Haltech F10X User Manual
F10X Manual
Warning
1. The F10X ECU must only be used with an F10X wiring
harness. Note that the wiring harness of the F10 will physically
plug into the F10X ECU (and vice-versa), however, the pin
connections are different and this will lead to improper operation
of the ECU and possible damage to it. The F10X wiring harness
is clearly labelled as “X” near the main ECU connector.
i
F10X Manual
Contents
INTRODUCTION....................................................................................................................7
SECTION 1 GETTING STARTED ............................................................................... 11
CHAPTER 1 Haltech ECU Installation ............................................................................... 11
1.1 The ECU and Associated Hardware........................................................................... 11
1.2 Installation Summary .................................................................................................11
1.3 Expanded Installation Guide ...................................................................................... 12
1.3.1 Manifold Absolute Pressure (MAP) Sensor........................................................ 12
1.3.2 Coolant Temperature Sensor............................................................................... 13
1.3.3 Inlet Air Temperature Sensor.............................................................................. 14
1.3.4 The Throttle Position Sensor (TPS) .................................................................... 15
1.3.5 Mount Optional Exhaust Gas Oxygen Sensor..................................................... 16
1.3.6 Route Wiring Harness and Connect Sensors....................................................... 16
1.3.7 Power Relays....................................................................................................... 16
1.3.8 Fuse Block Assembly.......................................................................................... 17
1.3.9 Electronic Control Unit (ECU) ........................................................................... 18
1.3.10 Flying Leads...................................................................................................... 18
1.3.11 Install and Connect Optional Idle Speed Motor................................................ 19
1.3.12 Install and Connect any Optional Outputs ........................................................ 19
1.3.13 Connect the Trigger Sensor............................................................................... 20
1.3.14 Connect the ECU............................................................................................... 20
CHAPTER 2 Installing The Software.................................................................................. 21
2.1 Computer Requirements............................................................................................. 21
2.2 Operating the Software............................................................................................... 21
2.2.1 Installing the Software ........................................................................................ 21
2.2.2 Running the Software.......................................................................................... 23
CHAPTER 3 Operating the Software .................................................................................. 24
3.1 The Menu Structure.................................................................................................... 24
3.1.1 The File Menu ..................................................................................................... 24
3.1.1.1 Load From File............................................................................................. 25
3.1.1.2 Save To File ................................................................................................. 25
3.1.1.3 Load E6K/F10/E6GM Fuel Maps ................................................................ 26
3.1.1.4 Quit............................................................................................................... 26
3.1.2 The Map Menu .................................................................................................... 27
3.1.2.1 Fuel Maps..................................................................................................... 27
3.1.2.2 Fuel Correction Maps................................................................................... 29
The Set-up Menu.......................................................................................................... 29
3.1.3 The Options Menu............................................................................................... 29
3.1.4 Data Page Menu .................................................................................................. 30
3.1.5 Password Protection ............................................................................................ 30
3.2 Online and Offline Operation..................................................................................... 31
3.2.1 Going Online....................................................................................................... 31
3.2.2 The Engine Data and Gauge Page....................................................................... 32
3.3 Hot Key Summary...................................................................................................... 33
CHAPTER 4 Configuring the ECU ..................................................................................... 34
4.1 Using the ECU Set-up Pages...................................................................................... 34
4.2 The ECU Set-up Pages............................................................................................... 34
ii
F10X Manual
4.2.1 Main Set-up Page ................................................................................................ 34
4.2.2 Fuel Set-up Page.................................................................................................. 36
4.2.3 Trigger Setup....................................................................................................... 39
4.2.4 The In/Out Set-up Page ....................................................................................... 39
CHAPTER 5 Haltech Maps ................................................................................................. 43
5.1 What are Maps?.......................................................................................................... 43
5.2 What is Mapping the Engine? .................................................................................... 44
5.2.1 Adjusting Bar Height In a 2D Map ..................................................................... 44
5.2.2 All Ranges........................................................................................................... 45
5.2.3 Percentage Changes............................................................................................. 45
5.2.4 Linearise.............................................................................................................. 46
5.2.5 Numeric Mode..................................................................................................... 47
5.2.6 3D View ..............................................................................................................48
5.3 The Haltech Maps ...................................................................................................... 49
5.3.1 Fuel Map – 3-Dimensional.................................................................................. 49
5.3.2 Fuel Correction Map ...........................................................................................49
5.3.2.1 Coolant Temperature Correction.................................................................. 49
5.3.2.2 Air Temperature Correction......................................................................... 49
5.3.2.3 Battery Voltage Correction .......................................................................... 49
5.3.2.4 Fuel Priming Map......................................................................................... 50
5.3.2.5 Post Start Map .............................................................................................. 50
5.3.2.6 Barometric Pressure Map ............................................................................. 50
5.3.2.7 Gas Pressure Map......................................................................................... 50
5.3.2.8 Gas Temperature Map.................................................................................. 50
5.3.3 Zero Throttle Map ............................................................................................... 51
5.3.4 Full Throttle Map ................................................................................................ 51
5.3.5 Turbo Waste-gate Maps ...................................................................................... 51
5.3.6 Torque Converter Control Map........................................................................... 51
5.4 Dual Maps .................................................................................................................. 52
