse button depressed and slide the mouse pointer down until Injector Opening Time is highlighted Release the left mouse button The screen below will open g Injector Opening Time Table Opening Time ms Battery Voltage In Open Time 0 91ms The purpose of this table is to allow the user to configure the ECU to maintain a constant injector flow rate with varying battery voltages Fuel injectors have a minimum pulse width in milliseconds required before they will open and let fuel flow For example with a constant battery voltage of 13 4V a 60 lb hr Bosch injector is not likely to open until the ECU sends a pulse width command of 1 4 to 1 5 milliseconds injector opening time is also influenced by fuel pressure Version 2 1 February
59. PM Hi 3000 2 Step REM Lo 1500 Crank reference deg Override Cam Sync Test gt Fan Contro Fuel Pump Prince Time 26 Second Pump On TPS 25 0 Fan On Temp F Fan Off Temp F f p33 A C Anticipate 15 EGT lacs O Cof On Help Close COP Crank Reference window for coil on plug applications only in the BigComm Operating Parameter Configuration Window Start with 350 360 for LSx amp Hemi engines and 329 for the Ford Mod Motor Version 2 1 February 2011 45 BigStuff3 Pro SEFI System Dash Window a0 30 az 30 fara a fu tl o7 fu T i jiu fu no no oH 114 J 49 20 al 40 I BU BU pi pi Br Bo fy 79 T 2 a lss so leo jeo les jes 0 15 118 a7 daa Ww Wa We lss i58 39 14 15 18 me 30 24 24 24 24 jog 129 20 4 14 is He 99 Joo a9 og fog fog og BOO 1200 1800 2400 3100 3600 4100 4600 5300 00g paon F300 Trg 8100 a200 Ww f eo ea o ler es lee fee
60. _From File Log session Replay 77 ConfigureReplay S Configure Replay Upload View_Replay_From File 82 Savea Calibration 121 Save Calibration Load a Calibration Acronym_ 85 Control Keys 2G Control Keys _ _ 86 Function or Quick Keys 127 Function or Quick Keys 87 _ Key Notes Summary from this manual Key Notes Summary ECU Pin Out 89 Frequently Asked Questions FAQs To avoid problems reading this manual and using the Hyperlinks download Adobe Reader 9 or higher free software available at www adobe com 1 Introduction Thank you for purchasing BigStuff3 s GEN3 Pro SEFI system The GEN3 Sequential Electronic Fuel Injection SEFI system includes Wide Band Oxygen WBO2 air fuel ratio control injector phasing and individual cylinder fuel and spark compensation as standard features These features along with numerous others make the GEN3 WBO2 SEFI system one of the most technologically advanced SEFI systems on the market E oe Version 2 1 February 2011 3 BigStuff3 Pro SEFI System 2 GEN3 PRO SEFI System Standard Features e Configurable Load amp RPM axes to enable optimization in desired operating range e Programmable peak amp hold injector drivers with current chopping capability e Programmable injector opening vs battery voltage e Wide Band Oxygen Sensor WB02 Air Fuel Ratio AFR control to eliminate base engine and transient fuel calib
61. ables can be connected to the vehicle cut off switch Power for the BigStuff3 GEN3 system and the ignition system should also be from the same source the battery or the cutoff switch To avoid the potential of severely damaging the ECU make the positive and negative connections to the battery first and then connect the header connectors to the ECU For coil on plug systems the main wire harness coil ground wire eyelet must also be grounded to the cylinder head engine No other ground locations are adequate If a 16V charging system is being used do not charge the battery with the ignition switch on The 16V battery charger can reach peak voltages above the maximum rated voltage of some of the electronic circuitry These over voltage conditions can completely damage the ECU This type of damage is easy to identify and is not covered under the factory warranty Also when running a 16V charging system with a GEN3 coil on plug system the maximum coil dwell cannot exceed 4 milliseconds If running a 12V system the maximum coil dwell cannot exceed 6 milliseconds Version 2 1 February 2011 8 BigStuff3 Pro SEFI System Harn Wire Label To Color Connector meee Connect To Further Details Label Type Definition Calport Black 3 way The Connect one end Click CalPort for Packard calibration of the RS 232 further information connector witha port that communications purple seal allows the cable supplied ECU to to the ECU and int
62. aft on the dampener Note The Static Test must be run with the engine RPM at 2 500 or above This feature can also be enabled as a quick way to verify the rotor phase using a timing light through a hole in the distributor cap at peak horsepower timing Enter the timing value for peak horsepower instead of the suggested 40 Note Do not forget to uncheck the Static Test Timing box once the test 1s complete although the Test Timing value becomes invalid once the TPS exceeds the Clear Flood TPS for safety reasons in case you forget to disable it and during cranking For more detailed information on how to use this feature and how to set the Crank Reference go to the BigStuff3 website under the How To Help section via this link http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf Return_to_Static_Test_Timing Fan Control This input screen allows the user to determine at what coolant temperature the GEN3 ECU will turn the engine cooling fan s on Fan On Temp and off Fan Off Temp The Fan Off temperature should be 5 to 10 less then the Fan On temperature The fan must be wired into the GEN3 system using a relay See the section above titled Fan for specific detail on how to accomplish this Return_to_Fan_Control_ Setup Version 2 1 February 2011 46 BigStuff3 Pro SEFI System Fuel Pump The Fuel Pump Configuration section has two input cells Both input cells assume that the GEN3 ECU will control
63. am input cam sync hooked up and operational Note The GEN3 LS1 Coil on Plug COP and the Stand alone COP systems are the only GEN3 systems with bi directional timing compensation Note The GEN3 ECU base system supplies 12 Volts sources current to the injectors vs providing a ground path sinking current as is the case with some competitive systems This approach provides better noise immunity and less power dissipation heat in the ECU Note Once the stages are turned on they stay on until the TPS and or RPM criteria are no longer true or the Timer Enable goes low off Note The Timer sequence will be reactivated every time the throttle is closed and then opened again since the Minimum RPM and Minimum TPS criteria are re satisfied Note The timing values inputted into the Start Line Timing table are the absolute values not timing retard values the ECU will use when the Boost Parameters minimum RPM and TPS are satisfied If zero 0 is entered into the table no starting line timing will be applied Version 2 1 February 2011 12 BigStuff3 Pro SEFI System e Note The inputs from this table are used by the ECU if Alpha N was the control algorithm selected during the Main Configuration set up If the Speed Density the control algorithm was selected the ECU ignores inputs from this table e Note Before saving the Log Window dash for the first time you need to navigate to the C Program Files BigStu
64. and run the Default Dash compilation while retaining your unique dash in the C Program Files BigStuff BigComm folder 69 Save to File Section 69 above described how to configure the 31 available Dash s The steps for saving a reconfigured dash in the Default Dash or unique dash compilation are outlined below To save a Dash go to Dash on the Main Menu screen Left mouse click on Dash and slide the cursor down to Save to File amp BigComm Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp MsESTI Logging Configuration PC Windows Help Configure Dash BO BE EET Pateshestim scastronri Release the left mouse button and the following screen will open lt BigComm ax File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help E 4 a Refresh 501ms Enter a filename f Save in BigComm x c Eg Help E Default dsh File name Default Save as type Dash File Cancel Name the Dash to be saved in the File Name sub window and hit Save The dash will be saved J E oe Version 2 1 February 2011 100 BigStuff3 Pro SEFI System 70 BigStuff3 Data Acquisition As an option the GEN3 ECU 1s capable of supporting both internal internal to the GEN3 ECU and external to a remote personal computer data logging The GEN3
65. ative to the current RPM operating point Use it as a point of reference to help calibrate the dMAP RPM Modifier table To change a value in the MAP RPM Modifier table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change STUFF Version 2 1 February 2011 82 BigStuff3 Pro SEFI System lt dMAP RPM Modifier Table dMAP RPM Modifier 0 ome25 25 22 11 0 25 50 75 100 100 600 600 1000 1111 1200 1500 1800 2000 2400 2800 3200 3600 4i RPM 1 0x52 RPM 1500 dMAP Correction 0 0 Same screen as above with the window maximized Bo BB Sanm jee dMAP RPM Modifier 22 11 0 25 50 75 100 100 600 800 1000 1111 1200 1500 1800 2000 2400 2800 3200 Scaled RPM 0X52 RPM 1500 dMAP Correction 0 0 51 MAP AE Decay Rate The third table is MAP AE Decay rate It is used to determine how quickly to decrease the Positive dMAP correction value after accelerating throttle tip in the engine at a given coolant temperature The ECU decrements the MAP correction by the MAP AE Decay Rate A MAP AE Decay Rate of 6 represents a decrease of the MAP Correction by 6 every crank interrupt until it reaches zero In other words if you input the number 6 into the table after 1 crank interrupt the MAP Correction will decrease 6 The 6 per interrupt continues until the MAP correction reaches zero The MAP
66. aving a reconfigured Dash so that it becomes part of the Default Dash are outlined below e After configuring a Dash hit OK at the bottom of the Dash Setup window The window will close e Go back to Dash on the Main Window tool bar and Select Save To File from the Dash drop down list The screen below will open Note Before saving the Log Window dash for the first time you need to navigate to the C Program Files BigStuff BigComm directory This step only occurs the very first time any Dash file 1s saved Subsequent Dash file saves will automatically be saved to the C Program Files BigStuff BigComm folder File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help 4 amp wn a Iffline C Program Files BigStuff BiglommLeo s C167 ette bi Enter a filename Save in BigComm amp a e Ea Help E Default dsh E dtps dt dsh E Learn Dash dsh E Log Window dsh E MAP AE Decay dsh File name D efault Save as type D ash File Cancel Version 2 1 February 2011 98 BigStuff3 Pro SEFI System Name the file Default and hit Save By selecting Default as the file name the Log Window dash becomes part of the compilation called Default Dash Again the file will be saved to C Program Files BigStuff BigComm directory e A unique file name can also be assigned by typing the name in the Fil
67. ay to configure the Default Dash is to configure each of available dash s or most frequently used dash s to your liking and then save them as the Default Dash This way every time you open the BigComm software the dash s will be open to the preferred configuration 66 Configure Dash To configure a Dash go to Dash on the Tool Bar Left click on Dash and the drop down screen shown below will open Keep the left mouse button depressed and slide the mouse pointer down until Dash Configure is highlighted Version 2 1 February 2011 95 BigStuff3 Pro SEFI System s BigComm Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp 8EEA Logging Configuration Windows Z E 9 Ka TA d Settings Leo Meaney My Documents Big Load from File Save to File s BigComm File Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost SEEN Transmission Torque Management Ethanol Logging Replay Configuration PC Windows Help Dash Configuration Z ie Offline 81810 Load from File Save to File Release the left mouse button The screen below will open Left Click on the Pick Dash drop down screen ma K E E Sh Pick Dash drop down screen Pick Dash Available Signals Act AFR MAP Add gt APM Scaled Load Add All gt gt Scaled RPM lt Remove lt lt Remove All Cancel Ap
68. bo applications The 2 step and 3 step functionality are available as options on the GEN3 distributor ignition based systems The 2 Step and 3 Step upgrade must be ordered along with part number BS3 005 025 Note The 2 step functionality is a base feature on all coil on plug systems 3 step control is an option on all GEN3 systems If the system is fitted with the BS3 2 step control the GEN3 ECU will maintain the engine RPM at the user defined 2 Step RPM limit if the following criteria are met e The DAI or optional DAE trigger switch is turned on 12V is applied to the data log trigger wire e 12V is applied to the yellow 2 step wire via a clutch foot brake or trans brake switch e The Throttle position TPS is above 25 The 25 throttle position must be achieved with a quick tip in rather than creeping up to 25 TPS level If the GEN3 system was ordered or upgraded with the optional 3 step a second wire will be supplied in header 2 terminal location W1 This wire must have 12V supplied to it for the 3 step to work For the optional 3 step to function correctly the following criteria must be met e 12V must be applied to the DAE wire Hdr 2 wire Y2 e The Throttle position TPS must be above 25 The 25 throttle position must be achieved with a quick tip in rather than creeping up to 25 TPS e 12V must be applied to the 2 step wire Hdr 1 wire B2 e 12V must be applied to the 3 step wire Hdr 2 wire W1 The 3 step function w
69. bsite via this link http bigstuff3 com pdf MAP Pressure pdf Back_to_Map Boost Black 4 way Packard Connector The 4 way boost connector The 4 way Boost connector in the main wire harness plays several key roles in the operation of the following base system features This connector is used to e Trigger the internal data logger connector location A e Trigger the internal timer known as the Timer Enable connector location A Version 2 1 February 2011 21 BigStuff3 Pro SEFI System e Trigger three 3 stages of timing and or boost control connector locations B C amp D All GEN3 DAI systems are all sold with the mating half 4 way connector terminal used for the Timer Enable DAI Trigger wire and seal Connector location A on all GEN3 base systems enables two 2 functions 1 The internal timer referred to as the Timer Enable No matter how the GEN3 system is configured or what options the system has Pin A of the Boost connector will always act as the internal timer trigger wire used for boost and traction control and other optional features The timer enable wire connector location A must have 12V applied to it at the exact moment the system is configured to start a timing sequence like boost or traction control Initiating both the timing sequence Timer Enable and internal data logger DAI trigger can be accomplished by inverting the 12V signal from the brake s
70. cipate Fuel_Pump_Configuration KC Steps EGT fe Off f On For setup detail go to Fueling Parameters Configuration Close Necccescccsccsscssoes For setup detail go to Fan_Control_Configuration The paragraphs below outline how each operating parameter should be configured The hyperlinks in the screen print below link to the instructional text for each subject item TPS This input screen allows the user to set e The TPS sensor to the correct output voltage when the throttle is completely closed e The Clear Flood TPS described later in this section Note It is important to have the TPS setup correctly The TPS sensor on the throttle body and software need to be setup properly to ensure that the full resolution 1 to 100 of the sensor can be utilized and the following related features function properly described later in the manual e Idle Spark Control See Idle Spark for more information e Decel Fuel Cutoff DFCO See MAP Parameters for more information How to Set Max TPS for Idle Note Make sure that the correct type of TPS GM or Ford is selected during the hardware configuration process outlined above See TPS Configuration In the input table set the Max TPS for Idle at 2 Next go to the TPS sensor located on the throttle body With the throttle blades completely closed and with the engine running at its normal Version 2 1 February 2011 42
71. ck on the cell and type a desired Air Fuel Ratio value from to 10 5 to 15 0 and hit Emter to save the change To make changes to multiple cells simultaneously left mouse click and drag the cursor down and to the right across the cell range to be changed Release the left mouse button and a secondary drop down screen will appear outlining three potential cell fill options Version 2 1 February 2011 55 BigStuff3 Pro SEFI System s BigComm Air Fuel Ratio Table amp Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help X z Kd Be ST Refresh 61ms 19 0 313 0 13 0 13 0 13 0 19 0 213 0 313 0 13 0 128 13 0 213 0 313 0 13 0 14 0 13 6 513 8 Fill Multiply Interpolate Cancel 14 0 14 0 600 on 1000 1111 1200 1500 1800 2000 2400 2800 3200 3600 4000 5000 6000 7000 RPM Boost 13 3psig WhenUSEARCH Q Search ay Specials The WhenUSearch Toolbar Saving You Time and Money Find out a C e r start Screen Prints a GEN1_BigComm manu BigComm Gq Ls Sry 4 32 PM e Fill Choosing Fill will open a secondary drop down screen which allows the selected cells to be changed to the value inputted into the window e Multiply Choosing Multiply will open a secondary drop down screen which allows
72. compared to a carburetor s power valve It is used to increase the base fuel pulse width when the manifold pressure increases significantly for a slight change in throttle opening MAP Transient Fuel is used to decrease the base fuel pulse width when the manifold pressure decreases significantly as a result of the throttle blades being closed The MAP and Transient Fuel control is comprised of 5 primary tables and 1 secondary table Each of the tables play an integral role as to how the base fuel pulse width will be increased or decreased for a given change in manifold pressure Below is a description of how and when each of the tables is used by the ECU From the tool bar on Main Menu screen left click on Transient Fuel The screen below will open The following paragraphs will describe how to calibrate each of the Transient Fuel drop down selections Version 2 1 February 2011 81 BigStuff3 Pro SEFI System File Spark Idle BAGEL a AA Air Fuel Ratio Individual C Windows Help Run Time Correction Z E 4E Position Correction Accel Pump Shot Power Valve Fuel dM4P RPM Modifier MAP AE Inc Rate MAP AE Decay Rate dMAP Parameters 49 Power Valve Fuel F10 Quick Key The first table is Power Valve Fuel It is used to determine the percent fuel correction either positive or negative for a change in manifold pressure MAPdt The ECU calculates the change in manifold pressure every 52
73. ctory installed isolation grommets are used to mount the ECU the bolt used must not extend beyond the 4 factory installed depth Using bolts or threaded rods that are longer than 4 will damage the ECU and void the warranty Also the isolators are not used for any type of electrical grounding Version 2 1 February 2011 120 BigStuff3 Pro SEFI System Note A CD ROM disk is no longer supplied with a CD ROM software Disc but one can be purchased from BigStuff3 Note BigStuff3 recommends checking all of the settings in the configuration tables to ensure the system as supplied will operate correctly Note The air fuel ratio will still be displayed and recorded while in Open Loop mode Note It is important to have the TPS setup correctly The TPS sensor on the throttle body and software need to be setup properly to ensure that the full resolution 1 to 100 of the sensor can be utilized Note Make sure that the correct type of TPS GM or Ford is selected during the hardware configuration process outlined above Note The engine may not run if there is no band between the On and Off rev limiter limits or the RPM inputs are reversed For example if the Rev Limit On is set for 7 100 RPM and the Rev Limit Off is set at 7 300 RPM the engine will not run Note The Static Timing Test must be run with the engine RPM at 2 500 or above Note Do not forget to uncheck the Static Test Timing box once the
74. d Stage Boost Spark 3rd Stage Boost Spark Boost Parameters Keep the left mouse button depressed and slide the mouse pointer down until Boost Parameters is highlighted Release the left mouse button The screen below will open 61 Boost Parameters 1 second resolution s Boost Parameters Boost Parameters Minimum RPh 1500 Minimum TFS 200 Integral Gain Pwt Boost Reference t MPH w APM Spark Retard Mode Boost Mode f 3 5tg Boost gt 1st Gear Staged E PWM 1st Gear Axis Units Time C RPM Ist Gear Timer OverRide 0 0 Sec 1st Gear Closed Loop Parameters Blend Rate 0 Counts Froportional Gain High Gear Atd Delay m Gor Derivative Gain High Gear Atd 0 00 Deg Integral Gain Help Close The GEN3 ECU allows the user to control boost parameters in two 2 modes Staged or Pulse Width Modulated PWM Staged mode turns on boost stages solenoid valves in a user defined time sequence PWM mode assumes the boost system is configured with a PWM boost valve When the PWM mode is enabled the Stage 3 timer input windows are made inactive as shown in the screen print above When Staged mode is selected the Stage Timer input windows are active as shown in the screen print below e STUFF Version 2 1 February 2011 91 BigStuff3 Pro SEFI System The Stage timer starts once the following criteria are satisfied Minimum RPM This input establishes the minimum RPM the engine must reach to initiate
