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M400/M600/M800/M880 User`s Manual

1. al xj 5250 5500 62 0 59 0 48 0 42 0 36 0 33 0 23 5 26 0 v 72 0 57 5 545 585 51 0 45 0 39 0 35 5 32 0 27 5 File Adjust View Tools Layout Utilities Help GC E dmpare Mode ON OFF t Select Compare File MoTeC Baviv Jump to Site Space at 15 0 RPh Quick Lambda Q 130 m Lam Quick Lambda Copy Up amp Right w Lambda Was D Lal Sensor 100 TR Overall Trim Table MAPI Interpolate VERTICAL Column EI Interpolate HORIZONTAL Row 0 00 Bat V Er c Cop VERTICAL Column RIGHT AT C Copy HORIZONTAL Row UP 0 80 EGT Copy Site Up and Right F11 ET C Fuel Set ALL values to current 118 0 L F AP F Dut Reset ECU R F Timi Clear ALL 84 0 Ignitior Clear Current x Del Ign Ac Set with BkSp 0 0 Dive Copy Table from another File Import CSV File ECU Connected Export CSV File lect Pallp PgDn Adjust Enter Set Value Note that the items on the menu will changes depending on which adjust table is shown for example Quick Lambda is not available for all tables The letter to the right of some menu items is the hot key Pressing this key will activate the item without selecting the Tools menu Compare Mode On Off Turns Compare Mode on or off Compare Mode shows the difference between the current file and the selected comparison file When Compare Mo
2. The ECU will remember the logged data even if the ECU power is turned off m If the logging memory becomes full the oldest data is overwritten so that the most recent data is always available m The ECU must have the Logging option to perform data logging Pro Analysis If the Pro Analysis option is enabled then advanced analysis options such as Track maps multiple graph overlays XY plots maths functions advanced track map analysis Available on M800 amp M880 only Unloading the Logged Data The logged data can be extracted by connecting the MoleC CAN Cable to the ECU and selecting Utilities Get Logged Data from the ECU Manager menu Data Logging Analysis The MoreC Interpreter software may be used to analyse the logged data The Interpreter software is supplied separately to the ECU Manager software The Interpreter software makes it easy to analyse mixture readings and other sensor readings by presenting the data in various graphical formats Refer to the Interpreter help screen for more detail Telemetry The MoleC Telemetry Monitor software may be used to view live information from the ECU via a radio link The Telemetry Monitor software is supplied separately to the ECU Manager software The Telemetry Monitor software shows the ECU data in various graphical forms including dial gauges bar graphs and chart recorders MoTeC Installation 19 Installation Throttle Position or MAP Load Sensing Th
3. Make sure that the Ignition Main Table is initialised with a conservative curve for the particular engine not too advanced and not too retarded Ignition Air Temp Check the Ignition Air Temp compensation table Typically the following table can be used MoTeC Initial Calibration 39 20 10 o 10 20 30 40 50 60 70 80 90 100 EEE ET 0 o CC o ENES EN ERE Other Ignition Compensation Tables Typically all other ignition compensation tables should bet set to zero MoTeC Initial Starting Procedure 41 Initial Starting Procedure The ECU Manager software should be used to assist during starting The ECU Manager software allows all diagnostics errors and sensor readings to be checked and allows the injectors ignition system and auxiliary outputs to be tested while the engine is stopped The calibration tables and setup parameters should also be checked Pre Start Checks Calibration Tables amp Setup Parameters Check that all Setup Parameters have been set appropriately Check that all calibration tables have sensible values in them Check that any advanced functions such as Traction Control are turned off Power to the ECU If the ECU has power then the ECU Manager software should indicate that the ECU is connected At the bottom left corner of the screen Diagnostic Errors Before starting the engine check the diagnostics errors on the ECU Manager Diagnostics Errors screen Any
4. 60V 5000 INJ4 2 4 60V 5000 INJ5 2 4 60V 5000 INJ6 2 4 60V 5000 INJ7 2 4 60V 5000 INJ8 2 4 60V 5000 Normally the current should not exceed the Nominal Max Current but in some circumstances it may exceed this value for a short period of time as long as it does not exceed the Min Current Limit and as long as the duty cycle is low The limiting factor is thermal dissipation in the output driver The total maximum low side current should not exceed 15A The minimum frequency for all outputs is 15Hz except when used as a switched output Items marked use a linear current limit all other outputs shutdown at the current limit 82 Appendices Appendix E Ignition Output Characteristics Source Current 20mA Single Coil Coil per Plug 40mA Wasted Spark Source Voltage 5 7V max at 20mA 4 6V max at 40mA Sink Current 1 Amp max nominal 3 Amp current limit MoTeC Appendices 83 Appendix F Injector Output Characteristics The Injector outputs can operate in two modes Peak and Hold mode and Saturated mode Peak and Hold Mode This mode is normally required for low resistance injectors 5 ohms or less This mode allows the injector current to build up to a high value to open the injector and is then reduced to minimise power dissipation in the injector Normally this means that the ECU has to dissipate a large amount of power MoTeC uses a switch mode technique to minimise power dissipation in t
5. Specifications are the same as the Analog Voltage inputs except the inputs include a 220k ohm resistor to 5V Digital Inputs Suitable for Switch to OV Logic signal amp open collector device eg Hall Switch Pullup Resistor 4700 ohms to 5V Voltage Range 0 to 15V Positive Trigger Threshold 3 5 V max Negative Threshold 1 0 V min Hysteresis 0 5 V Min Filter Time Constant 22usec Trigger Edge Programmable Measurement Methods Switched Speed Frequency Period Pulse Width MoTeC Appendices 81 Appendix D Auxiliary Output Characteristics The following tables list the characteristics for the Auxiliary Outputs including the Ignition and Injector Outputs when used as Auxiliary Outputs Output Low Side Driver High Side Driver General Nominal Min Nominal Min Fly Back Max Max Current Max Current Voltage Freq Current Limit Current Limit V Hz A A A A AUX1 5 7 5 7 Recirculate 10000 AUX2 5 7 5 7 Recirculate 10000 AUX3 1 3 60V 10000 AUX4 1 3 60V 10000 AUX5 1 3 0 7 0 7 Recirculate 200 AUX6 1 3 0 7 0 7 Recirculate 200 AUX7 1 3 0 7 0 7 Recirculate 200 AUX8 1 3 0 7 0 7 Recirculate 200 IGN1 1 3 60V 5000 IGN2 1 3 60V 5000 IGN3 1 3 60V 5000 IGN4 1 3 60V 5000 IGN5 1 3 60V 5000 IGN6 1 3 60V 5000 INJ1 2 4 60V 5000 INJ2 2 4 60V 5000 INJ3 2 4
6. V 8 00 Din1 Pos dea 0 0 Din2Pos deg 0 0 Din3Pos deg 0 0 Din4Pos deg 0 0 Reset Errors Reset Fuel Usea Reset Max RPM The View Screen has a number of pages that may be accessed by pressing Tab while holding down the Ctrl key or by pressing the first letter of the screen name It also allows resetting of The Diagnostic Errors Maximum RPM and the Fuel Used The Diagnostic Errors Screen may be accessed directly by pressing the F3 key Note that the view screen may be viewed with or without the ECU open but only if the ECU is connected MoTeC ECU Manager Software 73 Testing the ECU Outputs The ECU Outputs Fuel Injectors Ignition Outputs and Auxiliary Outputs may be tested by selecting Test Outputs from the Utilities menu This allows verification of the operation of the wiring and actuators It is also very useful in checking that the injectors are wired in firing order ECU Password A password may be set in the ECU to stop unauthorised access to the ECU configuration data The password may be set by selecting Adjust Security Setup from the main menu Channel Locking Note that the live channel information RPM Engine Temp may still be viewed even when the password is set unless the particular channel has been locked using the Channel Locking feature Channels that have been locked cannot be viewed on the View screens or sent as Telemetry data once the ECU
7. 395 420 450 455 395 245MM 360 390 390 40 0 350 310 310 330 2355 340 31 0 280 280 295 320 300 e 30 e Adjust Graphs The table values may also be shown graphically in an Adjust Graph The graph may be rotated if necessary by clicking on the rotation buttons or by holding down the Ctrl key while using the arrow keys Graph Table If there is no graph displayed the table object may be switched between table mode and graph mode by pressing the G key MoTeC ECU Manager Software 61 Y Axis Reversing On certain graphs it may be desirable to reverse the Y axis so that the graph surface is easier to see To do this select Reverse Y Axis on the Too s menu or press the Y key 62 ECU Manager Software Making Adjustments On Line Offline Changes may be made directly to the ECU Online or to a file Off line Online ECU Connected To make changes directly to the ECU connect the ECU then select Open ECU from the File menu When the ECU is opened the calibration data is first retrieved from the ECU then matched to a file If the ECU data does not match an existing file then a new file will be created at which point an Engine Description and Comment should be entered to describe the file Changes to the ECU are also saved to this file when the ECU is closed Offline ECU not Connected To make changes to a file with the ECU offline select Open from the File menu The file may be sent to the
8. 5 7 5 15 th pes Hall or Seet Injector 6 A29 6 th Magneto B2 Tr os B2 Injector 7 A30 7 th H Sig SYNC Injector 8 8 th St E ENEE ETEEN 4 A2 sy Eng AUX OUTPUTS Relays or 2 Open Aux 1 A18 Throttle A14 avi Aux2 A1 Position 4 Aux 3 A23 Aux 4 A24 Manifold c A15 Pressure B AV2 Stepper Motor Relays or Valves B3 Aux 5 2 e D D Air AT 1 Aux 6 A33 Temp Aux 7 Mn amp Aux8 A34 Engine B4 AT 2 12y A26 Tem p A B16 oy Eng B25 Note 2 See drawing aoe 4 B26 LA1S X25 for wiring LA1P in details B12 PS B13 LA2S Note 1 LA2P 20 Amp B5 AT 3 Note 3 Fuse B6 ANALOG mm 2 AT 4 o 6 TEMP INPUTS BI AT 5 E B19 AT 6 Ignition Switch A16 av 3 A ava ANALOG A25 ny 5 VOLTINPUTS gt BZ AVG AV7 Ignition 1 Ge Ignition z P lt AV8 Ignition 2 A5 System B8 i Ignition 3 DIGITAL Dig 1 S INPUTS 7 B9 Dig 3 Ignition 4 ae See Detail z B10 pig 3 Ignition 5 73 Drawings o2 Bi Dig 4 Ignition 6 Auxiliary Sensor 0 Volt 513 OV Aux Power Serial Connector 2 BAT RS 232 Tx cup LA10 A1 D9 female 3 p14 RS 232 Rx EIS DN Comms 1 Chassis 12 Volt CAN Connector 4 B24 CAN LO Earth Battery eltron B23 716 0 0501 SH Note 3 Power to Auxiliary lt AB 8V Aux Power ane ignition Eus relayshoulg p i activated using tne Fuel Pump contro sensors a 5V Aux Power wire to ensure that the ignition system is off when the engine is Looking i
9. Appendix G M880 Connechor emen 84 Appendix H Wire Specifications em 85 Appendix J CAN Wiring Multiple Device 86 Appendix K CAN Bus Wiring Single Device 87 Appendix L Pin list by Function mmm 88 For racing and off highway use only Not legal on emissions controlled vehicles unless appropriately certified Copyright Motec Pty Ltd 2001 2003 The information in this document is subject to change without notice While every effort is taken to ensure correctness no responsibility will be taken for the consequences of any inaccuracies or omissions in this manual 7 November 2003 MoTeC Introduction 1 Introduction Thank you for purchasing a MoTeC Engine Management System This manual will help you understand the installation and calibration requirements of your MoleC Engine Management System Additional Documentation Additional documentation is available in the form of Drawings and Tech Notes Please consult your local MoTeC distributor for details Drawing Categories Accessories ECUs Looms Ignition Modules Combined Module amp Trigger Systems Trigger Systems Valves Sensors Miscellaneous Tech Notes Traction Control Boost Control Idle Speed Control Closed Loop Lambda Control Wideband Lambda Sensor Others MoTeC Overview 3 Overview The MoleC M400 M600 M800 amp M880 ECU s are powerful and compact programmable Engine Man
10. B Do not use resistive suppression leads as they will reduce the spark energy Auxiliary Valves The ECU can control various auxiliary valves such as Idle Speed or Turbo Boost control valves Refer to the appropriate MoTeC drawing for setup and wiring details Refer also to any relevant Tech Notes ECU Mounting The ECU should be mounted in an area where the internal temperature of the ECU will not exceed 85 C generally this is in the passenger compartment Allow for adequate air circulation around the ECU The ECU internal temperature may be viewed using the ECU Manager software or it may be recorded using the data logging Mount so as to minimise vibration this will help to prolong the ECUS life ECU Cleaning Avoid high pressure washing or degreasing of the ECU MoTeC Initial Setup 33 Initial Setup Before attempting to start the engine the setup parameters must be correct Use the MoleC ECU Manager software to adjust the setup parameters Preferably start with a calibration file from a similar engine as this will make setup faster and easier Main Setup Injectors Injector Scaling IJPU Injector Current Injector Battery Compensation Refer to the ECU Manager help screens for details Calculation Methods Efficiency Calculation Method Load Calculation Method Refer to the ECU Manager help screens for details Load Sites Selection Selects the range of load points to suit the selected sensors op
11. Conditioner Fan Control Air Conditioner Clutch Control RPM Load Table Output Gear Change Light Output Fuel Used Pulse Output Slip Warning Output Alternator Control Spray Bars Output Status Output MoTeC DC Servo Motor Control Cam Control Power Hold Output Servo Stepper Motor Control Fuel Pressure Control Overview 13 MoTeC Software 15 MoTeC Software The following software is available Note that the same software is used for all ECU models ECU Manager Used for calibration setup diagnostics output testing upgrading unloading the logged data and enabling ECU options Interpreter Used to analyse the logged data Telemetry Monitor Used to show real time telemetry data PC Requirements B IBM PC compatible m 200 MHz Pentium or faster m The PC must have a 25 pin printer port parallel port for connection of the MoTeC CAN Cable m Operating System Windows 95 98 ME NT4 2000 XP Connecting a PC to the ECU The PC must be connected to the ECU by a MoTeC CAN Cable Note that the ECU must be wired with the mating connector MoTeC CAN Cable Connected to the Printer Port 16 Software Installing the Software The MoleC Software must be installed on to the PC hard disk before it can be used The main software required is the ECU Manager software if Data Analysis is required then the Interpreter software should also be installed if telemetry is required then the Telemetry Mo
