OMEX OMEM710 Hardware Manual

OMEM710 Hardware Manual 2v11

Hardware Manual

OMEM710

www.omextechnology.com

710 Series ECU

OMEM710 Hardware Manual 2v11

1 Introduction ................................................................................................................. 6

1.1 Notation Used in This Manual .................................................................................. 6

2 Setup Procedure ......................................................................................................... 7

3 Software ...................................................................................................................... 9

4 Inputs and Outputs ................................................................................................... 10

4.1 Ignition Coils ........................................................................................................... 10

4.2 Fuel Injector ............................................................................................................ 10

4.3 PWM Devices ......................................................................................................... 10

4.4 Switch Outputs ....................................................................................................... 11

4.5 Switch inputs .......................................................................................................... 12

5 Sensor Setup ............................................................................................................ 13

5.1 Throttle Position Sensor ......................................................................................... 13

5.2 MAP Sensor ........................................................................................................... 13

5.3 MAF Sensor ........................................................................................................... 14

5.4 Coolant Temperature Sensor ................................................................................. 14

5.5 Air Temperature sensor .......................................................................................... 15

5.6 Barometric Pressure ............................................................................................... 16

5.7 Road Speed Sensor ............................................................................................... 16

5.8 Crank Sensor ......................................................................................................... 17

5.9 Trigger Wheel ......................................................................................................... 18

5.10 Cam1 Sensor ......................................................................................................... 20

5.11 Cam2 Sensor ......................................................................................................... 21

5.12 Ignition Timing Alignment ....................................................................................... 21

6 Map Axes ................................................................................................................... 23

6.1 Engine Speed ......................................................................................................... 23

6.2 Engine Load ........................................................................................................... 23

OMEM710 Hardware Manual 2v11

7 Basic Fuel Setup ...................................................................................................... 26

7.1 Battery Voltage Compensation............................................................................... 27

8 Rev Limits ................................................................................................................. 30

9 Dashboard ................................................................................................................. 31

9.1 Tacho ..................................................................................................................... 31

9.2 Shift Light ............................................................................................................... 31

9.3 Gear dependent shift light speed ........................................................................... 31

10 Engine Start Condition ............................................................................................. 32

10.1 Ignition ................................................................................................................... 32

10.2 Fuel ................................................................................................ ........................ 32

11 Idle Strategies ........................................................................................................... 34

11.1 Without air bypass idle motor ................................................................................. 34

11.2 With air bypass idle motor ...................................................................................... 35

12 Transient Conditions................................................................................................ 39

12.1 Acceleration Fuel ................................................................................................... 39

12.2 Deceleration Fuel Cut Off ....................................................................................... 41

13 Conditions Corrections............................................................................................ 42

13.1 Coolant Temperature ............................................................................................. 42

13.2 Air Temperature ..................................................................................................... 42

13.3 Barometric Pressure .............................................................................................. 43

13.4 Individual Fuel Output Trims .................................................................................. 43

14 Cold Engine Running ............................................................................................... 44

15 Oxygen Feedback ..................................................................................................... 45

15.1 Narrowband ........................................................................................................... 45

15.2 Wideband ............................................................................................................... 48

OMEM710 Hardware Manual 2v11

16 Cooling Fans ................................................................ ................................ ............. 49

17 Knock Control ........................................................................................................... 50

18 Full Throttle Gearshift .............................................................................................. 51

19 Staged Injectors ........................................................................................................ 54

19.1 Twin Injectors ......................................................................................................... 54

19.2 Staged Injectors ..................................................................................................... 54

20 VTEC Cam Control .................................................................................................... 55

21 VVC Cam Control ...................................................................................................... 56

22 Turbo Boost Control ................................................................................................. 57

23 Anti-lag ...................................................................................................................... 58

24 Alt Function ............................................................................................................... 59

25 User1 .......................................................................................................................... 60

26 Internal Data Logging ............................................................................................... 61

27 Ignition Dwell Control ............................................................................................... 62

28 Security ..................................................................................................................... 63

29 Wiring ........................................................................................................................ 65

29.1 Semi Assembled Loom Construction ..................................................................... 65

29.2 ECU Connector Pins .............................................................................................. 66

29.3 Component Pin-outs ............................................................................................... 67

29.4 Diagrams ................................................................................................................ 68

OMEM710 Hardware Manual 2v11

Thank you for choosing Omex Engine Management. This manual is written to help the user through the specifics of the OMEM710 ECU. It is essential that the user reads all of the Omex manuals before attempting to install the system and before attempting to start the engine. Incorrect use of the Omex system could potentially lead to damage to the engine and personal injury. If you have any doubts about fitting these parts or using the software then please contact Omex for help.