5.4.1 Editing Dual Maps .............................................................................................. 52
SECTION2 TUNING THE ENGINE............................................................................ 53
CHAPTER 6 Starting the Engine......................................................................................... 53
6.1 Calibrating the Throttle Position Sensor .................................................................... 53
6.2 Checking the Trigger.................................................................................................. 53
6.3 Determining Engine Fuel Needs ................................................................................ 53
6.3.1 Starting using the Manifold Pressure Load Sensing ........................................... 54
6.3.2 Starting using the Throttle Position Load Sensing.............................................. 54
6.3.3 Useful Software Mapping features...................................................................... 54
6.3.4 Tuning for Idle .................................................................................................... 55
6.3.5 Tuning with No Load .......................................................................................... 55
6.3.6 Loading the Engine ............................................................................................. 56
6.3.6.1 On the Dyno ................................................................................................. 56
6.3.6.2 On the Road.................................................................................................. 56
6.3.7 Fine Tuning the Engine ....................................................................................... 56
CHAPTER 7 Throttle Effects .............................................................................................. 58
7.1 Throttle Response....................................................................................................... 58
7.2 Zero Throttle Map ...................................................................................................... 59
7.3 Full Throttle Map ....................................................................................................... 59
CHAPTER 8 Cold Starting and Running............................................................................. 60
iii
F10X Manual
8.1 Cold Cranking ............................................................................................................ 60
8.2 Fuel Correction Versus Coolant Temperature ........................................................... 60
CHAPTER 9 Correction Factors.......................................................................................... 61
9.1 Fuel Versus Air Temp Map........................................................................................ 61
9.2 The Battery Voltage Map........................................................................................... 61
9.3 Barometric Correction................................................................................................ 62
9.3.1 Barometric Correction - Method 1 ...................................................................... 63
9.3.2 Barometric Correction - Method 2 ...................................................................... 63
9.3.3 Barometric Correction - Method 3 ...................................................................... 64
9.4 Post Start Enrichment................................................................................................. 65
SECTION 3 SOFTWARE FEATURES......................................................................... 66
CHAPTER 10 Data logging................................................................................................. 66
10.1 The Data log Option................................................................................................. 66
10.1.1 Creating a Data log............................................................................................ 66
10.1.2 Selecting the Data Channels.............................................................................. 67
10.1.3 Logging the Data............................................................................................... 67
10.1.4 Displaying The Data.......................................................................................... 68
10.1.4.1 Displaying Channels .................................................................................. 69
10.1.4.2 Changing scales on a View ........................................................................ 70
10.1.4.3 Viewing Multiple Datasets......................................................................... 70
10.1.4.4 Removing A Dataset .................................................................................. 70
10.1.4.5 Data Values ................................................................................................ 71
10.1.4.6 Zooming ..................................................................................................... 71
10.1.4.7 Changing the Trace Width ......................................................................... 72
SECTION4 INPUTS & OUTPUTS ............................................................................... 73
CHAPTER 11 Output Options Set-Up................................................................................. 74
11.1 Idle Speed Control and O
Closed Loop Control..................................................... 74
2
11.1.1 Idle Control ....................................................................................................... 74
11.1.2 O2 Closed Loop Fuel Control ........................................................................... 76
11.2 The PWM Options Page........................................................................................... 78
CHAPTER 12 Digital Outputs & PWM Outputs................................................................. 79
12.1 Turbo Waste Gate Control (TWG)........................................................................... 79
12.2 Bypass Air Control (BAC) Valve ............................................................................80
12.3 Dual Intake Valve Control (DIV)............................................................................. 80
12.4 Torque Converter Clutch Lockup (TCC)................................................................ 81
12.5 Electric Thermo Fan Control (TF) .......................................................................... 81
12.6 Electric Intercooler Fan Control (IF) ...................................................................... 81
12.7 Shift Light Illumination (SL) .................................................................................. 82
12.8 Auxiliary Fuel Pump (AP) ...................................................................................... 82
12.9 Anti-Stall Solenoid Control (AS)............................................................................. 82
12.10 Staging Signal Function (SS) ................................................................................ 83
12.11 Turbo Timer (TT)................................................................................................... 83
12.12 NOS Switch ............................................................................................................ 83
12.13 Air Conditioning .................................................................................................... 84
12.14 Engine Control Relay............................................................................................. 84
12.15 VTECH................................................................................................................... 85
12.16 BAC2...................................................................................................................... 85
12.17 BAC/BAC2 Slave (Bipolar idle valves)................................................................. 86
iv
F10X Manual
12.18 TPS Switch............................................................................................................. 86
SECTION 5 APPENDICES ............................................................................................ 88
Appendix A Troubleshooting ........................................................................................... 88
Appendix B Injection outputs.......................................................................................... 93
Appendix C Injectors........................................................................................................ 97
Appendix D Fuel Systems & Staging ............................................................................... 98
Appendix E Trigger Interface......................................................................................... 103
Appendix G Haltech F10X Specifications...................................................................... 115
Appendix H Wiring Diagrams ........................................................................................ 120
Under copyright law, neither this manual nor its
accompanying software may be copied, translated or
reduced to electronic form, except as specified
herein, without prior written consent of Lockin Pty
Ltd trading as Haltech.