12. HEI or CDI HEI or CDI multi coil systems will generally run any engine to 15 000 RPM Two types of Multi Coil systems are possible MoTeC Installation 31 Coil per plug One coil for each spark plug fired sequentially Double Ended Wasted Spark Double ended coils have two high tension towers and fire two plugs at the same time one on the compression stroke and the other on the exhaust stroke Each coil is fired sequentially twice per engine cycle and must feed the appropriate two cylinders Ignition System Wiring amp Setup The wiring and setup parameters are specific to the particular ignition system Refer to the appropriate MoTeC Ignition System or Ignition Module drawing Distributor Button Alignment If using a distributor the button must be aligned so that it is leaving the tower at Top Dead Centre for that cylinder Button just leaving tower at TDC Ca Button Rotation The button must be a wide tip type to cater for a wide range of advance points since the advance is changed electronically rather than mechanically Make sure that the button still overlaps the tower at the maximum advance point The distributor should have no mechanical or vacuum advance as this is provided by the ECU Spark Plug Leads The spark plug leads should be high quality Inductive Suppression leads such as Magnicor leads and must be in good condition M Do not use wire leads as they can cause interference 32 Installation
13. Injector Outputs M400 Up to four injectors may be driven fully sequentially including very low ohm types 0 5 ohms M600 Up to six injectors may be driven fully sequentially including very low ohm types 0 5 ohms M800 amp M880 Up to twelve injectors may be driven fully sequentially by the ECU if the injectors are high resistance types 12 ohms or greater otherwise up to eight injectors may be driven fully sequentially including very low ohm types 0 5 ohms W Four of the Ignition Outputs are used for full sequential 12 cylinder operation m Twelve cylinder engines may also be driven as six groups of 2 injectors which leaves all six Ignition outputs available for wasted spark ignition m Outputs not used for Fuel Injection may be used as Auxiliary Outputs Ignition Outputs The Ignition Outputs may be used to drive many different types of ignition systems which are detailed in the various ignition system drawings 8 Overview M400 Up to four ignition outputs are available for multi coil applications M600 Up to six ignition outputs are available for multi coil applications M800 amp M800 Up to 6 ignition outputs are available for multi coil applications m Outputs not used for ignition may be used as Auxiliary Outputs m Up to 8 coils may be driven from one Ignition Output using a MoTeC CDI8 or MofeC Ignition Expander m Up to 12 coils may be driven from two Ignition Outputs using two MoleC CDI8 s or
14. Magnetic s B1 l 1 T B1 Injector 2 A21 2nd J H Klees REF Injector 3 A22 3 rd pon mg Injector 4 A27 4th SYNC Injector 5 5 715 th C Hall or See Injector 6 6th Magnetic EE H sz B2 Sig H B2 sync pod pr A2 Rela quas ys or Valves Ld ul 4 5V Eng AUX OUTPUTS A18 Note 4 Open Aux 1 e Throttle A14 Av 4 Aux 2 A1 Position 1 4 Aux3 ren Manifold c A15 Auxa Pressure 8 AN 2 Stepper Motor Relays or Valves o Aux 5 A31 a x 4 Air B3 AT 4 Aux6 A32 Temp Aux7 A34 gg B Aux 8 ee eal uw Aas DN Eng B25 Note 2 See drawing SEN L B26 LA1S X25 for wiring LA1P Bes details Lambda Ge LA2S Note 1 2 LA2P 20 Amp BS AT3 Note 3 Fuse ANALOG z P gt AT 4 TEMP INPUTS B7 AT 5 ii B19 Ignition ATS Switch EI ava AV 4 ANALOG A25 AV5 o Loa o VOLT INPUTS gt B20 AV6 A3 20 Amp gt B22 AV7 Ignition 1 A Ignition Fuse z AV 8 Ignition 2 A5 System B8 i Ignition 3 DIGITAL Dig 1 i INPUTS gt Bo Dr 2 Ignition 4 as See Detail B10 5 9 Ignition 5 Drawings oe ga B93 Ignition 6 A8 Dig 4 gnition Auxiliary Sensor 0 Volt 4 BI OV Aux Power Serial Connector 2 SH RS 232 Tx GND A10 A11 D9 female 3 B14 RS 232 Rx 5 mi 0V Comms 1 Chassis 12 Volt ben Connector B24 CAN LO Earth Battery 716 0 0501 Geen CAN HI 3 Note 3 Power to Auxiliary lt E EG 8V Aux Power The Ignition systemirelay should be sensors lt SV Aux Power SEH Note 1 The Fuse is essential to ensur
15. a scope m Bad REF SYNC alignment W Incorrect Setup No SYNC Two or more consecutive SYNC pulses are missing Possible causes m No SYNC signal check the wiring and SYNC sensor voltage levels with a scope m Abad REF signal has caused many extra pulses check voltage levels with a scope m Incorrect Setup Multiple REF SYNC Errors Multiple REF SYNC errors may occur often the first error to occur is the correct error Multiple errors may also occur due to incorrect Setup MoTeC Calibration 47 Calibration The Calibration Tables determine how the output devices should be controlled for various sensor readings For example the Fuel Main Table determines the pulse width for the Fuel Injectors for all combinations of RPM and Load The ECU Manager software should be used to adjust the various calibration tables to suit the engine Warning Alarms Set the Warning Alarms to warn if the engine temperature goes too high The warning alarms may be set in the functions menu Ensure that the engine is On Site The engine must be On Site for changes to the table values to affect the tuning this means that the engine must be operating at the same RPM and Load as the currently selected site in the calibration table Note that when the engine RPM or Load is between table sites the current fuel value or Ignition value etc is effected by the sites to either side For this reason when adjusting the calib
16. adjusted When used from the Fuel Second Load Table or the Fuel Individual Tables the change is made to that table rather than the Fuel Main Table Quick Lambda Copy Up amp Right As for Quick Lambda except that the new value is copied to the sites immediately above right and diagonally above and right if the sites do not contain a MoTeC ECU Manager Software 69 Lambda Was Adjusts the fuel table value by an appropriate amount by comparing the value entered by the user to the desired lambda value in the Lambda Table The value that is entered may be either the current lambda reading from a lambda meter if tuning online or the lambda reading from the logged data if tuning offline Note that if a lambda sensor is directly connected to the ECU then online tuning may be performed more easily using the Quick Lambda function Overall Trim Table Trims the whole Table by the percentage indicated by the Overall Trim then sets the Overall Trim back to 0 This is useful during initial tuning of the Fuel Main Table since an existing table can be used then trimmed to take into account variations in injector sizing etc Note that it is better to change the IJPU setup parameter if large changes are required as this will ensure that the Table numbers maintain sufficient range and resolution i e ensures that the table numbers do not become too small or too large Note that during the interpolation the engine may run incorrectly It is the
17. against the drawings Check that the ignition is wired in the correct firing order Check that the ignition is firing on the compression stroke not the exhaust stroke After Start Checks Ignition Timing Check Check the Ignition Timing with a Timing Light to ensure that the actual Ignition Timing corresponds to the ECU Ignition Timing as shown on the ECU Manager View screen Check the timing at high and low RPM to ensure that it is correct at all revs If the timing is correct at one RPM but incorrect at another RPM and the REF sensor is a magnetic type then the trigger edge may be incorrect or the sensor may be wired in the wrong polarity Adjust the setup parameter CRIP Crank Index Position to correct for small variations in the REF sensor positioning Adjust the Ignition Individual Cylinder Trim for cylinder number 1 and verify that it changes the ignition timing for cylinder number 1 rather than any other cylinder if not then the CRIP is incorrect and needs to be adjusted by multiples of the angle between cylinders Fuel Pressure Check that correct fuel pressure is maintained under all load conditions Operational Diagnostics Errors After the engine has started check for diagnostics errors To clear any non current errors press the Enter key while viewing the ECU Manager Diagnostics Errors screen The following operational errors may occur in a new installation MoTeC Initial Starting Procedure 45 Injector E
18. and is measured in milliseconds thousandths of a second abbreviated as msec The injector pulse width is controlled by the ECU according to the ECUs calibration data 30 Installation Duty Cycle The Injector Duty Cycle is a measure of the ratio of the time the injector is open pulse width to the available time per engine cycle For example if the injectors where on for half the available time then the duty cycle would be 50 The maximum allowable duty cycle is about 85 percent beyond this the injector does not have time to open and close and is therefore open continuously and cannot deliver more fuel The ECU will set a Diagnostics Error if the duty cycle exceeds the maximum allowed duty cycle Ignition System Ignition System Types Many different types of ignition systems are available with some better suited to different applications than others CDI Distributed CDI systems are suited to high revving engines with 8 or more cylinders and are generally capable of at least 12 000 RPM on an 8 cylinder CDIs are also good at firing fouled plugs HEI Distributed High Energy Inductive HEI distributed ignition systems are generally limited to about 8000 RPM on an 8 cylinder engine but will run a 6cylinder to 11 000 RPM and a 4 cylinder to 15 000 RPM Most modern road cars run HEI ignition systems that are equally well suited to high performance engines as long as the above RPM restrictions are observed Multi Coil
19. engine is Note 1 stopped Or use the Fuel Pump Looking into The Fuse is essential to ensure that the Relay to power the Ignition System Connector ECU is not damaged by reversed battery This also provides reverse battery on ECU polarity protection to the ignition system Note 2 Note 4 To avoid the fuse blowing due to reverse Aux 1 2 5 8 can also drive grounded battery polarity use a diode activated relay loads eg Bosch 0332 014 112 Aux 1 and 2 are High current Tite M880 ECU Wiring Sheet No Drawing No M O e C Date 22 08 2002 Drawn ST App AD Products ECU M880 ECU 96 Notes MoTeC Notes 97 98 Notes MoTeC Notes 99
20. errors must be rectified before starting the Engine To clear any non current errors press the Enter key on the PC while viewing the Diagnostics Errors screen m Note that the Diagnostic Errors are lost if the ECU power is turned off Sensor Errors If an error is shown for a sensor that is not fitted the sensor should be disabled by setting the sensor setup number to zero Sensor Errors may be due to bad wiring to the Sensor either short circuit or open circuit 42 Initial Starting Procedure Test the Sensors Before starting the engine test that all sensors are giving sensible readings by viewing their values on the ECU Manager View screen Vary the sensor readings if possible to check for correct operation Check that the Throttle Position Sensor varies smoothly from 0 to 100 when moved from fully closed to fully open Note that the TPHI and TPLO setup parameters must have been set correctly for correct operation of the Throttle Position sensor The MAP sensor should read barometric pressure when the engine is stopped approximately 100 to 102 kPa at sea level depending on the day The Engine Temp and Air Temp sensors must give correct readings Test the Ignition Use the ECU Manager Ignition Test On the Utilities menu to ensure that the Ignition System is functioning correctly m Some special ignition systems do not work in the Ignition Test screen eg Mazda Series 4 amp 5 and other direct fire ignition syste
21. placed within 0 5 m of the collector pipe on a normally aspirated engine or 0 5 m of the turbo on a turbo charged engine If placed too close to the exhaust outlet the reading may be effected by the outside oxygen The sensor can be contaminated by exhaust manifold sealant use an exhaust gas sensor friendly sealant The lifetime of the Sensor will be significantly reduced by leaded fuels Refer to the MoTeC Tech Notes and Drawings for more details Wiring Wiring Drawings Refer to the Loom wiring diagram for the loom wiring details Refer to the drawings at the back of this manual for more general wiring details The wiring details for the REF and SYNC Trigger Sensors and the Ignition Module are specific to the type of sensors and Ignition system MoTeC can provide wiring diagrams for most Trigger Sensors and lgnition systems 24 Installation Wiring Reliability The wiring is critical for reliable operation of the ECU The following points will help to ensure that the wiring is reliable Ground Wiring One of the most common wiring problems is poor ground wiring The ground wire must be grounded properly to the engine block There should be no paint or anodising between the ground wire and the engine block Temporary wiring is likely to cause problems use a proper eyelet terminal that is securely crimped to the ground wire Studs fixed in place by Loctite can also cause a problem as the Loctite becomes an insulator Thes
