MoTeC M400/M600/M800/M880 User’s Manual Contents Introduction ........................................................................ 1 Additional Documentation ................................................................................... 1 Overview ............................................................................. 3 ECU Models........................................................................................................ 3 Options ...............................................
Calibration ........................................................................ 47 Warning Alarms ................................................................................................ 47 Ensure that the engine is “On Site” ................................................................... 47 Site Tables........................................................................................................ 48 Dyno ..............................................................................
MoTeC Introduction Introduction Thank you for purchasing a MoTeC Engine Management System. This manual will help you understand the installation and calibration requirements of your MoTeC 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.
MoTeC Overview Overview The MoTeC M400, M600, M800 & M880 ECU’s are powerful and compact programmable Engine Management Systems or Engine Control Units (ECUs).
4 Overview • 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.
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 MoTeC Telemetry Monitor program. (Available on M800 & M880 only).
6 Overview ECU Inputs & 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.
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.
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 & M800 Up to 6 ignition outputs are available for multi coil applications. Outputs not used for ignition may be used as Auxiliary Outputs. Up to 8 coils may be driven from one Ignition Output using a MoTeC CDI8 or MoTeC Ignition Expander .
MoTeC Used for Telemetry Output (M800 & M880 only).
10 Overview Calibration & 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 combinations of RPM and Load. Other calibration tables will also affect the fuel injector pulse width such as Air Temperature compensation and Engine Temperature compensation.
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. The Setup Parameters must be correct before attempting to start the engine.
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 Func
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 IBM PC compatible. 200 MHz Pentium or faster.
16 Software Installing the Software The MoTeC 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 Monitor 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 Software 17 The items to be logged and the logging rates must be setup using the MoTeC ECU Manager software. This is done in the Data Logging Setup screens. The ECU will remember the logged data even if the ECU power is turned off. If the logging memory becomes full the oldest data is overwritten so that the most recent data is always available. The ECU must have the Logging option to perform data logging.
MoTeC Installation 19 Installation Throttle Position or MAP Load Sensing The 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.
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 preloaded to avoid the dead band. The Setup Parameters TPHI and TPLO must be set to indicate the fully closed and fully open positions. These parameters must be reset any time the sensor is moved or replaced.
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 engines 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.
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.
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.
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.
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 likely 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.
26 Installation Fuel System An ideal race fuel system is shown below Swirl Pot Fuel Rail Port Pressure Regulator Strainer Pressure Filter Filter 12 micron 100 micron Pump 4 micron Lift Pump Fuel Tank Injectors 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.
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 lb/hr for petrol or gasoline. Notes The pressure pump must be lower than the outlet of the swirl pot. Prime the pump with fuel before use.
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.
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/min/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.
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.
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 & Setup The wiring and setup parameters are specific to the particular ignition system.
32 Installation 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.
MoTeC Initial Setup 33 Initial Setup Before attempting to start the engine the setup parameters must be correct. Use the MoTeC 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.
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.
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).
MoTeC Initial Calibration 37 Initial Calibration Before attempting to start the engine the calibration tables should be initialised to sensible values. Use the MoTeC 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).
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. 0 kPa -100 100 kPa 0 200 kPa 100 300 kPa 200 400 kPa 300 500 kPa 400 This table is equally applicable whether the MAP sensor is used for barometric pressure measurement or for manifold pressure measurement.
MoTeC -20 -12 -10 -9 Initial Calibration 0 -6 10 -3 20 0 30 0 40 0 50 0 60 -3 70 -6 80 -9 90 -12 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 & Setup Parameters Check that all Setup Parameters have been set appropriately.
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.
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.
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 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.
MoTeC Initial Starting Procedure 45 Injector Errors 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 : The Injector Current Setup Parameter IJCU is set too high. The battery voltage is too low. Over Duty The injector duty cycle is too high, typically the duty cycle should not exceed 85%.
46 Initial Starting Procedure SYNC Error The SYNC signal has occurred before expected. Possible causes : A bad SYNC signal has caused extra SYNC pulses - check voltage levels with a scope. A bad REF signal has caused missing REF pulses - check voltage levels with a scope. Bad REF / SYNC alignment. Incorrect Setup No SYNC Two or more consecutive SYNC pulses are missing. Possible causes : No SYNC signal - check the wiring and SYNC sensor voltage levels with a scope.
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).
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.
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).
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.
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).
MoTeC ECU Manager Software ECU Manager Software 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 MoTeC Software section earlier in this manual. Connecting a PC to the ECU See the MoTeC Software section earlier in this manual. Installing the Software See the MoTeC 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 supersedes.