As the system is computer based, technical support is given on the assumption that the user is able to perform simple Windows based operations. The user will also need access to email as Omex will nearly always require a copy of the map in the ECU to give support.

Omex may not be held responsible for damage caused through following these instructions, technical, or editorial errors or omissions. If you have any doubts about fitting these parts or using the software then please contact Omex for help.

1.1 Notation Used in This Manual

Menu commands are signified in bold type with a pipe symbol | between each level of the menu. For example, File | Open indicates that you should click on the Open option in the File menu.

UPPER CASE TEXT is used to indicate text that should be typed in by the user.

1 Introduction

OMEM710 Hardware Manual 2v11

Wiring

Wire your semi-assembled harness or ready-built harness as shown in the Wiring section of this manual.

Trigger Wheel

If installing a trigger wheel of missing tooth type,

 Accurately mark TDC.  Turn the engine to approximately 90o BTDC.  Mount your crank position sensor (CPS) anywhere around the perimeter of the timing wheel

pointing towards the centre of the wheel with a sensor to wheel gap of approximately 0.5mm.

 Mount the trigger wheel with the missing tooth pointing at the sensor. If machining a trigger pattern into the front pulley then it is usually easiest to machine all of the teeth

in, mount the front pulley, and then remove the tooth pointing at the sensor at 90o BTDC.

Software

Follow the ‘Software’ chapter of this manual for instructions on how to connect to your ECU and send your startup calibration.

Setup before mapping

Follow the ‘Auxiliary Inputs and Outputs’ chapter, though we suggest that all non-essential functions (e.g. full throttle gearshift) are disabled until fuel and ignition mapping is complete. Follow the ‘Sensor Setup’ chapter.

Follow the ‘Rev Limits’ chapter. Follow the ‘Map Axes’ chapter (advanced users only).

For many engine configurations, the majority of these sections can be ignored as the start-up calibration will be set to suit the standard engine. Refer to the calibration’s notes field for information about sensors used in the calibration.

First start fuel

When attempting to start the engine for the first time you may need to change the injector scaling as the fuel requirements, injector flowrates, and fuel pressure vary between engines. The option

Microsec/bit is a linear scaling factor. A higher number is more fuel, a lower number is less.

First start ignition timing

Follow the ‘Ignition Timing Alignment’ section of the ‘Sensor Setup’ chapter.

Main fuel and ignition mapping

Ensure before mapping that the oxygen feedback is disabled by setting Standard | OX FB | OX FB Rate = 0.

If a road car, calibrate the injector battery voltage offsets before much mapping is done. Map all fuel and ignition in steady state conditions. Calibrate warm running transient fuel.

2 Setup Procedure

OMEM710 Hardware Manual 2v11

Calibrate warm engine starting fuel.

Cold starting / running setup

It is important to calibrate the cold running in the correct order as some of the tables are in effect all of the time and so will affect the results of others. Start engine from cold however you can (ignoring the cold cranking fuel for now), and calibrate the Coolant Fuel trim table and the Accel Coolant trim table. The Coolant fuel trim table is used for steady-state engine running, and the Accel Coolant trim table for increased acceleration fuel whilst cold. Refer to the relevant sections for further advice on this. When the cold running is complete, you can calibrate cold starting. Refer to the relevant section for advice on this.

OMEM710 Hardware Manual 2v11

Installing the software

Run SetupMAP4000.x.xx.xx.exe and follow the onscreen instructions.

