Haltech IG5 User Manual
Introduction.........................................................................................1
Installation Overview ........................................................................................................1
Before You Begin..............................................................................................................2
Tool/Supply Requirements................................................................................................3
How It Works ....................................................................................................................4
The Features of the IG5.....................................................................................................4
Haltech IG5 Specifications....................................................................................................5
SECTION 1 Getting Started............................................................8
CHAPTER 1 Haltech IG5 Installation ............................................................................8
1.1 Overview .....................................................................................................................8
1.2 Installation Summary...................................................................................................8
1.3 Expanded Installation Guide ......................................................................................9
1.3.1. Manifold Absolute Pressure (MAP) Sensor.......................................................9
1.3.2. Coolant Temperature Sensor............................................................................10
1.3.3. Inlet Air Temperature Sensor ...........................................................................10
1.3.4. The Throttle Position Sensor (TPS) .................................................................12
1.3.5. Mounting the Igniter.........................................................................................12
1.3.6. Route Wiring Harness and Connect Sensors....................................................14
1.3.7. Power Relays....................................................................................................14
1.3.8. Electronic Control Unit (ECU) .......................................................................15
1.3.9. Flying Leads .....................................................................................................15
1.3.10. Install and connect any Optional Outputs ......................................................15
1.3.11 Connect the Trigger Sensor..............................................................................15
1.3.12 Connect the ECU..............................................................................................16
CHAPTER 2 Getting Online .........................................................................................17
2.1 Connecting the Haltech IG5 to a Computer ..............................................................17
2.2 Operating the Software.............................................................................................17
2.2.1 Computer Requirements.....................................................................................17
2.2.2 Installing the Software........................................................................................18
2.2.4 Running the Software from the Floppy Disk. ....................................................19
2.2.5 Azerty Keyboards...............................................................................................20
2.3 The Online and Offline Modes..................................................................................20
2.4 Using the System Online...........................................................................................20
2.5 The Main Menu.........................................................................................................21
2.6 How to Quit...............................................................................................................21
2.7 Checking the Engine Data.........................................................................................21
CHAPTER 3 Engine Identification ...............................................................................22
3.1 Setting Engine Identification.....................................................................................22
3.2 Ignition Set-up...........................................................................................................23
Chapter 4 Using Haltech Software...................................................................................26
4.1 Using the Software ....................................................................................................26
4.2 What is mapping the Engine?....................................................................................26
4.3 What are maps? .........................................................................................................26
4.4 Accessing the Ignition Maps .....................................................................................27
4.5 The Ignition Maps .....................................................................................................27
4.6 Altering a Map...........................................................................................................28
4.7 How To Quit..............................................................................................................29
4.8 Time Saving Functions..............................................................................................29
ii
4.8.1 Current Location.................................................................................................29
4.8.2 All Ranges ..........................................................................................................29
4.8.3 Selecting Groups of Bars....................................................................................30
4.8.4 Percentage Changes............................................................................................30
4.8.5 Linearise .............................................................................................................30
4.8.6 Numeric Mode....................................................................................................30
4.8.7 Bar Increments....................................................................................................30
4.8.8 Online Help ........................................................................................................31
4.9 Command Summary for Maps .................................................................................32
Chapter 5 Starting the Engine ..........................................................................................33
5.1 Calibrate the Throttle Position Sensor .....................................................................33
5.2 Check the trigger signal............................................................................................33
5.3 Check the Base Timing ............................................................................................33
5.4 Loading an Ignition Library Map .............................................................................34
5.4.1 On the Dyno .......................................................................................................35
5.4.2 On the Road........................................................................................................36
SECTION 2 Other Adjustable Features......................................37
Chapter 6 Cold Starting and Running..............................................................................37
6.1 Cold Cranking ..........................................................................................................37
Chapter 7 Correction Factors ...........................................................................................38
7.1 The Ignition Coolant Map .........................................................................................38
7.2 The Ignition Inlet Air Temperature Map..................................................................38
SECTION 3 Software Features.....................................................39
Chapter 8 File Storage and Retrieval ...............................................................................39
8.1 Saving Maps and Identification................................................................................39
8.1.1 The Save Command ...........................................................................................39
8.1.2 Giving Your Map A Filename............................................................................39
8.2 Loading Maps and Identification..............................................................................40
8.3 File Management......................................................................................................40