22. positioning of the engine operating point MoTeC ECU Manager Software 65 For best calibration the indicator should be within or close to the centre rectangle this ensures that the ECU tuning is determined mainly by the site being adjusted and not by the adjacent sites Up Down Adjustment Up or Down adjustments may be made to the selected table value using the PgUp and PgDn keys m Fast adjustments may be made by holding the Ctrl key down while pressing the PgUp or PgDn keys This will increment the value by ten times the normal amount m If the PgUp or PgDn keys are held down the value will continue to change until the key is released Locking in the New Value When the desired adjustment has been made the new value must be locked in Set by pressing the Enter key this stores the new adjustment in the ECUs programmable memory m If the cursor is moved before pressing the Enter key the value will revert to its previous unadjusted value Direct Entry The table values may also be entered directly using the number keys followed by the Enter key Maths Operations Mathematical operations may be performed on the currently selected value or the WHOLE table or a BLOCK within a table To perform a maths function enter the value followed by an operation key 5 1 for example 2 5 will add 2 5 to the current table value To apply the maths operation to the whole table type a T before pressing the operation
23. two MoleC Ignition Expanders Auxiliary Outputs The ECUs have eight Auxiliary Outputs that may be used for Turbo Waste Gate Control Idle Speed Control Gear Change Light Driver Warning Alarm Tacho Output Fuel Pump Control Thermatic Fan Control Fuel Used Signal Air Conditioner Fan Control Air Conditioner Clutch Control RPM Load Activated Output or other functions CAN Communications The CAN Communications system is a high speed network communications system that allows multiple devices to be connected and communicate with each other The CAN connection is used for all communications with the PC via the ECU Manager software which includes calibration diagnostics checking retrieving the logged data firmware upgrading and enabling options CAN may be used to communicate with the MoTeC ADL Dash Logger CAN will also be used to communicate with future MoTeC devices RS232 Serial Communications Optionally used to communicate with the MoTeC ADL Dash Logger In this case the ADL is effectively picking up Telemetry data from the ECU Note that CAN communications may also be used to connect to the ADL MoTeC Overview Used for Telemetry Output M800 amp M880 only 10 Overview Calibration amp Setup Calibration Tables The Calibration Tables determine how the output devices should be controlled for various sensor readings For example the fuel calibration table determines the base injector pulse width for all co
24. 19 33 INJ1 A20 50 INJ2 Description Battery Positive Battery Negative 8V Engine Sensor Supply 5V Engine Sensor Supply OV Engine Sensor Supply 8V Auxiliary Sensor and CAN Supply 5V Auxiliary Sensor Supply OV Auxiliary Sensor Supply Auxiliary Output 1 Auxiliary Output 2 Auxiliary Output 3 Auxiliary Output 4 Auxiliary Output 5 Auxiliary Output 6 Auxiliary Output 7 Auxiliary Output 8 Ignition Output 1 Ignition Output 2 Ignition Output 3 Ignition Output 4 Ignition Output 5 Not available on M400 Ignition Output 6 Not available on M400 Injector Output 1 Injector Output 2 MoTeC Appendices 89 A21 63 INJ3 Injector Output 3 A22 66 INJ4 Injector Output 4 A27 24 INJ5 Injector Output 5 Not available on M400 A28 42 INJG Injector Output 6 Not available on M400 A29 57 INJ7 Injector Output 7 Not available on M400 amp M600 A30 62 INJ8 Injector Output 8 Not available on M400 amp M600 Analog Kaes Inputs A14 AV1 Analog Voltage Input 1 A15 18 AV2 Analog Voltage Input 2 A16 6 AV3 Analog Voltage Input 3 A17 7 AV4 Analog Voltage Input 4 A25 12 AV5 Analog Voltage Input 5 B20 36 AV6 Analog Voltage Input 6 B21 35 AV7 Analog Voltage Input 7 B22 44 AV8 Analog Voltage Input 8 Analog Temperature Input 1 B4 38 AT2 Analog Temperature Input 2 B5 30 AT3 Analog Temperature Input 3 B6 39 AT4 Analog Temperature Input 4 B7 29 AT5 Analog Temperature Input 5 B19 37 AT6 Analog Temperature Input 6 Digital Inputs B8 46
25. 9 L SJON Z L 40 29 H HOA ZL 9ZV NIA 008W fejoJ NOI wod AZL 6 NOILONNA jndino xny LNALNO AYVITIXNV SNOILONNA LNdLNO LNANI SJUSWUYBISSE jauueyo pue pesn apo aie sJosues Aew moy uo puedep IIIAA EPQUET xoino Josues uo peA eJ6ue 1equinu INTVA JequinN ed V 2J YlVA ed dNLIIS HOSN3S VQO8INVT dL 3S HOSN3S 8 3fllVA NOILVSHSITVO HOSN3S OL 3 YIVA zeT Le dNLAS HOSN3S 6 3 YlVA L N338HOS SLN3ANSISSV T3NNVHO d 113S HOSN3S Jes eue sJejeujeJed JOSUSS EPQUIET Buiwolo y eisu3 dnjes n53 di pue SA Z y NY AO JOSUSS MOIleX aH jam ZLoigigenle N ee p sn JON 9 92 Looking into Connector on ECU A1 AD 1 Tg Seeeeeee lleeeeeed 10 A17 B8 B13 Weeeeeeg Seeeen A18 A25 B14 B19 00000006 000000 A34 B20 Note 1 The Fuse is essential to ensure that the ECU is not damaged by reversed battery polarity Refer to the Sensors ECU Injectors Connect in firing order Trigger Drawi
26. Adjusted The cursor selects the table value that may be adjusted The cursor may be moved using the arrow keys or by pressing the Space Bar which will automatically move the cursor to the current engine operating point Note that the table does not show all values at once To view the additional values move the adjustment cursor to the edges of the table using the arrow keys this will cause the table to scroll and show the hidden values Make sure the Engine is On Site For adjustments to affect the current engine operation the engine operating point must be at the centre of the selected site The Adjust Table object provides Indicators and a Target to assist in this Fuel Main of IJPLI RPM 4250 45001 4750 5000 ME 5500 5310 Effey 900 595 620 550 530 590 675 780 ET 555 550 520 OR 5 L 40 0 360 350 310 3 0 330 355 30 0 315 310 280 280 295 320 Table Indicators Indicators are shown at the top and side of the table the black triangles The indicators show the current engine operating point and therefore indicate which table value or values the ECU is currently using The indicators must point to the same site as the adjustment cursor for any adjustments to change the current engine tuning The site that is closest to the current operating point is also indicated by a red rectangle Table Target A target is shown at the left of the table This allows more accurate
27. C ee CTI CNN Bat Ignition d Injectior T iming 1 Functions Foe d mn 4250 4500 4750 METT 5250 Individual Cylinder Second Load T able Secondary Injection gt Accel Enrichment D Cold Start Compensations 1 Digital Input Functions 540 625 66 540 595 62 540 555 55 540 520 49 50 0 470 44 450 41 0 39 40 0 360 35 350 315 31 320 270 25 570 540 620 550 530 59 0 520 51 0 545 455 460 48 0 405 395 420 345 360 310 310 33 0 280 280 29 5 26 0 260 260 1 Ignition Output Functions b b Lal Auxiliary Output Functions P b Injector Output Functions gt General Setup l Sensor Setup L Data Logging Setup gt D b CO OO OO OO OO ET Security Setup 11 Site Setup F Time deg 425 5 F Trim 0 0 La Was 0 89 F Trims ms 2 80 84 0 Ignition lgn amp dv dBTDC 39 2 Dwell ms 0 00 oe KE BEE TETEN Arrow Keys Select Paup PaDn diust Enter Set Value 7 Fuel Ignition Toggle F5 key The F5 key will quickly toggle the screen between the current Fuel table and the corresponding Ignition table or vice versa F6 F7 F8 Key Assignment The F6 F7 or F8 keys may be assigned to any table by pressing Alt F6 Alt F7 or Alt F8 This assigns the current table to the F6 F7 or F8 keys which allows that table to be returned to quickly 64 ECU Manager Software Changing Table Values Selecting the Item to be
28. DIG1 Digital Input 1 B9 45 DIG2 Digital Input 2 B10 52 DIG3 Digital Input 3 B11 53 DIG4 Digital Input 4 Trigger Inputs B1 49 REF Crank Reference Timing Input B2 56 SYNC Cam Sync Timing Input Lambda Inputs B26 60 LA1 P Lambda1 Pump Current B25 54 LA1 S Lambda1 Sense Voltage B13 61 LA2 P Lambda2 Pump Current Not available on M400 B12 55 LA2 S Lambda2 Sense Voltage Not available on M400 90 Appendices Comms B17 40 TX 232 RS232 Transmit Data B18 31 RX 232 RS232 Receive Data B24 47 CAN LO Can Bus Low B23 48 CAN HI Can Bus High B14 13 0V COM OV Comms A13 2 8V AUX 8V Auxiliary Sensor and CAN Supply Note Outputs marked do not have a recirculation diode see the Output Specifications for more detail 91 MoTeC S X Ljo L 088 008N sionpoid avay jas umeiq ON Buiweig on 3eeus L00Z 60 0 3a Josuag epquie D I YISOG any WEI op 04UOO J93e9H y JO pesn eq ues 1ndino uous 10 10joefu wn AUY T 9 oN ndui z epqwe 10 Buum sejeoipul sjexoeiq u uojeuuoju L 9 ON HAO aA04JOsuag Josuegs euibu3 Z IL a 19 9H Z ALON x SA szv1 SLVT ss vs dzv1 atv L9 09 Jayea HOA ZL Ly ZE Z sh H n23 088lN feje1 NOJ WOI4 AZL HAO le eE A010sueg Josues euiBu3 949 F LH Z ALON a SA szv1 SLvT zia sza dj dzv1 akV1 cia 97
29. ECU at a latter date by selecting Send File to ECU from the File menu Closing the ECU or File When the changes are completed the ECU or file should be closed by selecting Close from the File menu this will ensure that changes are saved to the associated file Warning Alarms If the Warning Alarms have been set then a warning screen will be displayed if any sensor goes outside its alarm limits This can be particularly useful for automatically monitoring engine temperature during a dyno session The alarms can be configured in the Functions table Help Context sensitive help is available by pressing F1 or clicking on the help button this shows help that is relevant to the current screen MoTeC ECU Manager Software 63 Selecting the Adjust Table Once a file or the ECU has been opened the appropriate table or setup screen may be selected from the Adjust menu by using the mouse or the keyboard To select the Adjust menu using the keyboard hold down the Alt key followed by the A key then use the arrow keys and the Enter key to make a selection Alternatively the Adjust menu may be displayed by pressing the Esc key This has the advantage that it shows the Adjust menu with the current table selected which often makes it easier to select the next table MoTeC M800 ECU Manager 02123000 MoTeC Test iol x File Adjust View Tools Layout Utilities Help S mitosis ak e Z SSM AZ 9 MoTe
30. M load sites Typically more fuel is required at cranking than at idle RPM The Quick Lambda feature may be used to quickly adjust each table value with one key stroke Press the Q key The adjustment is made to the value closest to the current engine operating point The Quick Lambda feature may only be used if the ECU is directly measuring the lambda reading The desired lambda value must be set in the Functions Lambda Control Table If the maximum value in the table falls bellow 60 then the setup parameter IJPU should be decreased to increase the table values This ensures that the table has sufficiently fine resolution Similarly if the table values reach the maximum of 99 5 the JPU setup parameter should be increased to decrease the table values Use the F5 key to change quickly between the Fuel Main Table and the Ignition Main Table Use the F6 key to change quickly between the Fuel Main Table and Fuel Timing Table Use the View Fuel Screens to check that all the fuel trims and compensations are correct Press the V key Refer to the ECU Manager software help for more details Press F1 Ignition Main Table The Ignition Main Table allows adjustment of the Ignition Timing at various RPM and Load points Start with a conservative curve for the particular engine not too advanced and not too retarded Use extreme caution when adjusting the Ignition Timing to ensure that the engine does not knock due to exce
31. MoTeC M400 M600 M800 M880 User s Manual Contents Introd tiOM RE 1 Additional Documentation 1 eiu asa 3 ECU Model CLE 3 E ee 4 ECU Inputs amp Outputs nn nnn nnn nhanh nana sa nana nna 6 Calibration amp Setup eiii cecinisse eed Deere conie rere idend 10 ECU FUNCHONS u RR 11 MoleC Software ee 15 PC Requirements nni ERNENNUNG 15 Connecting a PC to the ECU 15 Installing the Gofthware eren eren 16 Starting the Software serie ri iiaeeeaeo Ree aad 16 ECU Manager Softiware ener ennt 16 Data Bee e ale DE 16 Telemetny EE 17 Installation pet m 19 Throttle Position or MAP Load Sensing a 19 SENS rS address pe teat etl EE EE 20 WIPO BEE 23 Fuel Systems 1323 S s mous a ER 26 eigene au dte dene etr u qua E eant 30 Auxiliary EIS RE 32 ECU Mounting eot ts eta le e EE Eege ech 32 ECU eu EE 32 Initial Setup GE 33 Main ESTE EE 33 SENSOF SOUP EE 34 Input Output InLe EE 35 Other FUNCUONS 2 omen e eere DE DEE vested s 35 Initial Calibration WEE 37 puel Tables tee ence eee 37 Ignition E Le 38 Initial Starting Procedure 41 Pre Start Ghecks u ree eet eire 41 Starting iege mcer ee ee wire a Nasi 43 After Start CHeCKS is cccccccecssciccececciecicectassacovseudecuscicatsacvuscicecdaecssev
32. These parameters must be reset any time the sensor is moved or replaced It is very important to set these parameters with the butterfly in exactly the same place each time The resistance element inside the sensor may wear due to vibration in high performance engines which can cause erratic readings It is best to replace the throttle position sensor periodically Avoid high pressure washing as this may penetrate the seals and damage the sensor For wiring details refer to the appropriate MoTeC drawing MAP Sensor The MAP Manifold Absolute Pressure sensor measures Absolute Pressure ie pressure relative to a vacuum 0 kPa Absolute Complete Vacuum 100 kPa 1 Bar 14 5 PSI Atmospheric Pressure at sea level is approximately 100 to 102 kPa depending on the day MAP sensors normally produce a voltage between 0 and 5V depending on the pressure The pressure sensor may be used to measure the inlet manifold pressure or to measure the barometric pressure depending on the Load Sensing arrangement detailed earlier The ECU Sensor Setup parameters must be set to indicate the type and pressure range of the sensor MoTeC Installation 21 Avoid severe vibration of the sensor as this can cause fluctuations in the reading Do not mount rigidly to the engine Normally the pressure sensor is mounted to the vehicle body If used for Manifold Pressure Sensing For normally aspirated engines use a 100 kPa sensor For turbo charged e