Connection port

The ECU requires an RS232 serial connection. Desktop PCs and older laptops will have 9pin D shaped ports on them marked COM for this type of communication. If you have this port then this is the best to use for communication with the ECU. If your PC does not have one of these ports then you will need to use an adapter. We suggest using the USB to RS232 adapter from ‘ATEN’ as the software has been specifically designed for this adapter.

Connecting to the ECU

 Ensure that if you are using an adapter, the drivers software from the adapter manufacturer has

been installed.

 Join the data lead between the ECU and the PC  Open MAP4000 from the ‘Start bar’  Go to ECU | Connection Setup and select your port from the list  ECU | Connect  Ignition ON (do not crank the engine)  The ‘Receiving Calibration’ bar will start moving across. When completed, you are connected to

the ECU.

Sending the startup calibration to the ECU

It is not possible to start a new calibration from File | New. Please contact Omex for a suitable start-up calibration.

 Save the start-up calibration from the start-up disk or email to the hard-drive in the location

Documents\OMEX\MAP4000\Calibrations. (note that this folder is only created when MAP4000 is opened for the first time so you must have opened MAP4000 on this PC before)

 Connect to the ECU as described in the above section.  ECU | Send new calibration  Ignition ON (do not crank the engine)  Select your start-up calibration and press ‘open’  When the calibration has been sent to the ECU cycle ignition power OFF / ON

3 Software

OMEM710 Hardware Manual 2v11

The physical input and output pins for each function are in some cases fixed (eg Coolant Temperature sensor must always be on the same physical pin) but many are selectable. The physical pins have names based on their normal output type, but the names do not necessarily tell the user what they are being used as. The wiring section of the manual gives suggested pin-outs for most engines but some will need to be decided by the user. If you are in any doubt then please contact Omex. The ECU needs to be told which pins are being used for which functions. Much of this will be set in startup calibrations from Omex.

4.1 Ignition Coils

Ignition coils may be controlled on any of the IGN pins. To set an IGN pin as a coil driver it must have the IGNx and TOCx ON.

4.2 Fuel Injector

Injectors may be controlled by any of the FUEL pins and IGN3, IGN4, IGN5, or IGN6. To set a FUEL pin as an injector driver it must have the FUELx as injector ON and FUELx as PWM

OFF.

To set IGN3, IGN4, IGN5, or IGN6 pin as an injector driver they must have the TOCx and IGNx as

FUELx ON. IGNx must be OFF.

4.3 PWM Devices

PWM devices (such as idle motors, boost solenoids etc) may be controlled by any of the FUEL pins. To set a FUEL pin as a PWM driver it must have the FUELx as PWMx ON and FUELx as injector OFF.

Controls are then applied to these activated PWM outputs using the Setup | Output Pin Allocation

| PWM Outputs options group.

4 Inputs and Outputs

OMEM710 Hardware Manual 2v11

The PWM outputs will usually require inverting.

4.4 Switch Outputs

Switch outputs may be controlled by IGN pins, FUEL pins, or HIGHSIDE pins. To set an IGN pin as a switch output it must have both the IGNx and TOCx OFF.

To set a FUEL pin as a switch output it must have both the FUELx and PWMx OFF.

The HIGHSIDE pins are switch pins only so do not need the hardware switching to this output type. Controls are then applied to these switch outputs using the Switch Outputs drop-down options

group.

If the output needs to work in reverse (ie the output going OFF when the software function goes ON) then use the inverted option version.

OMEM710 Hardware Manual 2v11

There are also options of N.U., tacho and tele. Do not use these unless instructed to do so by Omex.

4.5 Switch inputs

Switch input pins are selected using the drop-down options. A switch input function can have any of the input pins on the list assigned to it so long as they are not being used already by sensors. (eg. If an oxygen sensor is being used on pin OX1, a switch clearly cannot be assigned to this pin). For a function to be active always without a physical switch to turn it on (sometimes this is the case with the Alt Function) select Switch is Always ON.