Copyright 2005 Lockin P/L
A.B.N 68 061 744 303
Also trading as HALTECH
10 Bay Road
Taren Point, NSW 2229
Australia
Ph: (+61) (02) 9525 2400
Fax: (+61) (02) 9525 2991
Sales-au@haltech.com
www.haltech.com
MS_DOS is a registered trademark of Microsoft
Corporation. IBM is a registered trademark of
International Business Machines Corporation
v
F10X Manual
Print Version: 3.02a.......................................................................................Date: 10 Aug 2005
This manual should accompany:
IBM compatible PC software .................................................................... HalwinX V1.0
Firmware Series ............................................................................................................. 11
Firmware........................................................................................................................ 11
vi
F10X Manual
Introduction
Congratulations on your decision to choose a Haltech Engine Management System. Haltech
EFI systems have been successfully installed on thousands of vehicles, from power offshore
boats to twin-turbo Ferraris to jet skis and snowmobiles. Over the past decade, many motorsport enthusiasts have discovered that the Haltech computer is easy to use and performs well
by enabling users to precisely control ignition timing and fuel delivery. Precise ignition and
mixture control leads to excellent drivability and fuel economy, something that is often
lacking in high-performance carburettor engines.
Haltech users have discovered that the flexibility of the Haltech Electronic Control Unit
(ECU) and PC based programming software leads to the easiest possible installation on
everything from traditional pushrod V8s to high performance turbocharged racing
motorcycles. We are proud of the fact that some of the most respected professional racers and
super-car builders in the world use Haltech equipment for the same reasons that Haltech is
popular with motor-sports enthusiasts: it is flexible and friendly; is installed easily; and you
can tune your Haltech simply, without having to make the project a major research effort.
Before You Begin...
1) IT IS BEST TO READ THIS ENTIRE MANUAL BEFORE STARTING.
The greater your knowledge of the operation of the Haltech system, the easier you will find it
to understand what you are doing, and why. Throughout the manual are Warnings and Notes
that will help your installation run smoothly and indicate the dangers that can exist for you the
installer and the Haltech ECU.
2) Read any additional material accompanying this manual that updates the document since it
was written.
3) You may need special parts, additional tools or test equipment in order to complete the
installation. Make sure you have these items on hand before you begin to avoid frustration.
Contact your Haltech dealer if you have difficulty.
4) Don't do the minimum work possible. Carelessness in the early stages of installation can
cause you major headaches later on, be it in a few days or a few months time. Carelessness
will cost you money and frustration in finding and fixing unnecessary problems. You have the
opportunity to make sure your Haltech system's operation is extremely dependable and easy
to use by doing it right the first time.
WARNING:
AVOID OPEN SPARKS, FLAMES, OR OPERATION OF
ELECTRICAL DEVICES NEAR FLAMMABLE SUBSTANCES.
ALWAYS DISCONNECT THE BATTERY CABLES WHEN DOING
ELECTRICAL WORK ON YOUR VEHICLE.
7
F10X Manual
DO NOT CHARGE THE BATTERY WITH A 24VOLT TRUCK
CHARGER OR REVERSE THE POLARITY OF THE BATTERY OR
ANY CHARGING UNIT
DO NOT CHANGE THE BATTERY WITH THE ENGINE RUNNING
AS THIS COULD EXPOSE THE ECU TO AN UNREGULATED
POWER SUPPLY THAT COULD DESTROY THE ECU AND OTHER
ELECTRICAL EQUIPMENT.
ALL FUEL SYSTEM COMPONENTS AND WIRING SHOULD BE
MOUNTED AWAY FROM HEAT SOURCES, SHIELDED IF
NECESSARY AND WELL VENTED.
MAKE SURE THERE ARE NO LEAKS IN THE FUEL SYSTEM AND
THAT ALL CONNECTIONS ARE SECURE.
DISCONNECT THE HALTECH ECU FROM THE ELECTRICAL
SYSTEM WHENEVER DOING ANY ARC WELDING ON THE
VEHICLE BY UNPLUGGING THE WIRING HARNESS CONNECTOR
FROM THE ECU.
5) Electromagnetic interference (EMI) from unsuppressed spark plugs and leads can cause the
ECU to fail. Please do not use them.
6) In hot climates, or with turbocharged engines, you may need to employ heat shielding to
prevent heat soak and damage to electrical and fuel parts. Use the coolest surfaces of the
chassis as a heat sink for components and use thermally conductive brackets where
appropriate.
7) We recommend having your system tuned by professionals. An exhaust gas analyser and
fuel pressure meter make tuning easier and help avoid potentially disastrous lean out
conditions that could destroy your engine. Should you wish to tune this unit yourself, make
sure you have some reliable means of determining if your engine is running lean. Haltech
offer the Haltuner for this very application. The Haltuner is an inexpensive air-fuel ratio
indicator that gives a full-scale deflection from rich to lean over a display of 30 bar segments.
It is compatible with all Oxygen Sensors that output a 0-1V and can be configured upon
request for other sensor ranges. If used in conjunction with a Haltech Oxygen Sensor, the
Haltuner will provide air-fuel indication for a range of 11.5:1 to 17:1.
Note: In this manual, reference will be made to MAP
Pressure - as in MAP sensor) and the fuel maps stored in the ECU. Both are
common industry terms, with entirely different meanings.
(Manifold Absolute
Tool/Supply Requirements
Installation of this system can be easily carried out by professional mechanics and most
experienced home mechanics if the following tools and components are available:
Voltmeter or Test Light
A selection of screwdrivers and spanners
Soldering Iron and solder (we recommend soldering all connections)
8
F10X Manual
Wire Cutters and Pliers
Crimping Tool and assorted terminals
Drill with assorted drill bits
3/8" NPT Tap
14mm x 1.5 Tap
Electrical Tape or Heat Shrink tubing
Teflon pipe sealing tape
Nylon cable ties
Jeweller’s file (may be needed for mounting Throttle Position Sensor)
Mounting hardware for ECU and relays (mounts/bolts/screws)
IBM-PC compatible computer (preferably laptop) with at least 640kb, one disk drive and
an RS232 serial port.