33. agement Systems or Engine Control Units ECUs ECU Models The different ECU s are characterised by the following features M400 4 injector outputs 4 ignition outputs Waterproof plastic connector with gold plated contacts 512kByte logging memory option 1 wideband lambda input option Other optional functions include Traction Control Boost Enhancement Anti lag Hi Lo Injection Gear Change Ignition Cut CAM Control Drive by Wire M600 6 injector outputs 6 ignition outputs Waterproof plastic connector with gold plated contacts 512kByte logging memory option 2 wideband lambda inputs option Other optional functions include Traction Control Boost Enhancement Anti lag Hi Lo Injection Gear Change Ignition Cut CAM Control Drive by Wire M800 8 injector outputs standard 12 injector outputs option occupies 4 ignition outputs 6 ignition outputs Waterproof plastic connector with gold plated contacts 1MByte logging memory option 2 wideband lambda inputs option 4 Overview e Other optional functions include Traction Control Boost Enhancement Anti lag Hi Lo Injection Gear Change Ignition Cut CAM Control Drive by Wire Pro Analysis Telemetry Multi Pulse Injection Servo Motor Control M880 e 8 injector outputs standard e 12 injector outputs option occupies 4 ignition outputs 6 ignition outputs Military style Autosport connector 4MByte logging memory option 2 wideban
34. ajor new feature of ECU Manager is that multiple screen layouts can be created by the user to suit the users preference and the task at hand See the topic on Layouts for more detail Utility Programs The utility programs such as Upgrade and Enable ECU Options are built in to ECU Manager rather than being separate programs and may be selected from the Utilities menu Note that Convert Files is selected from the File menu Notes Note that because the F10 key is used to access the menu as dictated by Windows the old F10 function of Copy Site up and Right has been reassigned to the F11 key Basics Starting ECU Manager To start ECU Manager double click the icon on the desktop or select ECU Manager from the Start menu for example Start Programs MoTeC M400 M600 M800 ECU Manager 2 1 Note that the desktop icon will start the latest version of ECU Manager Online Help Online help is available in two forms 56 ECU Manager Software Context sensitive help is available by pressing F1 or clicking on the help button this shows help that is relevant to the current screen General help is available from the Help menu Main Menu File Adjust View Tools Layout Utilities Help The Main Menu is used to access all of the features of the ECU Manager software Select a menu item by using the mouse or use the keyboard by holding down the Alt key followed by the keys corresponding to the underlined letter of the menu items t
35. compensation table Typically the following table can be used 40 30 20 10 o 10 20 30 40 50 60 70 80 ETE 6 4 2 o EEE EET 42 Fuel Engine Temp The Fuel Engine Temp compensation table may be used instead of the cold start warm up parameter If using Engine Temp compensation the following table can be used 10 o 10 20 30 40 50 60 70 80 90 100 110 60 50 40 30 20 10 5 2 0 0 0 0 5 38 Initial Calibration Fuel MAP Check the Fuel MAP compensation table The fuel must be increased by 100 every 100 kPa increase in air pressure Normally the MAP table should contain the following values with a straight line increase between values 100 kPa 200 kPa 300 kPa 400 kPa 500 kPa 10 o 100 200 300 400 This table is equally applicable whether the MAP sensor is used for barometric pressure measurement or for manifold pressure measurement Note that the higher pressure sites will only be available if a high pressure MAP sensor is used Fuel Cold Start Start with the typical values listed in the help Fuel Acceleration Enrichment Start with the typical values listed in the help Generally acceleration enrichment is not required above 4000 RPM Other Fuel Compensation Tables Typically all other compensation tables should bet set to zero Ignition Tables Ignition Main Table The table should be smooth
36. d lambda inputs option Other optional functions include Traction Control Boost Enhancement Anti lag Hi Lo Injection Gear Change Ignition Cut CAM Control Drive by Wire Pro Analysis Telemetry Multi Pulse Injection Servo Motor Control Options A number of options are available which allow the ECU to be configured for a particular need and can also be updated later if necessary The options may be enabled at any time by entering an enable password Data Logging Option Allows logging of the ECU sensors and operating parameters to the internal data logging memory The logged data may then be analysed in graphical format using the free MoTeC Interpreter Software Pro Analysis Enables more advanced functions in the data logging analysis software such as multiple graph overlays XY plots maths functions advanced track map analysis Available on M800 amp M880 only Wideband Lambda Option Single or Dual Allows Wideband Lambda Air Fuel Ratio measurement which may be used for data logging or closed loop control of the Air Fuel Ratio The ECU is compatible with Bosch LSU or NTK wideband lambda sensors it is not MoTeC Overview 5 compatible with the Bosch 4 wire LSM sensor Dual Lambda not available on M400 Telemetry Enables the ECU to send telemetry data via a radio to the pits The data can be viewed in graphical format using the MoleC Telemetry Monitor program Available on M800 amp M880 only Oth
37. de is turned on the selected compare file description is shown on the status line at the bottom of the screen 68 ECU Manager Software The comparison file may be selected by choosing Select Compare File from the Tools menu When Compare Mode is turned on an icon will appear at the left of the Adjust Menu items that contain differences Select Compare File Selects the file used for Compare Mode Jump to Site Moves the Cursor block to the Site closest to the current engine operating point Quick Lambda Adjusts the fuel value to achieve the lambda value in the Wideband Lambda table The Lambda Table may be accessed from the Functions Lambda Control menu or by pressing the F8 key The new fuel value is calculated by checking the difference between the Lambda sensor reading and the value in the Wideband Lambda Table The Lambda reading may be either Lambda 1 Lambda 2 or the Average of both this is configured in the Wideband Lambda setup The engine must be operating near the centre of the site for the calculation to give correct results Quick Lambda may be used from the Fuel Main Table Fuel Injection Timing Table Ignition Main Table Fuel Second Load Table amp Fuel Individual Tables When used from the Fuel Main Table the cursor jumps to the closest site if the cursor is not on site When used from the Ignition main Table or Fuel Injection Timing Table the Fuel Main Table site closest to the current operating point is
38. e comments apply to both the ECU ground wire and the Ignition system ground wire The ground wire must be at least 12 3 3 mm and must be kept as short as possible Power Wiring The power wire must be wired by the shortest path possible to the battery via a 30 Amp relay and a 20 Amp fuse The relay and fuse must be in good condition and the wires must be crimped securely to the appropriate terminals The relay should be activated by the Ignition Switch The ECU power must NOT be fed directly from the Ignition switch because it probably wont handle the required current The power wire must be at least 12 3 3 mm and must be kept as short as possible Spark Plug Leads The spark plug leads can cause interference in the ECU wiring Keep the ECU wires away from the plug leads wherever possible at least 100mm If it is necessary to cross the plug leads cross at right angles Terminal Crimping Use the correct crimping tool for each type of terminal Do a pull test on a sample wire and terminal to verify that the crimp is sound In theory the wire should break before the wire pulls out of the crimp Most crimp tools are only designed for a certain range of wire sizes so be sure to test the crimp with the particular wire size being used MoTeC Installation 25 Soldering the terminal is a last resort if the correct crimping tool is not available Soldering will cause a stress point where the solder wicks up the wire which is likel
39. e load point for the fuel and ignition calibration tables may be based on any defined load measuring sensor The most commonly used are the Throttle Position sensor or the MAP Manifold Pressure sensor Mass Air flow MAF sensors are also used particularly where regulations state that the sensors cannot be changed from the factory fitted sensors Turbo Charged Engines Normally use Manifold Pressure load sensing connect the MAP sensor to the inlet manifold A Throttle Position sensor is optional and will be used for acceleration enrichment if fitted Normally Aspirated Engines 3D Fuel and Ignition Tables Normally use Throttle Position load sensing The MAP sensor may be used to compensate for barometric pressure changes by venting it to atmospheric pressure m lf Idle Speed Control is used then the MAP sensor should be connected to the plenum or Manifold Pressure load sensing should be used This is required so that the fuel is varied as the idle speed control valve opens and closes 20 Installation Sensors Throttle Position Sensor The Throttle Position sensor must be a potentiometer type older switch types are not suitable The sensor will produce a voltage proportional to the angle of the throttle plate Throttle sensors generally have a dead band at either end and must be pre loaded to avoid the dead band The Setup Parameters TPHI and TPLO must be set to indicate the fully closed and fully open positions
40. e placed to measure the air temperature before the butterfly and after the inter cooler on turbo charged engines Avoid placing the sensor too close to the stand off vapour in a multi runner manifold as this will cool the sensor and give a false reading 22 Installation The ECU Sensor Setup parameters must be set to indicate the particular type of sensor Engine Temp Sensor The Engine Temperature sensor is mainly used for cold start enrichment The sensor contains a temperature dependant resistor and is designed for water immersion The ECU Sensor Setup parameters must be set to indicate the particular type of sensor Trigger Sensors REF amp SYNC The trigger sensors supply the necessary timing information to the ECU so that it knows when to fire the fuel injectors and ignition system Normally two sensors are used REF and SYNC Many different types of trigger sensors and chopper patterns may be used The wiring and ECU setup information for the trigger sensors are specific to the particular system Refer to the appropriate MoTeC drawing Home made sensor systems often cause problems Do not use Chrome molly for chopper disks as it is a non magnetic material Runout of the disk imperfections and bolt heads are also potential sources of problems Where possible it is best to use the manufacturers trigger system REF Sensor Supplies the crank position information Some sensors supply one pulse per Top Dead Centre 4 pul
41. e that the ECU is not damaged by reversed battery polarity system is off when the engine is stopped Or use the Fuel Pump Relay to power the Ignition System This also provides reverse battery protection to the ignition system Note 2 To avoid the fuse blowing due to reverse battery polarity use a diode activated relay eg Bosch 0332 014 112 Note 4 Aux 1 2 5 8 can also drive grounded loads Aux 1 and 2 are High current Tite M600 ECU Wiring Sheet No Drawing No MoTeC Date 21 08 2003 Drawn ST App AD Products ECU Menn ECU 94 Refer to the Sensors ECU Injectors Connect in firing order Trigger Drawings for sequential operation for details REF A12 RER Hall or Oj ES Sv Eng Injector 1 A19 1st Magnetic 4 B1 Haz B1 Injector 2 2 nd zk Sig REF Injector 3 A22 3 rd rol P Injector 4 457 4th H SYNC Injector
42. each file Any file may be sent to any ECU which will totally re configure the ECU according the calibration and setup data contained in the file Creating a New Calibration File To create a new calibration file open an existing file and save it to a new file by selecting Save As from the File menu Sending a Calibration File to the ECU To send a calibration file to the ECU select Send File to ECU from the File menu Note that the ECU must be connected to the PC using a MoleC CAN Cable Changing the Comments To change the file comments select Edit Comments from the File menu Versions amp Upgrading MoTeC is continually updating the software and newer versions may be downloaded from the web site at no charge www motec com au The software consists of the ECU Manager software that runs on the PC and the control software firmware that runs inside the ECU The ECU firmware may be updated at any time by the user which allows the latest features to be used The ECU Manager version may be viewed by selecting About from the Help menu The ECU firmware version is shown on the ECU Manager status line when the ECU is connected 58 ECU Manager Software Matching Versions The version of ECU Manager and the version of the firmware in the ECU must match in order to be able to communicate with each other To communicate with an ECU that has older firmware in it either the matching ECU Manager software must be used or the ECU
43. engine cycle so that the engine makes best use of the fuel In theory the fuel should end injection at a point where all the fuel will be sucked into the current induction stroke therefore the end of injection point should be some time before the intake valve closes The optimum point depends on the engine RPM and load Torque economy emissions and idle quality are all effected by the Injection Timing At high duty cycles the Injection Timing will have minimal influence since the injectors are on for most of the engine cycle Refer to the ECU Manager software help for more details Press F1 MoTeC Calibration 51 Fuel Cold Start The Cold Start parameters may be adjusted after the Fuel Main Table has been adjusted and the 0 RPM sites have been adjusted for good hot starting Refer to the ECU Manager software help for more details Press F1 Other Calibration Tables The other calibration tables may be adjusted as necessary Refer to the ECU Manager software help for more details Press F1 Data Logging amp Road Testing The calibration must be verified on the road This is best done by logging the air fuel ratio and other sensors and checking them using the MoTeC Interpreter software Data Logging is also very useful for identifying unexpected problems such as an incorrect air temperature reading due to fuel vapour cooling the sensor or excessive air temperature due to hot air entering the intake system Data loggi