75. d X amp Y axes allow only a small portion of the available map area to be used to calibrate the fuel and spark needs of the engine Version 2 1 February 2011 49 BigStuff3 Pro SEFI System This capability is extremely important if the engine is fuel or spark sensitive at a given load and or RPM For example if the engine transmission rear gear combination makes the engine sensitive to throttle changes at 2 200 rpm the user can configure the X axis in 200 or 300 RPM increments at or around 2 200 RPM If the Speed Density control algorithm was selected during the aforementioned Hardware Configuration step the screen should show MAP kPa in the Y axis and RPM in the X axes If the screen shows TPS and the preferred control algorithm is Speed Density go back to Main_Configuration and select Seed Density instead of Alpha N a Ke i Table Axis Configuration 105 Cell Number 16 J cn RPM re lis N eo 7800 1000 1200 1400 1600 1800 2000 2400 2800 3200 3600 4000 4400 4800 8000 l Scaled RPM Axis omit Close X Axis Scaled Load Axis Y Axis Scaled RPM inputs from this table define the RPM break points used in the following tables to name a few which are described later in this manual e Dwell Time Table e Injector Phase Angle degree Table e Boost Spark retard Table e Starting Line Timing Table Version 2 1 February 2011 50 BigStuff3 Pro SEFI System The follow
76. d be wired between the 12 Volt source and the timer enable pin to allow the replay function to be turned off After a pass with the ignition off the data will be maintained in the ECU s internal RAM for 30 minutes After thirty minutes the data will be lost so it needs to be uploaded to a PC within this time Once you ve verified the data is good turn off the Timer Enable pin via toggle switch for the next logging event Remember to turn the toggle switch back on prior to staging the car Note Even if the TPS is satisfied again clear flood to restart on the return road none of the data will be lost You can only record another run by turning the toggle switch connected to the data log trigger wire off and then back on Inside the Replay drop down there are three 3 submenus Each submenu will be described in the paragraphs below To get to the Replay drop down screen go to the main Tool Bar and left click on Replay and the screen below will appear Hold the left mouse down and drag it to the desired input screen and release the mouse button STUFF Version 2 1 February 2011 107 s BigComm BigStuff3 Pro SEFI System File Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Torque Management Ethanol Logging RGIS Configuration PC Windows Help 4 amp a Offline 8 18 10 Testing big Replay Configuration I Upload Replay view Replay From File
77. d to fine tune the interrelationships of the aforementioned tables The Trace function allows the engine to be quickly calibrated On line ECU powered up or Off Line PC only The Trace Function will be explained later in this manual Version 2 1 February 2011 54 BigStuff3 Pro SEFI System 24 AIR FUEL RATIO F11 Quick Key Use the air fuel icon to quickly access the air fuel ratio table The F11 Quick Key can also be used 25 Air Fuel Ratio Table Note In some cases the ECU shipped with your system will come pre configured with a table which will closely match your engine configuration The air fuel ratio table below allows the user to input desired air fuel ratios for sixteen 16 engine speed RPM and 8 load MAP or TPS combinations The X axis represents engine RPM and allows for 16 inputs and the Y axis represents engine load and allows for 8 inputs For each speed and load combination cell the engine operates within the ECU uses the WBO2 sensor feedback to achieve the desired air fuel ratio for that cell While the engine is running a real time Ellipse will move throughout the Air Fuel Ratio table relative to the current RPM amp Load operating point Use it as a point of reference to help calibrate the Air Fuel Ratio table To change a cell value in the Air Fuel Ratio table move the cursor using the PC s mouse or the arrow keys to the cell to be changed Cli
78. data once initiated by the TPS Trigger Level setting The data logging duration can be set from one 1 to eighteen 18 seconds TPS Trigger Level The throttle position TPS position in degrees that will trigger the GEN3 ECU to begin logging data internally Sample Rate If the GEN3 system is equipped with the Extended Replay option up to 4 different sample rates recording times can be selected as follows Version 2 1 February 2011 108 BigStuff3 Pro SEFI System Sample Rate Record Time seconds 16 2 During a Logging event the GEN3 ECU automatically logs fifty two 52 parameters referred to as Signals After an event has been logged hitting the letter C on the keyboard will open the Replay Configuration screen above Signals can be selected or de selected then graphed This feature allows the user to control the number of parameters Signals displayed in a graph Naming Replays Replays are named using the Logger Configuration window shown below The system is set up this way because the GEN3 system allows the user to record a Log external and Replay internal at the same time Allowing two different names to be assigned to the same logging event would be problematic Since Logging is a base feature that exists in every GEN3 system sold the name for each data record has to be established within in the Logger Configuration Once a default file name is set the ECU will automatically incl
79. e The two 30 way MWH header connectors are keyed such that they will only fit in only one 1 of the two 2 ECU mating half connectors To fasten the MWH connectors to the ECU use a 1 4 nut driver Make sure the header connectors on all the harnesses are tightened to 15 20 in lbs Do not over tighten the header connectors Connect header connector A through K first the L through Y Back_to_Header_Connector 5 Injector Harness Installation Black 10 way Packard Connector Once the main harness is installed and all the connections to it are made the injector harness can be installed and connected to the main harness Each injector connector on the injector wire harness is marked for the cylinder it needs to be attached to There are specific injector wire harnesses for Chevy Chrysler Ford and Buick V6 engines The firing order is configured within the GEN3 ECU Injector harness to main harness connector female ideo Tar a Version 2 1 February 2011 25 BigStuff3 Pro SEFI System The main harness to injector harness connection should be made on the end of the engine opposite the ignition distributor Injector Wire Harness diagrams and pin out information for Chevy Chrysler Ford and Buick V6 applications are available on the BigStuff3 website via the following links e Chevy and Chrysler http bigstuff3 com pdt Visio chevy 20Injector 20Harness pdf e Ford http bigstuff3 com pdt Visio Ford
80. e dMAP correction reaches zero The fixed axis values in the MAP AE Inc Rate table represent coolant temperature which increases from left to right The MAP AE Inc Rate table s input values need to increase as coolant temperature increases The larger the value in the table the slower the fuel 1s added While the engine is running a real time Ellipse will move within the MAP AE Inc Rate table relative to the current engine Coolant Temperature operating point Use it as a point of reference to help calibrate the MAP AE Inc Rate table To change a value in the MAP AE Inc Rate table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The inputs shown in the table below can be used as a baseline Xe MAP AE Inc Table MAP AE Inc Rate 3 6 14 8 33 8 99 4 17 9 Coolant F 53 Run Time Correction The fifth table is Run Time Correction It only influences the Positive MAP and dTPS Correction Values for a short period of time after the engine is running i e up to 8 minutes The Run Time E oe Version 2 1 February 2011 84 BigStuff3 Pro SEFI System Correction table s value is used to increase the positive MAP Correction value Therefore if the current MAP correction value is 200 and the Run Time Correction value is 25 the ECU will increase the MAP 200 correction value by 25 relative to the time at whic
81. e 12V applied to it at the exact moment the system is configured to start a timing sequence like boost or traction control Initiating both the timing sequence Timer Enable and internal data logger DAI trigger can be accomplished by inverting the 12V signal from the brake switch or trans brake as shown in the diagram above 2A Internal data logger know as the Replay function trigger wire BigStuff3 Data Log Trigger Timer Enable Starting Line Timing Wiring Diagram Off Foot Trans brake or Dual State Clutch Switch No BS3 2 Step Row 1 Row 2 Row 3 Switched 12V Source in the Vehicle GEN3 ECU Header 1 Terminals A K A BCDE F GH J K With Clutch IN 12V is supplied to the optional Foot brake Switch or systems wire Trans brake Button NOOO OOOO 12V applied to this wire when foot or trans brake button is depressed P With Clutch OUT 12V is supplied to the Timer Brake Lights Enable wire or Trans brake Dual State Clutch Switch Dash Mounted JL ON OFF Switch required to turn the Data Log Trigger On and Off Data Trigger Timer Enable Wire BigStuff3 Pro SEFI System 2 Step Yellow wire The 2 step function is not a standard feature on the GEN3 distributor ignition based systems but the yellow 2 Step wire can be hooked to enable starting line timing retard for stick shift cars and tur
82. e Idle Spark table To change a value in the Idle Spark table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The values shown in the table below can be used as a baseline See Throttle Follower_and_Idle_ Spark Setup below for more information on how to use the Idle Spark control in combination with the IAC Start Position to improve overall idle control s Idle Spark Table idle Spark deg imme i20 100 70 70 0 80 50 20 64 30 i 256 224 192 160 128 96 RPM Delta 43 IAC Start Position A general description of the IAC motor and valve plunger was described above in the Throttle Follower paragraph The IAC motor can be in one 1 of one hundred eighty 180 potential positions from fully open to fully closed Fully closed would represent position number one and fully open would represent position number 180 The ECU monitors key engine operating conditions and positions the IAC valve plunger accordingly When the engine is shut off the IAC goes to position number zero and then counts back to position number 90 or half way open and stays there When the engine goes into cranking mode the ECU reads the coolant temperature and instructs the IAC what position to go to Based on user defined inputs the IAC Start Position Table allows the ECU to position the IAC valve to a predetermined position while the
83. e Name sub window and clicking on Save 68 Load From File In addition to the Default Dash unique dash s can be configured and used e g Turbo Car dash To view a previously saved unique dash go to Dash on the Main Menu screen Left mouse click on Dash and slide the cursor down to Load from File s BigComm File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp 8EEA Logging Configuration PC Windows Help Configure Dash z B 9 i Save to File Release the left mouse button and the following screen will open with a message that reads This will destroy your current Dash setting Do you want to continue Zibo mm SET tenes Warning This will destroy your current dash settings Do you want to continue Select Yes The screen below will open All the previously saved log files will be listed Select the file to be opened by double clicking the left mouse button The selected logged file will open Version 2 1 February 2011 99 BigStuff3 Pro SEFI System BOE Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help BANE BO Siete Open a saved dash Look in BigComm f e Eg Help E Default dsh File name Files of type Dash File o Cancel The next time the BigComm software is opened it will automatically load
84. e _Battery_Fuse Header No label see BigStuff Engine Header Connector Connector link to photo Control Unit N A in Further ECU Details Column Injector Black 10 way Injector Connect to main Injector_Harness Harness Packard harness wire harness connector connector The paragraphs below further support the information outlined in the table above Calport ECU to PC interface cable 3 way black Packard connector Communications Cable supplied AMP RS 232 connector Do not connect the communications cable until all the software 1s installed on the PC that will interface with the GEN3 system See the Calport Resolution document on our website for more information Back_to_Calport Version 2 1 February 2011 11 BigStuff3 Pro SEFI System Primary Fuel Pump LS Single lead Packard connector with a single black white wire This is the PRIMARY pump connection If only one fuel pump is being used it must be wired to this low side connection PRIMARY FUEL PUMP LS This connector must go to the negative side of a fuel pump relay not directly to the fuel pump Terminating this connection directly to a fuel pump will damage the Big Stuff controller and will void the warranty The primary fan wire is red with a white stripe but the connector is identical to the fuel pump connector s so make sure to read the wire label to ensure the connector is terminated correctly Wire the prima
85. e amount of primary current in the ignition coil The longer the coil dwell the more primary current available for a spark event GM coils are current limited to a max of 7 Amps GM coils approx 98m of spark energy reach their current limit in approximately 6 ms of dwell time BigStuff3 also offers optional Hot coils 103 mj of spark energy BigStuff s GEN3 ECU allows for coil saturation at high RPM where maximum spark energy is required but also allows the coils to run at lower dwell times ms at lower RPM to avoid overheating the coils Directional coil dwell times to use are as follows e LSI coils with a 12V charging system e From idle to approximately 4 000 RPM use about 3 0 milliseconds near idle and no more than about 4 0 milliseconds at approximately 4 000 RPM e From approximately 4 100 Max RPM use no more than about 6 milliseconds of total dwell time at max RPM e LSI coils with a 16V charging system e From idle to approximately 4 000 RPM use about 2 0 milliseconds near idle and no more than about 3 0 milliseconds at approximately 4 000 RPM e From approximately 4 100 Max RPM use no more than about 4 0 milliseconds of total dwell time at max RPM The x 16 table allows coil dwell time to be set as a function of engine RPM Note The RPM values at the bottom of the dwell time input table are established when the Load vs RPM Axis table is configured File Spark Idle Transient Fuel Air Fuel Ratio Individual Cy
86. e corrupted and the ECU may need to sent back to BS3 so that it can be reconfigured If you load a calibration with Extended Replay firmware into an ECU with Original Replay firmware you will need to reset it by going to Configuration Check Replay Type When the next screen opens click on the box which says Set to Original Type Save your changes and then turn the ignition off for 20 seconds Lastly take all power disconnect the battery away from the GEN3 ECU momentarily If this fails contact BigStuff3 e How do I know if my Bosch WBO2 sensor is bad e First make sure the sensor to main wire harness connection is good e Add the UEGOR signal to the Dash Turn the ignition on The UEGOR value should count down from 255 to a value close to 80 If it does not the heater is bad The sensor should also read 15 9 in the open air e Also if the O2 sensor is stuck at 14 7 for gasoline the sensor is not connected or it s defective e How can I check if my NTK WBO2 Methanol sensor is working e First check the control circuitry by disconnecting the sensor from the harness Turn the ignition to the BS3 ECU on The AFR value in the Dash should read 6 4 Key off and reattach the sensor to the harness Turn the ignition to the BS3 ECU back on The sensor should read 6 9 Also check your last Replay The ECM Valid should read On to indicate the sensor is working Always wire you the NTK WBO2 on a separate supply switch and always turn the
87. e cursor is in the two point mode hold the left mouse button down and pull the edge of the window in or out to expand or contract the window J Bo Sa Bei tem Act AFR 001 STUFF Version 2 1 February 2011 60 BigStuff3 Pro SEFI System 29 AFR Parameters F11 Quick Key The Air Fuel Ratio AFR Parameters table allows the user to configure control parameters associated with closed loop fuel control using the WBO2 sensor The following paragraphs will describe the function of each control parameter RPM On amp RPM Off Inputs e RPM On Defines the RPM the engine needs to exceed before the ECU will allow the system to go into closed loop fuel control using the O2 sensor e RPM Off Defines the RPM the engine needs to fall below before the ECU will not allow the system to operate in closed loop fuel control The RPM Off value needs to be at least 100 RPM less then the RPM On value Max Step and Gain for the Oxygen Sensor Inputs e Maximum Step Defines the aggressiveness number of steps of the O2 sensor when it updates the O2 correction factor The step sizes can go from 1 to 12 For example if the O2 sensor needs to make a 15 correction and the Step Gain 1s set at one 1 the O2 correction loop will go through 15 iterative steps to close the O2 correction gap If the Step Gain is set to 12 the sensor will go through only a few steps to close the O2 correction gap e Gain Gain can range
88. e following additional logging parameters should set e Log For Setting This setting dictates how long the ECU will log the data Zero 0 to thirty 30 seconds To set the data Log period place the mouse cursor on the Log For slide Version 2 1 February 2011 102 BigStuff3 Pro SEFI System bar Keep the left mouse button depressed and move the slide bar left or right to achieve the desired data log time frame e Update Display While Logging Determines whether or not the logged data will be displayed in the Log Window screen Select Yes to display or No not to display e Set Default File Name The default file name for the data being logged A default file name needs to established and saved Once a default file name is set the ECU will automatically include number extensions for all subsequently saved files under the same default file name Once the desired changes have been made click OK at the bottom of the window Your changes will be saved 73 Record Log F8 Quick Key The Record Log function is another way to initiate a data Logging event To use this method go to the tool bar on Main Menu screen and left click on Logging When the drop down screen opens hold the left mouse button down and slide the mouse until Record Log is highlighted Release the mouse button A blank Log screen will open To start logging data depress the space bar on the laptop keyboard once
89. e is focused on engine launch RPM control Rev Limit On RPM and Rev Limit Off RPM section allows the user to set the maximum engine RPM before fuel shutoff occurs This setting is referred to as Rev Limit On RPM The screen also includes an input for Rev Limit Off RPM which is the RPM where fuel will be reintroduced to the engine A small RPM band at least 200 RPM is required between the Rev Limit On and Rev Limit Off RPM inputs so that the engine has a small band hysteresis between the rev limiter on and off limits The hysteresis for supercharged blower engines should be at least 1 000 RPM Note The engine may not run if there is no band between the On and Off limits or the RPM inputs are reversed For example if the Rev Limit On is set for 7 100 RPM and the Rev Limit Off is set at 7 300 RPM the engine will not run Return_to_Rev_Limiter_Setup Rev Limit On RPM and Rev Limit Off RPM section allows the user to set the 2 Step RPM Lo 2 Step engine RPM launch RPM 2 Step RPM Hi 3 step engine RPM launch RPM The 2 step Lo 2 Step and 2 Step Hi most commonly referred to as 3 step control are not standard features on the GEN3 distributor ignition based systems In base system form the 2 step wire can be used for starting line timing retard for stick shift cars and turbo applications The 2 step and 3 step functionality are available as options on the GEN3 distributor ignition based sy
