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v3 ECU

VEMS v3 ECU Installation Instructions And Setup Manual

12/16/2012
Installation Instructions and Setup Guide | Jason Russell
Table of Contents
Initial Information ........................................................................................................................................ 4
Legal Disclaimer ....................................................................................................................................... 4
Planning Guide ......................................................................................................................................... 4
Getting Started ............................................................................................................................................ 5
Power up on the bench ............................................................................................................................ 5
Grounds ................................................................................................................................................... 5
Power Grounds .................................................................................................................................. 5
Sensor Ground ................................................................................................................................... 6
+12V Supply ............................................................................................................................................. 6
Connecting serial port .............................................................................................................................. 7
2
Connect essential sensors ............................................................................................................................ 8
Crank Trigger ............................................................................................................................................ 8
Connecting the primary trigger (Crank) ................................................................................................... 8
Configuring the crank trigger ................................................................................................................... 9
Connecting the Secondary Trigger (Cam) ................................................................................................. 9
IAT – Inlet Air Temperature .............................................................................................................. 10
CLT – Coolant Temperature .............................................................................................................. 10
Secondary Sensors ..................................................................................................................................... 12
Primary Outputs ........................................................................................................................................ 14
Example coil connections ................................................................................................................ 16
Single coil ......................................................................................................................................... 16
Coil pack .......................................................................................................................................... 17
Coil on plug (COP) ............................................................................................................................ 18
Inputs ......................................................................................................................................................... 23
Misc Outputs ............................................................................................................................................. 23
List of Authorized Resellers ........................................................................................................................ 24
3
Appendix .................................................................................................................................................... 25
Initial Information
Legal Disclaimer
The authors, advisors, manufacturers, website maintainers or anyone involved in shipping or support are NOT responsible for consequences - even if it's proven that any injury, damage or inconvenience is directly caused by their advice.
No applicability of the hardware, firmware, other software, instructions, or documentation for a particular purpose is claimed.
All installers, diy-ers, and users are responsible for testing, installing, programming and using their units.
You understand that modifications are suitable to ruin your engine. Modifications usually invalidate any emission related certification, and most often invalidates the license to use the equipment (eg. car, snowmobile) at all. For off-road use only.
You understand that like any electronic or mechanical equipment, they can fail. Failing equipment in a vehicle can be fatal.
You are responsible for compliance with the laws of your jurisdiction. If any provision of these Terms and Conditions is found to be invalid by any court having
competent jurisdiction, the invalidity of such provision shall not affect the validity of the remaining provisions of these Terms and Conditions, which shall remain in full force and effect. No waiver of any of these Terms and Conditions shall be deemed a further or continuing waiver of such term or condition or any other term or condition.
In short, we can not cover every conceivable scenario. Please be aware of the consequences and plan accordingly. Be safe!
4
Planning Guide
Things you need to know before ordering an ECU:
• Crank trigger type
• Trigger wheel
• Cam trigger type (if applicable)
• Number of Cylinders
• Number of coils
• Type of coil (logic level or high current)
• Number of fuel injectors
• Type of fuel injectors (high impedance or low impedance)
• Type and value of temperature sensors
• Any accessories or options you may want
• MAP sensor range (2.5 bar, 3bar, 4bar, or external)
Order info, options, ignition outputs, EGT, Knock,
Getting Started
Initial Power up
Connect all the grounds
Grounds
From the outset it cannot be stressed enough just how important grounding is. 95% of all noise issues are due to poor grounding.
Grounds need to be connected with a clean connection and thick wire, and near the ECU. There are two branches so the fluctuation of power signals do not interfere with the measured signals (most importantly: the trigger):
Power Ground handles the noisy and high currents generated by driving injectors, coils and solenoids.
Sensor Ground handles 0 to 5v signals from crank, throttle and temperature sensors. VR-trigger sensor at low RPM (cranking) is the most sensitive to noise.
The GROUND rules:
• connect Sensor GND (EC36 pin 26) and the 4 Power GNDs with short (preferably 10..15cm, max
20..30cm from EC36), strong (preferably 0.75mm2 or stronger) wires.
o Power Grounds & Sensor Grounds MUST terminate at the same point - Common
Ground. Run the wires into a single ring crimp so that there is no chance of one ground coming free.
• Keep the Power Ground connection (EC36 pin26, 5,21,22,32) pins to the Common Ground point
short max 0.1 .. 0.3m,
o use strong wires. Preferably all 5 wires should be 0.75mm2 or stronger. Some
installations (particularly with no PWM-ing) could tolerate somewhat longer wires, but why risk it ? (ground problems are like ghosts, very hard to track down). The length of wire(s) from this common ground point to battery / chassis can be longer (and usually are long). Strong wires must be preferred (total 4mm2), and not longer than necessary. But at least nowhere near as sensitive as the wires right at the ECU.
o connect the ground of the sensors to the Common Ground point or to the sensor ground
branch, that is EC36pin26.
o Connect Power Grounds to the Common Ground point, or anywhere you like (except the
sensor-ground branch)
• Failure to connect Sensor Ground and Power Ground will damage your VEMS. Even on the test
bench !