8.3.1 Erasing Unwanted Maps ....................................................................................40
8.3.2 Changing Directories..........................................................................................41
Chapter 9 Printing Maps ..................................................................................................42
9.1 The Print Function....................................................................................................42
Chapter 10 DataLog.......................................................................................................43
10.1 The Data-log Option...............................................................................................43
10.1.1 Setting Up the Data-log Page ...........................................................................43
10.1.2 Creating a Data-log ..........................................................................................43
10.1.3 Viewing the Datalog.........................................................................................44
10.1.4 Data-Log File Management..............................................................................44
10.1.5 Printing Datalogs..............................................................................................45
Chapter 11 Customising the Software ...........................................................................46
11.1 The Set-up Page......................................................................................................46
11.1.1 The Display ......................................................................................................46
11.1.2 Com Port ..........................................................................................................46
SECTION 4 IG5 Optional Outputs..............................................47
Chapter 12 Software Access ..........................................................................................47
iii
12.1 The Output Options Page .......................................................................................47
12.2 Enabling Options....................................................................................................47
Chapter 13 Auxiliary Outputs........................................................................................48
13.1 Description ..............................................................................................................48
13.2 Turbo Waste Gate Control (TWG).........................................................................48
13.2.1 Description .......................................................................................................48
13.2.2 Using the Turbo Waste Gate Control...............................................................49
13.2.3 Using the Boost Controller...............................................................................50
13.3 Dual Intake Valve Control (DIV)...........................................................................51
13.4 Torque Converter Lockup (TCC)..........................................................................52
13.5 Electric Thermatic Fan Control (TF)......................................................................53
13.6 Electric Intercooler Fan Control (IF).....................................................................54
13.7 Shift Light Illumination (SL)..................................................................................54
13.8 Anti-Stall Solenoid Control (AS)...........................................................................55
13.9 Turbo Timer (TT)....................................................................................................55
13.10 NOS Switch...........................................................................................................56
SECTION 5 Appendices ................................................................58
Appendix A Troubleshooting ..........................................................................................58
A.1 Overview .................................................................................................................58
A.2 Control Program Problems......................................................................................59
A.3 Starting problems .....................................................................................................60
A.4 Idling Problems ........................................................................................................60
Appendix B ..................................................................................................................61
B.1 The IG5 Outputs ......................................................................................................61
B.2 Direct Fire Ignition ..................................................................................................62
B.2.1 Ignition Outputs.................................................................................................62
B.2.2 Coil Setup ..........................................................................................................62
B.2.3 Converting Individual Coils to Waste Spark.....................................................63
B.3 Rotary Engines..........................................................................................................63
B.4 Igniters ......................................................................................................................64
B 4.1 Constant Charge or “Dumb Igniters”.................................................................65
B.5 Alternative Ignition Systems ....................................................................................66
B.6 Pull-up Resistor Dip Switch Settings .......................................................................68
Appendix C Trigger Inputs ..............................................................................................69
C.1 The Input Trigger.....................................................................................................69
C.2 Trigger Devices ........................................................................................................70
C.2.1 Hall Effect Sensors ............................................................................................70
C.2.2 Optical Sensors ................................................................................................76
C.2.3 Magnetic Reluctor Sensors................................................................................76
C.3 Home Signal (synchronising) ..................................................................................78
C.3.1 Multitooth Triggers............................................................................................79
C.3.2 Motronic Triggers..............................................................................................79
C.3.3 Twin Triggers and Twin Distributors................................................................80
Appendix D Rotor Phasing ..............................................................................................81
iv
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 Invent
Engineering Pty Ltd trading as Haltech.
Copyright 1999 Invent Engineering Pty Ltd
A.C.N. 000 613 832
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
Haltech USA
Suite 309, 2156W
Northwest Highway
Dallas Texas
USA
Ph: (+1) (972) 831 9800
Fax: (+1) (972) 831 9802
Sales-us@haltech.com
www.haltech.com
MS_DOS is a registered trademark of Microsoft
Corporation. IBM is a registered trademark of
International Business Machines Corporation
Print Version: 3.0 ...................................................................................... Date: 3 August 2000
This manual should accompany:
IBM compatible PC software .....................................................................................v1.4
Firmware Series ...............................................................................................................4
Firmware..................................................................................................................... v1.4
v
Introduction
Congratulations on your decision to install a Haltech Ignition System to your vehicle. Haltech
systems have been successfully installed on thousands of vehicles, from power off-shore boats
to twin-turbo Ferraris, from pylon racing aircraft to jet skis and snowmobiles. Over the past
several years, many motor sport enthusiasts have discovered that the Haltech computer is easy
to use and gets the job done correctly - that job being to reliably make a lot of horsepower and
torque in an engine by enabling users to precisely control ignition timing. Precise ignition
control also leads to excellent drivability and fuel economy - something that is often lacking
in high-performance 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
supercar 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.