90. e of the screen Signals in the Dash All Signals shown under Signals in the Dash will now appear in the Cranking Fuel screen when that screen is used to calibrate the Cranking Fuel In the Cranking Fuel example below Air Temp Base Injector Pulse Width Coolant MAP and TPS where selected and added to Signals in the Dash z be E 2 TT Refresh 80ms Cranking Signal in the Fuel Dash Dash Available Signals Signals in this Dash Add gt MAP Add All gt gt lt Remove lt lt Remove All ores __ Version 2 1 February 2011 97 BigStuff3 Pro SEFI System In the screen print below notice that the same Signals appear in the Dash at the bottom of the Cranking Fuel screen 5g Cranking Table Pulse Width ms 12 8 412 8 12 8 12 8 10 2 10 2 10 2 10 2 7 7 7 7 54 5 1 5 1 5 1 33 8 44 6 55 4 66 2 77 9 90 1 102 111 125 144 169 196 230 24 Coolant F 67 Save a Dash Again the recommended way to configure the Default Dash is to configure each of available dash s or most frequently used dash s to your liking and then save them as the Default Dash This way every time you open the BigComm software the dash s will be open to the preferred configuration Once the Default Dash has been saved individual dash s can be changed and saved again as part of the compilation of dash s referred to as the Default Dash The steps for s
91. eaded rods that are longer than 4 will contact and damage the ECU and void the warranty The isolators are not used for any type of electrical grounding Version 2 1 February 2011 21 BigStuff3 Pro SEFI System The GEN3 system hardware installation process in now completed The next step is to install the BigComm software which allows the sensor interfaces to be checked and ultimately start and operate the engine The remainder of the manual will describe how to install and use the BigComm software to monitor and calibrate the GEN3 ECU parameters and variables 8 BigComm Software Overview The GEN3 system can be configured to operate on almost any engine configuration normally aspirated nitrous oxide injected supercharged and turbocharged applications The BigComm software was designed to control the engine and act as the interface between the BigStuff3 GEN3 ECU and the engine it is installed on View it as the screwdrivers and wrenches once used to make crude adjustments to a carburetor The BigComm software allows the user extraordinary fuel and ignition system tune ability for improved performance and drivability The BigComm software allows full user access to all of the tables needed to calibrate the GEN3 system Calibrations can be modified both on line and off line The engine control tables in the BigComm ECU are stored in non volatile memory allowing for the stored information not to be lost when power to
92. ebruary 2011 BigStuff3 Pro SEFI System Further Details Inductive pickup ignitions will not use this connection See paragraph below titled HEI for further relevant information Ignition Used only for injector phase angle and individual cylinder spark control System includes a mating 2 way Packard connector amp terminals Cam System includes a mating 2 way Packard connector amp terminals Crank Coolant_Temperature Air_ Temperature Meters and controls intake air around the throttle blades at idle and during cold starts IAC Senses the position of the throttle blades 0 throttle closed to 100 throttle wide open TPS 10 BigStuff3 Pro SEFI System H Wire Label To Color Connector meee Connect To Further Details Label Type Definition MA Green 3 way Manifold Connect to the Packard Absolute MAP sensor connector Pressure Sensor Crank Black 2 way Crankshaft Connect to System includes a Packard position crankshaft sensor mating 2 way Packard connector witha sensor input connector amp terminals separate ground Crank wire 3 8 ring 2 Step Single yellow 2 Step trigger Clutch or trans Two_Step Optional wire function brake switch feature Boost Black 4 way Staged or Connects to Boost connector with an PWM Boost optional 4 way orange seal Control connector to solenoid or PWM boost valve r Main Fuse amp N A N A Main_Fuse_and_Relay Relay Vehicle Vehicl
93. ect E85 even if straight E85 will be used Contact BigStuff3 for more details Engine Type Select either Ford or GM It is important that this selection be correct The GEN3 ECU uses this information for the individual fuel and spark control Second Injector Switch Point Injector Staging This feature is for 16 or 24 injector systems It allows for 16 or 24 injectors to be run sequentially in a staged configuration This feature is especially useful for engines running alcohol fuel where a large volume of fuel 1s required and two or three injectors per cylinder are being used By staging the injectors you get better idle quality and drivability The first set of injectors operate until the user defined injector duty cycle is reached then the second and or third set of injectors are introduced When this occurs the duty cycle of all the sets of injectors is recalculated and set to the same duty cycle even if the flow rates of the three sets of injectors are different Load Axis Scale The user can choose to see the fuel map spark map and Air Fuel Ratio AFR map in kPa or PSI EJET Applicable only if running the BigStuff3 s electronic carburetor system Contact BigStuff3 for more details 18 Operating Configuration F5 Quick Key Next the system Operating Configuration needs to be set up From the Main Menu screen Tool Bar left click on Configuration Keep the left mouse button depressed and slide the mo
94. elect Configure Dash from the Dash drop down list Select Log Window from the Pick Dash drop down selection window Select the Available Signals that you want to appear in the Log Window dash The selected signals will also be logged when Record Log Record Log Icon or F8 quick key are selected Be sure to select Scaled Load amp Scaled RPM if you want to use the Trace function to assist with the calibration of the Base Fuel and Spark Maps After selecting the Available Signals hit OK Select Dash again from the Main Window tool bar to save the Log Window dash Select Save To File from the Dash drop down list Before saving the Log Window dash you need to navigate to the C Program Files BigStuff BigComm directory Note Step 8 only occurs the very first time any Dash file is saved Subsequent Dash file saves will automatically default to the C Program Files BigStuff BigComm directory 9 Once you are in the C Program Files BigStuff BigComm directory you can save the Log Window dash You can assign a unique file name by typing the name in and clicking on Save or save it as the Default Dash by clicking on Save with Default highlighted as the file name By selecting Default the Log Window dash becomes one of the new dash s in the Default Dash compilation 10 Next select Logging from the Main Window tool bar to configure the data log parameters 11 Select Configure Log from the Logging drop down list 12 Select the TPS T
95. ential Electronic Fuel Injection AFR Air Fuel Ratio MPH Mile Per Hour EMI Electro Magnetic Interference ROM Read Only Memory WOT Wide Open Throttle TCC Torque Converter Clutch APW Asynchronous Pulse Width 85 Control Keys Control S Spark Table Control F Fuel Table Control A Air Fuel Ratio Table Control L Take Log Command Control V View Log Version 2 1 February 2011 119 BigStuff3 Pro SEFI System 86 Function or Quick Keys F1 Cranking Table F2 View Lambda Screen F3 Fuel Table F4 Spark Table F5 Operating Parameters Table opens all operating parameter tables F6 Coolant Correction Table F7 Open Key F8 Record Log Window F9 Upload Replay F10 Power Valve Fuel Table and MAP RPM Modifier Table F11 Air Fuel Ratio AFR and AFR Parameters Configuration Tables F12 Save Calibration Folder 87 Key Notes Summary from this manual e Note Additional components such as relays and special connectors may be required to complete your specific installation Contact your dealer for further details e Note The 4 BAR MAP sensor sold by BigStuff3 will read pressure up to 52 PSI e Note The GEN3 ECU will never deliver a spark timing value below 6 There are exceptions to this when the GEN3 system includes one of the optional traction control systems e Note If Starting Line Timing control is used in conjunction with the optional 2 Step or 3 ste
96. ere is 12V applied to pin A of the boost connector to enable DAI Replay and the Timer Enable the ECU will invoke the timing retard values in the Boost timing retard tables It seems like the timing I have inputted into my spark map is not be realized when I make a pass What can be causing this o There may be values in the Boost timing retard tables If there is 12V applied to pin A of the boost connector to enable DAI Replay and the Timer Enable the ECU will invoke the timing retard values in the Boost timing retard tables If I am tuning in Alpha N mode Hardware Configuration then Control Algorithm can I use my 1 Bar MAP sensor for barometric compensation o Yes the automatic barometric compensation is hard coded in the ECU Leave the MAP sensor vacuum port exposed to the atmosphere Do not plug the MAP vacuum port to the intake manifold How come I cannot see the active obelisk in my AFR Spark or Fuel maps o Both the Scaled Load and Scaled RPM signals must be selected in the Dash for each of these tables I have anew Windows Vista machine and unlike my old XP machine I cannot see the green or red ball in the upper right hand corner of the BigComm screen Why is this o Your PC must be running Window Vista Office Edition or higher and Windows Transparency box must not be checked uncheck the box The Transparency check box 1s found in the Window Color and Appearance section Go to Start Control Panel Appearance amp
97. erface with the other end to an external the serial port of computer an external computer Primary Fuel Single lead Low Side Connect to the Do not connect this Pump LS Packard drive negative side of wire directly to the Must be wired connector with a the fuel pump fuel pump A relay as the single relay must be used Primary black white wire Fuel_Pump pump Secondary Single lead High Side Connect to the Do not connect this Fuel Pump Packard drive positive side of wire directly to the HS Must be connector with a the fuel pump fuel pump A relay wired as the single red and relay must be used Secondary white striped wire pump Single lead Engine Connect to the Do not connect this Packard cooling fan negative side of wire directly to the fan connector witha connection a cooling fan or positive side of the single black red relay relay A relay must be wire used Fan Points Single white wire Connection Only to the MSD Points for inductive system white pickup ign points input wire 12V Switch Single pink wire Switched 12V Connect to a 12V See paragraph below supply input source that 1s titled Ignition live when the Connection for ignition key isin further relevant the start information position Switched_Ignition Battery 4 Four 4 3 8 ring Positive and The vehicle See paragraph below connections terminals Two Negative titled Battery 2 red wire Battery batter
98. f line mode to help calibrate the Base Fuel and Spark Maps in the Record Log files Calibrating with the Trace Function is outlined in the next chapter of the manual 76 Replay Internal Data Acquisition to GEN3 ECU Optional Feature The GEN3 ECU s optional internal data logging capability is called Replay Replay eliminates the need to keep your PC in the car while going down the track The Replay internal data acquisition system is capable of sampling fifty two 52 channels of data fifty 50 times per second The Replay option is available in two configurations the Original Replay option records for up to 18 seconds the Extended Replay option records for up to five 5 minutes Both Replay options are described in the sections below The matrix below outlines the engine and vehicle operating parameters that can be recorded with the GEN3 s internal data acquisition system The column titled Base Feature or Optional System Upgrade indicates whether the operating parameter can be recorded with the internal data acquisition system supplied with the base system or as part of a system upgrade It also shows the parameters available with the Original and Extended Replay options In order to record data to the internal RAM the Timer Enable pin Pin A of the 4 way Boost connector on the main wire harness Boost_Connector_Pin_Out and the TPS threshold setting must be met A toggle switch shoul
99. f3 website via this link http bigstuff3 com pdtf Cooling 20Fan 20 Wiring 20Diagram pdf The fan pump relay is not supplied with the system A standard 40 Amp four post relay available at most part stores will work Back_to_Fan Version 2 1 February 2011 13 Cooling Fan Relay LS Relay Wiring Battery Ground Black with red stripe wire from BS3 harness labeled Fan LS Standard 40 Amp relay Switched 12 Volt Line cm Battery Ground BigStuff3 Pro SEFI System Points Single white wire 9 Do not connect this wire if a factory ignition system is being used This is the GEN3 s points signal wire It needs to be connected to the points output connection from the aftermarket ignition module e g MSD 6A box e Note Applying 12V to the BS3 points wire will immediately damage the GEN3 ECU POINTS Back to Points 12V Switched Single pink wire A secure connection must be made to a switched 12V supply The best sourceis a switched 12V supply at the vehicle fuse block Twelve volts 12V must be present on this wire during and after cranking If the 12V supply does not remain during and after ae cranking the ECU will not power up and the engine will not start SWITCH and or remain running A simple way to determine if a live 12V supply exists durin
100. ff BigComm directory This step only occurs the very first time any Dash file is saved Subsequent Dash file saves will automatically be saved to the C Program Files BigStuff BigComm folder e Note The Dash for the Log Window needs to be configured so that all of the logged data is captured and displayed in the Dash at the bottom of the Log window e Note The Replay file must be downloaded from the GEN3 ECU to a PC within thirty 30 minutes from when the ignition switch is turned off After thirty 30 minutes the Replay data will be lost e Note If the GEN3 main wire harness positive battery lead 1s connected to the battery cut off switch strongly recommended and the switch is turned OFF before the Replay data is uploaded the data will be lost e Note The Scaled RPM Scld_RPM and Scaled Load Scld_Load signals must be logged in order to support the Trace function e Note See Saving On_Line_ Calibration _Changes to ensure calibration changes made On Line are properly saved e Notes o The ECU stays alive for thirty 30 minutes after vehicle ignition is off to allow for DAI uploads from the GEN3 ECU to a PC o The ECU cannot be programmed when the vehicle ignition is off o The Flash memory is only updated when calibrations changes are made Note The GEN3 ECU must be powered ON to load a calibration file into it X BigComm i aan Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder
101. file Once opened the Fuel or Spark table will turn yellow indicating that the Trace function is enabled A trace line representing the logged data file will superimpose itself over the fuel or spark table Note Scaled RPM Scld_RPM and Scaled Load Scld_Load must be logged in order to support the Trace function Version 2 1 February 2011 113 BigStuff3 Pro SEFI System Z kd a aa T Offline C Program Files BigS tuffsBiglomm TK SC_383 big MAP KPa 203 a0 17o see neee 150 125 Blue Ellipse represents the logged data file engine operating points 600 800 1000 1111 1200 1500 1800 2000 2400 2800 2200 3600 DOO S000 GODO 7000 RPM eee RPM 950 ran Spk Adv 32 Ideg Boost 2 Tpsig Scaled Load Ux Scaled RP ht Ux CF TFS b 04 What 13 64 MAP 01 kPa A Blue Ellipse will appear along the trace line highlighting the logged engine operating points To navigate the ellipse along the trace line depress and hold the Alt key while simultaneously depressing the left or right arrow keys As the blue Ellipse moves along the trace line the logged engine operating parameters will be displayed in the Dash The values displayed in the Dash can be used to calibrate the Fuel or Spark tables For example assuming the O2 Correction Signal was selected as a Dash display item the user can see how much fuel the ECU had to add or subtract at every point cell along the trace line The va
102. flow rate calculator it was determined that the actual pound hour flow rate of 160 hr injectors at 55 PSI is 177 pounds hour To get cubic centimeters per minute multiply the 177 value by 10 and the result is 1 770 cubic centimeters minute Input this value into the Fueling Parameters Injector Flow Rate A cell The same calculation is used for the second set of injectors in a 16 injector system except the calculated flow rate for the second set of injectors must be inputted into the Fueling Parameters Injector Flow Rate B cell For a 24 injector setup the combined flow rate of the first two sets of injectors must be inputted into the Injector Flow Rate A cell and the flow rate for the last set of injectors must be inputted into the Injector Flow Rate B cell Return_to_ Fueling Parameters Setup Crank Trigger See settings below for the input values Crank Ref Angle deg and Inductive Delay us to be used based on the most common configurations Additional information on this subject is available on the BigStuff3 website under the How To Help section via this link http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf The crank timing Crank Ref Angle should equal the value in the table Engine Type Crank Ref Angle Inductive Delay u seconds CE E 24 V6 DIS GMHE fH ST UFF Version 2 1 February 2011 44 BigStuff3 Pro SEFI System Return_to_Crank Trigger Configuration COP Setting
103. for 16 inputs and the Y axis represents engine load and allows for sixteen 16 inputs as well The X and Y axes are configurable For information on how to configure the X and Y axes see Load_vs_ RPM While the engine is running a real time Ellipse will move throughout the Fuel table relative to the current RPM amp Load operating point Use it as a point of reference to help calibrate the Fuel table To change a VE cell value in the Fuel table move the cursor using the PC s mouse or the arrow keys to the cell to be changed Click on the cell and type a desired VE value from to 15 0 to 200 and hit Enter to save the change To make changes to multiple cells simultaneously left mouse click and drag the cursor across the cell range to be changed Release the left mouse button and a secondary drop down screen will appear outlining three potential cell fill options x BigComm Fueling Table E Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC windows Help 0 X z Kd i Refresh 30ms MAP KPa Fill Multiply Interpolate Cancel Inj Fuel Flow 0 lb hr Gross Inj PW 0 0mS Base Inj PW 14 1mS RPM 0 Vol Ef 100 0 Act AFR 0 0 1 BLM Cor 0 0 CLT Cor 0 0 02 Cor 0 0 AFT Cor 0 0 AIR Cor 0 0
104. from 1 to 50 The gain function subtracts the desired air fuel ratio from the actual air fuel ratio then multiplies the difference by the user defined gain and affects the closed loop response Hot amp Cold Delay Inputs e Hot Delay This input in seconds is the time the ECU waits before allowing the system to go into closed loop fuel control when the engine coolant is above 60 F e Cold Delay This input in seconds is the time the ECU waits before allowing the system to go into closed loop fuel control when the engine is below 60 F The Minimum Coolant Temperature threshold described below also affects the Hot and Cold Delay parameters Minimum Coolant Temperature The minimum coolant temperature input is the temperature threshold the engine coolant needs to exceed before the ECU will let the system go into closed loop control To make changes to the values in these tables use the left or right arrow keys to move the cursor to the cell to be changed Input the desired value and click on OK at the bottom of the table STUFF Version 2 1 February 2011 61 BigStuff3 Pro SEFI System Z d E aen Offline 8 18 10 Testing big AFR Parameters Close Loop Parameters On RPM 1000 Hot Delay sec 2 Off RPM Cold Delay sec 20 AS Min Coolant Temp F 1110 7 Gain 2 Help Close 30 SPARK F4 Quick Key There are several ways to access the base Spark table The quicke
105. g cranking is to check it with an voltmeter Securely fasten the voltmeter s red positive wire to the ignition input on the fuse block Secure the voltmeter s black wire negative to a adequate ground location Crank the engine and the voltage meter should indicate an output of between 12 to 14 volts If the output voltage is below 12 volts check to make sure the battery is fully charged and all the cells of the battery are functioning properly NOTE If the engine cranks but does not start make sure the battery voltage is at or above 12V during cranking Low battery voltage conditions must be fixed prior to starting the engine Battery voltage especially during cranking is even more important with coil on plug applications Back to Switch Ignition Positive and Negative Battery Connections Four 4 3 8 ring terminals Two 2 red wire terminals and two 2 black wire terminals The GEN3 main wire harness ground cables and the ignition system must BOTH be grounded to the same negative post of the same battery Failure to run the ground cables from both these systems directly to the battery will cause performance issues and potentially damage one or both of the electronic systems No other ground paths solutions are acceptable To avoid ground loop issues and the hours of frustration that come with them ground the BS3 and MSD systems directly to the battery Also do not splice any other ground wires from other sys