A good quality Timing Light
An oscilloscope would be a useful tool, but not always required.
How It Works
While the technology involved with electronic fuel injection is complex, the underlying
principles of its operation are really quite straightforward. The object of any fuel delivery
system of a gasoline engine is to determine the amount of air being drawn by the engine, and
supply the appropriate quantity of fuel to "burn" all the oxygen in that mass of air.
A carburettor uses generally only one parameter to determine fuel metering: air speed. Higher
air speeds through the carburettor result in larger pressure drops across the venturis, resulting
in more fuel being drawn through the jets.
Electronic fuel injection is based on the use of solenoid-actuated injectors. These devices
employ a coil attached to a valve. When the coil is energised, the valve opens and fuel is
allowed to flow. As long as the pressure difference between the fuel and the air in front of the
injector nozzle is held constant, the rate of fuel flow will remain the same. By accurately
controlling the length of time the injector remains open, precise quantities of fuel can be
delivered to the engine.
Since there is no convenient means of directly measuring the amount of air entering the
engine to determine the amount of fuel to deliver, the injection opening time can be calculated
using a number of engine operating conditions. The ECU uses a table that breaks the engine's
operation into a series of rpm ranges, each range has a series of points that represents the
different loads on the engine, using either the position of the throttle or the manifold pressure
as a load reference.
The ranges in this table form a map of the volumetric efficiency for the engine. Our standing
assumption, therefore, is that for any combination of engine speed and load, we have a direct
reference to the amount of air that is being drawn into the engine by means of this map.
The ECU uses a digital microcomputer to measure engine speed and load, and uses them to
access the base fuel map. The base fuel map is a look-up table of injector opening times
stored in non-volatile memory i.e. when power is switched off, the contents of the memory
are retained. By using the programming software, the contents of this memory can be changed
so that you can match injector opening times to the injectors you are using, and to suit the
requirements of your engine.
Corrections for air temperature and barometric pressure are applied to the base fuel value,
since these variables affect the density of air. Extra injection time is also added, when
necessary, for transient throttle movement and the temperature of the engine. Once these
corrections have been applied the ECU knows the amount of fuel the engine requires.
9
F10X Manual
Injection pulses usually occur one or more times per engine cycle. The ECU uses a trigger
signal locked to engine speed in order to determine when to inject. When it receives an
appropriate trigger, the ECU applies a magnetising current to the injector coils for precisely as
long as the final computed injection time, providing an extremely accurate delivery of fuel
that will exactly suit the engine's needs.
10
F10X Manual
SECTION 1 Getting Started
CHAPTER 1 HALTECH ECU INSTALLATION
1.1 The ECU and Associated Hardware
The Haltech F10X system comprises the following components
Haltech Electronic Control Unit (ECU)
Main Wiring Harness
Haltech F10X system Instruction Manual
Programming Cable
Programming Disk
Relays
1.2 Installation Summary
The Following is a list of the procedures that will be followed in the installation of the ECU.
1. Mount Manifold Absolute Pressure Sensors.
2. Mount Coolant Temperature Sensors.
3. Mount Inlet Air Temperature Sensors.
4. Mount Throttle Position Sensors.
5. Mount optional Exhaust Gas Oxygen Sensor (if used)
6. Route Main Wiring Harness and connect sensors.
7. Mount and connect Power Relays.
8. Mount Fuse Block.
9. Mount ECU inside passenger compartment.
10. Locate and connect flying wires:
RED + 12 volts battery
GREY Ignition on 12 volts
BLACK Chassis ground
ORANGE (2 wires) Fuel Pump Circuit
11. Install and connect the optional Idle Speed Motor
12. Install and connect any Optional Outputs
13. Connect Trigger signal
14. Connect ECU and test.
11
F10X Manual
1.3 Expanded Installation Guide
1.3.1 Manifold Absolute Pressure (MAP) Sensor
The MAP sensor is used to convert the manifold pressure into an electrical signal for the ECU
to use. The MAP sensor is used to measure engine load or barometric pressure depending on
the application. The sensor works in absolute pressure that means when the sensor is used to
measure manifold pressure, the pressure reading in the manifold does not need compensation
due to changes in barometric pressure. Since the MAP sensor is an absolute pressure sensor it
can be used in some situations to measure changes in barometric pressure that in some
applications will have a great affect on air-fuel mixtures (Refer Barometric Correction, p62).
There are three types of MAP sensors that can be used with the ECU. The sensor required
depends on the engine set-up.
1 Bar Sensor (Part No.: 039 4070, 16137039 or 12569240)
(-100kPa to 0 kPa) Normally Aspirated Engines
2 Bar Sensor (Part No.: 886 3189 or 16254539)
(-100kPa to 100kPa) Turbo or Supercharged
Engines up to 100kPa boost
(15 psi , 1 atmosphere)
3 Bar Sensor (Part No.: 749 3169, 16040749 or 12223861)
(-100kPa to 200kPa) Turbo or Supercharged
Engines up to 200kPa boost
(30 Psi, 2 atmospheres)
Note: Make sure you have the correct MAP sensor for your engine. The first
three digits of the part number are stamped on the sensor housing.
