Electromotive tec3r Installation Manual & Users Manual Download Page 1

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Product Installation Manual

& User’s Guide

V1.11

Electromotive, Inc

703-331-0100

9131 Centreville Road

703-331-0100 fax

Manassas,VA 20110

[email protected]

Summary of Contents for tec3r

Page 1: ...Product Installation Manual User s Guide V1 11 Electromotive Inc 703 331 0100 9131 Centreville Road 703 331 0100 fax Manassas VA 20110 support electromotive com ...

Page 2: ...tallation 14 A 4 d Verifying Trigger Wheel Timing 16 A 4 e Camshaft Distributor Mounted Trigger Setups 18 A 4 f Full Sequential Applications Cam Synchronization 18 A 4 g TDC Tooth Setup Software Adjustment Parameters 19 A 5 Wiring the Tec3 r 22 A 5 a Tec3 r Main Power Connections 22 A 5 b Power Harness Installation 22 A 5 c Wiring the Fuel Injectors 23 A 5 d Wiring the DFU s 24 A 5 e Wiring the En...

Page 3: ... and Coil Firing Patterns for 2 CYCLE Engine continued 46 C 4 d Injector and Coil Firing Patterns for ODD FIRE Engines 46 C 4 d Injector and Coil Firing Patterns for ODD FIRE Engines continued 47 C 4 e Examples of Typical Engine Setups 47 C 5 Common Firing Orders 49 C 6 Odd Fire Engines 49 C 6 a To find the TDC Event Order 50 C 6 b TDC Tooth for DFU 2 needed for an Odd Fire Engine 50 C 6 c Harley ...

Page 4: ...able GPO Functions 85 F 4 b The Spare Output Function and Harness Layout 86 F 4 c Wiring the GPO s and the Spare Output 86 F 4 d GPO Wiring Harness Layout 88 G Tec3 r Input Functions and Wiring 88 G 1 The Manifold Air Pressure MAP Sensor 88 G 2 Throttle Position Sensor 91 G 3 Coolant Temperature Sensor 93 G 4 Manifold Air Temperature Sensor 95 G 5 The Exhaust Gas Oxygen Sensor 95 Mounting the Sens...

Page 5: ... b Fuel Related Idling Problems 112 M 1 c Spark Related Idling Problems 112 N 1 Low Medium and High Load Problems 113 N 1 a Air Related Load Problems 113 N 1 b Fuel Related Load Problems 113 N 1 c Spark Related Load Problems 113 O 1 Summary of Troubleshooting Topics 113 Appendix I Electromotive Tec3 r ECU Specifications 114 Outputs 114 Inputs 114 Tuning Features 115 Supported Engine Management Con...

Page 6: ...Tec3r Manual Version 1 11 Page 6 2017 Electromotive Inc White Connector 124 Appendix VIII Tec3 r Wiring Harness Layout 125 Appendix IX Tec3 r Power Harness Schematic 126 ...

Page 7: ...ed Warranty Service Notify us at support electromotive inc com or 703 331 0100 M F 8 30 to 5 00 EST Then send 1 a completed Electromotive Diagnostic Repair Request Form with a summary of the issues you are experiencing 2 a copy of your sales receipt and 3 the XDi or TEC unit Ship to Electromotive Repairs 9131 Centreville Road Manassas VA 20110 You must include the sales receipt and it must clearly...

Page 8: ... to repair or replacement of the defective product In no event will Electromotive be liable for any monetary damages whether direct indirect consequential special incidental punitive exemplary or other damages arising out of or in connection with any product including third party products sold or provided by Electromotive This exclusion applies to all monetary damages of any kind including but not...

Page 9: ...for most engine configurations Sequential operation is also available through the use of a cam position sensor Four dedicated user definable general purpose outputs GPO s are included with the Tec3 r to make your high tech engine setup a snap The GPO s can be used to control anything from wast egates for turbo setups to simple electric radiator or intercooler fans The possibilities are nearly limi...