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.
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 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 to be selected.
MoTeC ECU Manager Software 57 reason that it is not connected is shown where the Diagnostics Errors are normally shown. 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 each file.
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 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.
MoTeC ECU Manager Software 59 Screen Layouts The screen layouts are completely user 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. The image above shows one possible screen layout that suits an 800x600 screen.
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.
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 Tools 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.
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.
64 ECU Manager Software Changing Table Values Selecting the Item to be 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.
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. 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.
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. Note that this feature requires a Wideband Lambda sensor or meter to be connected to the ECU.
MoTeC ECU Manager Software 67 Tools 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. 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”.
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.
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.
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.
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.
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.
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.
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 PgDn Ctrl + PgUp Ctrl + PgDn Shift + PgUp Shift + PgDn Enter Alt+X Esc Tab Spacebar Adjust Up Adjust Down Fast Adjust Up Fast Adjust Down Slow Adjust Up (Not available on all tables) Slow Adjust Down (Not available on all tables) Set the adjusted Value Close the ECU or File Show the Adjust menu with the current screen item highlight Select the next Layout page Jump the cursor to the site closest to the current engine operating point.
76 Alt+1...
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 (1.10lb) M880: 0.525kg (1.16 lb) Power Supply Operating Voltage: 6 to 22 Volts DC Operating Current: 0.
78 Appendices Appendix B: Sensor Supplies Maximum Current 5V ENG Sensor Supply: 0.20 Amps Max 5V AUX Sensor Supply: 0.15 Amps Max 8V ENG Sensor Supply: 0.30 Amps Max 8V AUX Sensor Supply: 0.30 Amps Max Accuracy / Temp Drift 5V ENG Sensor Supply: ± 0.5% max at 25°C + 100ppm/°C max 5V AUX Sensor Supply: ± 0.
MoTeC Appendices 79 Appendix C: Input Characteristics Analog Voltage Inputs Suitable for: Potentiometers, Voltage output sensors & Variable resistance sensors. • Note that variable resistance sensors require a pullup resistor to the 5V sensor supply. (Normally a 1000 ohm resistor is used) Measurement Voltage Range: 0 to 15 V • Note that voltages outside this range may affect the readings on other inputs. Input Resistance: 100k ohms to 0V Resolution: 3.
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 0V 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.
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 Max Current (A) 5 5 0.7 0.7 0.7 0.
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.
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.
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 • 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.
MoTeC Appendices 85 Appendix H: Wire Specifications M22759/16 Wire Ratings (For Various Wire Gauges) Insulation Material : Tefzel Conductor : Tin Plated Copper Voltage Rating : 600 V Maximum Temperature : 150 °C Wire Gauge (AWG) Cross Sectional Area (mm2) Max Current at 100 °C Ambient (Amps) Resistance ( ohm / m ) Resistance ( ohm / 1000 ft ) 22 0.38 5 0.045 14 20 0.61 6 0.028 8.5 18 0.96 9 0.018 5.5 16 1.2 12 0.014 4.3 14 1.9 18 0.009 2.7 12 3.0 24 0.006 1.
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.
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.
88 Appendices Appendix L: Pin list by Function M400 M600 M800 Pin No M880 Pin No Abrev Description 23,32,41 14,15,19 VBAT GND Battery Positive Battery Negative 8V-ENG 5V-ENG 0V-ENG 8V-AUX 5V-AUX 0V-AUX 8V Engine Sensor Supply 5V Engine Sensor Supply 0V Engine Sensor Supply 8V Auxiliary Sensor and CAN Supply 5V Auxiliary Sensor Supply 0V Auxiliary Sensor Supply Battery A26 A10,A11 Sensor Supplies A12 A2 B16 A13 A9 B15 3 16 27 2 34 11 Auxiliary Outputs A18 A1 A23 A24 A31 A32 A33 A34 9 8 43 51 5
MoTeC A21 A22 A27 A28 A29 A30 Appendices 63 66 24 42 57 62 INJ3 INJ4 INJ5 INJ6 INJ7 INJ8 89 Injector Output 3 Injector Output 4 Injector Output 5 (Not available on M400) Injector Output 6 (Not available on M400) Injector Output 7 (Not available on M400 & M600) Injector Output 8 (Not available on M400 & M600) Analog Voltage Inputs A14 A15 A16 A17 A25 B20 B21 B22 26 18 6 7 12 36 35 44 AV1 AV2 AV3 AV4 AV5 AV6 AV7 AV8 Analog Voltage Input 1 Analog Voltage Input 2 Analog Voltage Input 3 Analog Voltage In
90 Appendices Comms B17 B18 B24 B23 B14 A13 40 31 47 48 13 2 TX-232 RX-232 CAN-LO CAN-HI 0V-COM 8V-AUX RS232 Transmit Data RS232 Receive Data Can Bus Low Can Bus High 0V Comms 8V Auxiliary Sensor and CAN Supply Note Outputs marked * do not have a recirculation diode, see the Output Specifications for more detail.