Engines that use Manifold Pressure as a load reference require an appropriate
MAP sensor to be connected to the MAP Input plug on the wiring loom.
Engines that use Throttle position load sensing do not need a MAP sensor to
measure Manifold pressure but require barometric correction. A MAP sensor
can be used for barometric compensation in the place of the barometric
pressure sensor inside the ECU. This MAP sensor must be a 1 Bar MAP
sensor (left open to atmosphere) and is connected to the Spare Input plug near
the Main Connector. For more information about barometric compensation
(Refer Barometric Correction, p62)
12
F10X Manual
Mounting
The MAP sensor is usually mounted high on the engine bay firewall or inner guard using two
screws and with the hose nipple facing outwards. Connect the sensor to the inlet manifold via
a short length of vacuum hose and fasten with either hose clamps or nylon cable ties. Connect
the sensor to the main wiring harness using the appropriate plug. (For 1 Bar sensors the plug
is green, for 2 and 3 Bar sensors the plug is orange). Avoid mounting the sensor below the
level of the fuel injectors, because fuel may collect in the vacuum hose and run down into the
sensor. The sensor assembly is weather-proof but it is good practice to mount the sensor in a
protected position away from moisture and heat.
1.3.2 Coolant Temperature Sensor
The ECU uses the coolant temperature to determine warm up corrections to adjust fuel
mixtures.
The coolant temperature sensor has a solid brass temperature-sensing tip. The coolant sensor
supplied is an industry standard component and some engines may already have provision for
this type of sensor.
The coolant temperature sensor is designed to screw into a threaded hole and protrude into the
engine coolant stream. For air-cooled engines, the sensor can be embedded directly into the
engine block or used to sense oil temperature.
Locate a suitable position on the engine which will allow the hole and thread to be machined,
and which gives access to the coolant stream. The sensor should be mounted after the engine
and before the thermostat in the coolant circuit. Since most engines have existing temperature
13
F10X Manual
sensor holes, it is often possible to mount the Haltech sensor in one of these holes. A thread
adapter is sometimes necessary. In some engines only one temperature sensor hole exists and
is used for the dashboard gauge sender. It is usually possible to install a tee-piece to allow
both the dashboard sender and the Haltech sender to share access to the same threaded hole.
If it is necessary to drain the coolant from the vehicle to fit the temperature sensor then the
factory manual for the engine should be consulted for the correct procedure to restore the
coolant and purge the cooling system of air.
1.3.3 Inlet Air Temperature Sensor
The air temperature sensor is used to compensate for changes in air density due to air
temperature. Cold air is denser than warm air and therefore requires a greater volume of fuel
to maintain the same air/fuel ratio. This effect is most noticeable in forced induction engines.
The ECU will automatically compensate using the signal received from the air temperature
sensor.
The sensor should be mounted to provide the best representation of the actual temperature of
the air entering the combustion chamber, i.e. after any turbo or supercharger, and intercooler,
and as close to the head as possible. The sensor needs to be in the moving air stream to give
fast response times and reduce heat-soak effects.
Note: The Haltech air temperature sensor will read temperatures up to 120°C,
temperatures above this will be interpreted as a fault condition. The air
temperature after some turbos and superchargers can exceed this. If this occurs
with your engine you should consider fitting an intercooler to reduce air
temperature and increase charge density. If this is not possible then the air
temperature sensor should be placed upstream of the turbo or supercharger to
monitor ambient air temperature.
14
F10X Manual
Once a suitable position has been located for the air temperature sensor a hole should be
drilled and tapped to accept the sensor. Remove the manifold or inlet tract from the engine
before machining the sensor mount. Do not allow any metal particles to enter the inlet
manifold of the engine as these will be drawn into the engine and damage it. Wash all
components before reassembly.
1.3.4 The Throttle Position Sensor (TPS)
The throttle position sensor is mounted to the throttle butterfly shaft to measure its rotation. A
TPS is common on many late model engines and maybe compatible with the Haltech ECU, if
it is not, the Haltech sensor should attach with little or no modification. The throttle shaft
must protrude from the side of the throttle body. This may require the machining of the
throttle body or the manufacture of a new throttle shaft. The inner mechanism of the sensor
rotates with the shaft. If the shaft is round then file a flat surface on the shaft so that it will
pass through the sensor assembly. The TPS should be mounted against the side of the throttle
body, using two screws, such that the throttle shaft and the sensor mechanism can rotate
freely. The absolute range of sensor movement is not important as the sensor can be
calibrated using the programming software.
Your engine may have a Throttle position sensor already fitted and it is often possible to make
use of this TPS. The Haltech supplied TPS has a resistance value ranging from 0 to 10kΩ.
The resistance value of the installed TPS does not have to be the same since the ECU uses a
throttle calibration function to determine actual throttle position.
Note:
Be sure to wire the TPS so that The Engine Data page shows “0%” for throttle
position when the throttle is closed. (Refer to 6.1 Calibrating the Throttle
Position Sensor, p53)
Make sure that the axis of rotation of the shaft is exactly aligned with the axis
of rotation of the sensor. Also, do not use the TPS as a throttle stop. In either
case, the TPS will be damaged.