Page 10: ...the throttle and are inherently easier to install than MAF sensors since they are not sensitive to vacuum leaks or engine airflow requirements A 1 Bar MAP sensor is designed for naturally aspirated engines A 2 Bar sensor is used for turbo supercharged engines with up to 15psi about 200kPa absolute manifold boost A 3 Bar sensor is good for up to 30psi 300kPa while a 4 Bar is good for up to 45psi 40...

Page 11: ...ed to supply additional fuel for cold weather or to take away some fuel on hot days The throttle position sensor TPS is used for functions similar to the accelerator pump on a carburetor Also the TPS reading is used in the TPS MAP Blend routine which is very useful for multiple throttle setups and radically cammed engines Additional Features Once all the necessary input sensors are in place and th...

Page 12: ... the Tec3 r must be mounted in an area that is partially exposed to the elements there should not be a problem the circuit board is completely sealed for harsh environment installations A well vented area is recommended particularly in engines utilizing most of the injector channels and operating at sustained high speeds It should be noted that the Tec3 r might get hot under prolonged high rpm ope...

Page 13: ...ngine acceleration rates As such Electromotive does not support other triggering systems particularly those of the flying magnet variety These systems can lead to vastly inaccurate spark timing and can contribute to engine damage For most applications the 60 2 tooth trigger wheel is mounted on the crankshaft damper or pulley Some applications may warrant the use of a camshaft or distributor mounte...

Page 14: ...n the trigger wheel to match the ledge diameter The trigger wheel can then be drilled to bolt it to the damper See Table A 4 1 below to determine the tolerances that must be maintained when mounting the trigger wheel These tolerances may require the use of a lathe to true the trigger wheel with the crankshaft centerline which can be accomplished by putting the entire damper trigger wheel assembly ...

Page 15: ...han the 11th tooth will cause an ignition timing retard or advance depending on the direction of the misalignment Each tooth represents six degrees so if the sensor is aligned with the trailing edge of the 12th tooth the timing will be advanced by six degrees Conversely if the sensor is aligned with the trailing edge of the 10th tooth the timing will be retarded by six degrees In the event that th...

Page 16: ...ayout for crank and cam sensors Note that the Cam Sensor is only used on full sequential applications It is NOT used on applications using the 120 4 tooth cam trigger wheel with no crank trigger A 4 d Verifying Trigger Wheel Timing The most important step in the trigger wheel installation process is to check the ignition advance with a timing light A timing indicator pointer should be attached to ...

Page 17: ...Tec3r Manual Version 1 11 Page 17 2017 Electromotive Inc ...

Page 18: ...xhaust strokes the spark on the exhaust stroke may cause unburned fuel in the intake manifold to ignite resulting in a backfire To remedy this situation advance the mechanical timing by manipulating the DFU A Trigger Wheel TDC Parameter If your crank sensor is aligned with the 11th tooth of the trigger wheel at TDC 1 setting the Tooth Offset to a number LOWER than 11 will add mechanical advance If...

Page 19: ...ignal from the sensor is going into terminal G10 If using a magnetic sensor with a custom steel trigger wheel we recommend using our magnetic sensors The red wire from the sensor should go to terminal G10 Keep in mind that when adapting an OEM cam trigger setup to a Tec3 r the wheel may need to be rotated to place the rising edge in the appropriate degree window for the Tec3 r A 4 g TDC Tooth Setu...

Page 20: ...o the Ignition Advance Table Some applications may require less mechanical timing some rotary users may wish to do this Assuming the crank sensor is aligned with the 11th tooth at TDC this can be done by entering a value for the Change DFU A Trigger Wheel TDC that is MORE than 11 Each tooth more that 11 represents 6 degrees of retard that is subtracted from the Ignition Advance Table If an odd fir...

Page 21: ...ing values will be automatically ADVANCED by 6 degrees The Ignition Advance Table values will now be incorrect the displayed values will be 6 degrees lower than the actual advance Note In the past aligning the sensor with the 12th tooth would advance the mechanical timing by 6 degrees NOTE 12 Cylinder applications require that the center of the sensor be aligned with the trailing edge of the 8th t...