Installation Overview
The Haltech IG5 system utilises a special-purpose programmable microcomputer designed for
engine management. The IG5 system includes the ECU, engine sensors, and a special wiring
harness to connect them, plus programming software and cable for tuning the system.
Installation requires the mounting of four electronic engine sensors; two for temperature, one
for throttle position and one to sense intake manifold pressure. A harness is supplied for
connecting the 12V, ground and signal wires, and plugs to the engine sensors. An igniter will
be mounted in the engine bay and connected to the harness or the original igniter may be used.
Finally the ECU is mounted. The ECU requires a trigger with a fixed timing relationship to
the engine crankshaft from a distributor, crank angle sensor, or cam angle sensor. If you
vehicle lacks one or more of these components, your Haltech dealer can help you obtain them.
When component installation is completed an IBM compatible PC is connected to the ECU
via the supplied communications cable. The Haltech Programming software then allows you
to configure the IG5 to your engine requirements. The programming software has been
designed to be functional, "friendly" and intuitively easy to use.
For initial engine start up the ECU has a quick map feature This feature which is discussed in
more detail later in the manual offers you a simple and effective way of forming an ignition
curve as a starting point. Once the motor is running, fine-tuning to develop maximum
performance can be easily accomplished through the Haltech software.
1
Before You Begin...
1) IT IS BEST TO READ THIS ENTIRE MANUAL BEFORE STARTING.
At the very least you should read Section One of the manual and the Appendices relevant to
your installation. 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 or additional tools or test equipment in order to complete
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.
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.
2
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) IGNITION MODULES It is essential that the user fully understands what type of ignition
module (igniter) is to be used with the Haltech ECU. Constant charge and constant duty igniters
are available and the ignition set-up page must be set accordingly before power is applied and the
ignition modules are connected to the main loom. Failure to do so may damage the igniters and
coils.
Constant Duty is used with “Intelligent” igniters such as the Haltech supplied EB023. Constant
Charge is used with “Dumb” igniters that can also be obtained from Haltech as single, double or
triple igniters.
Most standard OEM supplied igniters are of the “dumb” type but if in any doubt it is necessary to
check or purchase suitable igniters through your Haltech supplier.
WARNING:
HALTECH WILL NOT REPLACE ANY IGNITION COMPONENTS
DAMAGED BY FAILURE TO COMPLY WITH THE ABOVE
PROCEDURES.
Previously Haltech ECU’s were only compatible with constant duty type igniters; therefore
numerous references are made to the EB023 BOSCH module which is supplied by Haltech.
Haltech can supply both constant duty and constant charge modules to suit the IG5. Many of the
modules have a similar external appearance and it is essential that the installer be able to identify
the unit as constant charge or constant duty.
Note: In this manual, reference will be made to a MAP sensor (Manifold
Absolute Pressure sensor) and the ignition maps that are tables stored in the
ECU. Both are common industry terms but with entirely different meanings.
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)
3
Wire Cutters and Pliers
Crimping Tool and assorted terminals
Drill with assorted drill bits
3/8" NPT Tap
1/4" GAS Tap
Electrical Tape or Heat Shrink tubing
Teflon pipe sealing tape
Nylon cable ties
Jeweler’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
How It Works
The Haltech IG5 uses a digital microcomputer to measure engine speed and load and uses these
values to access a look-up table of ignition advance (°BTDC). This look-up table is called a base
ignition map and is stored in non-volatile memory (i.e. memory which is retained when power is
switched off). Programming software allows the contents of this memory to be changed to match
the requirements of the engine.
The Features of the IG5
The IG5 is designed to be easily programmed and is capable of being used on a wide variety of
applications. A typical IG5 installation could be 4, 6 or 8 cylinders, turbo/supercharged or
normally aspirated, distributed ignition (only one ignition output) or Direct Fire ignition (multiple
ignition coils). It will also provide the ability to control some other features, such as Turbo
Wastegate Control, Thermofans, Torque Converter Clutch Lockup, etc.
Note: You should read Appendix B & C before you install the system to be
fully aware of your hardware and installation requirements.
The following variants are catered for by the Haltech IG5 system
Direct Fire Ignition
Rotary Engines
Twin Triggers
Twin Distributors
Multitooth Trigger Systems
The above will be determined by your engine configuration. If your engine has no distributor, for
example, you will need to use Direct Fire. All the features will be determined by your engine setup.