106. g this Price List software The build date is located on the back side of the ECU The cost for firmware updates is 100 USD plus S amp H Please call BigStuff3 for more information Products Downloads FAQL Upgrades Wednesday February 11th 2009 o a was T anne Version 2 1 February 2011 29 BigStuff3 Pro SEFI System Double click on Run 0 of BigComm_Setup exe from 173 201 161 195 File Download Security Warning Do you want to run or save this file _ Name BigComm_Setup exe _ Type Application 3 13MB From 173 201 161 195 While files from the Internet can be useful this file type can potentially harm your computer If you do not trust the source do not tun or save this software What s the risk 13 of BigComm_Setup exe from 173 201 161 195 fa O amp J BigComm_Setup exe from 173 201 161 195 Estimated time left 6 min 4 sec 288KB of 3 13MB copied Download to Temporary Folder Transfer rate 8 37KB Sec O Close this dialog box when download completes Open Open Folder SmartScreen Filter checked this download and did not report any threats Report an unsafe download Verifying BigComm_Setup exe from 173 201 161 195 4 x Internet Explorer Security Warning The publisher could not be verified Are you sure you want to run this software Ls De x This file does not have a valid digital signature that verifies its publisher You Name
107. g to about 10 degrees while maintaining the desired idle RPM at normal engine operating temperature The cells below and around the obelisk the floating football shape will be used See the example screen print below Abate Version 2 1 February 2011 76 BigStuff3 Pro SEFI System oa SNA E E ea MAP KPa In this example the area within the orange square is where the obelisk will be floating when the engine is idling at normal operating temperature Working back and forth between the spark table and idle set screw decrease the timing values in this area to about 10 degrees while opening the throttle to maintain the desired idle RPM The spark value in this cell should be set to about 22 to 24 degrees This is the cold start timing It is used when the throttle is below the Max TPS for Idle calibration Under Operating Configuration and when the coolant is below the Coolant AFR Temperature AFR Parameters calibration This helps with the cold engine fast idle function R00 1000 1111 1200 1500 1800 2000 2600 3200 3750 4200 4800 5200 5800 6250 RPM Press lt Ctrl gt lt Enter gt keys together to Update Window Again this is an iterative process If the timing values within the orange square above were to be decreased from 30 degrees to 10 degrees all at once the engine would die To avoid this slowly work back and forth decreasing the timing and then opening the throttle blade with the set screw un
108. gStuff3 Pro SEFI System Release the left mouse button and the selected graph area will fill the screen Again the left and right arrow keys on the keyboard can be used to display the actual engine operating parameters recorded at each point in the graph r E CT fine C Program Files BigStuff BigComm Leo s C167vtte bi Fa Scaled Load OxF0 m ia fs Scaled RPM i Red Zoom In box created when left mouse button is depressed in the upper left hand corner and dragged down and across to create a box over the desired area l Spk Ady 24 8dey Boost 15 5psig 1 Once the left mouse button is released the graph area inside the red box above will fill the screen as shown below b 88 25 Time 30 04 ec Viewing Log History Press R to re triqger T Iffline C Program Files Bigs tuff BigCommiLeo s C167ette bi Scaled Load Scaled RPMI Spk Ady 27 deg e Red cursor line Time 18 63se Viewing Log History Press R to re triqger The left and right arrow keys on the keyboard can be used to move the red cursor line to display the actual engine operating parameters recorded at each point in the graph Click the right mouse key to get back to original Log Window screen Version 2 1 February 2011 105 BigStuff3 Pro SEFI System 75 Dash Logging procedure to record Data Log session Select Dash from the Main Window tool bar S
109. h the acceleration event occurred The amount of Run Time Correction fuel is decreased as time transpires and the engine warms up The first cell in the table all the way to the left represents the first 2 minute of engine run time The cell all the way to the right represents the end or eighth minute of engine run time The Run Time Correction table s input values need to decrease as you work from the left to right While the engine is running a real time Ellipse will move within the Run Time Correction table relative to the current Run Time Modifier operating point Use it as a point of reference to help calibrate the Run Time Correction table To change a value in the Run Time Correction table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The inputs shown in the table below can be used as a baseline Run Time Correction Table Run Time Correction 50 ers 22 19 17 16 12 8 0 0 0 Run Time 0353 AE Run Corr 0 0 54 MAP Parameters The Secondary Transient Fuel table is MAP Parameter Configuration This table is used to control auxiliary MAP and TPS transient and base fuel functions mz E SE dMAP Parameter Config IF loj x AAE MAF Limit 105 KPa TPs Clip feo FCO GFCO n 30 KPa DFCO OFf 35 KPa AE Temperature Run Temperature 120 2 deg F Close Versio
110. he Hardware Main Configuration table is relatively self explanatory Working from the top of the table select the parameters in the screen print above as follows e Select the number of cylinders the engine has e Select whether system will operate using a speed density engine speed and engine load or Alpha N throttle angle and engine speed algorithm The majority of the engine applications use the Speed Density control algorithm If the camshaft duration exceeds 260 at 050 lift the Alpha N control algorithm should be considered Contact BigStuff3 if you are uncertain whether Speed Density or Alpha N control is best for your application e Select the fuel feed back control configuration Open Loop control uses the oxygen O2 sensor feedback to ensure the user defined air fuel ratio is achieved Open Loop control does not use the oxygen sensor feedback to ensure the desired air fuel ratio is achieved In most cases tuners will set the initial calibration and perform subsequent fine tunes in Closed Loop but will race with the O2 sensor turned off Open Loop Note The air actual air fuel ratio will still be displayed and recorded via the Replay feature while in Open Loop mode e Select the type of Throttle Position Sensor TPS being used to output throttle angle to the ECU The TPS is located on the side of the throttle body at the end of the throttle shaft GM style TPS sensors have a 5V to 4 5V out
111. he percent of fuel added is greater at the two temperature extremes The largest amount of fuel is needed when the engine is coldest A larger amount of fuel is also added when the engine is hot versus the mid range temperatures to release any vaporized fuel that may have boiled in the fuel rail s during a hot soak While the engine is running a real time Ellipse will move within the After Start Correction table relative to the current engine coolant temperature operating point Use it as a point of reference to help calibrate the After Start Correction table Version 2 1 February 2011 71 BigStuff3 Pro SEFI System To change a value in the After Start Correction table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change i EC AfterStart Correction Table ojx AfterStart Corr Coolant F 38 AfterStart Decay The After Start Correction fuel being added by the ECU during an engine starting routine is only required for a very short period of time The ECU pulls the fuel back out or decays it as a function of crankshaft interrupts and coolant temperature The ECU decays the After Start Correction Fuel over the number of interrupts depending on the temperature the engine is currently operating at defined in the After Start Decay table The decay period mentioned here is very very short The table below shows 8 i
112. hreshold 0 100 TPS Log for 0 30 seconds amp Update Data While Logging yes or no settings Next type in a Log File name and hit OK Note Once the initial Log File name is entered the BigComm software automatically increments with number extensions and saves the subsequent Log Files associated with the initial file name You will need to create a new Log File name to initiate another log data session that is not related to the initial file name 13 After entering a Log File name a Record Log session can be initiated Again there are several ways to initiate a log session Below are the different log initiation options e Option 1 Hit the F8 key e Option 2 Select the Record Log Icon in the Main Window tool bar When the log window opens hit the PC s space bar to start the logging event e Option 3 Select Logging from the Main Window tool bar Then select Record Log from the Logging drop down list Note Steps 1 through 13 can be configured off line or on line However you need to be on line to record a data log session 14 After selecting one of the above Record Log options the Log Window Dash will be displayed Hitting the PC s Space Bar or exceeding the TPS Threshold setting can initiate the Record Log session 15 Once the Record Log session 1s initiated the BigComm software will begin to record the Log Window Dash signals The logged signals will be displayed in the Dash at the bottom of the screen as well as
113. ifications are inputted into the correct input cells Entering a smaller pulse width into the cell representing an engine coolant temperature of 144 will not help start the engine when the temperature is 55 Note If the throttle is opened to position greater than what was set in the Clear Flood TPS setting the ECU will not add fuel See Clear_Flood_Setting for more details Pulse Width ms 12 8 312 8 12 8 12 8 10 2 10 2 10 2 10 2 ou tr edl el ei 6l eil i 14 8 15 8 33 8 44 6 55 4 66 2 77 9 90 1 102 111 125 144 169 196 230 244 Coolant F While the engine is cranking a real time Ellipse will move within the Cranking table relative to the current engine coolant temperature operating point Use it as a point of reference to help calibrate the Cranking table Version 2 1 February 2011 70 BigStuff3 Pro SEFI System To change a value in the Cranking table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change Once the engine starts the ECU will detect the rapid change in engine speed the ECU will ignore the Cranking table and begin using inputs from the After Start Delay see section 37 36 AfterStart Delay Once the ECU detects the engine has started it uses the vehicle coolant temperature sensor and inputs from the After Start Delay table to decide when to introduce the After Start Correction Fuel The ECU begi
114. ill automatically override the two step function when 12V is applied to the 3 step wire with 12V still applied to the 2 step wire Note If the GEN3 system has both 2 step and 3 step functionality and only one of the two rev starting line rev limiters will be used BigStuff3 recommends using the 3 step two step high control Note The internal or optional external data logger trigger wire describe in the Boost section below must be enabled 12V supplied to the data trigger wire for the 2 step and or 3 step to function Back_to_2_ Step STUFF Version 2 1 February 2011 24 BigStuff3 Data Log Trigger amp Timer Enable Wiring Diagram Off Foot Brake amp Trans brake Switches With Optional 2 Step Row 1 Row 2 Row 3 Row 1 Row 2 Row 3 Switched 12V Source in the Vehicle Foot brake or Trans On Off Switch brake Switch 12V required for applied to this wire when Data Trgger wire foot or trans brake button GEN3 ECU Header 1 Terminals A K is depressed A BCDE F GH J K Brake v7 Lights or Trans Yellow 2 Step Wire To Hdr 1 B2 brake To Hdr 2 Y2 Optional Dash Mounted ON OFF Switch to turn the Timer Enable On and Off This Switch is Required with Optional SR2 System BigStuff3 Data Log Trigger amp Timer Enable Wiring Diagram Off Foo
115. in the firing order inputted into the software What the GEN3 system cannot do without the cam camshaft position input hooked up is to determine where to inject fuel the position in crankshaft degrees relative to TDC for each cylinder Since the GEN3 system was designed with one injector driver per cylinder for up to 24 injectors it s easy to see how individual fuel control per cylinder is achieved Why is the spark timing recorded in the Replay different from the timing configured in the spark map o The Staged Boost control is active and there are spark retard values in one or more of the three 3 spark retard tables under Boost Control o A similar situation will occur if the idle spark control is active at idle Version 2 1 February 2011 123 BigStuff3 Pro SEFI System e Will the GEN3 ECU drive high and low impedance injectors O Yes it can drive both high and low impedance injectors The GEN3 ECU can even drive both injector types of injectors simultaneously with the 16 or 24 injector options The GEN3 ECU auto detects the type of injector being used so no set up is necessary e At what injector duty cycle are my injectors considered out of control or static O Loss of injector control does not occur at 100 duty cycle but at approximately 85 duty cycle At 85 duty cycle the injectors are most likely not opening and closing in a controlled fashion This condition is termed static vs dynamic control An
116. ing table offers default Load schedules for 1 2 3 amp 5 BAR MAP sensor applications Load Schedule for 1 BAR MAP Load Schedule Load Schedule Load Schedule Sensor for 2 BAR MAP for 3 BAR MAP for 5 BAR MAP Normally Sensor Up to Sensor Up to Sensor Over 30 Aspirated 15 PSI of Boost 30 PSI of Boost PSI of Boost Engine 106 MAP KPa Y Axis Cell Number l6 106 f 25 se a pA 5 _ 10 B I6 R2 85 1590 u 3 f 15 0 5 5 ae V S 65 105 110 pS 6 5 5 4 5 S5 E E 95 250 400 229 150 200 175 150 85 300 150 45 95 100 _ _ 50 35 The following table offers default RPM Schedules for several engine configurations RPM Schedule for a High RPM Racing Stock Torque Mild Street Engine Engine 9 500 Max Engine 6 500 Max RPM RP M o 9 A002 800 6000 P8000 00 S o 6 160 8008500 4A 200200500 pd RPM Schedule for a RPM Schedule for a RPM Y Axis Cell Number Version 2 1 February 2011 51 BigStuff3 Pro SEFI System 21 Firing Order Once the Load and RPM axes have been configured go back to the Configuration on the Tool Bar Left click on the Configuration and the drop down screen will open Keep the left mouse button depressed and slide the mouse pointer down until Firing Order is highlighted Release the left mouse button The screen below will open Xi
117. ion Cars For automatic cars the ignition timing should not be retarded You want to use whatever ignition timing values the engine requires to build boost and make the car leave hard Version 2 1 February 2011 94 BigStuff3 Pro SEFI System Offline 7 8 18 10 Testing big mo jo 11 0 mo mo 11 0 600 a00 1000 4444 4200 4500 4800 2000 2600 3200 3750 4200 4500 5400 6000 6500 RPM Note The timing values inputted into the Start Line Timing table are the absolute values the ECU will use when the Boost Parameters minimum RPM and TPS are reached If you enter zero Q in the table there will be no starting line timing Boost Connector Pin out Configuration A Timer Enable 2 Stage 1 PWM Output Stage 2 Oo Sage o o pg O 65 Dash A Dash short for Dashboard can be configured and displayed at the bottom of most of the Operating Screens within the BigComm software A Dash needs to be selected configured and saved as a default before it will appear at the bottom of a BigComm software Operating Screen Up to thirty one 31 individual Dashes can be configured to display various engine parameters also referred to as Signals When the BigComm software is launched it uses the Default Dash which contains the 31 separate dash s from the C Program Files BigStuff BigComm folder The Default Dash is actually a compilation of the 31 available dash s The recommended w
118. ion Table Upgraded Systems with Advanced Firmware Z E d B aam Offline 8 18 10 Testing big sc Ind Cyl Fuel Corr Table RPM 64500 6000 6400 4800 4200 3750 3200 2600 2000 1800 1500 1200 1111 1000 800 600 0 Cylinder 60 Boost The GEN3 ECU allows the user to control boost parameters Two boost strategies can be employed 1 A Pulse Width Modulated PWM valve can be used to control boost as a function of engine RPM The duty cycle of the valve can be changed as a function of engine speed 2 A staged boost strategy can also be used Up to three stages of boost can be switched on using solenoid valves in a user defined timed sequence The vehicle can be configured to come out of the hole with one stage applied and as time distance down the track expires the second and third stages of boost can be turned on The Boost Parameters can be configured from the Main Menu screen Tool Bar Left click on Boost The following screen will open Version 2 1 February 2011 90 BigStuff3 Pro SEFI System BigComm le x Fie Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Transmission Torque Management Logging Replay Configuration PC Windows Hel ia Start Line Timing z E _ as T offne c Program Files BigS goost pwm Desired Boost 1st Stage Boost Spark 2n
119. ixed inputs in the table below represent the firing order configured during the firing order configuration process Firing Order_Config The input cells allow the user to define the amount of timing retard up to 10 for or each cylinder in the table Timing corrections are made to the values in the Spark Table Note The GEN3 LS1 Coil on Plug COP and the Stand alone COP systems are the only GEN3 systems with bi directional timing compensation 3 kd Bs m Refresh 32ms s Individual Spark Table Timing Correction deg 0 5 SES 1 0 00 0 0 1 8 7 2 6 Cylinder Number 59 Individual Cylinder Fuel The fixed inputs in the table below represent the firing order configured during the firing order configuration process Firing Order_Config The input cells allow the user to define the percent of fuel to be increased or decreased up to 25 for or each cylinder in the table The individual fuel correction values modify the base pulse width in the Fuel Table To change a value in these tables move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change Version 2 1 February 2011 89 BigStuff3 Pro SEFI System Individual Cylinder Fuel Correction Table Base Systems 2B D E aa eterein ss Individual Fuel Table Fuel Correction 0 0 0 0 1 6 0 0 6 5 1 Cylinder Number Individual Cylinder Fuel Correct
120. k Film Ignition TFI Pin out Detail Top To BigStuff Connector Pin B To BigStuff Connector Pin A Not Used Connector Clip gt 12V Switched Power supply Ignition run and start To Negative Coil Lead or Points Input on Ignition System To BigStuff Connector Pin D Note BigStuff Connector Pin C is not used with the Ford TFI Ignition More Ford TFI ignition wiring information is available on the Bigstuff3 website via this link http bigstuff3 com pdtf Ford 20TFL pdf GM High Energy Ignition HEI Pin out Detail For Distributors with Ignition Coil in the Distributor Cap Connector Clip BigStuff Harness Connector Pin A Pin B Pin C Pin D To distributor connector pin D To distributor connector pin C To distributor connector pin B To distributor connector pin A Version 2 1 February 2011 16 BigStuff3 Pro SEFI System GM High Energy Ignition HEI Pin out Detail For Distributors with External Ignition Coil Connector Clip BigStuff Harness Connector Pin A Pin B Pin C Pin D To distributor connector pin A To distributor connector pin B To distributor connector pin C To distributor connector pin D More GM HEI ignition wiring information is available on the Bigstuff3 website via this link http bigstuff3 com pdt Visio Small 20Cap 20HEI 20Drawing pdf Buick Direct Ignition System DIS Pin out Detail Connector Clip BigStuff Harness Connector Pin A Pin B
121. l fine adjustments may be required msa o fs pufa Next from the main BigComm tool bar go to Idle and then Idle Spark in the drop down The table below will open Input the values shown below into your Idle Spark table Z ag H Ore 20 4902 be Idle Spark Table Idle Spark deg In an effort to maintain a stable idle the GEN3 ECU will e Add advance the timing values to the left of the zero RPM cell to the base spark map timing values e Subtract retard the timing values to the right of zero RPM cell from the base spark map timing values Since the timing values in the spark map are now approximately 10 degrees at idle the Idle Spark Table now has significant authority in maintaining idle stability by introducing large as a percent of 10 degrees of timing timing values when the engine RPM decreases or increases Do not put negative values into the cells to the right zero RPM in the table The ECU automatically treats these as timing retard values Lastly from the main BigComm tool bar go to Configuration Operating Configuration TPS Make sure the Max TPS for Idle value is 2 to 3 above the TPS at idle For example if the TPS that was set at idle is 2 the value in this table should be 4 or 5 otherwise there will be no Idle Spark Control STUFF Version 2 1 February 2011 78 BigStuff3 Pro SEFI System 5 x Crank Trigge Drivetrain Crank reference deg