Page 22: ...all amount of current less than 1 amp This wire can be placed on the ignition switch circuit See Figure A 5 1 for a wiring diagram If you are using the Tec3 r Power Harness refer to the next section on installing the Switched 12 Volt Input into the Power Harness A 5 b Power Harness Installation Electromotive s Power Harness PN 070 40000 for the Tec3 r is capable of supplying the 12Volt high ampera...

Page 23: ...put for Tec3 r turn on request The Wiring Diagrams in the DFU and Injector wiring sections of this manual show the terminals on which the power should be brought in Any reference to fusing the power source in these sections is unnecessary when using the Power Harness since the connections are already fused Figure A 5 1 Tec3 r Power Harness PN 070 40000 A 5 c Wiring the Fuel Injectors The Injector ...

Page 24: ... DFU connector is the 12Volt connection The Tec3 r harness has two cables for the DFUs The first cable has three 16awg wires with a shield The second cable has two 16awg wires with a shield The 3 wire DFU cable has the outputs for A B and C channels The 2 wire DFU cable has the outputs for C and D channels Channel C is in the second cable for ease of wiring 8 cylinder and 2 rotor engines The Tec3 ...

Page 25: ...l perform poorly and overheat the exhaust in short order We are looking for the happy medium here Keep in mind that the timing settings are solely dependent on the crank trigger installation angle If the crank sensor is aligned with the 13th tooth of the trigger wheel when the engine is at TDC 1 the engine timing will be mechanically advanced by two teeth 12 degrees When this occurs the timing val...

Page 26: ...ng look to SE 1 the Constant One Second Starting Enrichment If SE 1 is too high the engine will flood out during cold AND hot cranking since its value is added regardless of temperature If both of these values are set very low and the engine still floods during starting look to PW 0 the Fixed One Second Starting Pulse Width Most engines will not need PW 0 so it is generally best to set this to zer...

Page 27: ...timing does not help either make sure the coils are wired correctly Also check that the spark plug wires are all connected to the appropriate cylinders Check the wiring section if you are unsure on this one If the MAP sensor reading is fluctuating at idle or its value is above 75 kpa it is recommended that the TPS MAP Blend feature be turned on The Tuning Wizard does this automatically when a radi...

Page 28: ... the VE Table zeroed out as long as the engine is not overly radical If you start making drastic adjustments to the VE Table there is likely something amiss in your POT and or UAP settings Radically cammed high rpm engines may require some substantial VE Table adjustments though When making changes to the VE Table it is a good idea to watch the injector pulsewidths on the bottom of the screen If t...

Page 29: ...unning too rich The pulse width should stabilize once the proper settings are established B 7 Tuning for Cold Engines and Cold Weather When an engine is cold or when the intake air is cold it will require additional fuel To add this fuel the TEC uses coolant temperature enrichments that are activated as functions of cranking normal running and accelerating These enrichments are best tuned after an...

Page 30: ...e speed setting the throttle plate is opened too far or there is a vacuum leak on the engine Try spraying carburetor cleaner around the intake manifold sealing surfaces to check for vacuum leaks if the throttle plate is fully closed If the engine is idling lower than the desired idle speed setting then the IAC motor is not able to supply the engine with enough air on its own When this occurs open ...

Page 31: ...to start the engine If the engine starts hard try reducing the maximum duty cycle until the startup revs are under control Unfortunately this trick does not work with the 4 wire IAC If the engine starts too hard with the 4 wire try increasing the Positive rate of change to help arrest high startup revs After starting the engine the first time chances are that it will not hold idle In some cases th...

Page 32: ...ity will result in very little reaction If the RPM is dropping rapidly as in example B in Figure 2 the reaction will be larger The Rate of Change calculation will always work against the direction of motion This is the adjustment that will prevent the engine from stalling when the throttle is closing It can be thought of as an adjustable dashpot Tuning Tips In most cases the default values given i...