4
HALTECH IG5 SPECIFICATIONS
Engine Suitability
• Up to 16,000 rpm
• 1, 2, 3, 4, 5, 6, 8, 10, 12 or 16 cylinders (1-2 rotors)*
• 2 or 4 stroke
• Normally aspirated or supercharged up to 200 kPa (30 psi) – Higher boost pressure MAP sensors
available by special arrangement
• Load sensing by throttle position or manifold pressure
• Distributed ignition systems, or direct fire systems with 1 to 4 coils
Power Requirements
•••• Power Source
8.6 to 16 Volts DC
•••• Consumption
Haltech ECU: 270 mA at 12 Volts
Physical Specifications
• ECU Dimensions
Length: 153 mm (6 1/16")
Width: 105 mm (4 1/8")
Depth: 32 mm (1 1/4")
• Weight
ECU: 760g (1.68 lb)
Loom: 1.92kg (4.2 lb)
Sensors: 500g(1.1 lb)
Shipping Weight: 4.5kg (9.9 lb)
(Including manual/packaging)
Input Sensors
• Manifold Absolute Pressure (MAP) Sensor, (optional at extra cost)
1 Bar -100kPa to 0kPa (Naturally Aspirated)
2 Bar -100kPa to 100kPa (up to 1 Bar or 15 psi boost)
3 Bar -100kPa to 200kPa (up to 2 Bar or 30 psi boost)
Higher boost pressure MAP sensors available by special arrangement
• Temperature Sensors (Air and Coolant), (optional at extra cost)
NTC temperature dependent resistor type.
Operating Range
Continuous -40°C to 100°C (-40°F to 212°F)
Intermittent up to 125°C (257°F)
• Throttle Position Sensor, (optional at extra cost)
10 kΩ rotary potentiometer driven from throttle shaft
5
• Engine Speed Pickup
Compatible with most trigger systems:
- 5 or 12-volt square wave;
- Pull-to-ground (open collector)
A Reluctor adaptor is available for magnetic (or ‘reluctor’) triggers supporting most standard tooth
patterns. Applications requiring a motronic trigger input need to be specified at the time of order.
Only a 60-tooth wheel with 2 teeth missing is supported.
ECU Outputs
• Ignition Output
(May also be compatible with other igniters. Ask your Haltech dealer.)
Optional ECU triggered Haltech Ignition Module for firing the coil.
System Programming Requirements
• Computer
IBM-PC or compatible, preferably laptop or notebooks
CGA, EGA or VGA, colour or monochrome display
640+ kb RAM
• Disk Drive
3.5" Floppy Disk Drive
(5.25" disk available on request)
• Serial Port
Standard RS232C port - 9 pin D connector
(25 pin cable available on request)
COM1 or COM2 (selectable)
Adjustable Features
• Ignition Map
22 Ignition ranges, every 500 RPM to 10,500, or
17 Ignition ranges, every 1000 rpm to 16,000
32 Load points per range, up to 50° advance, with 1° resolution
6
• Correction Maps
• Ignition
Crank Advance - 32 points
Coolant Temperature Advance/Retard - 32 points
Air Temperature Advance/Retard - 32 points
• Programmable Rev-Limit
• Programmable Output Options
• Turbo Wastegate Control
• Dual Intake Valve Control
• Torque Converter Lock-Up
• Electric Thermatic Fan Control
• Intercooler Fan Control
• Shift Light
• Anti-Stall Solenoid Control
• Turbo Timer
• NOS Switch
Miscellaneous
• Map Storage and Retrieval
Maps may be stored to disk and re-used
• Datalogging
Engine data information saved at a nominal rate of 10 samples per second.
Data storage to memory or disk.
Limited only by available memory (approx. 11k/minute).
• US or Metric Units
• Real Time Programming
Instant, hesitation free adjustment while engine is running
•••• Optional Ignition Trim Module
Provides -8° to +7° adjustment for fast tuning
• Rugged Aluminium Casing
Black anodised with integral cooling fins and mounting brackets.