122. l values will increase or decrease by a value of one 1 for every keystroke To exit this mode depress any one of the arrow keys The illustration below shows the areas of the base fuel map that the ECU accesses under different driving conditions Hint Use the 02 Correction feedback in the Dash to help calibrate the Fuel table VE values MAP Kpa Engine Load 80 so 80 so 87 90 91 i w EIEI H E 125 80 c eTe a a u afefe 111 SN Hote i ara fi 90 90 weaeetatatetars malls acon 5 90 7 7 so so so so 75 82 Jo annnnnE ee STETE TEETE TE REEE 6o 66 f 66 60 60 OOO if a 59 59 er 87 Sees W 2 2 OP 2 56 ge 50 eye el sps Ie A Jant oo 7 PR REEREE REE ge EEE Eola Es eer ota 800 71 000 1 150 1 200 1 500 1 800 2 000 2 400 2 800 ae 3 600 4 000 5 000 6 000 7 000 RPM The BigComm software allows the user to configure the Load MAP and RPM axes allowing for a larger number of cells map area to be used for the fuel and spark tables Note Be sure the ECU 1s properly configured and the Base Fuel and Spark Tables are calibrated before configuring and calibrating any of the following engine operating parameters 34 STARTING The Starting drop down selections allow the user to calibrate parameters associated with starting cranking and running the engine for a short period of time temperature dependent after the engine 1s initially started STUF
123. lded vertical or TAN a ANN T e Make sure sensor cabling is routed and secured away from the exhaust system Stainless steel mounting bungs are also available for turbocharged applications Drill a 7 8 15 16 hole in the exhaust pipe Weld a WBO2 sensor mounting bung into the exhaust pipe The mounting bung was manufactured with a lip to help locate it prior to welding it to the exhaust pipe The entire circumference of the mounting bung must be welded and free of exhaust leaks Exhaust leaks around the bung will affect sensor readings Carbon and stainless steel bungs are available from BigStuff3 This side with the mounting lip goes into the exhaust pipe to locate it prior to being welded Once the sensor mounting bung is welded into place thread the sensor into the bung Installation torque is about 10 15 ft lbs Connect the oxygen sensor 6 way connector with gold plated terminals to the main wire harness 7 ECU Installation The ECU must be installed in the passenger compartment The ECU has four 14 20 x 5 16 x 42 threaded isolation grommets threaded into the bottom of the housing To avoid the potential of severely damaging the ECU connect the head connectors to the ECU only after the battery connections are made Note If the factory installed isolation grommets are not used to mount the ECU the bolts used must not extend beyond the 4 factory installed depth Using bolts or thr
124. linder Starting Fuel WarmUp Boost Dash Transmission Torque Management Ethanol Logging Replay Maeieiieimi PC Windows Help Injector Opening Time z kd E Offline 48 18 10 Testing big Firing Order IO Status Load vs RPM Axis Injector Phase Angle Hardware Configuration Operating Parameter Configuration Auto Shifter Configuration Barometric Correction Check Replay Type An example of a default table supplied with the system 1s shown below E oe Version 2 1 February 2011 48 BigStuff3 Pro SEFI System Offline 8 18 10 Testing big 600 a00 1000 1411 4200 4500 4800 2000 2600 3200 3750 4200 4800 5400 6000 6500 RPM This is the same table as 1s shown above with the window maximized z SCC Refresh 15ms Dwell Time ms 600 800 100011111200 1500 180020002400280032003600400050006000 7000 20 Load vs RPM The BigStuff3 GEN3 SEFI system offers configurable Load amp RPM axes Pye Oo EJ Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Factory PC Windows Help ba Injector Opening Time kd Refresh Rate Firing Order IO Status Fuel Parameters Hardware Configuration Operating Configuration This feature allows the user to configure the X axis RPM and Y Axis Load so that a majority of the available16 cell by 16 cell fuel and spark map area is available for calibrating Systems with fixe
125. lows for easier tuning e Windows 95 98 2000 NT XP Vista and Windows 7 compatible calibration software e Compact black powder coated aluminum extruded ECM with integrated rubber isolators e Electronics rated from 40 C to 105 C STUFF Version 2 1 February 2011 4 BigStuff3 Pro SEFI System e Aesthetically pleasing nylon braided wire harnesses with integrated ECU and Injector WBO2 fuse protection e OEM style Packard amp TYCO waterproof connectors amp terminals GEN3 PRO SEFI System Optional Features e New four 4 Stage Dry Nitrous Oxide System available in February 2011 For more information see the manual on our website under Manuals e Integrated CO2 Boost controller No longer any need for a separate standalone system e EJET Electronic carburetor Call BigStuff3 for more details e Wide band methanol control down to 2 9 1 A F ratio e Engine Torque Management systems ETM and SR2 or ETM SR2 using cylinder cut off spark or a combination of both e CAN interface to e Various RacePak dashes Send GEN3 engine operating information directly to a RacePak dash e Racepak V300 or 500 data acquisition systems Send GEN3 engine and powertrain data to a Racepak data acquisition system and avoid having to buy redundant sensors e RacePak EGT monitoring and recording The GEN3 system can also data log RacePak EGT Data without the need for another external data acquisition system e E10
126. lues in the cells along the trace line can be increased or decreased in the Trace screen by the amount of the O2 correction shown in the Dash The values in the cells next to and surrounding the trace line can also be increased or decreased To change the Fuel or Spark Table values while in the Trace screen simply left click on the desired cell input the new value and hit the Enter key Continue this process for all of the traced cells To make changes to multiple cells simultaneously left mouse click and drag the cursor across the cell range to be changed Release the left mouse button and a secondary drop down screen will appear outlining three potential cell fill options Version 2 1 February 2011 114 BigStuff3 Pro SEFI System x BigComm Fueling Table E Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC windows Help 8 X i 9 22 MAP KPa so 80 8 s 80 8 80 8 8 8 W s s eo s o 75 75 amp 8 B 7mo n o 7 W W 70 e a 7 7 8 w w w w xW 7 7 ECCI 8 eae Em m 5 08 so sao oaoa oao s8 oa Comm 1000 1111 RPM 4950rpm Spk Adv 32 0deg Boost 2 psig Scaled Load 0x80 Scaled RPM 0x CF TPS 6 0 vhat 13 61 MAP 61 7kPa WhenUSEARCH Q Search g Specials The WhenUSearch Toolbar Saving You Time and Money Find out 13 start ia GEN1_BigComm T3 Micros
127. me Ahat ontact Dealers How To Help Manuals Price List Products What s New Software Downloads Th gFarlyDays The Great Ones Videos Newsletter 4 items remaining Downloading picture http f bigstufF3 com wp content themes wordie images lee zane png amp Internet fo 100 Double click on the BigComm_Setup exe link shown below Software Downloads BigStuff3 com Windows Internet Explorer DER G 3j v e bigstuff3 com FR elx B oi File Edit view Favorites Tools Help x convert X F Select x Google v 29 Search gt M P7 Sharey b Ap Check Translate I AutoFill P Sa meane yy Favorites 543 Capuchin Soup Kitchen UE v FreeHotmail z gt Software Downloads BigStufF3 com fh 7 EC mp Page Safety gt Tools Featured Software Downloads The Early Days The Great Ones Videos Newsletter Pages Archive for the Software Downloads Category About Software Downloads Why BigStuff3 Friday May 8th 2009 Contact pasa ara l isles For BiaStuf atest software go to the link below BigComm_Setup exe How To Help When the link opens select Run twice Next four times and Install once The program will then self install creating Manuals the correct file hierarchy which is C Program Files BigStufiBigComm Price List Note If your GEN3 ECU has a build date before January 2008 you should update the firmware before installin
128. n 2 1 February 2011 85 BigStuff3 Pro SEFI System The first entry of the MAP Parameter Configuration table is Asynchronous Acceleration Enrichment AAE It is used to set the MAP transient fuel thresholds relative to MAP kPa and TPS values Below is a brief description of each e MAP Limit Establishes the MAP value in kPa at which the dMAP transient fuel is disabled For example if the MAP Limit value is set to 80 kPa the dTPSdt transient fuel will be disabled above MAP values of 80 kPa e TPS Clip Establishes the TPS value as a percentage at which the dMAP transient fuel is disabled For example if the TPS Clip value is set to 80 the dMAP transient fuel will be disabled above TPS values of 80 The second entry of the MAP Parameter Configuration table is Deceleration Fuel Cut Off DCFO It is used to calibrate when the Base Fuel Map pulse width fuel is turned off and on relative to MAP kPa values Below is a brief description of each e DCFO On Establishes the MAP value in kPa at which the Base Fuel Map pulse width is momentarily disabled It is used to calibrate deceleration drivability For example if the DCFO On value is set to 30 kPa the base pulse width will go to zero 2 5 seconds after falling below a MAP value of 30 kPa with the throttle closed The Base Fuel Map pulse width is turned back on based upon the DCFO Off value see DCFO Off e DCFO Off Establishes the MAP value in kPa at which the Base
129. n the Air Fuel Ratio Table The input values in the tables below add or subtract fuel as a percentage for each cell in the entire engine Load row The cell all the way to the left corresponds to the bottom row in the air fuel ratio table and the cell all the way to the right corresponds to the top row of the air fuel ratio table The user input values in the Positive O2 Correction table need to be positive numbers and the input values for the Negative O2 Correction table need to be negative numbers as shown in each table To make changes to the values in these tables use the left or right arrow keys to move the cursor to the cell to be changed Input the desired value and hit Enter STUFF Version 2 1 February 2011 59 BigStuff3 Pro SEFI System Xe Positive 02 Correction Table Positive O2 Correction 27 Negative 02 Correction This table is configured and operates in the same way as the table above The difference being that this table limits the amount of Negative O2 Correction Negative 02 Correction Table Negative O2 Correction 13 3 14 1 11 7 28 View Lambda F2 Quick Key The View Lambda allows the user to view the current Lambda status in a large LED like format The window can be expanded or contracted by locating the mouse cursor at the edge of the window The cursor will change shape from an arrow with one 1 point two an arrow with points on both ends When th
130. n to hyperlink at the end of the text Note Additional components such as relays and special connectors may be required to complete your specific installation Contact your dealer or BigStuff3 for further details Important System Wiring Grounding Notes BigStuff3 cannot stress the importance of properly grounding the GEN3 system The GEN3 main wire harness ground cables and the ignition system ground cable s MUST BOTH be grounded to the same negative post of the same battery Failure to run the ground cables from both of these systems directly to the battery will cause performance issues and potentially damage one or both of the electronic systems No other ground paths solutions are acceptable A common practice is to run a AWG 1 through AWG 4 isolated ground from the battery to a firewall ground lug and then run every other electrical system ground to it This grounding solution will create ground loop issues If the isolated ground lug is only going to be used for the GEN3 and ignition system then it will work The problem with this approach is that with time other systems also end up being grounded to this lug which will then cause ground loop issues To avoid ground loop issues and the hours of frustration that come with them ground the BS3 and MSD systems directly to the battery Also do not splice any other ground wires from other systems components into either the MSD or BS3 ground cables The GEN3 system 12V power c
131. n will appear Name the file in this example Norwalk Calibration 2 and hit the PC s Enter key or left click on the Save button m BigComm _ T mz _ Fie Spark Ide Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel Warmip Dash Traction Logging Configuration Factory PC Windows Help B 9 BE SE eere Save Calibration File Save in gt BigStuff Calibrations Mid Michigan Calibration big E Morwalk Calibration 1 big File name Norwalk Calibration 2 Save as type big Cancel When using the BigComm software with GEN3 ECU special care must be taken to properly save On Line calibration changes Working On_Line means the BigStuff3 ECU is powered up the ignition is on and is connected and communicating with the PC A green ball will be seen moving back and forth in the upper right hand corner of the screen as long as an operating window is open with a dash selected See Green_Sliding Ball for more details GEN3 On Line or real time calibration changes are temporarily stored in the ECU s Random Access Memory RAM Once the desired calibration changes are made they are not permanently saved to the GEN3 ECU s Flash memory until the engine is turned off and the ignition switch remains in the Off position for fifteen 15 seconds If further calibration changes are going to be made the ignition switch must be turned back Version
132. ngine is running a real time Ellipse will move throughout the Spark table relative to the current RPM amp Load operating point Use it as a point of reference to help calibrate the Spark table To change a cell value in the Spark table move the cursor using the PC s mouse or the arrow keys to the cell to be changed Click on the cell and type a desired Spark value from to 15 0 to 63 8 and hit Enter to save the change To make changes to multiple cells simultaneously left mouse click and drag the cursor across the cell range to be changed Release the left mouse button and a secondary drop down screen will appear outlining three potential cell fill options x BigComm Spark Advance Table 4 File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help G x z Kd TT Refresh 30ms MAP KP a 203 nB Multiply s Interpolate 1 Cancel a fan an woo an an an 1000 1111 1200 1500 1300 RPM 0 Spk Adv 15 0 deg Act AFR 00 1 Scaled Load 0x00 Scaled RPM 0x00 TPS 0 0 Vbat 13 5V MAP 8 0kPa e Fill Choosing Fill will open a secondary drop down screen which allows the selected cells to be changed to the value inputted into the window e Multiply Choosing Multiply will open a secondary drop down sc
133. nk Trigger BS3 Connector A Red wire BS3 Connector B Black wire Reference MSD Distributor Violet Black wire Orange Black wire MSD Crank Trigger Accel 44000 Series Accel Crank Trigger MAP Manifold Absolute Pressure Green 3 way Packard connector The GEN3 system is supplied with Packard green connector which directly mates to a GM style 1 BAR Manifold Absolute Pressure MAP sensor For normally aspirated engines a 1 bar sensor is used For blown or turbocharged applications a 2 BAR MAP sensor must be used for boost pressures up to 15 PSI For boost pressures up to 30 PSI a 3 BAR MAP sensor must be used If a 2 or 3 BAR MAP sensors are used the harness side MAP sensor connector can be easily modified or replaced The modification involves cutting a new key way in the connector Contact a BigStuff dealer if questions come up related to the MAP sensor supplied with your system and to procure the necessary connectors BigStuff3 s four 4 BAR MAP sensor is capable of sensing pressures up to 52 PSI A new connector available from BigStuff3 must be used with the four 4 BAR MAP sensor For speed density applications the MAP sensor must be connected to an intake manifold port For Alpha N systems a 1 BAR MAP sensor can be used to sense ambient air pressure in the hood scoop or air cleaner Do not attach the sensor pressure port to the manifold More MAP sensor wiring information is available on the Bigstuff3 we
134. ns Coil Wire Harnesses for the LS1 style and BigStuff3 Hot coils 89 Frequently Asked Questions E oe What does working On line vs Off line mean o Working Off line The BigStuff3 ECU is not powered up PC Only The red ball is moving in the upper right hand corner of the BigComm software o Working On line The BigStuff3 ECU is powered on the communication cable is connected between the GEN3 ECU and a PC and the two are communicating with each other The Green ball is moving in the upper right hand corner of the BigComm software The changes I make to cells in the table do not stay What s wrong o The PC s Enter key must be depressed for changes to be temporarily saved To permanently save changes go to Save_Calibration section above Should I use the camshaft position input cam sync with my distributor based GEN3 system o Without the camshaft position input cam input connector in the main wire harness hooked up the GEN3 system still provides sequential fuel injection and individual fuel control per cylinder but injector phasing where the fuel is injected and individual spark control will not function How can the GEN3 system provide sequential fuel injection and individual fuel control per cylinder without the cam camshaft position input hooked up o When the engine starts cranking over the GEN3 ECU begins firing the injector drivers assigned to each injector
135. ns counting the crankshaft interrupts When the ECU counts off the number of interrupts defined in the After Start Delay table for the current engine operating temperature the ECU adds the After Start Correction Fuel The delay mentioned here is very very short The table below shows that nine 9 interrupts were used at 14 and 16 interrupts at 230 One can appreciate how quickly nine 9 or sixteen 16 crankshaft interrupts occur at an engine speed of 800 RPM While the engine is running a real time Ellipse will move within the After Start Delay table relative to the current engine coolant temperature operating point Use it as a point of reference to help calibrate the After Start Delay table To change a value in the After Start Delay table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change ie AfterStart Delay Table AfterStart Delay ae ee eee e ee ee 33 8 aA 4 24 125 14 5 102 164 230 Coolant F 37 AfterStart Correction As outlined above the ECU delays the introduction of After Start Correction fuel once the engine Starts The table below allows the user to define the amount of After Start Correction fuel to be added as a function of coolant temperature The After Start Correction fuel is added synchronously as a percent of the base pulse width defined in the Fuel table As you will notice in the table t
136. nterrupts were used at 14 and 22 interrupts at 230 While the engine is running a real time Ellipse will move within the After Start Decay table relative to the current engine coolant temperature operating point Use it as a point of reference to help calibrate the After Start Decay table To change a value in the After Start Decay table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change AfterStart Parameters Me AfberStart Parameters Coolant F Version 2 1 February 2011 12 BigStuff3 Pro SEFI System 39 Idle The Idle drop down offers the user five tables to calibrate the engine idle quality Each input table will be described in the paragraphs below To get to the Idle drop down screen go to the main Tool Bar and left click on Idle and the screen below will appear Hold the left mouse down and drag it to the desired input screen and release the mouse button i Biglomm File Spark Learning Transient Fuel Eun Throttle Follower Desired Idle RPM Idle Spark IAC Start Position IAC tain Terms 40 Throttle Follower Throttle bodies used with electronic fuel injection systems have an air by pass channel molded or machined into the valve body to allow air to be bypassed around the throttle blades when they are fully closed The air entering the engine through the bypass channel is used to