Page 33: ...hese values should both generally be the same If the engine revs very high when starting hard start try decreasing the maximum duty cycle value This will reduce the amount that the idle motor can open thus reducing how high the engine can rev on startup If when revving the engine the engine rpm oscillates a little bit around the decel rpm while falling reducing the reset value should help to preve...

Page 34: ...ing will be retarded by this amount until the knock level has dropped below the Knock Threshold If the knock level drops below the Knock Threshold the TEC will add back ignition advance in increments defined by the Rate of Advance Increase parameter If the knock level does not drop below the Knock Threshold the TEC will stop retarding the ignition timing when the Maximum Retard Allowed parameter i...

Page 35: ...g the idle MAP RPM point Keep in mind that if the EGO is detecting an AFR around the stoichiometric point the reading will be bouncing around slightly but not nearly as erratically as when the engine is misfiring If the EGO reading is still bouncing around and richening up the mixture does not fix the problem the EGO is too cold for closed loop operation at idle When the idle is tuned in this mann...

Page 36: ...gure C 1 2 for terminal locations 3 Coil DFU s Part Number 070 33600 The 3 coil DFU s utilize all four of the terminals in the yellow connector Here is the pin out Terminal A Ground Pulse for Coil A Terminal B Ground Pulse for Coil B Terminal C Ground Pulse for Coil C Terminal D Full Time 12 Volt Source 9 amps On a standard 6 cylinder even fire application this DFU will be used On 12 cylinder and ...

Page 37: ...liced or lengthened 16awg wire should be used See Figure C 1 1 for details on the coil outputs in the wiring harness Figure C 1 1 ECU Coil Output Wires note shield wire is connected inside the TEC unit not at the coils WARNING The DFU chassis MUST be grounded A ground wire must be connected to battery negative or to a good chassis ground FAILURE TO GROUND THE DFU S MAY RESULT IN SEVERE ELECTRICAL ...

Page 38: ...h the cable connected to pins W1 W2 and W3 The number 2 will identify the second DFU with the cable connected to pins W4 W5 and W6 Coil notation is shown in Figure C 2 1 Note Each coil has two towers for spark plug wires The towers are identical and should be thought of as the same coil For example if the engine setup guide refers to cylinder 1 connected to Coil A1 and cylinder 6 connected to Coil...

Page 39: ...Figure C 2 3 8 Cyl 4 cyl Dual Plug and 2 Rotor DFU Setup Note that the 2nd DFU coils will not be labeled C and D from Electromotive When the 2nd DFU is wired as shown the coil labeled A will fire coil output A2 The coil labeled B will fire coil output B2 Figure C 2 4 6 Cyl DFU Setup ...

Page 40: ...ery 120o of crankshaft rotation The firing goes A 120 o B 120 o C 120 o A 120 o B 120 o C etc When an 8 cylinder engine is chosen DFU 1 Coils A1 B1 and DFU 2 Coils A2 B2 will fire every 90o of crankshaft rotation However on the 8 cylinder setup the coils fire A1 A2 B1 B2 instead of A1 B1 A2 B2 The firing goes A1 90o A2 90o B1 90o B2 90o A1 90o B1 90o A2 90o B2 etc Note To clarify these seemingly c...

Page 41: ... 0o for all engine speeds Engine Mazda 2 Rotor Rotary Spark Plug Setup Leading Trailing Plugs on Both Rotors Coil Firing Order A1 A2 B1 B2 1st or 2nd Rotor 1st rotor 1st rotor 2nd rotor 2nd rotor Leading or Trailing Leading Trailing Leading Trailing Note In the software the timing split between the leading and trailing spark plugs can be set for different engine speeds Engine 4 cylinder 2 stroke F...

Page 42: ...s Leading plugs will go to Tec3r white connector pin W1 white wire first rotor leading Tec3r pin W2 red wire second rotor leading Trailing plugs will go to Tec3r pin W4 white wire first rotor trailing Tec3r pin W5 red wire second rotor trailing Refer to the wiring diagram layout for signal wire hookup 3 Rotor Odd Fire and 2 cycle engines would also use this type of coil ...