– cuts ignition preventing over revving of the engine
7
SECTION 1 Getting Started
CHAPTER 1 HALTECH IG5 INSTALLATION
1.1 Overview
The Haltech IG5 system comprises the following components
Haltech Electronic Control Unit (ECU)
Main Wiring Harness
Haltech IG5 system Instruction Manual
Programming Cable
Programming Disk
Relay
Optional Items (at extra cost)
Coolant Temperature Sensor
Inlet Air Temperature Sensor
Throttle Position Sensor (TPS)
Manifold Absolute Pressure (MAP) Sensor, (1,2 or 3 Bar)
Ignition Module
Ignition Timing Trim Control
Reluctor Adaptor - for magnetic triggers
Ignition Coils
Haltech Dual Hall-Effect sensor
1.2 Installation Summary
1. Mount Manifold Absolute Pressure Sensor. (If applicable)
2. Mount Coolant Temperature Sensor. (If applicable)
3. Mount Inlet Air Temperature Sensor. (If applicable)
4. Mount Throttle Position Sensor. (If applicable)
5. Mount Ignition Module
7. Route Main Wiring Harness and connect sensors and ignition module.
8. Mount and connect Power Relay.
9. Mount ECU inside passenger compartment.
10. Locate and connect flying wires:-
RED + 12 volts battery
GREY Ignition on 12 volts
BLACK Chassis ground
11. Install and connect any Optional Outputs
12. Connect Trigger signal
13. Connect ECU and test.
8
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 IG5
ECU to use. The sensor works in absolute pressures, thus its calibration is not affected by
changes in barometric pressure.
There are three types of MAP sensors that can be used with the IG5 system. The sensor
required depends on the specific engine configuration.
1 Bar Sensor (Part No. 039 4070)
( -100kPa to 0 kPa) Normally Aspirated Engines
2 Bar Sensor (Part No. 886 3189)
(-100kPa to 100kPa) Turbo or Supercharged
Engines up to 100kPa boost
(15 psi , 1 atmosphere)
3 Bar Sensor (Part No. 749 3169)
(-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 is stamped on the sensor housing.
Mounting
The MAP sensor is usually mounted high on the engine bay firewall or inner guard using two
screws 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 system, 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.
9
1.3.2. Coolant Temperature Sensor
The coolant temperature is used by the computer to determine the required corrections to
ignition timing.
The coolant temperature sensor has a solid brass temperature sensing tip. Refer to the
diagram for technical details of the sensor. 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 before the
thermostat in the coolant circuit. Since most engines have existing temperature sensor holes,
it is often possible to mount the Haltech sensor in one of these holes. A thread adaptor is
sometimes necessary. In some engines only one temperature sensor hole exists and is used for
the dashboard gauge sender.
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
10
14mm x 1.5
The air temperature sensor is used to compensate for changes in air density due to air
temperature. This effect is most noticeable in forced induction engines. The Haltech IG5 will
allow compensation for ignition timing 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, ie. 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
and temperatures above this will be interpreted as a fault condition. The air
temperature after some turbocharger's 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.
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 thoroughly before reassembly.
11
1.3.4. The Throttle Position Sensor (TPS)
The throttle position sensor is mounted to the throttle butterfly shaft to sense its rotation. A TPS is
common on many late model engines and 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. 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. The
absolute range of sensor movement is not important as the sensor can be calibrated using the
programming software.
Note: If a Throttle Position Sensor is already fitted this sensor can often be
used instead of a Haltech supplied TPS. The rotary potentiometer in the
Haltech TPS has 10k Ω resistance value but the alternate TPS can have a
different value as the software allows calibration of the throttle input.
1.3.5. Mounting the Igniter
The igniter must be mounted on a flat surface (eg. the firewall) to ensure proper heat dissipation and
to avoid stress on the wiring connections. It is important to protect the module from overheating by
mounting it away from hot components such as exhaust manifolds and turbocharger's.
Included with the Bosch Ignition Module (the EB023 supplied by Haltech) is the ignition subloom. This connects the Ignition module to the Main Harness. Locate this loom and connect
it to the ignition module but do not connect the ignition sub-loom to the main loom until
the ignition settings in the ECU are verified by connecting the ECU to a computer.
Connect the 3 flying leads of the ignition sub-loom. The black wire with the eye terminal is a ground
connection. This should NOT be grounded to the same point as the ECU to prevent ignition noise
getting into the power supply circuit of the ECU. The blue wire goes to the negative side of the coil.
The red wire should be supplied with 12 volts when the ignition is on. This can often be obtained
from the positive side of the coil.
12
WARNING:
NOTE: IF USING THE BOSCH IGNITION MODULE (THE EB023
SUPPLIED BY HALTECH ON AN ANGLE BRACKET) CONSTANT
DUTY SHOULD BE SELECTED IN THE IGNITION SETUP PAGE.
Bosch Ignition Module. The module must be mounted on the bracket, and the bracket must be
mounted to a suitable surface.
13
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 TURBOCHARGER'S.