137. oe Marla Meaney s Documents My Network Places Files of type Log Files CSY v Cancel Time 00 00sec Laim From File Inj Fuel Flow 0 lb hr Boost 13 3psig RPM 0 Spk Adv 15 0 deg Act AFR 0 0 1 Eng Accel pms Inj Duty Cycle 0 TPS 0 0 Vbat 13 5 Air Terp 14 0F MAP 6 0kPa 02 Cor 0 0 An example log screen is shown below In this example the Log Window Dashboard was setup to collect and display Scaled Load Scaled RPM TPS V bat MAP RPM Spark Advance and Boost as shown on the right side of the screen The left and right arrow keys on the keyboard can be used to move horizontally across the logged data graph As the vertical red cursor line is moved across the graph the Log Dash displays the actual engine operating parameters recorded at each point in the graph 4 b gt o as T tine c Program Filee BigStuf BigComm Lec s C167Vette bi This window identifies the file name and location where the Logged Data was automatically stored Red vertical cursor line Time 14 97 sec Viewing Log History Press R to re trigger The user can also zoom in on a particular area of the logged data in the graph To zoom in on a particular area of the graph depress and hold the left mouse button Drag the mouse to cover the desired area A red box is created around the selected area as shown in the screen print below Version 2 1 February 2011 104 Bi
138. oft Word BigComm BigComm Goa thd 7 59 PM e Fill Choosing Fill will open a secondary drop down screen which allows the selected cells to be changed to the value inputted into the window e Multiply Choosing Multiply will open a secondary drop down screen which allows the values of the selected cells to be changed by the Multiply value inputted into the window For example if the values in the cells selected are 13 and the inputted Multiply value was 80 the new cell values would be 10 4 e Interpolate If a series of cells in the same row are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way to the left and the cell value all the way to the right and interpolate the numbers in between so that the values are linear Cell Changes using the Page Up amp Page Down Keys Fuel and Spark Tables Multiple cell values can also be changed simultaneously using the Page Up and Page Down keys This approach offers a quick alternative to using the mouse Use the keyboard arrow keys up down left right to maneuver to area of the map where the desired cell changes will be made Next depress and hold the keyboard Shift key Now use the arrow keys to maneuver through the cells to be changed As the cells are being selected they will become highlighted Once the desired cell range has been highlighted release the
139. on the right hand side of the Log Window Dash screen The signals will be recorded for as long as the Record Log Time setting 0 30 seconds Note After the Record Log session has timed out the Log Window Dash signals will continue to be displayed in real time at the bottom of the screen assuming that the engine is still running Also 1f power is turned off before the Record Log session has timed out the Log File data will be lost STUFF oe ge ee ee oo eee Version 2 1 February 2011 106 BigStuff3 Pro SEFI System 16 Once the Record Log session has timed out you can either view the Logged data file see step 17 or initiate another Record Log session by hitting the R key Once triggered hitting the PC s Space Bar or exceeding the TPS Threshold setting can initiate another Record Log session 17 There are a couple of ways to access the Record Log data file Below are the options e Option 1 Select the View Log File Icon from the Main Window tool bar e Option 2 Select Logging from the Main Window tool bar Drag the mouse to View Log File from the Logging drop down list 18 After selecting one of the above View Log File options select the Log File you want to view and click on Open Once opened the Log File data will appear in the Log Window Refer to the Logging section of the BigComm instruction manual to learn how to navigate the Log Window screen 19 The Trace function can also be used in the on line or of
140. one or two fuel pumps If a mechanical pump is being used or if the fuel pump s will be controlled via an independent switch no inputs are need in this section Assuming the GEN3 will control the fuel pump s the first input is the fuel pump Prime Time in seconds allowing the user to set the amount of time the fuel pump will run when the ignition is turned to the On position This allows the user time to prime the fuel pump and check for leaks before the engine is started A time period of up to 25 seconds can be inputted into this screen See the section above titled Fuel_Pump for additional information The second input Second Pump On TPS is only needed if the GEN3 ECU is being used to turn on a second fuel pump as a function of throttle position TPS See the section above titled Fuel_Pump for additional information Return_to Fuel Pump_ Setup Drivetrain The vehicle final drive ratio and tire diameter inputs are required to enable the ECU to make the correct Mile Per Hour MPH calculations Return_to_Drivetrain_Setup Pickup Wheels This section allows the user to configure the pulses per rev input for the following pickup wheels e Driveshaft Pulse rev Assumes GEN3 system is equipped with the DAE SR2 or ETM options Input options 1 2 4 or 40 pulses per rev For the SR2 and ETM systems using a 4 magnet pinion collar use 4 pulses per rev For the optional GM transmission control system use 40
141. op down screen below will open mmm iai File Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Torque Management Logging Replay Mennin teaa PC Windows Help Bo ae Injector Opening Time Offline C Program Files BigStuff BigComm L98_SEFI_30_PID big Firing Order IO Status Load vs RPM Axis Injector Phase Angle Hardware Configuration drop down Main_Configuration Hardware Configuration Main tool bar Operating Parameter Configuration Auto Shifter Configuration Dwell Time Table Barometric Correction Check Replay Type To set up go to OPerating Configuration Keep the left mouse button depressed and slide the mouse pointer down until Hardware Configuration is highlighted Release the left mouse button The screen below will open Version 2 1 February 2011 39 BigStuff3 Pro SEFI System Hardware Configuration Table E Hardware Configuration Humber of Cylinders Control Algorithm E Cylinders Speed Density Alpha H Control Feedback C Upenboop Closed Loop Throttle Position Sensor Type f Ford f Gh Manifold Absolute Pressure Fuel Type 3 MAP Sensor a Engine T J PoE RRE Second Injector Bank Switeh Paint C e Ford GM 40 Injector Duty Cycle EJET Load Axis Scale Ztodswitch TFS E fe KPa C pel Ato 2 switch TPOZ 7 OK Help Cancel T
142. ositive battery lead is connected to the battery cut off switch strongly recommended and the switch is turned OFF before the Replay data is uploaded the data will be lost 79 View Replay from File Once data has been logged and transferred to a PC it can be viewed in the same way as externally Logged data To view Replay logged data go to Replay on the Main Menu bar Left click on Replay and drag the mouse down until View Replay From File is highlighted File Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Torque Management Ethanol Logging MG3S Configuration PC Windows Help Replay Configuration z Ta TA Offline 7 8 18 10 Testing big Upload Replay mua Release the mouse button and the screen below will open showing the available Replay logged files The file can also be accessed using the same method as externally logged files are accessed The Trace function can also be used with Replay internal data logger logged files For more information on how to use the Trace function go to the next chapter titled Calibrating with _the_Trace_Function Abate Version 2 1 February 2011 110 BigStuff3 Pro SEFI System i Fie Spark Fuel Ethanol Replay Windows Help Z Fy Offline 8 18 10 Testing big Choose a Replay File Look in O Milan Testing 8 19 10 v ex EJ El Milan 8 18 10_Replay000 El Milan 8 18 10_Replay001 Eh Milan
143. p Shot pulse width is less than the injector opening time the fuel will not be delivered asynchronously Instead it will be accumulated and added to the next synchronous pulse width Note The value in the first cell the cell all the way to the left must always be zero 0 Working from left to right each input cell in the Accel Pump Shot table represents a 1 change in throttle angle for a total percent change of 15 This is plenty of resolution since the ECU looks for changes every 20 milliseconds As a reference point it typically takes approximately 250 milliseconds for a person to slam the throttle open While the engine is running a real time Ellipse will move within the Accel Pump Shot table relative to the current Accel Pump Shot operating point Use it as a point of reference to help calibrate the Accel Pump Shot table To change a value in the Accel Pump Shot table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The values need to be larger as you work from the left to right The greater the throttle angle rate of change the larger the Accel Pump Shot table value needs to be a li x Accel Pump Shot Table Pulse Width ms CRORE 2 02 2 02 2 02 2 02 2 20 2 20 2 20 2 20 2 20 2 20 2 20 2 20 2 20 2 20 2 20 Throttle Rate 56 AE Position Correction The second TPS transient fuel control table
144. p control make sure the minimum RPM under Boost Parameters is 1 500 RPM below the 2 Step LO RPM under Operating Parameter Configuration Rev Limit 2 Step RPM LO enable RPM e Note If the engine cranks but does not start make sure the battery voltage is at or above 12V during cranking Low battery voltage conditions must be fixed before trying to start the engine Battery voltage especially during cranking is even more critical with coil on plug applications e Note The 2 step functionality is not a base feature on distributor ignition based systems It is a base feature on all coil on plug systems 3 step control is an option on all GEN3 systems e Note If the GEN3 system has both 2 step and 3 step functionality and only one of the two starting line rev limiters will be used BigStuff3 recommends using the 3 step two step high control e Note The internal or optional external data logger trigger wire describe in the Boost section below must be enabled 12V supplied to the data trigger wire for the 2 step and or 3 step to function e Note The Timer sequence will be reactivated every time the throttle is closed and then opened again since the Minimum RPM and Minimum TPS criteria are re satisfied e Note The three 3 stage Boost control feature can be used to just retard the timing without switching solenoids on if the criteria outlined in the section directly above are met e Note If mounting bolts other than the fa
145. play an integral role as to how the TPS Transient Fuel requirements are calibrated for abrupt throttle changes that causes the engine to accelerate TPS transient fuel is asynchronously injected relative to a rate of throttle change dTPSdt The asynchronous pulse can be modified relative to the throttle position STUFF Version 2 1 February 2011 86 BigStuff3 Pro SEFI System where the acceleration event occurred AE Position Correction Below is a description of how the TPS Transient Fuel requirements are calibrated using the dTPSdt and AE Position Correction tables 55 Accel Pump Shot The first TPS Transient Fuel control table is Accel Pump Shot and as the name insinuates it can be compared to a carburetor s accelerator pump shot The ECU uses the Accel Pump Shot table value to compute the size of the Asynchronous Pulse Width APW for a given rate of throttle change It does so by sensing the rate of the throttle change and then using the corresponding Accel Pump Shot table value to calculate the size of the asynchronous pulse width For example if the ECU detected a throttle change of 10 degrees second dTPSdt it would immediately look up the corresponding Accel Pump Shot table value of let s say 2ms After the asynchronous pulse is looked up the ECU then uses AE Position Correction table see below to modify the asynchronous pulse size relative to the throttle position at which the dTPSdt event occurred If the Accel Pum
146. ply The screen below will appear Version 2 1 February 2011 96 BigStuff3 Pro SEFI System Offline 74 48 12 10 Testing big Dash Configuration JD AFR Window 30 Fuel window 3D Spark Window Accel Pump Shot Table AE Position Correction Table AFA Window AlterStart Correction Table AfterStart Decay Table AfterStart Delay Table Air Fuel Ratio Table Ar Temp Correction Table Barometric Corection Table Boost PM Table This is the list of thirty one 31 available Dashboards Once configured these Dashboards will show up at the bottom of the corresponding operating screens Desired Driveshaft Table E Desired Idle APM Table OMAP RPM Modifier Table Oriveshatt Recovery Table ESS AE Cor Table ESS Boost Offset Table E85 Coolant Corr T able E85 Crank Corr Table ESS Lambda Offset Table E6o Primary Factor Table E65 Spark Offset Table Fuel T able Gear 1 Retard Graph After selecting a Dash to configure Signals need to be selected and added to the Dash After the Signals are selected added and saved they will be displayed in the Dash at the bottom of the relevant BigComm software screens The left side of the drop down screen below shows the Available Signals The right side of the drop down screen below shows the Signals in the Dash To add Signals to the Dash highlight a desired Signal on the left and click Add The Signal will move to the right sid
147. put a check mark in the box next to Launch BigComm as shown below a Jt Wt ie ern j i Setup BigComm Completing the BigComm Setup a Wizard Setup has finished installing BigComm on your computer The application may be launched by selecting the installed icons Click Finish to exit Setup Launch BigComm Connecting to the PC The BigComm software has now been successfully installed on your personal computer A 5 communication cable connects the BigStuff3 ECU with a personal computer PC A 25 cable is also available from BigStuff3 Using the communication cable supplied with the system connect the 3 way Packard connector to the mating half 3 way connector marked CalPort on the Main Wire Harness Connect the RS232 connector to the back of the personal computer Version 2 1 February 2011 33 BigStuff3 Pro SEFI System Packard connector Connects to the Main Wire Harness 5 Communication Cable l supplied AMP RS 232 connector Connects to PC CALPORT connector on the Main Wire Harness Connects to the Communications cable CalPort Problems If the RS 232 connector located at the end of the interface cable supplied with the system cannot be connected to your PC a 9 pin serial port interface adapter will need to be procured If the PC is a newer model it will most likely have a USB port If the PC being used is an older model it may only have a 25 pin se
148. put and Ford sensors have a 9V to 4 5V output e Select the Manifold Absolute Pressure MAP sensor setting for the application Make sure the appropriate MAP sensor has been purchased for the boost pressures that the engine will see For normally aspirated engines a 1 BAR MAP sensor should be used and the 1 BAR MAP setting should be selected For blown or turbocharged applications with boost pressures up to 15 PSI a 2 BAR MAP sensor should be used and the 2 BAR MAP setting must be selected For boost pressures up to 30 PSI a3 BAR MAP sensor should be used and the 3 BAR MAP setting should be selected For boost pressures up to 52 PSI a4 BAR MAP sensor should be used and the 4 BAR MAP setting should be selected For boost pressures up to 60 PSI gage a 5 BAR MAP sensor should be used and the 5 BAR MAP setting should be selected Ifa 5 BAR MAP sensor is going to be used contact BigStuff3 to make your 9 Version 2 1 February 2011 40 BigStuff3 Pro SEFI System system was supplied with the correct firmware and MAP sensor Return_to_Main_ Configuration Select the type of fuel the engine will run on The ECU firmware contains algorithms enabling the following fuel types to be used Gasoline Ethanol E98 Methanol E85 Do not select this setting unless running BigStuff3 s E85 Flex fuel system OO Q Although E85 can be selected it should not be used unless the optional E85 Flex Fuel system has been purchased Do not sel
149. ration guesswork Optional system methanol system capable of reading AFR down to 2 9 1 e Capable of driving smart Coil on Plug COP ignitions with the stock sensors for the GM LSX engines and the Ford MOD motor The GEN3 system for Hemi s is capable of driving the stock dumb coils e Injector phasing at the start of the fuel injection event e Ignition system type is software configurable for GM HEI Ford TFI LT1 V6_DIS and IPU e GM Idle Air Control AC e Individual cylinder fuel amp spark compensation e Turbocharged starting line timing curve e An integrated 2 Step is a base feature on all Coil On Plug COP ignitions based systems and is optional on distributor ignition based systems Optional 3 Step is also available on all systems e 1 2 3 4 and 5 BAR MAP sensor compatible e Comprehensive transient fueling algorithms e Seamless decel fuel cut off e Excellent cold starting and drivability e The Throttle Position Sensor voltage output is linearized between 5V and 4 5V for GM and 9V to 4 5V for Ford e Low side drive fuel pump and engine cooling fan functionality see relay diagrams below e Capable of controlling two fuel pumps in a stage configuration The low side pump is the primary pump The high side drive pump is the secondary controlled as a function of TPS e Closed Loop PID WBOZ2 heater control to insure accurate and consistent AFR control e Improved EMI algorithms e True Speed Density algorithm al
150. red with identification labels at the end of each wire or connector to ensure that connections are properly made The main wire harness has two halves one half 1s intended to be located inside the vehicle with the ECU the other half connects to the sensors in the engine compartment The two halves of the harness are separated by a firewall grommet designed to fit snuggly in a 2 1 8 hole in the firewall The best location for the hole is in an unobstructed location on either side of the engine closest to where the ECU will be mounted in the passenger compartment Care should be taken to keep the harness as close to the center of the vehicle as possible Locating the hole too far away from the vehicle center may affect wire lengths that connect to sensors on the engine Once the main harness is installed the connections need to be made to sensors the ECU etc The paragraphs below describe how and where each connection should be made Version 2 1 February 2011 7 BigStuff3 Pro SEFI System The instructions below are specific to the BigStuff engine management systems Hyperlinks underlined blue wording in the column titled Further Details were included to further assist with the main wire harness installation Left clicking the PC s mouse on the hyperlink will immediately link to a photo of the connector along with additional installation information To return to the same location in the table simply left click on the Retur
151. reen which allows the values of the selected cells to be changed by the Multiply value inputted into the window For example if the values in the cells selected are 13 and the inputted Multiply value was 80 the new cell values would be 10 4 e Interpolate If a series of cells in the same row are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way to the left and the cell value all the way to the right and interpolate the numbers in between so that the values are linear Version 2 1 February 2011 63 BigStuff3 Pro SEFI System Cell Values Selected in a Row Cell value to the left Cell value to the left Interpolated Result from Cell Values Selected Above 29 5 285 27 8 If a series of cells in the same column are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way at the bottom and the cell value all the way at the top and interpolate the numbers in between so that the values are linear Cell Values Selected in a Column 27 8 Interpolated Result from Cell Values Selected Above 27 8 If a range of cells multiple rows and columns are selected and the Interpolate cell fill option is selected the ECU will use the value in the cells at the bottom left and top left corners bottom left and bottom right corners and the bottom left
152. rial port Make sure the 25 pin port on the back of the PC is a serial port and not a parallel port there is a difference The parallel port will not work Parallel ports are typically printer ports that let data travel in only one direction If your PC is configured with only a USB port a USB to 9 pin adapter must be procured USB to 9 pin or 25 pin to 9 pin serial adapters are readily available at Radio Shack or comparable stores Radio Shack s USB port to 9 pin serial adapter is part number 26 949 40 00 Prior to establishing communication with the GEN3 ECU the PC s COM port needs to be selected In order to complete the PC COM port selection a quick overview of the Tool Bar is required The configuration tables within the BigComm software are accessed using the BigComm Tool Bar explained below For additional information on how to resolve Com Port communication problems go to the BigStuff3 Website Next go to the How To Help Section The BigStuff3 website link is http bigstuff3 com pdf Comport 20Connection 20Resolution pdf 11 Using the Tool Bar The Tool Bar is located at the very top of the BigComm Main Menu screen All of the BigComm software functionality 1s accessed using the Tool Bar and associated drop down screens 18 x File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel warmip Dash Logging Kemmimiesss PC Drop Down A green sliding ball indicates On line