44. equire a pullup resistor to the 5V sensor supply Normally a 1000 ohm resistor is used Measurement Voltage Range 0 to 15 V e Note that voltages outside this range may affect the readings on other inputs Input Resistance 100k ohms to OV Resolution 3 74 mV Filter 150Hz 1 order Measurement Method Absolute Analog Temp Inputs Suitable for 2 wire variable resistance sensors and some voltage output sensors e Note that some voltage output sensors may not be able to drive input resistance Measurement Voltage Range 0 to 15 V e Note that voltages outside this range may affect the readings on other inputs Input Resistance 1000 ohms to the 5V sensor supply and 100k ohms to OV Resolution 3 74 mV Filter 150Hz 1 order Measurement Method Absolute When used as Switch Inputs The Analog Temp Inputs may also be used as Switch Inputs Trigger Levels Programmable 0 to 15V Hysteresis Individually programmable high and low levels 80 Appendices Lambda Inputs Wideband Sensor Type NTK or Bosch LSU Measurement Range 0 70 to 32 0 Lambda Narrow Band The LA1S and LA2S inputs may be used to measure the voltage of normal narrow band oxygen sensors Note If closed loop control is to be used then an external 33k ohm bias resistor from the input to OV is required to bias the input to stoichiometric 0 45V while the sensor is cold Voltage Input The LA1S and LA2S inputs may be used as ordinary voltage inputs
45. er Other options include CAM Control Drive by Wire Traction Control Overrun Boost Enhancement Anti lag Gear Change Ignition Cut Hi Lo Injection Servo Motor Control M800 amp M880 only amp Multi pulse Injection M800 amp M880 only 6 Overview ECU Inputs amp Outputs The ECU analyses signals from the sensors then controls the Fuel Injectors Ignition System and other auxiliary devices according to the Calibration and Setup Data which is stored in the ECUs programmable memory The Inputs and Outputs are shown below Wheel Speed or Switch _______pJ Dig 2 Wheel Speed or Switch Dig 3 Wheel Speed or Switch ____ Dig 4 Communications RS232 Communications CAN Communications M400 M600 M800 M880 Main Engine Sensors REF Trigger Sensor _____ REF INJ1 Fuel Injector Outputs Sync Trigger Sensor _____ SYNC INJ2 INJ3 L gt Throttle Position Sensor _____ TP INJ4 Manifold Pressure Sensor MAP INJS Note INJ 5 amp 6 not available Engine Temp Sensor NET INJ6 gt on M400 Air Temp Sensor p AT INJ7 Note INJ 788 not available INJ8 L p on M400 amp M600 Optional Sensors Wide Band Lambda Sensor pi LA1 IGN1 __ Ignition Outputs Wide Band Lambda Sensor LA IGN2 p Note IGN3 6 may be used as IGN3 Injector outputs on M800 A eg Oil Temp i IGN4 p M880 with 10 12 cyl option eg Intercooler Temp p AT4 Wes s 8 IGNS L Note IGN 5 amp 6 not ava
46. er Software Alt 1 0 Select Individual Cyl 1 10 table Only when an Individual Table is currently selected MoTeC Appendices 77 Appendices Appendix A General Specifications Physical Case Size 147mm x 105mm x 40mm 5 8in x 4 1in x 1 6in Weight M400 M600 M800 0 50 kg 1 10Ib M880 0 525kg 1 16 Ib Power Supply Operating Voltage 6 to 22 Volts DC Operating Current 0 5 Amps Max excluding sensor and load currents Reverse Battery Protection via External Fuse Battery Transient Protection Operating Temperature Internal Temperature Range 10 to 80 C 14 to 176 F Ambient Temperature Range 10 to 70 C 14 to 158 F typical depending on output loading 78 Appendices Appendix B Sensor Supplies Maximum Current 5V ENG Sensor Supply 5V AUX Sensor Supply 8V ENG Sensor Supply 8V AUX Sensor Supply 0 20 Amps Max 0 15 Amps Max 0 30 Amps Max 0 30 Amps Max Accuracy Temp Drift 5V ENG Sensor Supply 5V AUX Sensor Supply 8V ENG Sensor Supply 8V AUX Sensor Supply Protection Short to ground Short to battery Thermal overload 0 5 max at 25 C 100ppm C max 0 5 max at 25 C 100ppm C max 5 max over entire temperature range 5 max over entire temperature range MoTeC Appendices 79 Appendix C Input Characteristics Analog Voltage Inputs Suitable for Potentiometers Voltage output sensors amp Variable resistance sensors e Note that variable resistance sensors r
47. er definable and may be optimised to suit the user s preference the screen resolution and the task to be performed For example it may be useful to have screen layouts to suit different types of engines or to perform particular tasks such as CAM Control or individual Cylinder tuning MoTeC M800 ECU Manager 03010202 MoteC Test6 of xj File Adjust View Tools Layout Utilities Debug Help casi RER SAGAN MoTeC RPM 7810 Lambda1 0 88 LaDif ET C BatV V Sensors Fuel Lambda 1 Aim Value 032 005 110 0 16 0 Effcy 93 0 F APW ms 1155 erm 1 20 Load X 330 F Duty 2 748 S456 t TP 93 0 F Time deg 3474 3 T MAP kPa 126 0 F Trims ms 273 S 0 03 86 0 14208 ar cj 260 24 9 5 EGT 1 OK Ignition X Bi H 100010 3 070 Lal 0 88 Ign Adv dBTDC 326 005 200 80 La2 Trims dBTDC 0 0 Fuel Main of IPU RPM 5500 6000 em 7250 7500 do 7790 Effcy 100 0 745 775 800 805 795 775 93 0 69 0 740 760 770 765 750 0 0 655 700 725 695 67 0 8 70 0 575 610 635 625 610 600 B00 os 540 540 535 540 510 SN 500 430 470 460 455 445 430 NE 400 395 425 40 410 30 30 RV ANNS 300 355 35 35 350 330 320 DN OSS x RSS Un SN FTims ms 273 OOS SIS kN ROTH now Keys Select PoUp PoDn Adjust Enter Set Va
48. erational range For example 0 to 100 for a Throttle position sensor Refer to the ECU Manager help screens for details Number of Cylinders CYLS 4 Stroke engines use positive numbers eg 8 for 8 cyl 2 Stroke engines use negative numbers eg 2 for 2 cyl Rotary engines use 2 for 2 rotor and 3 for 3 rotor Trigger Setup Ref Sync Mode REF 34 Initial Setup Crank Reference Teeth CRT Crank Index Position CRIP These parameters are dependant on the type of trigger system Refer to the appropriate MoTeC Trigger drawing or Ignition System drawing Note that the trigger sensor type Hall Mag Edges etc must be setup in the Sensor Setup screens Ignition Ignition Type IGN Number of Coils COIL Ignition Dwell Time DELL Ignition Delay Time These parameters are dependant on the type of Ignition Module Refer to the appropriate MoTeC Ignition Module drawing or Ignition System drawing Sensor Setup Throttle Position Sensor Hi Lo TPLO Throttle Position LO Closed Throttle TPHI Throttle Position HI Wide Open Throttle The Throttle HI and LO points must be set every time the throttle position sensor is moved or replaced so that the throttle can be correctly scaled between 0 and 100 REF SYNC Sensor Setup The REF SYNC setup parameters must be set to suit the trigger sensors Refer to the MoTeC Trigger drawings for details Sensor Calibrations The sensors calibrations must be set to suit the con
49. ers The filters are necessary to ensure that the fuel pump is not damaged and to ensure that the injectors do not become blocked m The strainer before the pressure pump is essential to prevent the pump from seizing A strainer is used because the pressure pump won t suck through a paper filter Fuel Lines The fuel feed lines must be high pressure type and should be at least 8mm 5 16 inch diameter The return lines should also be at least 8mm 5 16 inch diameter to ensure that the fuel is easily returned to the tank Use proper high pressure hose clamps to ensure that the lines do not blow off under pressure Keep the fuel lines as cool as possible to avoid fuel vaporisation The temperature of the fuel will also affect the mixture due to the change in fuel density Avoid fire risk by ensuring that all hoses and fittings are in good condition and installed correctly 28 Installation Fuel Rails The fuel rails must be free of any debris that could block the injectors Welded fuel rails can often cause a problem unless they have been properly treated to remove all scale and debris and even then they may corrode and cause problems Aluminium fuel rails mounted directly on the injectors are recommended as they do not suffer these problems The fuel rails must have sufficient volume to minimise fuel pressure pulsation and resonance problems Fuel Pressure Regulator The fuel pressure regulator maintains constant fuel pressure t
50. firmware must be upgraded to match the version of ECU Manager on the PC Upgrading the ECU To upgrade the ECU firmware select Upgrade ECU Version from the Utilities menu This will send the new firmware to the ECU and automatically convert the calibration data in the ECU to ensure it is compatible with the new firmware Calibration File Versions The calibration files that are stored on the PC must also match the version of software being used To ensure that older version calibration files are not rendered useless the older version calibration files may be converted in order to be used with the new version of the software To convert older files select Convert from the File menu Calibration files may also be converted from some older ECU models M4 M48 amp M8 Minor Version Updates Minor version updates do not require the calibration data to be converted but still require the firmware to be sent to the ECU by selecting Upgrade ECU Version from the Utilities menu Minor updates usually contain bug fixes or minor enhancements A minor update is one where the number before the decimal point and immediately after do not change for example 2 10A 2 10C 2 11A are all minor updates of version 2 1 Software Version Release Notes The changes between the various software versions may be viewed by selecting Release Notes from the Help menu MoTeC ECU Manager Software 59 Screen Layouts The screen layouts are completely us
51. g then a single termination resistor may be used The resistor should be placed at the opposite end of the CAN Bus to the CAN Cable connector Single Device See Appendix K CAN Bus Wiring Single Device MoTeC Appendices 87 Appendix K CAN Bus Wiring Single Device When a single device such as an ECU is connected to the CAN bus then the wiring scheme shown below may be used to provide a connection point for the MoTeC CAN cable If the wiring length is less than 2m 7ft then the terminating resistor is recommended but not essential If other devices are connected to the CAN bus a special wiring scheme is required see Appendix J CAN Wiring Multiple Device 5 Pin Connector M800 M880 Black A13 2 B24 47 X X XXX B23 48 CAN HI These wires must be Twisted 100R Resistor Minimum one twist per 50mm 2in Not essential if the wiring length is less than 2m 7ft 5 Pin Connector Type Deltron 716 0 0501 Non Latching Neutrik NCSFDL1 Latching 88 Appendices Appendix L Pin list by Function M400 M600 M800 M880 Pin No PinNo Abrev Battery A26 23 3241 VBAT A10 A11 14 15 19 GND Sensor Supplies A12 3 8V ENG A2 16 5V ENG B16 27 0V ENG A13 2 8V AUX A9 34 5V AUX B15 11 0V AUX Auxiliary Outputs A18 9 AUX1 A1 8 AUX2 A23 43 AUX3 A24 51 AUX4 A31 59 AUX5 A32 65 AUX6 A33 58 AUX7 A34 64 AUX8 A3 1 IGN1 A4 5 IGN2 A5 4 IGN3 A6 10 IGN4 A7 17 IGN5 A8 25 IGN6 Injector Outputs A
52. he ECU The opening current is referred to as the Peak current and the reduced current as the Holding current The peak current is fully programmable from 0 to 6 Amps and is suitable for very low ohm injectors including 0 5 ohms Holding Current 2596 of Peak Current Flyback Voltage 60V Diagnostics Open Circuit Short to Battery Peak current not reached Saturated Drive Mode This mode is normally used for high resistance injectors 12 ohms or greater Nominal Maximum Current 2 Amps Current Limit 4 Amps Flyback Voltage 60V Diagnostics Open Circuit Short to Battery High Low Injection The injector output characteristics may be set independently for High Low injectors allowing two different types of injectors to be used 84 Appendices Appendix G M880 Connector Mating Connector for M880 only Deutsch AS6 18 35SN Wire Wire to suit connector 22 Tefzel Mil Spec M22759 16 22 Crimp Tool Crimp Tool M22520 2 01 Positioner for Crimp Tool M22520 2 07 e Note that the Crimp Contacts are type 22D this is needed to set the crimp tool correctly Wire Stripping Tool The following tool is recommended Ideal Industries 45 2133 stripping tool with LB1195 wire stop Heatshrink Boots Straight Racychem 202K153 Hellermann 156 42 G Right Angle Racychem 222K153 Hellermann 1156 4 G MoTeC Appendices 85 Appendix H Wire Specifications M22759 16 Wire Ratings For Various Wire Gauges Insulation Mater
53. ial Tefzel Conductor Tin Plated Copper Voltage Rating 600 V Maximum Temperature 150 C Cross Max Current Resistance Resistance Sectional at 100 C ohm m ohm 1000 ft Area mm Ambient Wire Stripping Tool The following tool is recommended Ideal Industries 45 2133 stripping tool with LB1195 wire stop 86 Appendices Appendix J CAN Wiring Multiple Device The CAN bus should consist of a twisted pair trunk with 100R 0 25Watt terminating resistors at each end of the trunk The preferred cable for the trunk is 100R Data Cable but twisted 22 Tefzel is usually OK The maximum length of the bus is 16m 50ft including the MoTeC CAN Cable PC to CAN Bus Communications Cable CAN Devices such as MoTeC ADL BR2 etc may be connected to the trunk with up to 500mm 20in of twisted wire The connector for the CAN Communications Cable may also be connected to the trunk with up to 500mm 20in of twisted wire and should be within 500mm of one end of the trunk If desired two CAN Cable connectors may be used so that the MoTeC CAN Cable may be connected to either side of the vehicle Both connectors must be within 500mm of each end of the trunk CAN Cable Connector 100R Terminatin 2 Resistors at inb These wires must be Twisted end of the CAN Bus Minimum one twist per 50mm 2in 500mm lt lt CAN Bus gt gt Max 500mm Max CAN Short CAN Bus If the CAN Bus is less than 2m 7ft lon