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 is one relay used with the Haltech IG5, (the Main Power Relay)
It should be mounted on the firewall or an inner guard with the connector terminals to the
bottom as shown in the diagram.
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1.3.8. Electronic Control Unit (ECU)
The Haltech IG5 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.
1.3.9. Flying Leads
Locate and connect the following flying leads.
Black - (Ground) Locate a good chassis ground point and connect the black wire. The best
spot is direct to the battery negative terminal.
Red - (Supply 12V) Locate a source of continuous 12 volts and connect the red wire.
Connecting direct to the positive battery terminal is suggested.
Grey - (Switched 12V) The grey wire is used to control the operation of the Haltech IG5
power relay. It needs to be connected so that it sees 12V only when the ignition 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.
1.3.10. 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 13, Auxiliary Outputs.
1.3.11 Connect the Trigger Sensor
Refer to Appendix C Trigger Inputs for detailed information on trigger connections. If the
engine has a magnetic reluctor type signal which requires a Reluctor Adaptor you should
install the Reluctor Adaptor now. For details on how to connect the Reluctor Adaptor to the
main loom and to the trigger refer to Appendix E Wiring Diagrams.
Hall Effect and Optical triggers have three connections - ground, power and signal. The
trigger connector on the Main Harness has four pins shown in the diagram below. The
Secondary (Home) Trigger is used for Direct Fire Applications. (See Appendix C.3).
15
The secondary input can also be used as the Road Speed input if it is not being used as a home
trigger.
You will need to know what wiring your trigger requires. Some triggers need a series resistor
on the power line in order to limit current. Check your trigger system thoroughly. An
incorrectly wired trigger can cause damage, usually to the trigger.
The IG5 requires one trigger input signal per ignition event. For example, a V8 engine will
require 4 triggers per engine revolution. It is recommended that you read Appendix C,
Trigger Inputs for more detailed information on the trigger requirements of the IG5.
1.3.12 Connect the ECU
The ECU can now be connected. The system can now be tested as described in the following
chapters.
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CHAPTER 2 GETTING ONLINE
Now that your Haltech IG5 is installed with all the sensors in place the system can be
connected to the programming computer. This will allow the readings from all the sensors to
be displayed on the screen and checked for correct operation.
To connect the PC to the Haltech IG5 ECU you will need the programming cable and
programming disk supplied.
2.1 Connecting the Haltech IG5 to a Computer
The programming cable supplied with the Haltech IG5 is a standard serial link extension
cable. One end of the cable will plug into the Main Harness PC Interface connector (near the
main connector). The other end should plug into the mating connector at the back of your
computer. The plug on the computer may be marked "Serial", "Mouse" or "COM". Almost
all laptops will have this plug. If there is no 9 pin plug which it will connect to, check to see
if there is a 25 pin D-type plug available (some desk top computers will have this). If this is
the case, an appropriate cable can be supplied on request. Alternatively, most electronic
retailers will have a 25-pin to 9-pin converter.
Any time you wish to communicate with the IG5 ECU it needs to be supplied with power.
This usually involves just turning on the ignition switch. If at any stage power is not on, or
the programming cable is disconnected while attempting to communicate, the programming
software will display the message RECONNECT HALTECH. To rectify this, reconnect
power and/or the programming cable.
2.2 Operating the Software
2.2.1 Computer Requirements
The computer required to program the Haltech IG5 can be any IBM compatible personal
computer from the XT onwards (ie. the AT, 386, 486 or Pentium computers). The
requirements are fairly modest. The computer must have at least 640K of RAM (with about
615kb free for executable programs), one 3.5" disk drive and a CGA, EGA, or VGA screen.
(Virtually all reasonably modern laptops running MS-DOS (version 5.00 or higher) will fit
this description).
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2.2.2 Installing the Software
The Programming Disk supplied with the Haltech IG5 has an installation program that allows
you to install the software onto the PC’s Hard Disk. Most modern PCs have a hard disk. If
your PC does not have a hard disk, the IG5 Program can run directly from the disk supplied.
Installing the software on the Hard Disk will speed up program execution and avoid having to
fiddle around with floppy disks. The installation program needs only to be run once.
If you do not have a Hard Disk, go to the section titled Running the Software from the
Floppy Drive.
To install the software follow these steps.
Boot up Computer
Turn your PCs power on and boot up MS-DOS as instructed by the computers Users Manual.