Page 43: ...different injection and ignition firing patterns that are available on the Tec3 r It will be necessary to know the firing order for your engine before using the engine configuration tables some common firing orders are given in the following section Once this is known simply wire the vehicle s injectors and coils to reflect the data in the tables Odd Fire applications must know the TDC event order...

Page 44: ...Tec3r Manual Version 1 11 Page 44 2017 Electromotive Inc C 4 a Injector and Coil Firing Patterns for EVEN FIRE Engines continued ...

Page 45: ..._______________________________________ Tec3r Manual Version 1 11 Page 45 2017 Electromotive Inc C 4 b Injector and Coil Firing Patterns for ROTARY Engines C 4 c Injector and Coil Firing Patterns for 2 CYCLE Engines ...

Page 46: ...__________________________________ Tec3r Manual Version 1 11 Page 46 2017 Electromotive Inc C 4 c Injector and Coil Firing Patterns for 2 CYCLE Engine continued C 4 d Injector and Coil Firing Patterns for ODD FIRE Engines ...

Page 47: ...romotive Inc C 4 d Injector and Coil Firing Patterns for ODD FIRE Engines continued C 4 e Examples of Typical Engine Setups Figure C 4 1 Typical In Line 4 cylinder DFU wiring Firing Order 1 3 4 2 depicted here Figure C 4 2 Typical In Line 6 cylinder DFU wiring Firing Order 1 5 3 6 2 4 depicted here ...

Page 48: ...2017 Electromotive Inc Figure C 4 3 Typical GM 8 cylinder DFU wiring Firing Order 1 8 4 3 6 5 7 2 depicted here Remember 8 cylinder setups fire the coil channels in the order of A1 A2 B1 B2 Figure C 4 4 Typical Porsche 6 cylinder Dual Plug DFU wiring Firing Order 1 6 2 4 3 5 depicted here ...

Page 49: ...DFU Firing Order A B C Buick 3 0 3 8 60o V6 1 6 5 4 3 2 1 4 6 3 5 2 Chevrolet 2 8 60o V6 1 2 3 4 5 6 1 4 2 5 3 6 Chevrolet 4 3 90o V6 1 6 5 4 3 2 1 4 6 3 5 2 Ford 2 8 60o V6 1 4 2 5 3 6 1 5 4 3 2 6 Chrysler Slant 6 1 5 3 6 2 4 1 6 5 2 3 4 Porsche Flat 6 1 6 2 4 3 5 1 4 6 3 2 5 Datsun Inline 6 L6 1 5 3 6 2 4 1 6 5 2 3 4 Nissan 3 0 V6 60o V6 1 2 3 4 5 6 1 4 2 5 3 6 VW VR6 15o V6 1 5 3 6 2 4 1 6 5 2 ...

Page 50: ...and C2 will be wired to cylinders 4 6 and 2 respectively The most important step to setting up an odd fire engine is to determine the TDC event order for the engine and to find the degree split between the first two TDC cylinders Also the concepts of TDC Order and Firing Order must be separated in order to fully understand what is occurring on an odd fire distributor less ignition C 6 a To find th...

Page 51: ...nition but a power loss will occur Keep this in mind when trying to diagnose ignition wiring problems Rotor 1 Leading Coil Channel A1 Trailing Coil Channel A2 Coil Channel A1 and A2 are split by the value in the Dual Plug Timing Split Rotor 2 Leading Coil Channel B1 Trailing Coil Channel B2 Coil Channel B1 and B2 are split by the value in the Dual Plug Timing Split C 8 Dual Plug Engines For dual p...

Page 52: ...ping across the spark plug gap since the energy consumed at the spark plug gap won t be any more than what is needed to jump the gap For a more obvious example of this a 25watt light bulb won t use any more energy or produce any more light if it s screwed into a socket wired for a 1000watt bulb Due to the extremely high energy in the Tec3 r coil charging circuit spark plug wires may wear out faste...