54. ignition timing will stay fixed at the value set under Test Advance This allows the CRIP to be adjusted if necessary until the timing matches the Test Advance m Dial back timing lights such as the Snap On brand may not work correctly at cranking use a traditional timing light E For some trigger modes one tooth per firing the Ignition Timing is set by the sensor position only In this case the ECU only controls the timing above 500 RPM E If the spark is going to the wrong cylinder on a Direct Fire Ignition then the ignition may be wired incorrectly or the CRIP Crank Index Position setup parameter may be out by a multiple of the angle between cylinders Starting Fuel System Power up the fuel pumps and check the fuel system for leaks before attempting to start the engine Fuel Overall Trim Use the FUEL Overall Trim to vary the mixture when trying to start the engine to see if the engine needs more or less fuel this ensures that the mixture is varied equally for all RPM and Load points Establish how much trim the engine needs on average then trim this out by adjusting the setup parameter IJPU Injector Pulse Width Scaling or by using the Overall Trim Table item in the Tools Menu 44 Initial Starting Procedure If the Engine won t start Check for correct fuel pressure Check for fouled plugs Re check for diagnostics errors Re check the Ignition Timing with a Timing Light Check the setup parameters
55. ilable eg Fuel Temp ATS IGN6 on M400 eg Diff Temp _____p AT6 eg Exhaust Temp y AV3 AUX1 _ Auxiliary Outputs eg Fuel Pressure p AV4 AUX2 S i eg Gear Lever Force AV5 AUX3 Auxiliary Devices such as I eg Lateral G Force 5 AV6 AUX4 gt Idle Speed Motors eg Driver Fuel Adjustment AN AUX5 y Boost Control Valves eg Driver Boost Adjustment _____ AV8 AUX6 Relays AUX7 ZER Lights Wheel Speed or Switch ______J Dig 1 AUX8 gt ele lt lt Main Engine Sensors The Main Engine Sensors are required for correct operation of the ECU The engine RPM is derived from the REF trigger sensor The SYNC trigger sensor is required to synchronise the Fuel and Ignition to the correct engine cycle for sequential injection and correct firing of multicoil ignition systems MoTeC Overview 7 The Throttle Position Manifold Pressure Air Temp and Engine Temp are used as inputs to the various calibration tables Optional Sensors The Optional Sensors are not required for basic operation of the ECU The Lambda Inputs may be used for wideband air fuel ratio measurement or wideband or narrow band closed loop lambda control The Digital Inputs may be used for wheel speed measurement or to activate functions such as Dual RPM Limit or Nitrous The other inputs may be used for data logging eg Exhaust Gas Temp Gear Box Temp Driver Boost adjustment etc or for special calibration features Fuel
56. ill effect the engine tuning The fuel pressure is critical to the injector flow and should be monitored during dyno tuning Incorrect fuel pressure will result in incorrect tuning Note that on turbo engines the fuel pressure will vary as the manifold pressure varies because the regulator maintains a fixed pressure above manifold pressure Fuel Main Table The Fuel Main Table allows adjustment of the fuel at various RPM and Load points Work through all the table values systematically so that all points are adjusted for the correct Air Fuel Ratio reading Use extreme caution when adjusting the fuel to ensure that the engine does not run lean at high loads It is best to start rich A temperature compensated wideband Air Fuel Ratio Meter is essential to ensure correct air fuel ratio m If the engine is missing for any reason including over rich the sensor may falsely read lean due to the oxygen in the unburnt mixture MoTeC Calibration 49 The Air Fuel Ratio should be adjusted according to the engine load and the desired results e g power economy emissions etc At high loads the mixture should be approximately 0 89 Lambda for maximum power On turbo charged engines a richer mixture may be required to reduce exhaust temperatures and help avoid knocking At lighter loads the mixture may be adjusted for best emissions 1 00 Lambda or best economy 1 05 Lambda The cranking starting fuel may be adjusted by adjusting the 0 RP
57. key for example 2 5T will add 2 5 to the whole table Block Operations To mark a block hold down the shift key while pressing the arrow keys then perform a maths operation 66 ECU Manager Software Quick Lambda The Quick Lambda feature allows the Fuel Main Table values to be adjusted to the correct lambda by simply pressing the Q key This feature uses the Wideband Lambda reading and the value from the Lambda Table to calculate the new fuel table value The Lambda Table may be accessed by pressing the F8 key m Note that this feature requires a Wideband Lambda sensor or meter to be connected to the ECU Set Indicators A will appear next to items that have been set with the exception of tables that are dependent on the engine operating point where a will only appear if the engine operating point corresponds to the currently selected site The indicates that the point has been tuned The s may be cleared individually or all Te may be cleared at once To clear an individual press the Delete key To clear ALL s select Clear ALL s from the Tools menu MoTeC Tools ECU Manager Software 67 The Tools Menu allows selection of various functions as listed on the menu below The Tools Menu may also be displayed by pressing the F9 key in this case the previously selected item will be highlighted which makes it easier to do repetitive operations MoTeC M800 ECU Manager 02123001 7 MoTeC 7 Testi
58. lf way between the value of the current site the value of the site to the left Available only in the Site setup screens Delete Site Delete the current site Available only in the Site setup screens 72 ECU Manager Software View Screen The View Screen may be shown by pressing the V key or by selecting the desired view page from the View menu The View Screen displays all the operating details of the ECU including B Sensor data m Diagnostics errors m Fuel injection detail including all trims and compensations m Ignition detail including all trims and compensations B Boost control detail m Status information m Output Status m Internal Voltages etc Diagnostic Errors Fuel Ignition Boost Calculated Status Outputs Internal Trigger Sensors Main Sensors Gear Sensors RPM 5560 Bat V V 14 2 EGT 2 C 457 G Sft F Max RPM rpm 19246 Lal C 1 EGT 3 Gear V SyncPos Z 50 0 Laz C4 EGT 4 Gear 6 Ref V v 4 86 TP Z 79 0 TP2 Sync V V 3 72 MAP kPa 465 TPD Ref Max V 4 86 EMAP TPD2 Speed Sensors Ref Min V 0 28 ET C 84 0 ThRadP 2 0 0 Gnd Spd 0 0 SyncMax V 3 76 AT C 20 0 DCSvoP Dry Spd 0 0 SyncMin V 3 71 ECU T C 46 7 Speed 1 MAF Speed 2 0 BAP Speed 3 FT C 40 0 Speed 4 Sensor Supplies in Slip 0 0 DV Aux V 5 00 op Sv Eng V 4 97 Knock V Input Positions DV Aux V 7 94 I EGT 1 SyncPos deg 0 0 Sv Eng
59. lue A The image above shows one possible screen layout that suits an 800x600 screen Layout Pages Separate layouts may be defined on separate pages A number of pages may be loaded at once and may then be selected by clicking on the tabs at the top of the pages or by pressing the Tab or the Ctrl Tab keys The layout pages are saved to files To open close or create new pages select the appropriate menu item from the Layout menu 60 ECU Manager Software Layout Objects To add an object to the layout page select Add from the Layout menu or right click on an empty space in the layout page and select Add To change the properties settings of any object right click on the object and select Properties To delete an object right click on the object and select Delete Adjust Tables and Adjust Graph Objects In order to make adjustments the layout page must contain an Adjust Table or an Adjust Graph or both Note that only one Adjust Table and one Adjust Graph are allowed per page Adjust Tables Adjust Tables show the values for the currently selected table and allow adjustments to be made They also show axis indicators and a target to help positioning of the engine operating point Fuel Main of IJPU RPM 4500 4750 5250 5500 5750 A NE E va see smo Effcy 100 0 66 0 570 540 620 720 745 73 0 620 550 530 590 675 685 90 0 S00 p 550 520 510 545 61 0 s 20 490 455 460 480 51 0 535 60 0 440 405
60. mbinations of RPM and Load Other calibration tables will also affect the fuel injector pulse width such as Air Temperature compensation and Engine Temperature compensation The ECU determines the amount of fuel to inject by first calculating the RPM and Load then extracting the corresponding value from the table If the RPM and Load do not match an RPM and LOAD point exactly then the values from the closest sites are mathematically interpolated to arrive at an intermediate value A typical 3 dimensional fuel calibration table is shown below Fuel Main of IJPU p pew Man 500 750 1000 1250 1500 Load 50 0 350 405 440 440 440 440 Fuel 4 NN EEN AS RAR SRR SQ MoTeC Overview 11 Setup Parameters The Setup Parameters allow the ECU to be configured for almost any engine The Setup Parameters include Number of Cylinders Ignition Type Sensor Types Injector Current Auxiliary Output Functions etc m The Setup Parameters must be correct before attempting to start the engine ECU Functions The ECU s can perform a large number of functions in addition to the normal Fuel and Ignition control capabilities including Hi Lo injection Individual Cylinder tables for Fuel and Ignition Rotary ignition split and various sensor compensations The functions are setup using ECU Manager either in the Functions menu the Digital Input Functions menu or
61. ms m Ifthe Ignition System is wired via the Fuel Pump relay then the ignition test will not work unless this relay is activated m It will be necessary to place a spark plug on the lead from the ignition coil if the ignition system uses a distributor Test the Injectors Use the ECU Manager Injector Test on the Utilities menu to ensure that all injectors are working and that they are wired in the correct firing order for sequential operation WARNING Ensure that the fuel pump is off during this test Initial Cranking Crank the engine without fuel pressure and check the RPM reading Check that the RPM reading is sensible if the RPM is too high or too low or is erratic then the Setup may be incorrect or there may be a problem with the REF sensor signal If there is no RPM reading then the REF sensor is not working MoTeC Initial Starting Procedure 43 Check that no REF or SYNC Diagnostic Errors occur during constant cranking Diagnostic errors may occur as cranking winds up this is OK but the errors need to be cleared by pressing the Enter key while viewing the ECU Manager Diagnostics Errors screen so that constant cranking may be checked for errors Diagnostic errors may occur as cranking winds down this is also OK Cranking Ignition Timing Check that the Ignition Timing is correct during constant cranking This can best be done in the Crank Index Position setup screen under the ignition menu While in this screen the
62. n hp 8 injectors 600 x 5 8 275 cc min Note that the flow rate of any particular injector is dependant on the fuel pressure applied to it Sometimes oversize injectors are used to maintain lower duty cycles since high duty cycles reduce the effect of sequential injection since the injectors are turned on for most of the time However this can affect idle fuelling as the injector may have trouble delivering small amounts of fuel Flow Rate Matching The flow rate of injectors can vary between injectors of the same type It is advisable to match the flow rates of injectors by testing each injector on a flow bench Fuel Pressure The fuel pressure applied to the injector will directly affect the amount of fuel that the injector delivers Doubling the pressure however only increases the fuel flow by about 1 4 times Most injectors will only operate correctly over a certain range of fuel pressures If the pressure is too low then the fuel may not atomise properly If the pressure is too high then the injectors may not turn off fully Many injectors will operate correctly at 2 5 bar 29 psi and some will operate up to 5 bar 73 psi Current Different injectors require different operating currents The ECU injector drives must be programmed to suit the injector using the Injector Current setup parameter Pulse Width The amount of time that the injector spends open during each injection pulse is called the Injector Pulse Width
63. nected sensors Refer to the ECU Manager help screens for details MoTeC Initial Setup 35 Input Output Functions Setup any essential Input Output functions It may be best to start with any non essential functions turned off eg Idle Speed Control Dual RPM Limit etc Refer to the ECU Manager help screens for details Other Functions Ensure any other functions such as Boost Control Traction Control etc are all set appropriately It may be best to start with any non essential functions turned off eg Traction Control Lambda Control etc Refer to the ECU Manager help screens for details MoTeC Initial Calibration 37 Initial Calibration Before attempting to start the engine the calibration tables should be initialised to sensible values Use the MoleC ECU Manager software to initialise the ECU calibration tables Preferably start with a calibration file from a similar engine as this will make initial calibration faster and easier Clear any s from the tables by selecting Clear s from the ECU Manager software Tools Menu Press the F9 key The s indicate values that have been set correctly which is inappropriate at this stage Fuel Tables Fuel Main Table Check the Fuel Main Table The table should be smooth In general turbo tables look quite different from throttle position tables so it is best to start with a table from a similar engine Fuel Air Temp Check the Fuel Air Temp
64. ng may also be used to verify and fine tune the operation of the various advanced functions such as traction control The light load and overrun calibration must also be completed on the road as these areas cannot be adjusted on a dyno MoTeC ECU Manager Software 53 ECU Manager Software MoTeC M800 ECU Manager File Adjust View Tool ayout Utilities Help gj cil 2 8 Serial Number 12 ECU Enables Advanced Functions Cam Control Cylinders 12 Drive by Wire Enable Normal Enable Old Lambda Dual Logging 4M Multi Pulse Pro Analysis Remote Logging Servo Control Telemetry ECU Connected 2 00A Diagnostic Errors 11 Introduction The following is an overview of the main concepts of the ECU Manager software More detailed information is available from the online help The ECU Manager software is used for Calibration and Setup Sending calibration files to the ECU Viewing Sensor readings Viewing Diagnostics information Testing the Outputs Unloading the logged data Upgrading the ECU firmware Enabling ECU options 54 ECU Manager Software PC Requirements See the MoleC Software section earlier in this manual Connecting a PC to the ECU See the MoleC Software section earlier in this manual Installing the Software See the MoleC Software section earlier in this manual This topic covers information that may be helpful for users that have previously used the MoTeC EMP Software which ECU Manager supe