15
F10X Manual
1.3.5 Mount Optional Exhaust Gas Oxygen Sensor
The optional exhaust gas oxygen sensor must be mounted in the exhaust pipe near the exhaust
header or extractors, usually after the collector. The sensor uses the exhaust gas to detect if
the engine is lean or rich. Many late model engines already have provision for an exhaust gas
oxygen sensor and the sensor provided should fit any standard exhaust mount. Some exhaust
systems have the sensor mount up to around half a meter (2 feet) down stream from the
exhaust headers.
If the exhaust system does not have an existing sensor mount then a new mount will have to
be welded to the exhaust system.
When routing the electrical connections to the exhaust gas oxygen sensor do not allow the
harness to touch the exhaust pipe, as the heat will damage them.
1.3.6 Route Wiring Harness and Connect Sensors
Lay the main wiring harness out in the engine bay with the sensors mounted to ascertain the
best fit for the harness. Pass the wiring loom through a hole in the engine bay firewall and
into the passenger compartment where the ECU will be mounted. Either use an existing hole
or cut a new hole to suit. Use a rubber grommet or similar device to protect the harness from
being damaged by rubbing on the sharp edge of the hole.
WARNING:
DO NOT ALLOW THE HARNESS TO TOUCH HOT EXHAUST
PARTS INCLUDING MANIFOLDS OR TURBOCHARGERS.
TRY TO ROUTE THE MAIN HARNESS AWAY FROM HIGH
VOLTAGE IGNITION LEADS. UNDER NO CIRCUMSTANCES RUN
ANY WIRING PARALLEL TO, OR IN CONTACT WITH THE
IGNITION LEADS.
Note: Be neat. Run the harness in a tidy fashion. Try to run the harness along
paths used by original wiring. Use nylon cable ties to secure the harness in
place, but do not stress the wiring or connectors.
Once the harness is fitted, connect all the sensors to their appropriate plugs.
1.3.7 Power Relays
There are two relays used with the ECU, the Main Power Relay (with a grey wire) and the
Fuel Pump Relay (two orange wires). These relays are identical parts so it is not important
which relay goes in what connector.
16
F10X Manual
These relays should be mounted on the firewall or an inner guard. Do not mount the relays
such that they could catch and collect splashed water. Residual water inside the relay housing
will cause them to fail. Mount them with the tab upwards as shown in the diagram.
1.3.8 Fuse Block Assembly
The fuse block assembly holds the fuses that protect the various components of the Haltech
system.
The fuse block is supplied from the factory with fuses installed. The fuse ratings are shown in
the diagram and should not be changed except in special circumstances, as these have been
selected for best protection. In some applications where multiple low impedance injectors are
being used, the main 3A ECU fuse may blow. In such applications, please replace this fuse
with a 10A fuse.
The fuse block should be positioned so that it can be easily accessed in case of fuse failure.
Do not mount the fuse block where it could be exposed to water. Mount via the two screws
holes in the block. Ensure that vibration will not cause the screws to vibrate loose.
17
F10X Manual
Connect the Fuse Block assembly to the Main Harness.
1.3.9 Electronic Control Unit (ECU)
The ECU is not designed to be waterproof. It is desirable that the ECU be given as much
protection from the environment as possible. It is recommended that the ECU be mounted
inside the passenger compartment, either on the firewall, under the dashboard or under the
passenger seat.
The ECU has four mounting holes that allow it to be mounted to most flat surfaces. In
extreme cases of vibration, the ECU should be mounted on rubber anti-vibration pads. When
mounting the ECU remember that the communications connector on the loom should remain
accessible for ease of programming.
1.3.10 Flying Leads
Locate and connect the following flying leads.
Black (Ground)
Locate a good chassis ground point and connect the black wire.
Red
(Battery Supply +12V) Locate a source of continuous +12 volts and connect the red
wire. Connecting direct to the positive battery terminal is suggested.
Grey
(Ignition Switched +12V) The grey wire is used to control the operation of the ECU
power relay. It needs to be connected so that it sees 12V only when the ignition switch
is on and during cranking. This wire does not draw a large amount of current (< 0.5A).
Do not connect to the accessory outputs of the ignition switch since +12V is not
available during cranking in many cases.
Green
(Aux In) The green wire is used as the Aux In channel. The Aux In channel is used by
a number of functions and is further described in 4.2.4 The In/Out Set-up Page, p39)
The following diagram is an example of how to wire the Aux In circuit:
NOS, Anti-lag, Flat-Shift
Switch, etc
Aux In
GND
18
F10X Manual
Orange
The two orange wires are used to operate the fuel pump. When the ECU wants to
operate the fuel pump it will close the fuel pump relay connecting the two orange
wires together. The diagrams show two examples of wiring the fuel pump. Do not add
extra relays to the fuel pump circuit.
Example 1: Conne cting to the po s itive s ide of the f ue l pump.
Example 2: Conne cting to the ne gative side of the f ue l pump.
It does not matter which example is used, as both will operate correctly. Note that the orange
wires are connected internally within the loom when the relay is closed. As a result it does not
matter which orange wire is used to connect to the fuel pump.
1.3.11 Install and Connect Optional Idle Speed Motor
If you are not using the Idle Speed Control, tie the loom connector back neatly in the engine
bay. If the engine has a suitable Idle Speed Motor then you may connect it to the wiring loom,
otherwise you can install a Haltech supplied idle air control motor.
1.3.12 Install and Connect any Optional Outputs
If you are planning to use any of the Programmable Optional Outputs, install and connect
them now. Depending on what options you are using, the wiring will be different. For details
on wiring your particular options, refer to CHAPTER 12 Digital Outputs & PWM Outputs,
p79.