Page 53: ...ield excellent results D Fuel Injector Configurations D 1 High vs Low Impedance Injectors The Tec3 r is equipped with 8 fuel injector channels These channels are pull to ground outputs meaning that they provide a ground connection for the injectors when they fire The injector channels can be configured to run in one of two modes either 2 amps peak with 0 5 amps hold for one low impedance injector ...

Page 54: ... points in mind use Table D 1 1 to determine the correct fuel injector type for your application Table D 1 1 Recommended fuel injector selection for various wiring configurations Note that the values given are for individual injector resistance NOT for the total circuit resistance TBI style injectors cannot be run with more than one per channel To determine the current flow through an injector cir...

Page 55: ... This firing mode pairs injectors together just like the waste spark coil firing scheme On a standard inline 4 cylinder four stroke engine cylinders 1 and 4 will always be on top dead center at the same time but one cylinder will be on compression when the other is on exhaust The same hold true for cylinders 2 and 3 As a result it is possible to use just two injector channels to drive four low or ...

Page 56: ...lb hr primary and 100 lb hr secondary injectors could be used Piston engines with very high rpm power bands like motorcycle engines can also benefit from staged injection for the same reasons as the rotary example Staged injection can be used with sequential phased sequential and TBI firing schemes The Wintec software dedicates the unused injector channels for each setup for staged injectors The o...

Page 57: ...ires two injectors one on compression and the other on exhaust Each injector channel will fire once per revolution so each cylinder will see a shot of fuel on both the exhaust and compression stroke In an 8 cylinder application each injector channel has its own staged injector channel 16 low impedance injectors could be used with this firing scenario See Figure D 2 2 for a typical 8 cylinder phase...

Page 58: ...ne TDC is not all that is needed to determine which cycle the engine is on For this a camshaft reference is needed With a full sequential setup each injector channel is independent and each injector is fired once per engine cycle every two revolutions on a four stroke on the end of the exhaust stroke Rotary and 2 stroke applications are inherently full sequential without the need for a cam referen...

Page 59: ...uld be turned on gradually at medium and high RPM Load points Since a rotary engine completes a combustion cycle every revolution with both rotors the rotary injector firing mode will fire the injectors on every revolution Rotor 2 will fire 180o after rotor 1 The two staged injectors will be paired to rotor 1 and rotor 2 The staged injector pulse width is determined by the settings in the Staged I...

Page 60: ...___________ Tec3r Manual Version 1 11 Page 60 2017 Electromotive Inc D 3 Injector Wiring Figure D 3 1 TEC STD injector channel pin out Figure D 3 2 TEC 6 12 injector channel pin out Figure D 3 3 TEC r Injector channel pin out For Reference Only ...

Page 61: ...retor That is the UAP has a large effect on the high load injector pulsewidths while the POT has a large effect on the light load injector pulsewidths UAP dynamically manipulates the raw fuel curve as a function of load while POT adds or subtracts a fixed pulse width to the raw fuel curve for all load points See Figures D 4 1 5 for graphical representations of the UAP and POT correlation The follo...

Page 62: ...recommended that the Volumetric Efficiency Table be manipulated once the engine is running acceptably well to attain optimum drivability and power Volumetric Efficiency Corrections To provide both RPM and Load corrections for engines that stray from thermodynamic linearity the TEC r software has a Volumetric Efficiency VE table This table allows corrections to the raw fuel curve at all rpm and loa...

Page 63: ...se the equations below for once per revolution injection schemes i e phase sequential and once per engine cycle injection schemes i e full sequential Note that the result from these equations is in SECONDS not milliseconds Theoretical UAP once per rev injection Calculated Injector Size Actual Injector Size 60 Max Engine RPM Injector Recovery Time POT Theoretical UAP once per engine cycle injection...

Page 64: ...he Maximum MAP Sensor Voltage is divided by 5 we refer to this as the Load Percentage this is the number in the first column of Table D 4 2 Load Percentage MAP Voltage 1 Bar kPa 2 Bar kPa 3 Bar kPa 0 0 00 10 8 8 3 6 5 0 25 15 18 17 10 0 50 20 28 33 15 0 75 24 38 48 20 1 00 29 48 64 25 1 25 34 58 80 30 1 50 39 68 96 35 1 75 43 78 111 40 2 00 48 88 127 45 2 25 53 98 143 50 2 50 58 108 159 55 2 75 62...