153. rrection 13 3 22 7 22 7 31 2 39 8 TPS 10 0 57 Individual Cylinder Individual cylinder control allows the user to define the amount of fuel positive and negative and spark advance retard correction for each cylinder This feature is used to calibrate out intake manifold inefficiencies Note A cam input cam sync is required for individual spark control and injector phasing to be operational Without a cam sync the GEN3 system still injects fuel sequentially and allows for individual fuel control per cylinder All coil on plug systems must have the cam input cam sync hooked up and operational For additional information on how to set up and configure a cam sync go to the BigStuff3 website then to How To Help Ignition system Setup Tutorial The link is http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf From the Main Menu screen Tool Bar left click on Individual Cylinder The screen below will open The following paragraphs will describe how to calibrate each of the Individual Cylinder drop down selections File Spark Idle Transient Fuel Air Fuel Ratio Boe mereien Gea Starting Fuel WarmUp Boost Dash Transmission Torque Management Ethanol Logging Replay Configuration PC Windows Help Individual Spark l 4 Fy EJ peers ine 8 18 10 Testing big Ind Cyl Fuel Corr Table Version 2 1 February 2011 88 BigStuff3 Pro SEFI System 58 Individual Cylinder Spark The f
154. ry low side fuel pump relay per the diagram below This diagram is also available on the Bigstuff3 website via this link http bigstuff3 com pdtf LS 20Fuel 20Pump 20Wiring 20Diagram pdf The fuel pump relay is not supplied with the system A standard 40 Amp four post relay available at most part stores will work Back _to_Fuel_ Pump Secondary Fuel Pump HS Single lead Packard connector with a single red and white striped wire This is the SECONDARY pump connection If only one fuel pump is being used it must be the Primary Fuel Pump LS shown above The secondary fuel pump turns on as a function of throttle position and is configurable S HI dN Nd ABONDO ia This connector must go to the positive side of a fuel pump relay not directly to the fuel pump Terminating this connection directly to a fuel pump will damage the Big Stuff controller and will void the warranty The fan connector is identical to the fuel pump connector s so make sure to read the wire label to ensure the connector is terminated correctly Wire the secondary high side fuel pump relay per the diagram below This diagram is also available on the Bigstuff3 website via this link http bigstuff3 com pdt HS 20Fuel 20Pump 20Wiring 20Diagram pdf The fuel pump relay is not supplied with the system A standard 40 Amp four post relay available at most part stores will work Back_to_Fuel_Pump i STUFF Version 2 1 February 20
155. ry PC Windows Help bo BB Com Port Available x Resynchronize v Press the PC s Enter key or left mouse click on Yes and the Com Port will resynchronize Next double click the left mouse button on the BigComm short cut icon located on the Windows desktop BigComm desktop icon Et BigComm The BigComm software will attempt to establish a connection between the PC and the GEN3 ECU The Version 2 1 February 2011 35 BigStuff3 Pro SEFI System following screen will appear Be Ba Bei mm Synchronizing Communication Faded R Retna Work Olne If the GEN3 ECU is not powered up the ignition key is not in the Run position and the Communications cable is not connected communication cannot be established The following screen will appear This may also occur if the Comm Port is not configured correctly If this occurs use the above process of configuring the Comm Port until communication is established E o RE oeno ooo Left mouse click the Work Offline button The BigComm software will ask what calibration should be used off line The following screen will appear informing the user that a calibration file must be loaded to work off line BO EE Wem ets Communication Faded Warning You must laad a calhration Pla to wark oftina Do you want to continue Left mouse click on Yes and the BigComm software should go to the
156. s to navigate the cursor horizontally and or vertically to the cell to be changed Input the desired value and hit Enter e Using the Mouse Use the Mouse to navigate the cursor to the cell to be changed and left Mouse click on the cell Input the desired value and hit Enter to save the change Version 2 1 February 2011 38 BigStuff3 Pro SEFI System 15 Closing Windows Open windows can be closed using the PC s mouse To close an open window left mouse click on the X in the upper right corner of any window or simply hit the PC s Esc key If multiple windows are open continue to hit the Esc key until all windows are closed and the main BigComm window is displayed Hitting the Esc key too many times may result in a message stating Do you really want to quit Hit No to continue working with the BigComm software Hit Yes to close the BigComm software 16 Configuration The BigStuff3 ECU needs to be configured to the engine it will control For example the ECU needs to know if it is operating a 4 6 or 8 cylinder engine along with other important engine parameters and variables The initial configuration steps can be accomplished with the vehicle ignition key in run position and the engine off The ECU must be supplied with 12V 14V for the ECU to be live 17 Hardware Configuration From the tool bar on Main Menu screen left click on the Configuration and the dr
157. securely in place Again the plastic Packard style connector mates with the main wire harness connector labeled Calport Turn the PC on and power up the BigComm ECU by turning the vehicle ignition to the Run position Left mouse click double click the BigComm icon on the Windows desktop The following screen will appear Version 2 1 February 2011 37 BigStuff3 Pro SEFI System z i BB emn Offline No File Once communication has been established the BigComm Main Menu screen will open and the Green_Sliding Ball in the tool bar will become active 13 BigQomm Main Menu Screen 1 Bll m OT Refresh 975753ms View logged data short cut Fuel Table Air Fuel ratio short cut Record Log short cut Spark Table short cut The engine is not yet ready to be started Additional items need to be configured before attempting to start the engine In some cases the ECU may be delivered with a calibration that will closely match your engine configuration This base calibration will allow the engine to be started and run If this is not the case the following steps need to be taken Note BigStuff3 recommends checking all of the settings in the configuration tables to ensure the system as supplied will operate correctly 14 Inputting Values into a Cell There are two methods for inputting values into cells as follows e Arrow Keys Use the PC keyboard arrow key
158. ses input from this table for air temperature compensation The fixed numbers in the input table represent air temperature from 14 8 to 244 F The ECU uses the user defined inputs for each temperature point to add or subtract fuel relative to the base fuel map values While the engine is running a real time Ellipse will move within the Air Temperature table relative to the current engine Coolant Temperature operating point Use it as a point of reference to help calibrate the Air Temperature table To change a value in the Air Temperature table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change The input values need to be smaller working from the left to right As the engine warms up it needs less Air Temperature correction added fuel The inputs shown in the table below can be used as a baseline Version 2 1 February 2011 79 BigStuff3 Pro SEFI System 6 Air Temperature Correction Table Correction 0 0 1 2 2 3 3 3 3 3 l 3 66 2 77 9 90 1 102 111 125 144 169 196 230 24 Air Temp F BF AR Corr 0 0 47 MAP vs Coolant The GEN3 ECU s MAP vs Coolant table offers an improved warm up routine The table applies a fuel correction a increase or decrease to the base pulse width as a function of both Load MAP and coolant temperature The cells in the table represent ninety six 96 differen
159. side header connectors interfacing with the GEN3 ECU are attached and tightened to no more than 15 20 inch Ibs Make sure the battery voltage is at or above 12V during cranking Low battery voltage conditions must be fixed before trying to start the engine Battery voltage especially during cranking is even more important with coil on plug applications Make sure you can see an RPM signal in the Dash While turning the engine over you should see at least 100 150 RPM If no RPM signal is present check that the crank input crank trigger or distributor signal wire is connected to the red wire in the BS3 Crank connector Swap the 2 wires and try again For distributor ignition based applications make sure the BS3 points wire is connected to the ignition system points input terminal wire Applying 12V directly to the BS3 points wire will immediately damage the GEN3 ECU For COP engines LSx and other standalone COP engine the cam input cannot occur at the same time as the crank input If this is the case the engine will not start The cam synch pulse must occur before a crank pulse Ideally 10 before the crank pulse For more information on ignition system setups go to the How To Help section on the BS3 website then to Ignition System Setup Tutorial With all coil on plug engines make sure the coil ground eyelet is securely fastened to the cylinder head or engine block No other grounds locations should be used Ver
160. sion 2 1 February 2011 124 BigStuff3 Pro SEFI System o For Ford Modular COP engines the UEGOR value in the Dash must read 28 Ifa number other than 28 is being reported the cam pulse is occurring at the same time as the crank pulse For more information on how to resolve this issue contact BigStuff3 o The ECU may be in Clear flood Mode Make sure the TPS sensor reads near 1 2 when the throttle is closed and near 100 when fully opened If it reads near 100 when closed the ECU is in clear flood mode and is not injecting fuel Swap TPS pins A amp Cin the TPS connector o Make sure the crank sensor is connected e The LSI Cam sensor connections are e A Signal B Ground e C 12V e The LS2 cam sensor connections must be terminals A amp C are swapped e A 12V e B Ground e C Signal o The rev limiter Engine Saver On amp Off values are not correctly set The engine may not run if there is no band between the On and Off limits or the RPM inputs are reversed For example if the Rev Limit On is set for 7 100 RPM and the Rev Limit Off is set at 7 300 RPM the engine will not run e My engine timing does seem right what should I check o Make sure the firing order is correct o Both the BS3 GEN3 main wiring harness and the MSD ignition system must be connected directly to the battery If not ground loop issues are likely to occur o For coil on plug applications make sure the cam pulse is occurring at least
161. st Spark table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change 64 Start Starting Line Timing The GEN3 s Starting Line Timing feature is primarily focused at stick shift and turbo charged vehicles turbo cars with stick or automatic transmissions This feature allows the engine to build boost at the starting line The Starting Line Timing feature can be used in conjunction with the 2 Step to maximize starting line performance How to Use With Stick Shift Cars For stick shift cars the ignition timing needs to be retarded in order for the engine to build boost at the starting line with the clutch in If this feature is used with the 2 Step make sure that Boost_Parameters RPM input is set 1 500 RPM below the 2 Step RPM enable point Once the TPS and RPM Boost Parameters criteria are satisfied and there is 12 volts supplied to the two step wire the ECU will use the timing values from the Starting Line Timing table If the RPM and TPS criteria are not met and or 12 Volts is not supplied to the two step wire the ECU will default to the timing values in the main spark map The values in the main spark map may not allow the engine to build boost so it is important to properly configure the relationship between the Boost Parameters RPM and TPS criteria and the 2 Step RPM It takes 12V to activate the 2 Step How to Use With Automatic transmiss
162. st methods are to hit the F4 Quick Key or left mouse click on the Spark Table icon accessible from the main BigComm Screen The Main Tool Bar can also be used to access the Spark table From the Main BigComm software screen tool bar left click on Spark and the drop down screen will open S BigComm 2 mo 5 x File Ide Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help z z SparkTable Ctri 5 ii m i T Refresh 150ms 4 L L ESC Parameters Spark Table Icon 31 Spark Table B 9 SS SE MAP KPa The ellipse will move throughout the Spark table relative to the current RPM amp Load operating point 600 800 1000 1111 1200 1500 1800 2000 2400 2800 3200 3600 4000 5000 6000 7000 RPM RPM 0 Spk Adv 15 0 deg Act AFR 0 0 1 Scaled Load 0x00 Scaled RPM 0x00 TPS 0 0 Vbat 13 5V MAP 14 3kPa Version 2 1 February 2011 62 BigStuff3 Pro SEFI System The Spark table uses actual timing values in each of the 256 cells in the table The Spark table allows the user to input Spark values for sixteen 16 engine speed RPM and sixteen 16 load MAP or TPS combinations The X axis represents engine RPM and allows for 16 inputs and the Y axis represents engine load and allows for sixteen 16 inputs as well The X and Y axes are configurable For information on how to configure the X and Y axes see Load_vs_ RPM While the e
163. stems Version 2 1 February 2011 43 BigStuff3 Pro SEFI System Note The 2 step functionality is a base feature on all coil on plug systems 3 step control is an option on the GEN3 coil on plug systems If the GEN3 system is equipped with 2 Step control and 12 Volts is applied to Header Connector 1 pin B2 the ECU will begin rev limiting the engine to the user define 2 Step Lo RPM setting If the GEN3 system is equipped with both the 2 Step and 3 Step mostly used for turbo applications features and 12V is applied to Header Connector 2 pin W1 the ECU will begin rev limiting the engine to the user define 2 Step Hi RPM setting When 12V is applied to Header Connector 2 pin W1 the 2 Step Hi wire the GEN3 ECU will automatically override the 2 Step Lo RPM and seamlessly jump to the 2 Step Hi RPM level Return_to_Two_Step_ RPM Fueling Parameters This screen requires the user to input the fuel injector flow rate and the engine displacement in cubic inches A flow rate calculator is available on the BigStuff3 website via this link http bigstuff3 com pdt Fuel 20Pressure Injector 20flow 20Calc xls The flow rate constant that must be inputted into the Fueling Parameters table is centimeters per minute not pounds hour Once the injector flow rate in pounds per hour is calculated the flow rate in cubic centimeters minute cc min can be calculated by multiplying the lbs hr rate by 10 For example using the on line
164. t Brake amp Trans brake Switches With Optional 2 Step amp 3 Step Switched 12V Source in the Vehicle Foot brake Switch 12V applied to this wire Trans brake Button 12V applied to this wire when trans brake button is depressed On Off Switch required for Data Trgger wire when foot or trans brake button is depressed GEN3 ECU Header 1 Terminals A K A BCDE F GH J K Row 1 C C C C C C CIC O C To Hdr 2 W1 Few POQOOO O0O000 row 3K DO QOO OOOOO l GEN3 ECU cader 2 Terminals L Y To Hdr 2 Y2 L MN P R ST W Y brake Rw HO OOOO OO Few FOOOOO O0O Pw K 00 O00 OOOO p Yellow 2 Step Wire in z To Hdr 1 B2 Boost Connector from Main Wire Harness To Boost Connector Pin A CED Wire used to Activate the Timer Enable Optional Dash Mounted ON OFF Switch to turn the Timer Enable On and Off This Switch is Required with Optional Ground SR2 System BigStuff3 Pro SEFI System Main Fuse amp Relay WBO2 amp Coil V Batt Relay Hi WBO2 amp Coil V Batt 30 Amp fuse n Tar Back to Main Fuse and_Relay ECU 3 Amp Fuse This fuse protects the ECU electronics Back_to_Vehicle_Battery_Fuse To avoid the potential of severely damaging the ECU connect the head connectors to the ECU only after the battery connections are mad
165. t Identifier 4 by 1 In line IAC Connector Pin out Identifier More IAC wiring information is available on the Bigstuff3 website via this link http bigstufft3 com pdft IAC pdf Back_to_IAC TPS Throttle Position Sensor Black 3 way Packard connector The main harness TPS connector was designed to work with a GM L98 style TPS If a late model GM or Ford TPS is being used refer to the pin out tables or the BigStuff3 website link below GM Late Model BS3 3 by 1 TPS Connector Pin out Identifier GM Late Model Round 3 Point TPS Connector Pin out Identifier Ford TPS BS3 3 by 1 TPS Connector Pin out Identifier Ford TPS Connector Pin out Identifier More TPS wiring information is available on the Bigstuff3 website via this link http bigstuff3 com pdf TPS pdf Back_to_TPS Crank Black 2 way Packard connector with a separate ground wire 3 8 rin The black Packard connector must be connected to the inductive pickup crankshaft sensor or distributor not supplied The black wire ring terminal should be securely fastened to the engine block The GEN3 system is supplied with the sensor side mating connector terminals and seals The table below shows the wiring configuration of several commonly used crank trigger references Other crank trigger systems can be used assuming the connections are properly made Back to Crank Version 2 1 February 2011 20 BigStuff3 Pro SEFI System Cra
166. t MAP and coolant temperature combinations The same calibration technique should be used with this table as was employed with the base fuel map This table should be calibrated after the base fuel map To change a value in the MAP vs Coolant table move the cursor using the PC s mouse or arrow keys to the cell to be changed Input the desired value and hit Enter to save the change A Bo E EET x Map vs Coolant Table MAP vs Coolant 102 90 1 Coolant F The values in the X amp Y axes are factory set and therefore not configurable Coolant 231 1F MAP CLT Ptr OxOE Same screen as above with the window maximized The values shown in the table below can be used as baseline Version 2 1 February 2011 80 BigStuff3 Pro SEFI System Bo BB Belo MAP vs Coolant 244 230 196 169 144 125 111 102 90 1 77 9 66 2 55 4 44 6 33 8 15 8 14 8 Coolant F Coolant 231 1F MAP CLT Pir 0x0E 48 TRANSIENT FUEL Transient Fuel is the fuel added to the engine during non steady state conditions as a function of dTPSdt and dMAPdt Transient Fuel is applied relative to a rate of throttle change dTPS and a rate of MAP change AMAP TPS transient fuel is added asynchronously Asynchronously means fuel added between the regularly scheduled injector pulses MAP transient fuel 1s added synchronously to increase or decrease the base fuel pulse width MAP Transient Fuel MAP Transient Fuel can be
167. tems components into either the ignition or BS3 ground cables The BigStuff3 GEN3 system 12V power cables can be connected to the vehicle cut off switch Power for the BigStuff3 GEN3 system and the ignition system should also be from the same source the battery or the cutoff switch Abate Version 2 1 February 2011 14 BigStuff3 Pro SEFI System The positive and negative battery cable lengths have been designed are long enough to accommodate a trunk mounted battery If the cable lengths are not long enough splice solder and shrink wrap AWG 8 wire the remaining distance to the battery Make sure the two clearly marked black wires battery are securely fastened to the negative battery post NO EXCEPTIONS The red cable battery must be securely fastened to the positive battery post Connecting the positive and negative cables to the wrong battery post will damage the ECU This type of damage is easy to identify and is not covered under the factory warranty To avoid the potential of severely damaging the ECU connect the head connectors to the ECU only after the battery connections are properly made Back_to_Batt_Connections Ignition Systems Setup For additional information on ignition system setups go to the BigStuff3 website and then the document titled Ignition System Setup Tutorial The link is http bigstuff3 com pdf Ignition 20Guide 20rev 201 2 pdf The Ignition System Setup Tutorial document covers the follo