If a shell program or menu utility runs automatically when you boot your computer, exit it
now. You should see a prompt similar to this:
C:\>_
This is the ‘DOS Prompt’. It is DOS’ way of indicating that it is waiting for a command. The
C: indicates that the C drive is the drive currently selected. If you do not have a hard disk,
your prompt will look similar to this:
A:\>_
Select the Drive
To run the INSTALL program, you must insert the supplied disk in the disk drive. To select
the appropriate disk drive (this will most probably be A: or B:) type:
The ←←←← key is the Enter Key. On some keyboards it may be called the Return key. You
should now see the prompt:
A:\>_ or B:\>_
Run the INSTALL Program
To run the Install program type:
α:←
or
ινσταλλ←
Β:←
18
The Install program will now run. Follow the instructions given. The program will suggest
that the software will be placed in the HALTECH directory. You can change the destination
directory, but this is not recommended unless you understand how directories work.
When it is finished, the installation program will tell you if the installation is successful. If it
was not, consult the trouble shooting section of this manual.
The IG5 Program is now ready to run.
2.2.3 Running the Software from the Hard Disk
Boot up your computer as described earlier. If your computer is already on, make sure the C
drive is currently selected. To change to the HALTECH directory type:
or, if you used a different destination directory, type that path.
To start the program type:
The IG5 program will now run. The next section is on running the software from a floppy
drive. If you intend to run the program from the hard drive you can skip this section and go
straight to the section entitled Azerty Keyboards.
χ∆ ∴ηαλτεχη←
ιγ5←
2.2.4 Running the Software from the Floppy Disk.
To run the software from a floppy drive, boot up your computer as described earlier. Insert
the Programming disk in the disk drive. To select the appropriate disk drive (this will most
probably be A: or B:) type:
You should now see the prompt :
A:\>_ or B:\>_
To start the IG5 program type :
The IG5 program will now run.
α:←
or
ΙΓ5←
Β:←
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2.2.5 Azerty Keyboards
Most countries use a keyboard where the first six letter keys across the top row are :
This is called a Qwerty keyboard. Some countries use an alternative, which is called an
Azerty keyboard, where the Q and W keys are swapped with the A and Z keys respectively. If
you have an Azerty keyboard, you need to run the software slightly differently. When you
would normally type :
to run the programming software (not the installation software), you need to type:
The /A tells the program you have an Azerty keyboard. The program will adjust accordingly.
θωερτψ
ΙΓ5←
ΙΓ5/α←
2.3 The Online and Offline Modes
On the IG5 system title page, the software asks whether to operate in ONLINE or OFFLINE
mode. The Offline mode is very useful to familiarise yourself with the Haltech software, but
should not be used to make lasting adjustments to the ignition maps unless there is a special
reason for doing so. If you wish to experiment and familiarise yourself with the software
press N for Offline mode, but if the ECU is installed and power is available then we suggest
the Online mode be selected. Press Y to select online mode.
2.4 Using the System Online
In the Online mode there is a two-way flow of information between the ECU and the
programming computer. The communication cable must be installed and power must be
available to the ECU before the system can communicate. The Online mode will be used
most frequently. While using the system Online, you can view engine information directly
and make adjustments. Any changes or modifications made on the computer are
instantaneous and will be immediately recorded in the ECU. When the programming cable is
removed and the ignition switched off, the ECU will retain all of its memory. The maps do
not need to be saved, but keeping a copy on disk is always good practice and is recommended.
Note: If power is removed or the communication cable is disconnected or
interfered with, the following message will be displayed on the computer
screen.
RECONNECT HALTECH
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If this message appears check all connections and ensure that the communications cable is not
being interfered with. Also be sure that the Haltech IG5 unit is receiving power. (i.e. ignition
switch is turned "on".)
2.5 The Main Menu
When you select Online or Offline mode the Haltech MAIN MENU bar appears. This menu
bar allows access to sub-menus giving access to maps, file storage/retrieval, engine data and
options.
2.6 How to Quit
Throughout the program you can exit from any application by using the menu bars or hot
♣θ
keys. Pressing
♣θ
in any page will prompt you to exit the program (i.e. pressing
♣θ♣θ
θθθθ
while
holding down the
♣♣♣♣
key). If you wish to exit press
ΨΨΨΨ
when prompted.
2.7 Checking the Engine Data
The engine data option can only be used when the system is Online. This function allows all
of the engine data variables to be displayed on the screen
This is a very useful function for analysing the engine sensors. To display the engine data
♣ε
♣ε
press
pressing
Do not attempt start the engine if the Engine Identification has not been set up. View the
engine data page to ensure all the sensors are operating properly.
from any application. Alternatively it can be accessed through the menu bar by
♣ε♣ε
ƒΟ
ƒΟ
and then
ƒΟƒΟ
ΕΕΕΕ
for Engine Data.