INPUT/OUTPUT FUNCTIONS - AUXILIARY OUTPUT FUNCTION = 9 Aux Output SENSOR SETUP - LAMBDA SENSOR SETUP VALUE = 1 Type VALUE = number engraved on sensor Cal Number Will depend on how may sensors are Quick Lambda used and channel assighnments Mode SENSOR SETUP - SENSOR CALIBRATION VALUE = 38 La1 ( La2 ) SENSOR SETUP - CHANNEL ASSIGNMENTS - SCREEN 1 VALUE = 9 La1 VALUE = 10 La2 ECU Setup Ensure the following "Lambda Sensor" parameters are set.
92 Sensors Refer to the Trigger Drawings for details REF (Magnetic) + A12 REF (Hall or Optical) + Sig _ B1 _ B1 + Sig _ B2 + REF for sequential operation Injector 1 Injector 2 Injector 3 Injector 4 A19 A20 A21 A22 1 st 2 nd 3 rd 4 th B2 SYNC A2 _ A14 AV 1 Manifold Pressure A15 AV 2 B4 AT 2 B16 0V Eng B25 LA1S B26 LA1P Lambda 1 B5 B6 B7 B19 A16 A17 A25 B20 B21 B22 B8 B9 B10 B11 B15 ANALOG TEMP INPUTS ANALOG VOLT INPUTS DIGITAL INPUTS Auxiliary Sensor 0 Volt Serial Connector D9
MoTeC 93 Sensors Refer to the Trigger Drawings for details REF (Magnetic) + + Sig _ _ SYNC (Magnetic) + A12 REF (Hall or Optical) B1 B1 + Sig _ A2 5V Eng Throttle Position A14 AV 1 Manifold Pressure A15 AV 2 Engine Temp Lambda See drawing 1 X25 for wiring details Lambda 2 ANALOG TEMP INPUTS ANALOG VOLT INPUTS DIGITAL INPUTS Auxiliary Sensor 0 Volt Serial Connector D9 female CAN Connector Deltron 716-0-0501 2 3 5 1 4 5 3 Power to Auxiliary sensors B24 CAN LO B23 CAN HI B1 B7 A10 A
94 Sensors Refer to the Trigger Drawings for details REF (Magnetic) + + Sig _ _ SYNC (Magnetic) + A12 REF (Hall or Optical) B1 B1 REF + Sig _ B2 SYNC A2 _ A14 AV 1 Manifold Pressure A15 AV 2 ANALOG TEMP INPUTS ANALOG VOLT INPUTS DIGITAL INPUTS Auxiliary Sensor 0 Volt Serial Connector D9 female CAN Connector Deltron 716-0-0501 2 3 5 1 4 5 3 Power to Auxiliary sensors B24 CAN LO B23 CAN HI B1 B7 A10 A17 B8 B13 A25 B14 B19 B20 1 st 5 th B26 2 nd 6 th 3 rd 7 th 4 th 8 th
MoTeC 95 Sensors Refer to the Trigger Drawings for details REF (Magnetic) + 3 REF (Hall or Optical) + Sig _ 49 _ 49 8V Eng REF SYNC (Hall or Optical) SYNC (Magnetic) + Sig _ 56 + 56 SYNC 16 _ 26 AV 1 Manifold Pressure 18 AV 2 38 AT 2 27 0V Eng 54 LA1S 60 LA1P 55 LA2S 61 LA2P 30 AT 3 39 29 AT 4 AT 5 37 AT 6 6 AV 3 7 12 AV 5 36 AV 6 35 AV 7 44 AV 8 46 Dig 1 45 52 Dig 3 53 Dig 4 Engine Temp Lambda See drawing 1 X25 for wiring details Lambda 2 ANALOG TEMP INPUTS ANALOG VOLT INPUTS DIGITA
96 Notes
MoTeC Notes 97
98 Notes
MoTeC Notes 99