OMEM710 Hardware Manual 2v11

5.1 Throttle Position Sensor

The parameter TPS raw gives the raw number output of the sensor which is scaled by options TPS min and TPS max to give a throttle that works between 0 and 100%. To calibrate;

 A live reading is shown for TPS raw. TPS raw will be between 0 and 255. The throttle position

sensor can often be rotated by the user. If so, the position should be set so that the sensor never reaches 0 or 255 during its closed throttle to open throttle movement. It is preferable to have the sensor set so that the values do not go close to either extreme. Typically a value of approximately 20 at the idle position will give an acceptable value at WOT (wide open throttle).

 The number for TPS raw at WOT needs to have 1 added to it, then be inputted to the options

box as TPS max (i.e. if TPS Raw is 220, then input 221). The number for TPS raw at the idle position needs inputting to the options box as TPS min.

The Autozero options allow the ECU to automatically re-learn the idle position of the throttle sensor every time the ECU is turned on. 0 disables this feature.

5.2 MAP Sensor

If you are using MAP for engine load sensing then set MAP for Load ON. MAP min and MAP max should be 0 and 255. Do not change these unless instructed to by Omex. MAP Cal is the the time over which the ECU averages the MAP sensor input. Measured in internal

units. Typically 12. As standard, the fuel map and ignition map will show load values of 0-100KPa. This is not KPa, this

is simply 0-100% of the range of the sensor. It is possible to tell the ECU what range the sensor has so that you can read the true KPa value on the maps.

Load Scalar

The multiple of 1 that describes the theoretical 0-5V full scale of the sensor.

Load offset

Most MAP sensors do not have 0V at 0KPa, they have a slight offset. This option describes the offset.

5 Sensor Setup

OMEM710 Hardware Manual 2v11

Omex have the values for the sensors sold by Omex. If you want to calibrate your own sensor then either find the voltage output information (total scale, and offset) from the manufacturer, or follow this procedure;

 Select a suitable start point for Load Scalar to suit your sensor e.g. for a nominally 2bar sensor,

enter 2

 Note the current value for MAP as Load  Change the pressure at the sensor by a known amount using a vacuum pump  Ignoring the absolute value, adjust Load Scalar until the correct change in value is shown by

MAP as Load to suit that pressure change e.g. if you have reduced the pressure by 50kPa, then adjust Load Scalar until MAP as Load shows 50kPa less than it did before the pressure change was made

 Remove the pressure change and try the above again. As this is an iterative procedure you may

need to do it several times before the correct change is shown on the ECU Remove any pressure changes from the sensor and adjust Load offset until MAP as Load shows the current barometric air pressure.

5.3 MAF Sensor

Contact Omex if you would like to use MAF as the load sensor.

5.4 Coolant Temperature Sensor

The coolant temperature sensor used by the Omex ECU is a resistive sensor. The raw output of this sensor is calibrated in the ECU to give the information in a more usable form, oC. Sensors are calibrated in the Coolant Temp Sensor table. The values for many sensors are known but you may

OMEM710 Hardware Manual 2v11

need to calibrate your sensors. It is essential that these sensors are calibrated correctly as many functions are temperature based.

To calibrate a sensor;

 Place the sensor and a thermometer in a kettle or pan of water  The ECU will highlight the current raw input value from the sensor along the upper line of the

table. Below this input value, enter the current thermometer reading in degrees centigrade.

 Heat the water. As the temperature increases, repeat the temperature readings.  When the water is fully heated, repeat the process as the water cools  Using the graph view, smooth the curve to remove any mistakes, and extrapolate to

unobtainable temperatures.

Coolant Fail Low and Hi are the failure points of the sensor and should be set to just within the reading limits of the sensor. Example- If the lowest temperature in the sensor table is –25 then Coolant Fail Low should be set 1 higher at –24. If the highest temperature in the sensor table is 125 then Coolant Fail Hi should be set 1 lower to 124. Coolant Temp Default is the temperature to which the input defaults if the sensor goes into failure.

5.5 Air Temperature sensor

The air temperature sensor used by the Omex ECU is a resistive sensor. The raw output of this sensor is calibrated in the ECU to give the information in a more usable form, oC. Sensors are calibrated in the Air Temp Sensor table. The values for many sensors are known but you may need to calibrate your sensors. It is essential that these sensors are calibrated correctly as many functions are temperature based.