Page 65: ...s low load conditions but a small percentage of change on high pulse width values high load conditions Due to the fact that POT is added or subtracted to the fuel curve at all points the UAP must be adjusted in order for the injectors to remain at the same on time at full load That is if an engine performed well under high load with a UAP of 7 milliseconds and a POT of 0 milliseconds it would be n...

Page 66: ... VE table a 256 point interpolation is occurring to smooth out the fuel curve Otherwise the fuel curve would step from cell to cell and wouldn t be much of a curve The VE table allows the user to select between Offset Absolute Pulse Width and Duty Cycle for the display mode The Offset view mode will display zeros when there is no change to the raw fuel curve at a particular point The Offset Number...

Page 67: ...RPM Load points above the torque peak This type of modification results in a straight line modification to the raw fuel curve Figure D 4 4 What if the same engine needs less fuel at around 80 90kPa for a particular RPM point assuming a 1 Bar sensor The modification to the Raw Fuel Curve at the problem RPM may look something like Figure D 4 5 Figure D 4 5 D 4 e TPS MAP Blend Corrections The TPS MAP...

Page 68: ...e modified MAP Value would be 2 Volts for this setup The Blend Percentage can be changed as a function of RPM Typically the Blend Percentage should be highest at low RPM s and lowest usually zero at higher RPM s Typical 4 6 and 8 cylinder street based engines with individual throttles respond well when the TPS voltage is tapered to zero by 4000rpm Around the idle speed 0 2000RPM the Blend Percenta...

Page 69: ...It does this by decreasing the VE Absolute percentage An EGO reading that is numerically higher than the table value indicates a leaner than desired air fuel ratio When this occurs the TEC will begin to increase the injector pulse width It does this by increasing the VE Absolute percentage When discussing the air fuel ratio of an engine these terms are often used Air Fuel Ratio AFR The ratio of in...

Page 70: ...e pulse width modifications This number is used to control engine speed oscillation Increasing this number generally helps to reduce oscillation associated with changing AFR s Number of Samplings for Avg Error Defines the size of the injector pulse width modifications when the EGO reading is changing slowly termed the average error A small number in this parameter causes large pulse width modifica...

Page 71: ...chiometric when under medium to high load D 4 g Warm Up Enrichments Coolant Temperature Based Since engines need more fuel when the block valves cylinder head and intake manifold are cold a coolant temperature based enrichment curve is included in the software The coolant temperature enrichment serves the same function as the choke plate on a carburetor This parameter has the ability to provide di...

Page 72: ...o see the dependence of temperature on air density Since the majority of engines will run MAT readings at around 70o 100o F 20o 40o C Figure D 4 10 shows a recommended MAT enrichment curve Note that the MAT enrichment is zeroed around the normal operating temperatures This is a good idea because it eliminates one more variable from the tuning process on a fully warmed up engine Please note that th...

Page 73: ...aller numbers make the MAP enrichments more sensitive to MAP changes The Tec3 r will only enter into either TPS or MAP Acceleration Mode not both at the same time TPS Acceleration Mode always takes precedence to MAP Acceleration Mode Thus if the TPS Rate of Change Sensitivity level is reached while in MAP Acceleration Mode the TEC will change to TPS Acceleration Mode However with the exception of ...

Page 74: ...leration Mode is engaged This number adds to the Pulse Width Offset Time POT Time to Add the Fixed Pulse Width Enrichment ACE 9 This number sets the amount of time that ACE 8 adds to the injector pulse width when the Acceleration Mode is engaged D 4 j Starting Enrichments One Second Starting Enrichments Temperature Based One Second Starting Enrichment SE 0 This enrichment adds to the injector puls...