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CHAPTER 3 ENGINE IDENTIFICATION
3.1 Setting Engine Identification
The Identification page tells the IG5 information about the engine characteristics. Without
this information being correct the engine cannot run properly. The Identification is made up
of several fields. Each field can have a number of settings, and you can change most of the
fields.
′′′′
Use the Up and Down arrow keys (
Selection type, or Text type. The Selection type fields give you a number of valid entries for
that field. For example, the valid number of cylinders can be set to 1, 2, 3, 4, 5, 6, 8, 10 or 12.
and
≤≤≤≤
) to move between fields. The fields are either
The Tab and Enter keys (
the Tab key will display the next selection. The Shift and Tab keys together will step
backwards through the selections. Once the desired selection is displayed, the Enter key is
pressed to program that selection. Text Fields require you to enter either text or numbers.
Once the field is selected, the new text can be typed in, with the Enter key to finish. An
example is the Rev Limit. This field can be set between 2000 and 16000 rpm. If you want the
rev limit to occur at 7000rpm, then you would need to select this field using
7000←
7000←
type
7000←7000←
Here is a description of each of the Identification fields:
Cylinders
Load Sensing
MAP Sensor
RPM Limit
.
The number of engine cylinders needs to be entered here. This parameter is used to
determine the engine speed.
The IG5 can use either the manifold pressure or the throttle position as a means of
determining the engine load. Most engines operate using manifold pressure to sense
engine load. If your engine employs any form of supercharging, you must run in
manifold pressure mode. Only wild cams, motorbikes or heavily ported rotaries
require throttle mode – i.e. engines whose vacuum signal is small, or fluctuates
greatly. If you are unsure what to use, contact your Haltech dealer.
The IG5 needs to know the pressure range of Manifold Absolute Pressure (MAP)
sensor being used. Refer to Chapter 1 [1.3.1]. The selected value can be 1, 2 or 3bars.
The IG5 can limit the maximum rpm at which the engine will operate. Above this
level the IG5 completely cuts ignition to the engine. When the engine speed drops
below the RPM Limit the IG5 will resume normal ignition delivery. This is known as
hard limiting. If the RPM Limit is not wanted then set this value above the highest
operating point of the engine.
♥♥♥♥
and
←←←←
) keys are used to change this type of field. Each stroke of
′′′′
≤≤≤≤
or
and then
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Units
The Haltech IG5 programming software can display parameters in either Metric or US
units.
RPM Mode
The IG5 ignition maps may be arranged either in 500 rpm increments to 10,500 rpm,
or in 1000 rpm increments to 16,000 rpm. Select the high - or low - rpm mode here.
Changing settings alters the way the ECU reads the Maps, and will change the tuning
of the engine dramatically. Do not change this setting once tuned.
Road Speed Value
This value calibrates the Road Speed reading. Some configurations cannot use the
Road Speed input trigger in which case this field will not be displayed.
Trim Control
The optional Trim unit can be used to control one of several parameters. This field
selects the controlled parameter. If there is nothing connected to the trim plug, the
trim will have no effect (except with boost control). The available functions are :
Ignition +7 to -8 degrees adjustment of ignition advance.
Ign Trailing +7 to -8° adjustment for Rotaries only
Boost Control Boost trim for Wastegate control only.
Aux. In Function
The Auxiliary Input on the IG5 can be configured for one of a number of functions.
Most of these functions relate to the configuration of the system. The available
functions are:
Disabled No effect on ECU operation.
Nos Input Input - This input is used in conjunction with the
Nos Optional Output. [13.10]
TCC Input Input - This input is used in conjunction with the
TCC Optional Output. [13.4]
Turbo Timer Input - This input is used in conjunction with the
Turbo Timer Optional Output. [13.9]
Since the Auxiliary Input line can only perform one duty, all of the above functions are
mutually exclusive, i.e. although four programmable outputs exist on the IG5, only one of the
NOS, TCC and Turbo Timer may be chosen. Keep this function in mind when deciding on
the IG5 configuration you wish to run.
3.2 Ignition Set-up
The Ignition Set-up works in an similar way to Engine Identification. Its fields relate to the
way the ignition advance is determined for the engine. Enter the Ignition Set-up by pressing
ƒσ
ƒσ
ƒσƒσ
then
ΙΙΙΙ
. The fields in the Ignition Set-up are:
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