19
F10X Manual
1.3.13 Connect the Trigger Sensor
The Trigger is used by the ECU to determine Engine Speed and Position.
When connecting the trigger (crank or cam position) sensors it is important to identify the
type of sensor being used to measure engine speed and position from the following options:
Optical, Hall Effect or Coil Negative.
Optical and Hall effect Triggers
Optical and Hall effect triggers behave in a similar way and are treated the same by the ECU
and the term “Hall Effect” should be taken to include Optical triggers.
Hall Effect triggers generally have 3 connections: power, ground and signal and the output of
the sensor is a square wave digital signal.
Coil Negative Trigger
The F10X can be triggered by the signal found on the negative side of an Ignition Coil. The
F10X has a sole purpose input wire for this signal called “Negative Coil” which is Pin 36 on
the F10X ECU. Please make sure that in the Trigger Setup page, the Trigger Type is set to
Coil Negative if this type of trigger is to be used.
Tacho Output Trigger
Some popular ignition systems have a tacho output signal, which can be used to trigger the
F10X through the Coil Negative Trigger Input. It is necessary to use this tacho output if the
ignition system used is a Capacitive Discharge Ignition System with multiple spark function.
For more information on trigger systems Refer to Appendix E
1.3.14 Connect the ECU
The ECU can now be connected, be sure to engage the clip on the main connector. The
system can now be tested as described in the following chapters.
20
F10X Manual
CHAPTER 2 INSTALLING THE SOFTWARE
Now that your ECU is installed the programming software must be installed so that tuning
can begin.
This Chapter will explain how to install and run HalwinX, the Haltech Programming
Software.
2.1 Computer Requirements
HalwinX requires a PC running Windows 95 release 2, Windows 98, Windows 2000,
Windows Millennium or Windows XP with the following specifications.
Minimum Requirements:
233MHz processor
VGA colour display 800x600 (preferably 1024x768)
4 MB of memory
10 MB of free Disk space
Recommended:
PIII 500MHz processor
VGA colour display 1024x768
16 MB of memory
10 MB of free Disk space
2.2 Operating the Software
2.2.1 Installing the Software
Installing Halwin onto your PC is performed similar to any other Windows software package.
Installation is outlined below to ensure correct installation:
1. Insert the CD-ROM into your PC’s CD-ROM drive.
2. Double click on the “My Computer” icon on the
desktop
21
F10X Manual
3. Double click on the CD-ROM icon to open the CD-ROM. If the setup software does
not automatically open, then double click on the “SETUP.EXE” icon to start the setup
software.
4. After double clicking on the ‘SETUP.EXE’ icon, the following screens will appear.
22
F10X Manual
5. Click on ‘Next >’ to continue and follow the instructions given to you on the windows
that appear.
6. When prompted for which type of installation to perform, choose ‘Typical’ if you are
unsure.
2.2.2 Running the Software
After installing the software, an icon should appear on your desktop similar to the one shown
in the picture below.
Double click on the icon to start Halwin.
23
F10X Manual
CHAPTER 3 OPERATING THE SOFTWARE
Once the ECU is installed, the programming software allows the user to change the settings
currently stored in the ECU. The ECU requires information about the engine it is to operate
such as:
- Number of cylinders (or rotors): it needs this to calculate engine speed, ignition timing
and fuel quantity
- Engine Type: Piston or Rotary, the ECU requires this information since the ignition
system for a rotary engine is significantly different from that of a piston engine.
This information is called set-up information.
The ECU also requires information about the amount of fuel or ignition timing it must supply
based on various engine-operating conditions. An example of this is the amount of fuel the
engine requires based on the current intake air temperature, this information is stored in a
“Map”. As the intake air temperature changes so do the fuel requirements of the engine, so
the ECU has data for the amount of fuel injected for various different temperatures, this set of
data is known as a “Map”. These ideas of data storage are discussed further in CHAPTER 4
Configuring the ECU, p34 and CHAPTER 5 Haltech Maps, p43
3.1 The Menu Structure
All of the windows, maps and settings can be accessed via the menu shown at the top of the
Halwin software screen. These menus can be accessed in the usual methods with the mouse or
by keyboard
To access the menus via keyboard press and hold ALT and then Press the key corresponding
to the first letter of the menu title which you wish to access F, M, S or O. This will cause a
menu to appear from which a series of menu item are available. To choose a menu item use
the up and down cursor keys:
↑↑↑↑, ↓↓↓↓
When the desired menu item is highlighted:
Press Enter
When a key combination like:
Press and Hold ALT and then Press F
Is required it will be abbreviated in the manual to ALT-F.
The following describes the individual Menus and their contents.
3.1.1 The File Menu
To open the File menu Press ALT-F or alternatively use the mouse to select the File menu.
The file menu contains the following items:
- Load From File
- Load E6K/F10/E6GM Fuel and Ignition Maps
- Save to File
- Quit (Ctrl Q)
24
F10X Manual
3.1.1.1 Load From File
Load From File allows the user to load a file that contains all the “set-up” and “map” data the
ECU requires to run a particular engine. This file has been saved during a previous tuning
session when the programming PC was connected to the ECU. When the ECU is “Offline”,
the Load Map function can be used to load the information from an F10X map file (denoted
by the .6XM file extension) into the front-end software to view its contents. If the ECU is
“Online” using the Load Map function will cause the ECU to be loaded with the information
stored in the file and all information previously stored in the ECU will be lost.