168. ternal disc go through the steps above except select Load Calibration from the drop down screen Note The GEN3 ECU must be powered ON to load a calibration file into it The following screen will appear warning that loading a new calibration will overwrite the ECU s current calibration Left click on Yes to continue loading the selected calibration file z Kd om a Refresh Rate Warning This will destroy your current calibration Do you want to continue The following screen will appear listing all the available calibration files In this example only one calibration is listed Mid Michigan Calibration big Left click on the file It will be highlighted in blue and click Open Version 2 1 February 2011 118 BigStuff3 Pro SEFI System Biglomm BEIE Fie Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Traction Logging Configuration Factory PC Windows Help b 9 BB Open Calibration File Look in gt BigStuff Calibrations Mid Michigan Calibration big Filename Mid Michigan Calibration Files of type big Cancel The following screen will open showing the status of the file loading Once the file finishes loading the selected calibration will be loaded into the GEN3 ECU S d A TT Refresh Rate Calibration Update Programming 43 Complete Please Wait 84 Acronym Definition SEFI Sequ
169. th care Communication Cable Communications Cable _ aS Main Wire D ae Harness ra eee Injector Wire Harness Wide Band Oxygen O2 BigStuff Sensor ECU The base GEN3 system for distributor ignition applications includes the following three sensor kits The 4 way connector to the left is the mating half connector to the Boost which is located on the main wire harness The terminal and seal provided need to go into terminal location A used to trigger the internal Replay data logger and Timer Enable wire Fore more information on how to wire and use these base system features go to the Boost section below Version 2 1 February 2011 6 BigStuff3 Pro SEFI System The gray 2 way connector kit below is the mating half connector to cam input Fore more information on how to wire the cam sync go to the Cam section below The black 2 way connector kit below is the mating half connector to crank input Fore more information on how to wire the crank input go to the Crank section below Terminal location 66 A 99 Mating half connector to Mating half connector for Mating half connector for the Boost connector on the Cam input cam the crank input from the the main wire harness sync distributor or crank Used for the trigger sensor Use terminal A Firewall grommet 4 Main Wire Harness Installation To improve the overall wire harness installation process the harness was manufactu
170. the values of the selected cells to be changed by the Multiply value inputted into the window For example if the values in the cells selected are 13 and the inputted Multiply value was 80 the new cell values would be 10 4 e Interpolate If a series of cells in the same row are selected and the Interpolate cell fill option is selected the ECU will use the value in the cell all the way to the left and the cell value all the way to the right and interpolate the numbers in between so that the values are linear Cell Values Selected in a Row Cell value to the left Cell value to the left Interpolated Result from Cell Values Selected Above 14 139 138 13 8 If a series of cells in the same column are selected and the Interpolate option is selected the ECU will use the value in the cell all the way at the bottom and the cell value all the way at the top and interpolate the numbers in between so that the values are linear Version 2 1 February 2011 56 BigStuff3 Pro SEFI System Cell Values Selected in a Column Interpolated Result from Cell Values Selected Above If a range of cells multiple rows and columns are selected and the Interpolate cell fill option is selected the ECU will use the value in the cells at the bottom left and top left corners bottom left and bottom right corners and the bottom left and top right corners of the entire range and
171. the ECU 1s removed The minimum computer requirements to run the BigComm software are Microsoft Windows 95 98 Me 2000 NT XP Vista amp Windows7 300 MHz or faster Pentium processor BigStuff3 recommends a minimum of 128K of RAM RS 232 serial port recommended A USB port can also be used with a port adapter not included Initial engine calibrations are best performed on a dynamometer If the user elects to calibrate the engine in the vehicle BigStuff3 strongly recommends that two people be involved one person to drive the vehicle the other to operate the laptop computer 9 BigComm Software Installation The GEN3 system software is available from the BigStuff3 website via www BigStuff3 comm From the website home page go to Software Downloads as shown in the screen print below Note A CD ROM disk is no longer supplied with a CD ROM software Disc but one can be purchased from BigStuff3 Version 2 1 February 2011 28 BigStuff3 Pro SEFI System gt BigStuff3 com Windows Internet Explorer Ge ed E t bigstuff3 com File Edit Yiew Favorites Tools Help x convert z F Select x Google v Search gt Sj d Sharer amp Ap Check gt Translate W AutoFill A Se meane yy Favorites 943 Capuchin Soup Kitchen E v FreeHotmail BigStuff3 com a D E aby Page Safety Toos gt i Ca info bigstuff3 com EE i a 248 887 5636 Ho
172. the bottom and the cell value all the way at the top and interpolate the numbers in between so that the values are linear Cell Values Selected in a Column If a range of cells multiple rows and columns are selected and the Interpolate cell fill option is selected the ECU will use the value in the cells at the bottom left and top left corners bottom left and bottom right corners and the bottom left and top right corners of the entire range and interpolate the numbers in between so that the values are linear Range of Cell Values Selected e Cancel Hit cancel to disregard making any changes Cell Changes using the Page Up amp Page Down Keys Fuel and Spark Tables Multiple cell values can also be changed simultaneously using the Page Up and Page Down keys This approach offers a quick alternative to using the mouse Use the keyboard arrow keys up down left right to maneuver to area of the map where the desired cell changes will be made STUFF Version 2 1 February 2011 68 BigStuff3 Pro SEFI System Next depress and hold the keyboard Shift key Now use the arrow keys to maneuver through the cells to be changed As the cells are being selected they will become highlighted Once the desired cell range has been highlighted release the Shift key Depress the Page Up key to increase the cell values and the Page Down key to decrease the cell values The cel
173. tical boost events e Transmission Input Shaft Speed TISS The GEN3 ECU can accommodate input wheels with 1 2 4 or 31 teeth Calculates a 16 bit rpm This is an optional feature within the DAE system e Transmission Output Shaft Speed TOSS The GEN3 ECU can accommodate input wheels with 1 2 4 or 40 teeth Calculates a 16 bit rpm e Torque Converter Control TCC Slip Percent Calculates the slippage between the engine and the drive shaft and displays the result as a percentage slip This is an optional feature within the DAE system 80 Calibrating with the Trace Function The BigComm software includes a very powerful calibration tool called the Trace Function The Trace Function allows the user to calibrate Fuel and Spark Tables using a Logged data file On Line or Off Line To use the Trace function open the Fuel or Spark Table Once opened hit the T key on the PC keyboard and the screen below will open 3 BigComm Log Window File Spark Idle Learning Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Dash Logging Configuration PC Windows Help i 28 Choose a Log File Look in BigComm ssi io Help E BigLogo90 4 piastuffooo Files of type Log Files CS V x Cancel The Choose a Log File Screen shown above will open and display the available previously logged files Select and open the desired log
174. til the engine idles at the desired RPM with only about 10 degrees of spark timing in the cells below and around the obelisk 5 From the main BigComm tool bar go to Idle and then Throttle Follower Table in the drop down 6 Loosen the TPS the settings to use if your TPS is not adjustable are covered below Adjust the TPS to 2 3 so the obelisk is floating inside the first cell of the Throttle Follower Table Tighten the TPS sensor down Make sure the desired IAC value Des IAC in the Dash is decreasing towards the minimum value of 5 7 Ifyou are able to adjust the TPS so that the obelisk is completely inside of the first cell input the values in the example table shown below into your Throttle Follower Table These values represent a good starting point Some additional fine adjustments may be required msa o 8 r ia e e e e If after adjusting the TPS the obelisk is straddling the first two cells input the values in the example table shown below into your Throttle Follower Table These values represent a good starting point Some additional fine adjustments may be required z5 Version 2 1 February 2011 77 BigStuff3 Pro SEFI System Jit ee ee ae ee ee If the TPS is not adjustable and the obelisk will not fit inside the first cell s input the values in the example table shown below into your Throttle Follower Table These values represent a good starting point Some additiona
175. tivated has a corresponding timing retard table associated with it The timing retard stages can be configured in the BigComm software under Boost from the main tool bar If no timing retard is desired for any one of the three stages leave zeros in the timing retard tables In order to activate the three 3 boost stages and corresponding timing retard stages the following criteria must be met e The minimum RPM and TPS settings under Boost Parameters must be met These parameters are user configurable From the main BigComm tool bar go to Boost see screen print below e There must be a value in each of the three timer cells e The time period for each of the three timers cells must be larger than the preceding timer value even if only one 1 of three 3 stages is going to be used For example if stage 1 is set for 5 seconds then stage two must have a timer value greater than 5 and stage 3 must have a timer value greater than the value used in stage 2 If there is a zero value in any of the timer Version 2 1 February 2011 22 BigStuff3 Pro SEFI System cells the staged boost and timing retard control will not work since a zero value forces the ECU to automatically revert to the base timing map Note The three 3 stage Boost control feature can be used to just retard the timing without switching solenoids on if the criteria outlined in the section directly above are met Boost Parameters
176. tive 02 Correction Negative _O2_Correction View Lambda 29 AFRParameters 5 CAR Parameters 31 SparkTable O O Spark Table O Fuel Table Starting 35 Cranking y O 8 Cranking 36 After Start Delay After Start Delay 37 After Start Correction 70 After Start Correction After_Start_Decay 39 Ide le _ _ OS Throttle_Follower Desired_Idle RPM 42 IdleSpark Hie Spark S OS IAC_Start_Position IAC_Gain_Terms Warm_Up Air_Temperature_Correction 47 MAPvs Coolant 738 CMAP vs Coolant 48 Transient Fuel 79 Transit Fuel 49 dMAPCorrection 80 Power Valve Fuel SO_ DMAP RPM Modifier 8l MAP_RPM Modifier MAP_AE_Decay_Rate ics E oe Version 2 1 February 2011 2 BigStuff3 Pro SEFI System Table of Contents Continued pf Chapter Page ypertink MAP_AE Inc Rate Run_Time_ Correction 54 dMAPParameters 385 MAP Parameters 55 DTPSd 8 Accel Pump Shot AE _Position_Correction 60 Boot Boost Control S Boost Parameters Boost_Parameters Boost PWM 63 Boost Stage spark 1 2 amp 3 94 Boost Spark 1 2 and3 65 Dash Dash 66 Configure Dash 9 Coonfigure Dash 67 SaveaDah 02 Save a Dash 68 LoadfromPile 1 Load FromFile _ 69 SavetoFile S Save to File _ _ _ 70 BigStuff3 Data Acquisition BigStuff3_Data_Acquisition 71 LoggingtoanExtemaltoPC Logging to PC 72 ConfigueLog 108 Configure Log Record_Log View_Log
177. ude number extensions for all subsequently saved files under the same default file name For example a Replay file name Vegas2010 will record the first Replay as Vegas2010_000 The second Replay of the day will be recorded and automatically saved as Vegas2010_001 WE Logger Configuration BHA TPS Trigger Level 52 r LogFor 3 105ec Update Display While Lagging fe Yes f Mo All Logs amp Replays are named using the Logger Configuration window From the main tool bar go to Logging then Logger Configuration Vehicle Type fe Car C Bike Default Filename BigLog Help Close 78 Upload Replay Upload is the high speed GEN3 ECU to PC data transfer process When the Upload drop down is selected a progress bar will open displaying the progress of the data being transferred Version 2 1 February 2011 109 BigStuff3 Pro SEFI System z 4 EN i Refresh 547ms Uploading High Speed PETKANA ANTAN MNN 64 Complete 20248 Please Wait Once 100 of the data has been transferred a file 1s automatically written to the folder hierarchy C Program Files BigStuff BigComm Note The Replay file must be down loaded from the GEN3 ECU to a PC within thirty 30 minutes from when the ignition switch is turned off After thirty 30 minutes the Replay data will be lost Note The Replay data could be lost if the battery cut off switch is turned off If the GEN3 main wire harness p
178. uration Operating Configuration Dwell Time Table Offline 8 18 10 Testing big 600 500 1000 1111 1200 1500 1800 2000 2600 3200 3750 4200 4800 5400 6000 6500 RPM Same screen print as is shown above with window maximized Version 2 1 February 2011 J9 BigStuff3 Pro SEFI System E BB 4am as Inj Phase Angle deg yi 300 280 260 240 240200 180 160 140 120 100 80 60 40 20 600 800 1000111112001500 1800200024002800320036004000500055006000 Scaled RPM 0x52 Vbat 14 2V Base Inj PW 2 7ms You have now reached a milestone The following necessary tasks have been completed e The BigComm software has been installed e Communication with the ECU has been established e The hardware and operating parameters have been configured The following sections of the manual will outline how to use the Air Fuel Ratio table O2 Correction tables and the Fuel Table Calibrating the engine for steady state operation is an iterative process using these tables The fuel calibration process in order of importance is as follows e The air fuel ratio table must be configured to desired ratios for the different engine speed and load combinations e The positive and negative O2 correction tables must be configured e The volumetric efficiency VE values in the Fuel Table must be calibrated Once these tables are configured as a baseline the Calibrating with_the_Trace_Function a great feature can be use
179. use pointer down until Operating Configuration is highlighted Release the left mouse button The screen below will open STUFF Version 2 1 February 2011 4 BigStuff3 Pro SEFI System ES a SET Offline 8 18 10 Testing big For setup detail go to Crank Trigger Configuration For setup detail go to W Operating Parameter Conn For setup detail go to TPS Ea Drivetrain Configuration For setup detail go to anal tee TPS Configuration ax amp tOr die rank rererence deg Clear Flood TPS Inductive Delay u Drivetrain Rear Gear Ratio n 1 3 41 45 Tire Diameter in 28 5 Aew Limit Static Test Timing Pickup Wheels hi For setup detail go to For setup detail go to Rey_Limiter_Configuration Rev Limit On RPM 6500 Test Timing deg 32 00 Driveshaft Pulse rev 40 Pickup Wheels Rev Limit Off RPM 6350 Enable Test Timing a Crankshaft Pulse tev 24 2 Step RPM Hi 4000 cop Input Shaft Pulse rev 31 For setup detail go 2 Step RPM Lo 3400 Crank reference deg 350 00 Turbo Shaft Pulse rev Zz to Override Cam Sync Test 7 For setup detail go to Two Step RPM Fue Puno as eee a Coil on Plug COP Prime Time s Bo S as bi Flowrate 4 seta ETN Tri ap Can a uP Second Pump On TPS 40 0 P F Injector Flowrate B cc min 60 Fan Off Temp F 160 8 Engine Size in 366 For setup detail go to C Anti
180. vr Ber a 800 1 000 1 150 1 200 1 500 1 800 2 000 2400 2800 3 200 3 600 4 000 5 000 6 000 7 000 RPM LOAD Version 2 1 February 2011 58 BigStuff3 Pro SEFI System Turbocharged Engine 30 PSI 4 CT e e e eE s tt 11 75 11 75 11 75 11 75 11 75 wile sapen Fane ile 11 75 11 75 11 75 11 75 RY an e e ej eee ejeje eje raed EE LOAD Sa de S OO A pases we Jedaiah 14 7 147 147 147 147 147 1 000 1 150 1 200 1 500 1 800 2 000 2 400 2 800 3 200 3 600 4 000 5 000 6 000 7 000 RPM 26 Positive 02 Correction x BigComm bal File Spark Idle Transient Fuel Air Fuel Ratio Individual Cylinder Starting Fuel WarmUp Boost Dash Transmission Torque Management Ethanol Logging Replay emni meim PC Windows Help z kd Ti Offline 8 18 10 Testing big Positive O02 Correction Table Positive O2 Correction 2141 9 21 9 219 25 0 125 0 125 0 80 100 150 200 MAP KPa The air fuel ratio table above allows the user to specify desired air fuel ratios for 128 speed amp load combinations The positive and negative O2 correction tables below allow the user to specify how much fuel the O2 Correction will be allowed to add or subtract to achieve the user defined air fuel ratio The positive and negative O2 Correction tables limit the amount added or subtracted The eight 8 horizontal input cells in the tables below correspond to the eight 8 vertical Load rows i
181. wing nine 9 ignition system setups 1 Stand alone IPU Distributor Only 2 Modified IPU Distributor serving as the cam sync with a Crank Trigger Setup 3 MSD Distributor Used to Only Distribute Spark from an MSD 6A 7A 8A box with a Crank Trigger 4 MSD 2340 Cam Sync Distributor with a Crank Trigger Setup 5 MSD All in One Crank and Cam Sync Distributor 6 GM s CAM Sync Drive with BigStuff3 s 24 Tooth Crank Wheel 7 MSD Mag44 Magneto 8 GM LS1 2 7 COP System 9 Ford Mod Motor COP System Also in the How to Help section of the website there 1s additional information on the setting up the Ford TFI GM HEI GM Opti spark amp MSD8 ignition systems More information along with the appropriate links to the website 1s provided below HEI Ignition Black 4 way Packard connector The main harness HEI connection is designed to work with a GM Y car Corvette distributor The HEI connection also includes a bypass connector for setting the timing GM Y amp F car bypass connector Re configuring the A B C and D pins of the main harness HEI connector allows for other types of types of ignition systems to be used The diagrams below outline connector configurations that can be made to interface with Ford TFI Buick DIS GM Optispark and GM Northstar ignition systems Back_to_Ignitions Version 2 1 February 2011 15 BigStuff3 Pro SEFI System Ford TFI GM HEI Buick DIS Ford Thic
182. witch or trans brake as shown in the diagram below 2 Internal data logger know as the Replay function trigger wire When upgrades options are added to the GEN3 system the data log trigger wire may be moved to header 2 terminal location Y2 When the GEN3 system is upgraded to include optional features like DAE DAE2 SR2 and ETM traction control 16 or 24 injector upgrades and the NTK methanol upgrade the wire used to trigger the internal data logger is moved from Hdr 1 pin location L2 to header 2 pin location Y2 No matter how the GEN3 system is configured or what options the system has Pin A which runs to Header connector terminal L2 of the Boost connector will always act as the Timer Enable trigger wire used for boost control nitrous control traction control and other optional features Note The Timer sequence will be reactivated every time the throttle is closed and then opened again since the Minimum RPM and Minimum TPS criteria are re satisfied The other three terminal locations B C amp D in the Boost connector can be used to turn on three 3 stages of boost control via relays along with corresponding and independent timing retard tables for each stage The three stage Boost control can also be used to control other types of solenoids e g in a wet nitrous system The boost solenoids must be turned on using relays in a low side configuration for each stage Each boost stage solenoid that is ac
183. y 2011 130
184. y Connections for terminals and two Connections further important 2 black wire information terminals Battery_Connections Version 2 1 February 2011 9 Harness Label Wire Color Connector Type Black 4 way Packard connector Gray 2 way Packard connector with a separate ground wire 3 8 ring terminal Black 2 way Packard connector with a separate ground wire 3 8 ring terminal Black 2 way Packard connector Gray 2 way Packard connector Black 4 way Packard connector Black 3 way Packard connector Label Definition High Energy Ignition Original Equipment OE ignition Camshaft Position Sensor Input Crankshaft Position Sensor Input Engine Cooling Fluid Temperature Input Engine Intake Air Temperature Input Idle Air Speed Control IAC input Throttle Position Sensor Connect To Connect to GM factory installed ignition system Connect to the camshaft position sensor on the engine Connect to the crankshaft position sensor on the engine Connect to the GM only coolant temp sensor typically located on the intake manifold Connect to the GM only air temp sensor typically located in the air intake duct between the air cleaner and the throttle body Connect to the IAC motor assy located on or near the throttle body The TPS located at the end of the throttle shaft on the throttle body Version 2 1 F

GEN3 User Manual – Feb 2011 – Rev 2.2

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GEN3 User Manual &ndash; Feb 2011 &ndash; Rev 2.2

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GEN3 User Manual – Feb 2011 – Rev 2.2