OMEM710 Hardware Manual 2v11

To calibrate your sensor, see the calibration of the coolant temperature sensor. Air Temp Fail Low and Hi are the failure points of the sensor and should be set to just within the

reading limits of the sensor. Example- If the lowest temperature in the sensor table is –25 then Air Temp Fail Low should be set 1 higher at –24. If the highest temperature in the sensor table is 125 then Air Temp Fail Hi should be set 1 lower to 124. Air Temp Default is the temperature to which the input defaults if the sensor goes into failure.

5.6 Barometric Pressure

As the air pressure changes, so does the amount of oxygen per volume of air. Changes in most countries are relatively little, but if driving in large mountain ranges, these changes can be significant. The 710 ECU has an in-built 1bar MAP sensor which may be used for barometric correction. As the 710 has an inbuilt sensor, no calibration is required, the function is simply enabled or disabled. Baro must NOT be checked if using the internal sensor for load. There is a Baro Source option to allow the use of external baro sensors where required.

5.7 Road Speed Sensor

The road speed sensor is only required if you wish to use gear dependent shift light speeds. The input should be a pre-differential driven wheel input e.g. propshaft rpm.

The road speed sensor can only be calibrated once the engine is running. The option Road Speed M is a scalar and should be adjusted until the parameter Road Speed

reads the current road speed. Rd Spd Falling Edge and Rd Spd Rising Edge specify the edge of the input waveform from the

sensor to use as the significant edge. Typically Rd Spd Falling Edge. Road speed can be displayed as either mph or kph. To adjust the units used go to Configure |

Units/Scaling | Road Speed Units.

Jumper

To allow for different types of sensor, physical jumpers need to be set. The following diagram shows an aerial view of the ECU board with the main wiring connector on the right-hand side.

OMEM710 Hardware Manual 2v11

Sensor Type

Jumper Position

Typical MVR

OFF

Hall Effect ON

5.8 Crank Sensor

The crank sensor input can be from either a Magnetic Variable Reluctance (MVR) sensor or a Hall Effect sensor. The two types of sensor require different software and hardware jumper settings.

MVR

The crank sensor high and low gain settings allow a user definable change point for high sensitivity to allow for low magnetic crank sensor outputs at low engine speeds. Typically the values are just above idle speed.

Magnetic sensors can use either the rising or falling edge of the generated waveform. If the edge is incorrect then the engine will misfire at some point in the engine speed range. There is also the possibility that if the edge is incorrect on a magnetic sensor of the ignition timing on the engine deviating from the ignition timing calculated by the ECU as the engine speed changes. To find the correct edge either see which edge does / does not produce ignition timing changes, or using an oscilloscope to look at the waveform. If the signal falls through the missing tooth section use Crank Rising Edge, and if it rises through the missing tooth section use Crank Falling Edge.

OMEM710 Hardware Manual 2v11

Hall Effect

Hall effect sensors require values of 0 for the high and low gain settings as their output is the same amplitude regardless of engine speed.

Hall Effect sensors can use either the rising or falling edge, though typically the falling edge would be used.

Jumpers

To allow for different input ranges of the crank sensors, physical jumpers need to be set. The following diagram shows an aerial view of the ECU board with the main wiring connector on the right-hand side.

Sensor Type

Jumper Position

Typical MVR

none

High Output MVR

1 2

Hall Effect

2 3

5.9 Trigger Wheel

The pattern of teeth on the crank pulley or flywheel that the crank sensor faces is known as a trigger wheel. The pattern is evenly spaced teeth with missing or extra teeth as reference points. As different manufacturers use different trigger patterns, the ECU is programmable to suit. The information required in the ECU for many of the popular patterns is already known, some of which are listed below. If you have a different pattern on your engine please contact Omex for advice.

OMEM710 Hardware Manual 2v11

It is very easy to make an engine run, but not run properly by incorrectly entering these options and tables. If possible please contact Omex for a calibration aspect or email an existing calibration to Omex to be changed to a different trigger pattern.