NOTE:
When using the load function be aware that when the ECU is online all “set-
up” and “map” data currently stored in the ECU will be overwritten.
To choose the desired map simply select the desired file from the dialog and press enter. This
is illustrated below,
The selected filename will be displayed in the horizontal black bar below the text “ Opening
File”:
Press Enter
When the ECU is “Online” the central Status Bar will turn red and indicate the load status of
the map.
3.1.1.2 Save To File
The ECU programming software allows the user to save all the information in the ECU to a
file on the programming PC. This allows the user to save a map and continue tuning and
then, if required, revert to a previous map.
25
F10X Manual
NOTE:
When the save function is used it saves the current map loaded in the
programming software. If the ECU is “Offline” the map available in the
programming software may not be the map that is stored in the ECU.
When you choose the “Save To File” menu item a file dialog similar to the Load map will be
displayed. In this case you navigate to the directory of your choosing and type in the filename
of your choice.
3.1.1.3 Load E6K/F10/E6GM Fuel Maps
This option allows the user to import all the fuel and ignition maps from an E6K/F10/E6GM
into the F10X user map. To select this the user selects File -> Load Fuel Maps. The following
form shall be displayed to the user,
The user selects the maps they wish to import by selecting the appropriate items by clicking
on them. In the example shown above all items have been selected. Once the user has selected
the items needed, the user clicks on the Import File button. This brings up the file dialog box
and the user selects the desired unit file. Please note: this feature will only import maps and
NOT set up details.
3.1.1.4 Quit
Quit allows the user to leave the programming software and return to the operating system.
The user can also quit the software using the quit “Hot-Key”:
Press CRTL-Q
26
F10X Manual
3.1.2 The Map Menu
The map menu allows access to the maps contained in the ECU. The following is a
description of the map menu and is not a complete description of the maps, for more
information on all the maps available and their function refer to CHAPTER 5 Haltech Maps,
p46.
To open the map menu Press ALT-M.
The map menu contains the following items:
- Fuel Map CTRL-F – 2D View, CTRL – ALT - F – 3D View
- Fuel Correction Maps
- Zero Throttle Map
- Full Throttle Map
- Injector Phase Map
- Waste-gate Map 1
- Waste-gate Map 2
- Torque Converter Map
3.1.2.1 Fuel Maps
The Fuel Map is constructed of individual ranges containing Injector Pulse Width against
Engine Load as shown below.
The individual ranges represent different engine speeds; in the example above the map shown
is from the 2000rpm range.
27
F10X Manual
The Fuel map menu item will open a sub-menu which allows access to all the fuel map ranges
from 0 –8500rpm. The keys:
N for Next and
P for previous
Allow the user to cycle through all the available rpm ranges and allows access to the rpm
ranges not accessible via the sub-menu.
The 3D view is shown below,
To go through the load ranges the user uses the left and right arrow keys. To cycle through the
RPM range the user uses the up and down arrow keys. To select multiple bars the user presses
the Ctrl arrow keys to select the bars they wish to tune. To change the bars the user can use
“a” and “s” to change the fine increments and Pg-Up and Pg-Down for the rest of the
increments.
28
F10X Manual
3.1.2.2 Fuel Correction Maps
Fuel correction maps allow the ECU to calculate corrections to the amount of fuel injected
based on the information received from the engine sensors.
The fuel correction maps menu item will open a sub-menu that allows access the fuel
correction maps:
- Coolant Temperature
- Air Temperature
- Battery Voltage
- Coolant Temperature Prime
- Post Start
- Barometric Pressure
- Gas Temperature (used for Gas (LPG or similar) fuel vehicles)
- Gas Pressure (used for Gas (LPG or similar) fuel vehicles)
The Set-up Menu
The set-up menu allows access to the ECU set-up pages (which contain most of the
information about the engine that the ECU is to control) and the program set-up page.
The set-up menu contains:
- Main Set-up CTRL-M
- Fuel Set-up
- Trigger Setup
- In/Out Set-up
- Throttle Setup
- ComPort Setup
- Set Password
- Screen Colour
3.1.3 The Options Menu
The options menu allows access to the option pages. The options set-up pages allow the user
to modify the setting for idle control, closed loop O2 Control and the 4 PWM channels and
any available digital outputs.
The options menu contains:
- Idle Speed Control
- Closed Loop O
- PWM and Digital Output options
- Throttle Pump
- Injector trims
- Log Data (CTRL – D)
- View Data Log
Further description of the contents of the options menu is distributed throughout the manual.
control
2
29
F10X Manual
3.1.4 Data Page Menu
This allows the user to access the engine data in online mode so they can deduce how their
engine is performing. The menus that access this are,
- Gauge Page
- Engine Data page.
- Firmware Version Info.
These shall be discussed in detail further on.
3.1.5 Password Protection
The maps in the ECU can be password protected at the user’s choice. To Set the password the
user selects Setup-> Set Password where the user must enter an 8 character password such as
“haltech1” or “Beatrice”. The user must use an 8 character password and this password is case
sensitive. The dialog for this is illustrated below, and is activated by pressing OK.
If at any time the user wishes to remove the password protection, they may do so by selecting
Setup-> Null Password.
When a ECU that has been password protected is first connecting to the laptop, the data will
transfer 99% of the data before prompting the user for the password to continue. If the
password is correct, the user will be given full access to the ECU, if the password is incorrect,
the user will only be given access to Data pages and diagnostic data.
30
Loading...