5
Power Grounds
Also called as "GND5" in some documents
• EC36-pin5 to Common Ground
• EC36-pin21 to Common Ground
• EC36-pin32 to Common Ground
• EC36-pin22 to Common Ground
Sensor Ground
• EC36-pin26 to Common Ground. NOTE: Sensor Ground pin has many connections (CAS, TPS, IAT,
CLT ...) make provision for this in your wiring loom.
6
+12V Supply
• EC36-pin25 3A Fused +12v supply
Note that if you have moved the battery to the rear of the car you may want to run separate wires for the starter/alternator and for the cars electrical system to the battery. Otherwise the several meters long cable will cause a significant voltage drop during cranking that will cause the ECU to reset when the battery starts to run low. This may prevent the car from starting even if the engine cranks over.
Once you have connected and checked the continuity of ground you can connect your VEMS unit to the EC36 plug and apply the power supply. There is little point in connecting power until the serial connector is added though.
Connect the serial port
7
Connecting serial port
To allow the connection of the VEMS unit to your PC a serial port plug must be connected as follows.
• EC18-pin14 to DSUB9-pin3
• EC18-pin15 to DSUB9-pin2
• EC36-pin26 to DSUB9-pin5 (GND).
Start VemsTune and test connectivity
If you don't already have VemsTune, you can download it from here: http://www.vems.hu/vt
Always stay up to date with VemsTune. This is especially important when updating the firmware on the ECU. Older VemsTune releases may not understand and properly handle the newer firmwares.
Start VemsTune, select the COM port that is connected to the ECU. You may notice that a TCP connection is also supported if you have a TCP serial adapter.
Connect essential sensors
Crank Trigger
The trigger is the engine management system's most fundamental sensor, without one VEMS cannot calculate engine speed or crank angle. If you are connecting VEMS to an engine that has an existing engine management system, if not then a triggering method will need to be put in place.
The simplest type of trigger is to use the existing distributor to provide a pulse for each cylinder. This type of trigger is more than adequate for driving ignition through a distributor and batch fire injection.
Connecting the primary trigger (Crank)
Magnetic sensor / Variable reluctance (VR) Mechanical considerations
If you are fitting a crank sensor to an engine it is advisable to use a hall sensor rather than a VR sensor. They are more forgiving to wheel design and noise. Generally, VR sensors should be used in applications utilizing factory sensors.
The VR sensing circuitry is very sensitive to electrical noise, shielded cable (coax) must be used and good grounding is vital.
• EC36-pin27 VR+ Note that some other ECUs trigger on positive-going edge so their schematic
might mark the + and GND swapped: so don't blindly follow naming from autodata pinout or some schematic, keep in mind that + and - might need to be swapped. Measure to be sure:
InputTrigger/TriggerLog
8
• EC36-pin26 VR-
Shielding should be grounded to engine block close to the VR Sensor.
Hall Sensor
VEMS is available configured for Hall sensors, these are more noise tolerant and require a +5V (or sometimes +12V for some sensors) supply.
• EC36-pin27 Hall signal
• EC36-pin26 Ground
• EC36-pin28 +5V
9
Configuring the crank trigger
Crank Trigger configuration can be accessed from the Base Setup menu in the Primary Trigger Settings option. Trigger Edge should normally be rising for VR, falling for Hall. A hall sensor may be configured for rising if the trigger edge needs to be moved the width of a tooth, but this is generally not needed. Select the trigger type. Missing tooth is most common and includes 36-1, 60-2, and other common wheels with missing teeth. If the wheel doesn't have any missing teeth, that is coil-type. Missing tooth type should be n-1 if there is one missing tooth on the wheel, and n-2 if there are two missing teeth on the wheel. Number of teeth on the wheel is the number of remaining teeth. 58 for a 60-2 wheel for example. There are very useful defaults at the bottom of the window to set up your trigger wheel. TDC after the trigger needs to be measured and set with a timing light. Use the Tools → Ignition Lock menu item to set your timing at 0.25 degrees and crank the engine and verify cylinder 1 fires at TDC. Adjust the TDC after the trigger until correct. You may need to change the First Trigger Tooth if the TDC after the trigger value gets below 40 degrees or above 100 degres. 60 degrees is a good value to aim for. Pressing F1 on the Primary Trigger Settings window, or any window in VemsTune, will give you some detailed help with more specific information.
Connecting the Secondary Trigger (Cam)
VR type
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