65. ngines a 300 kPa absolute sensor will measure up to 200 kPa 29 psi of boost above Atmospheric If higher boost will be achieved a sensor with a higher pressure range will be needed The sensor should be connected to the inlet manifold plenum via a short hose less than 1m The sensor should be mounted above the level of the plenum with the port facing down to avoid moisture accumulating on the sensor element The hose should run downwards all the way to the plenum The plenum take off point should be at a position that best represents the average manifold pressure and has minimal pressure pulsations A small restrictor may be needed at the manifold end of the hose to help reduce pressure pulsations The take off point should not be teed in with other items such as idle speed control valves as they can affect the pressure reading If used for Barometric Pressure Sensing Use a 105 kPa sensor Vent the sensor to the atmosphere with the port facing down Avoid mounting at a point where air buffeting occurs any pressure fluctuations will directly affect the mixture It may be desirable to sense the pressure at the air intake as the pressure may vary due to aerodynamic effects Air Temp Sensor The Air Temperature sensor is mainly used to correct for air density change due to air temperature variation The sensor contains a temperature dependant resistor and is designed for high speed response in an air flow The Air Temp sensor must b
66. ngs m for sequential operation for details REF A12 8V En un Hall or Optical g Injector 1 pen 1st t Magnetic 8 B1 l 1 T B1 Injector 2 A21 2nd d Klees REF Injector 3 453 3 rd og peus Injector 4 4 th SYNC ve Hall or Optical Magnetic sz B2 Sig B2 sync p Ld MR ONCE 4 A2 sy Eng AUX OUTPUTS gages P abide Open Aux1 A18 e Throttle T AM ay 4 Aux 2 A1 Position lt C Aux3 A23 Manifold c Aux4 A24 Pressure 5 A15 ay 2 Stepper Motor Relays or Valves M Aux 5 A31 e Air B3 AT 1 Aux6 A32 Temp Aux7 A34 ne B Aux 8 Engine AT2 A26 Temp B16 bul DV Eng B25 Note 2 See drawing ree B26 LA1S X25 for wiring LAP details L Not 4 ote 20 Amp B5 AT3 Note 3 Fuse ANALOG 221 AT 4 56 TEMP INPUTS gt B7 AT 5 I latino pr AT6 Switch AMT AV 3 AV 4 ANALOG z 25 avs o Loa o VOLT INPUTS B20 av 6 20 Amp gt BA AN T Ignition 1 As Ignition Fuse z AV 8 Ignition 2 A5 System DIGITAL x 88 pig 1 Ignition 3 1 75 INPUTS B9 pia 2 Ignition 4 See Detail gt B10 Dig 3 Drawings DX B pig 4 Auxiliary Sensor 0 Volt 4 815 DV Aux Power Serial Connector 2 SH RS 232 Tx GND A10 A11 D9 female 3 Big RS 232 Rx 5 ai DN Comms CANC 1 Chassis 12 Volt Deltron add 4 B23 ARTEN marh Battery 716 0 0501 I CANHI Power to Auxiliary 4 EG 8V Aux Power une GEN ee un i activated using the Fuel Pump control sensors lt SV Aux Power wire to e
67. nitor software should be installed The software can be downloaded from the MoTeC web site at www motec com au or is available on CD MoTeC is continually updating the software and newer versions may be downloaded from the web site at no charge To install the software after downloading from the web double click on the downloaded file and follow the instructions Note that a separate folder directory is automatically created for each version of the software Old versions are kept so that they may be used if necessary M Do not change the MoTeC directory structure or move the software to a different directory otherwise the software will not operate correctly Starting the Software To start the MoleC Software double click the appropriate icon on the desktop or select the appropriate program from the Start menu For example Start Programs MoTeC M400 M600 M800 ECU Manager 2 1 ECU Manager Software The ECU Manager software is covered in more detail later in this manual Data Logging Data Logging allows the ECU operational data to be recorded in a memory chip inside the ECU the data may then be extracted for analysis on a PC Data logging is extremely useful for checking mixture readings sensor readings diagnostics errors and other operating information MoTeC Software 17 The items to be logged and the logging rates must be setup using the MoleC ECU Manager software This is done in the Data Logging Setup screens
68. nsure that the ignition system is off when the engine is stopped Or use the Fuel Pump Relay to power the Ignition System This also provides reverse battery protection to the ignition system Note 2 To avoid the fuse blowing due to reverse battery polarity use a diode activated relay Note 4 Aux 1 2 5 8 can also drive grounded loads A26 00000000 I ene eg eg Bosch 0332 014 112 Aux 1 and 2 are High current Tite M400 ECU Wiring Sheet No Drawing No MoTeC Date 14 10 2003 Drawn ST App AD Products ECU M400 ECU MoTeC 93 Refer to the Sensors ECU Injectors Connectin firing order Looking into Connector on ECU Y Y Y A1 AD 1 Tg Seeeeeee lleeeeeed 10 A17 B8 B13 Weeeeeeg Seeeen A18 A25 B14 B19 00000006 OD OUR A26 A34 B20 B26 00000000 0 00000 I Trigger Drawings o for sequential operation for details REF A12 8VE HEF Hall or Optical Gs Injector 1 pen 1st
69. nto Connector on ECU Note 1 stopped Or use the Fuel Pump AT WX 1T Tg The Fuse is essential to ensure that the Relay to power the Ignition System 0060606906000 90000000 ECU is not damaged by reversed battery This also provides reverse battery A10 A17 B8 B13 polarity protection to the ignition system 00000000 000000 A18 A25 B14 B19 Note 2 Note 4 ion 000000 K bd eee p To avoid the fuse blowing due to reverse NKA 2 5 8 can also drive grounded battery polarity use a diode activated relay loads eee eee ae eg Bosch 0332 014 112 Aux and 2 are High current Tite M800 ECU Wiring Sheet No Drawing No M O e C Date 21 08 2002 Drawn ST App AD Products ECU M800 ECU MoTeC 95 Refer to the Sensors ECU Injectors Connectin firing order Trigger Drawings o for sequential operation for details REF 3 8V En SS Hall or Optical g Injector 3 1st e Magnetic p r Fag Injector 2 2nd Klees REF Injecto
70. o be selected For example to select File Exit hold down the Alt key then press F then X Alternatively press the F10 key then use the arrow keys and the Enter key to select the desired menu item Unavailable Menu Items Note that some menu items may be unavailable if the ECU is not connected or a file is not opened Unavailable items appear grey Button Bar Toolbar e HR RR zez e CZ The Button Bar provides an alternative way of activating some of the commonly used items on the main menu To find out what each item does hold the mouse pointer over the button of interest until a hint appears Note that some items will not be available depending on whether the ECU is connected and if a calibration file is open Status Bar ECU Connected V2 00A Diagnostic Errors _1 Z The bottom line on the screen is called the Status Bar and shows the following m ECU Status Connected or NOT Connected if the ECU is connected the ECU firmware version is also shown If the ECU is not connected the MoTeC ECU Manager Software 57 reason that it is not connected is shown where the Diagnostics Errors are normally shown m The number of diagnostics errors if the ECU is connected Calibration Files ECU Manager records the ECU calibration and setup data in files that are stored on the PC hard disk this ensures that a permanent record of the data is kept The files also record comments to allow easy identification of
71. o the injectors which is necessary to ensure constant metering of the fuel Any variation in the fuel pressure will cause a corresponding mixture change The fuel pressure regulator should be mounted at the end of the fuel rail so that fuel is always flowing through the rail This helps to avoid vapour locks Adjustable pressure regulators are available If using Manifold Pressure Load Sensing Connect the regulator port to the plenum as this ensures that constant pressure is maintained across the injectors Note that this will cause the fuel pressure required from the pump to increase as the manifold pressure increases If using Throttle Position Load Sensing Leave the regulator port open to the atmosphere unless the MAP sensor is connected to the manifold as is recommended when using idle speed control in which case the regulator port should be connected to the manifold Fuel Injectors The fuel injectors meter the fuel by opening for a short but defined time once per engine cycle sequential operation The injectors must be wired in the firing order of the engine Sizing The size of the injector determines the maximum amount of fuel that can be delivered to the engine MoTeC Installation 29 As a rule of thumb the engine will require about 5cc per minute per horse power for petrol or gasoline For alcohol a higher flow rate is required For example A 600 hp V8 will require each injector to flow at least 600 hp x 5 cc mi
72. on all tables Enter Set the adjusted Value Alt X Close the ECU or File Esc Show the Adjust menu with the current screen item highlight Tab Select the next Layout page Spacebar Jump the cursor to the site closest to the current engine operating point F1 Show Help F3 Show the Diagnostics Errors screen F5 Toggle between the Fuel and Ignition screens Alt F6 Remember the current screen Show it when F6 is pressed Alt F7 Remember the current screen Show it when F7 is pressed Alt F8 Remember the current screen Show it when F8 is pressed F6 Select the Fuel Timing screen or the Remembered screen F7 Select the Boost Limit screen or the Remembered screen F8 Select the Lambda Table screen or the Remembered screen F9 Show the Tools menu F10 Select the main menu F11 Copy site up and right C Turn Compare Mode Off On E Edit the File Comments G Switch table between table mode and graph mode L Lambda Was Q Quick Lambda W Quick Lambda plus copy up and right V Show the last View screen S Show the sensors tab on view screen Y Reverse the Y axis on the table graph or both Delete Delete at the current site Backspace Place at the current site Home Select one of a number of default view angles for the graph Ctrl Arrrow Change the view angle of the graph Shift Arrow Mark a block on the table mathematics may be applied to the block Ctrl Shift Arrow Copy the current table value to an adjacent cell 76 ECU Manag
73. password has been set Channel locking may be set by selecting Adjust Security Setup from the main menu File Encryption File Encryption allows a configuration file to be distributed to a customer without the customer being able to view the contents of the file An encrypted file can only be sent to an ECU that has it s password set to the same value as the Encryption Number that was used to encrypt the file An encrypted file cannot be sent to an ECU with no password The data in an encrypted file cannot be viewed The comments for an encrypted file are the same as those of the file from which it was created The comments cannot be edited It is possible to create files with the same comments so care needs to be taken to ensure the correct files are used Any unnecessary files should be deleted 74 ECU Manager Software Enabling ECU Options A number of options are available which allows the ECU to be configured for a particular need or updated later if necessary The options include Data Logging Wideband Lambda measurement Drive by Wire and more The options may be enabled at any time by selecting Utilities Enable ECU Options from the main menu and entering the enabling password MoTeC ECU Manager Software 75 Keyboard Reference PgUp Adjust Up PgDn Adjust Down Ctrl PgUp Fast Adjust Up Ctrl PgDn Fast Adjust Down Shift PgUp Slow Adjust Up Not available on all tables Shift PgDn Slow Adjust Down Not available
74. r 3 a 3rd i el ear Injector 4 75 4th SYNC Injector 5 42 5 th So Hall or Optical Injector 6 5I 6 th Magnetic Se Injector 7 7th SE 56 sig 56 sync Injector 8 82 8 th po P Ld Kee ee 4 16 5y Eng AUX OUTPUTS Renya or pg Open Aux1 H 9 D Throttle 26 ay4 Aus 3 8 Position lt Aux 3 43 Aux 4 51 Manifold c 18 Pressure B AN 2 Stepper Motor Relays or Valves Aux 5 59 k Air 28 AT 1 Aux6 8 Temp Aux 7 64 3 og Aux 8 Engine AT2 23 32 41 12V T emp 27 ov Eng 54 Note 2 See drawing SEN 4 60 LA1S X25 for wiring LA1P Be details 55 rampag 61 LA2S Note 1 LA2P 20 Amp 30 AT3 Note 3 Fuse ANALOG mm AT 4 e TEMP INPUTS gt 291 AT 5 37 are Ignition 6 Switch 7 AN 3 ANALOG 12 AV o Lo aS E 7 VOLT INPUTS gt 36 AV6 i 20 Amp gt uA Ignition 1 Ignition Fuse H Av8 Ignition 2 7 System DIGITAL 39 Dig 1 Ignition 3 75 INPUTS gt 2 Dig 2 ignition 17 See Detail i gnition Drawings p c gt 53 D93 Ignition 6 29 9 m i g OV To Auxiliary 11 Sensors OV Aux Power Serial Connector 2 SI RS 232 Tx D9 female 3 21 RS 232 Rx GND 5 Di 0V Comms 1 Chassis 12 Volt CAN Connector i 47 CAN LO Earth Battery Deltron 5 48 CAN HI 716 0 0501 3 Note 3 Power to Auxiliary lt 2 8V Aux Power The Ignition system relay should be sensors lt 34 5V Aux Power activated using the Fuel Pump control wire to ensure that the ignition system is off when the
75. ration values it is important that the engine RPM and Load are centred on the current adjustment site to ensure that the values from the adjacent sites have minimal influence on the value being adjusted Use the Target at the left of the table to ensure that the engine operating point is centred on the site being adjusted During initial tuning if large adjustments are required to a particular site ensure that the sites around it are also adjusted to a similar value so that the adjacent sites have minimal influence Use the SPACEBAR key to quickly move the adjustment cursor to the engines current operating point 48 Calibration Site Tables The RPM and Load sites for the various calibration tables may be modified in the Setup Sites screen A number of site tables are available which affect different calibration tables Use the help to check which calibration tables are effected by which site tables To insert or delete sites use the Tools menu press the F9 key When sites are inserted or deleted the calibration tables may be adjusted so that the new sites do not affect the tuning Dyno The alternator should be connected while tuning the engine to ensure that the injectors are working at normal operating voltage The exhaust system should be the same as that in the vehicle as it will effect the engine tuning On multi runner intake manifolds the air box should be fitted as it is an integral part of the intake system and w