36-1

Tooth Control table:

0 1 2 3 4 5 6 7 8 9 10

19 5 4 4 5 4 4 5 4 4 5 4 4 5 4 4 5 4 4 5 4

39 4 5 4 4 5 4 4 5 4 4 5 4 4 5 4 3 3 3 3 3

59 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

60-2

Tooth Control table:

0 1 2 3 4 5 6 7 8 9 10

5 4 4 4 4 5 4 4 4 4 5 4 4 4 4 5 4 4 4 4 20

5 4 4 4 4 5 4 4 4 4 5 4 4 4 4 5 4 4 4 4

5 4 4 4 4 5 4 4 4 4 5 4 4 4 4 5 4 4 3

Rover K-Series (late)

OMEM710 Hardware Manual 2v11

Tooth Control table:

0 1 2 3 4 5 6 7 8 9 10

19 4 4 5 4 4 5 4 4 5 4 4 5 4 5 4 5 4 4 5 4

39 4 5 4 4 5 4 4 5 4 5 4 5 3 3 3 3 3 3 3 3

59 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

5.10 Cam1 Sensor

If an engine is to control the injectors sequentially or ignition coil-per-plug, it needs information about what part of the engine cycle it is in (there are two crank revolutions per engine cycle for a 4 stroke engine). The cam sensor provides this information (as there is only one cam revolution per engine cycle for a 4 stroke engine).

Cam1 Lo Gain Above

Some VR cam sensors give too high an output at high engine speeds. This feature allows the sensitivity of the ECU to be switched to lower above the set engine speed to allow for this. Typically 1500rpm.

Cam1 Hi Gain Below

High channel sensitivity when below this value. Should be set below the on value (hysteresis). Logic level sensors (hall effect) set to 0

Cam1 Rising Edge

rising edge of the crank signal is used as the significant edge if ON. Typically OFF

Cam1 Falling Edge

falling edge of the crank signal is used as the significant edge if ON. Typically ON

The cam input can be from either a MVR or Hall sensor. Jumpers on the board must be set to allow for these two sensor types.

Sensor Type

Jumper Position

Typical MVR

none

High Output MVR

1 2

Hall Effect 2 3

OMEM710 Hardware Manual 2v11

5.11 Cam2 Sensor

The Cam2 sensor is used for some engines, typically twin VVC engines.

Sensor Type

Jumper Position

Typical MVR

OFF

Hall Effect ON

5.12 Ignition Timing Alignment

The ECU recognises the engine position by a missing or extra tooth on a pattern of evenly spaced teeth. Different manufacturers have this reference in a different place on the trigger wheel so the ECU needs to have adjustment for this. The numbers are known for most manufacturers and will be set in the start-up calibration but if they are unknown or if you are using an Omex external 36-1 wheel, you will need to find this value yourself. To find this value you will need a strobe light and an accurate TDC mark on the engine.

 Hold the engine at 2000-3000 rpm (ie out of the idle condition where the ignition timing is stable)  Check the engine speed shown on the strobe light. Most strobe lights will see the wasted spark

on DIS systems and so will show double engine speed and so also double ignition timing. If this is the case then halve all ignition timing figures shown on the strobe light.

 Check the ignition timing with a strobe light and compare this number to the number in Target

Timing.

 If the engine is retarded compared to Target Timing (the strobe light shows a lower value) then

advance the engine. If the engine is advanced compared to Target Timing (the strobe light

OMEM710 Hardware Manual 2v11

shows a higher value) then retard the engine. The larger buttons make larger changes, the

smaller buttons make smaller changes. The Target Timing on the PC will not change, but the

timing mark on the engine will move, so each adjustment will require the strobe light resetting.

Repeat these changes until the strobe light timing figure agrees with the Target Timing figure. If you cannot get the engine to start and believe this is because the ignition timing is incorrect then

you can perform the above tests whilst cranking the engine. Timing lights will not work correctly during normal cranking as the engine speed varies so much due to the compression of each cylinder. Therefore the spark plugs should be removed (to remove compression), put back into the HT leads, and placed onto an earthed part of the engine, then the process documented above can be followed but at cranking speeds. When this is done and you get the engine started, it should be repeated at normal running speeds.

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OMEX OMEM710 Hardware Manual

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