76. refore best if the engine is stopped during the interpolation If the engine is running a warning will be given before the interpolation is started Interpolate Vertical Column Linearly interpolates the current Column between the Upper most value and the Lower most value leaving the Upper most value the Lower most value and points marked with an unchanged Note that it may be necessary to use the Backspace key to mark the desired points with an Interpolate Horizontal Row Linearly interpolates the current Row between the left most value and the right most value leaving the left most value the right most value and any points marked with an unchanged Note that it may be necessary to use the Backspace key to mark the desired points with an 70 ECU Manager Software Copy Vertical Column Right Copies the data in the current Column to the Column immediately to its right Copy Horizontal Row Up Copies the data in the current row to the row above Copy Site Up And Right Copies the value of the current site to the sites immediately above right and diagonally above and right if the sites do not contain an Reverse Y Axis Reverses the Y axis for the Graph or Table or both This makes some graphs easier to see Toggle Table Mode If a table is displayed and there is no graph displayed this will switch the table between table mode and graph mode Set All Values To Current Set all values in the current table to the
77. rrors Open The Injector is open circuit check the wiring Short The Injector is short circuit check the wiring Peak The Injector peak current was not reached Possible causes W The Injector Current Setup Parameter IJCU is set too high W The battery voltage is too low Over Duty The injector duty cycle is too high typically the duty cycle should not exceed 85 If the injectors exceed their maximum duty then larger injectors or higher fuel pressure is needed REF SYNC Errors The possible causes of the various errors are detailed below REF Error Too many REF pulses have occurred between SYNC pulses Possible causes m A bad REF signal has caused extra pulses or a SYNC pulse has been missed check voltage levels with a scope m Bad REF SYNC alignment m Incorrect Setup No REF Two SYNC signals have occurred without a REF signal Possible causes m If the RPM is 0 then there is no signal check the wiring and sensor voltage levels with a scope m f RPM is not 0 then a bad SYNC signal has caused extra pulses check voltage levels with a scope m If RPM is low then the REF and SYNC signals may have been swapped W Incorrect Setup 46 Initial Starting Procedure SYNC Error The SYNC signal has occurred before expected Possible causes m Abad SYNC signal has caused extra SYNC pulses check voltage levels with a scope m Abad REF signal has caused missing REF pulses check voltage levels with
78. rsedes For EMP Users Windows The main difference between ECU Manager and the old EMP software is that itis a full Windows application This has allowed a significant number of improvements to be made the most obvious being the improved graphical user interface Familiarity The operation of ECU Manager is very similar to EMP including most keyboard shortcuts such as F5 to switch between Fuel and Ignition and V to show the view screen The Adjust menu item is the same as the EMP Select Screen menu and may still be activated by pressing the Esc key Pressing the Esc key has the advantage of highlighting the currently selected screen item which often makes navigation to the next screen easier All the adjustment screens should be familiar so there is no need to relearn how to configure the ECU The Tools menu replaces the old Function menu and may still be activated by pressing the F9 key Communications All communication is done using the MoTeC CAN Cable No need for both a Serial Cable and a CAN Cable MoTeC ECU Manager Software 55 This also allows the configuration to be sent and retrieved much faster Making Adjustments To enter adjust mode select Open File or Open ECU from the Adjust or File menus This is equivalent to selecting Adjust from the EMP main menu The usual keys are used for making adjustment Arrow keys to move around PgUp and PgDn for making changes Enter to set the value Screen Layouts A m
79. ses per engine revolution on a V8 others supply as many as 360 pulses per engine rev The Engine RPM is derived directly from this signal SYNC Sensor Used to indicate each engine cycle which is required for sequential injection and multi coil operation Generally supplies one pulse per engine cycle ie once every 2 revs on a 4 stroke engine M On some special trigger systems the ECU can be synchronised using the REF sensor only eg Ford Narrow Tooth MoTeC Installation 23 REF SYNC Alignment Most modern distributors supply both REF and SYNC signals in which case the alignment is pre set When using separate REF and SYNC sensors the alignment of the two sensors relative to one another is critical Ensure that the sensors are aligned correctly for the type of trigger system being used Refer to the appropriate drawing Allow for any slop in the distributor drive system if the SYNC signal is derived from the distributor Exhaust Gas Sensor Lambda Sensor The ECU may optionally use a wideband exhaust gas sensor for data logging or closed loop control of the Air Fuel Ratio The ECU is compatible with the Bosch LSU wideband sensor and the NTK wideband sensor These sensors are different to the sensors used on previous model ECUs Note that the sensor heater must be connected to these sensors at all times and must be controlled by the ECU by connecting it to one of the Auxiliary Outputs The sensor should preferably be
80. seusecsccnuateactucet 44 Calibrationu uuu u ui u uu u us 47 FEIER 47 Ensure that the engine is On Gite 47 Site ET 48 DYMO EE 48 Fuel EIERE 48 Ignition Main Table _ oin eed asas ee ee eave eet 49 Fuel Injection TIMIN iii eiiie ideio terida iieiaei 50 Fuel Cold Start u eee E e ein edente p Dea doe eaa 51 Other Calibration Tables u uuu or u ua ple teri eot Penes 51 Data Logging amp Road Testing I 51 ECU Manager Software 53 IMROGUCTION RE 53 For TEE 54 ELE 55 Calibration Files u usa trennen trece dee dene ire reine 57 Versions amp Upooradimg nnne nennen 57 EN e 59 Making Adjustment cccccccecsecceceeeceeeceeeaeeeeeeeeeccaaeceseeesesenaeeeeeeeseseenanaeess 62 Me III 72 Testing the ECU Outputs sss eene emen 73 ECU Ecco RE 73 File Eneryption rssigiiuu again beste teo ein SE 73 Enabling ECU Options uu u u uu anar eo crest reet adi Enn air dera tenen 74 Keyboard Reference nennen ennt nemen eren nns 75 ee D 77 Appendix A General Specifications 77 Appendix B Sensor Supplies 78 Appendix C Input Characteristics a 79 Appendix D Auxiliary Output Characteristics a 81 Appendix E Ignition Output Characteristics eee eenen 82 Appendix F Injector Output Characteristics sse 83
81. ssive advance Re check the Ignition Timing with a Timing Light to ensure that the what the ECU thinks is the ignition advance is in fact the actual advance 50 Calibration The Ignition Timing should be adjusted for maximum torque without knocking by increasing the advance until the torque stops increasing Make sure there is at least 3 or 4 degrees margin to the knock limit Too much retard will cause excessive exhaust gas temperature At idle a more retarded ignition setting is desirable approximately 10 to 15 degrees This makes the idle speed less sensitive to load changes Also the ignition should be flat over the idle RPM range so that timing variations do not cause the engine to hunt since variations in the timing will vary the engine torque The Quick Lambda feature may also be used from the Ignition Main Table which allows ignition timing adjustments to be made while also maintaining correct mixture readings Use the View Ignition Screen to check that all the fuel trims and compensations are correct Press the V key Refer to the ECU Manager software help for more details Press F1 Fuel Injection Timing The Fuel Injection Timing table allows adjustment of the Fuel End of Injection Timing at various RPM points and optionally at various Load points This table is only effective if the injectors are fired sequentially Adjusting the Injection Timing ensures that the fuel is injected at the optimum point in the
82. the Auxiliary Output Functions menu Help on each function is available from within ECU Manager by pressing the F1 key when the appropriate screen is shown Tech Notes are available from MoTeC on the more complicated functions such as Traction Control Note that some functions may not be available depending on the ECU Model and options The functions are as follows Functions The following functions are setup in the Functions menu Boost Control Warning Alarms Gear Detection Overrun Fuel Cut Ground Sped Limiting Gear Change Ignition Cut Boost Enhancement Antilag Lambda Control Traction Control must also be setup in the Digital Input Functions must also be setup in the Auxiliary Output Functions 12 Overview Digital Input Functions The following functions are setup in the Digital Input Functions menu Speed Measurement Period Measurement Pulse Measurement Dual RPM Limit Air Conditioner Request Nitrous Nitrous Dual RPM Limit Ignition Switch Brake Logging Enable Clutch Beacon Power Steering Cam Position Telemetry Control Mass Air Flow Frequency Measurement RPM Speed Limiting Auxiliary Output Functions The following functions are setup in the Auxiliary Output Functions menu Idle Speed Control Aux Table Controlled Output Tacho Signal Drive by Wire Control Drive by Wire with Idle Speed Control Stepper Idle Speed Control Fuel Pump Control Thermatic Fan Control Air
83. the engine during cornering and acceleration Fuel starvation can also cause damage to the pressure pump as it relies on the fuel for cooling lubrication and speed limiting The swirl pot also forms a header tank for the pressure pump since the pressure pump is not capable of lifting the fuel from the tank if the tank is lower than the pump Place the swirl pot at the same level or higher than the pressure pump Pressure Pump The Pressure Pump is a high pressure pump that must be capable of delivering the required amount of fuel at the correct pressure at full power MoTeC Installation 27 It is very important that the pump is capable of maintaining the correct fuel pressure at full power otherwise the engine could be damaged due to a lean mixture A 600 hp engine requires a flow rate of approximately 250 Ib hr for petrol or gasoline Notes B The pressure pump must be lower than the outlet of the swirl pot m Prime the pump with fuel before use B The pumps flow capability is dependant on the required pressure the flow capability of the pump will be less at higher pressures A small pump will maintain correct pressure at light load but will not maintain correct pressure as the flow requirement increases B On boosted engines the pressure required from the pump increases with boost pressure because the regulator maintains constant pressure above manifold pressure W Avoid running the pump dry as this may destroy the pump Filt
84. value of the current site Reset ECU Resets the ECU This can be useful if changes have been made to a setup item that requires the ECU to be reset normally this does not happen until a different screen is selected Clear All Clears all s in either the currently displayed table or all tables The s are normally used to indicate which sites have been tuned Clear Current Clears the on the current site Set with Sets an on the current site whether or not the engine is currently at that site MoTeC ECU Manager Software 71 Copy Table from Another File Copy a table from another calibration file into the current table Warning The current table data will be overwritten Import CSV File Read a CSV Comma Separated Value file into the current calibration table Normally the CSV file is one that has been written out from another configuration file possibly for a different ECU type Warning The current table data will be overwritten Note that the CSV file must be for the same type of table Note also that the site values are not imported therefore the site values must be the same as the sites in the CSV file for the table to have the same result Export CSV File Write the current table to a CSV Comma Separated Value file May be used to transfer data between different ECU types or foruse ina spreadsheet Insert Site Insert a site to the left of the current site The new site value will be ha
85. y to fracture unless all movement is avoided Solder flux can also cause corrosion and may affect the contacts Terminal Damage The various connector terminals are easily damaged if probes are inserted into them Do not insert probes of any kind into the terminals If checking a circuit for continuity gently touch the side of the terminals only or preferably attach a mating connector Wire Splicing Preferably use a crimp Splice If soldering a wire splice wire movement near the joint must be avoided otherwise a fracture may occur at the stress point created by the solder Use heatshrink sleeving to insulate and provide support to the wires Wire Strain Avoid pulling the wires tight at the connectors Wire Movement Avoid wire fatigue by tying the wires down close to the connectors Heat Keep the ECU wires away from the exhaust system 26 Installation Fuel System An ideal race fuel system is shown below Pressure Regulator Strainer Pressure Filter 100 micron Pump 4 micron Filter 12 micron UUU Injectors Lift Pump J Strainer Water Separator Lift Pump The Lift Pump is a low pressure pump designed to lift the fuel from the fuel tank to the swirl pot header tank The Lift Pump must be capable of flowing enough fuel for full power operation Swirl Pot The swirl pot header tank maintains a reserve of fuel to avoid fuel starvation to

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