Page 75: ... s volt setting on BT0 would add 0 360 milliseconds to the injector pulse width when the battery is at 11 volts The battery voltage parameter allow the Tec3r to adjust the injector open times up or down to compensate for low or high battery voltages The value specifies how many microseconds to add or subtract to calculated open time based on the current battery voltage The compensation value is sp...

Page 76: ...od grasp on the entire functionality behind tuning a fuel injected vehicle hopefully you are still awake and of sound mental health Since there are so many enrichments that affect the injector pulse width calculation it is sometimes hard to find the exact pulse width at a given instant in time For this reason the Wintec software displays a value called Total Fundamental Pulse Width Percentage TFPW...

Page 77: ...l consumption or even catastrophic detonation Additionally the size of the injector plays a large role in tuning a vehicle Injector sizes flow rates are generally given in either pounds per hour lbs hr or cubic centimeters per minute cc min Note that 1 lb hr 10 5 cc min These ratings are either made by the injector manufacturer or by an aftermarket injector modifier In either case the importance o...

Page 78: ... This scenario occurs on engines with injectors that are too small To properly size an injector the following sequence of equations should be followed HP x BSFC Total Fuel Flow Requirement for the Engine TFFR TFFR of Injectors Uncorrected Injector Size UIS 60000 Peak RPM Available Injection Time ms per Revolution AIT AIT Injector Recovery Time in ms AIT Maximum Duty Cycle MDC UIS MDC Required Inje...

Page 79: ... shows the peak injector pulse width assuming an injector recovery time of zero that is possible using both once per revolution firing and once per engine cycle 2 revolutions on a 4 stroke firing modes If the operating pulse width approaches the values in Table E 1 1 the injectors are effectively maxed out Larger injectors would be necessary if the engine needed more fuel Note that the injector re...

Page 80: ...1500 40 0 80 0 2000 30 0 60 0 2500 24 0 48 0 3000 20 0 40 0 3500 17 1 34 3 4000 15 0 30 0 4500 13 3 26 7 5000 12 0 24 0 5500 10 9 21 8 6000 10 0 20 0 6500 9 2 18 5 7000 8 6 17 1 7500 8 0 16 0 8000 7 5 15 0 8500 7 1 14 1 9000 6 7 13 3 9500 6 3 12 6 10000 6 0 12 0 10500 5 7 11 4 11000 5 5 10 9 11500 5 2 10 4 12000 5 0 10 0 12500 4 8 9 6 13000 4 6 9 2 13500 4 4 8 9 14000 4 3 8 6 14500 4 1 8 3 15000 4...

Page 81: ...re regulator The reason for this is quite simple the Tec3 r allows you to set the precise fuel injector pulse width for a given RPM load point In so doing you do not need to change the fuel pressure to change the amount of fuel introduced into the cylinders you simply need to change the injector pulse width There are however some guidelines to be followed for selecting a regulator When you select ...

Page 82: ...IAC s The stepper motor allows the pintle of the IAC motor to move in and out very quickly to allow varying amounts of air into the intake manifold This way even with the throttle closed the IAC motor can supply additional air to the engine See Figure F 1 1 for an IAC motor plumbing diagram See Figure F 1 3 for IAC wiring instructions Section B 8 covers the tuning of the IAC Parameters The idle sp...

Page 83: ...AC will not be activated unless the TPS voltage is BELOW the TPS Closed Throttle Voltage value As an example if the TPS voltage is 1 5 volts when the throttle is fully closed the IAC motor will not be activated unless the TPS Closed Throttle Voltage setting is GREATER THAN 1 5 volts Fig F 1 3 Common 4 wire idle air control motor wiring Note that for the Tec3 r 6 12 terminals B11 B12 B13 and B14 ar...

Page 84: ...tion coil C These types of coils require the use of a tachometer amplifier since they are designed to trigger off of a 120 Volt signal Tachometer amplifiers PN 150 15210 are available from Electromotive to suit these applications F 3 The Fuel Pump Relay Output The fuel pump output is designed to provide activation of the fuel pump relay on a vehicle It is NOT designed to power the fuel pump direct...

Page 85: ...obtained from the Coolant Temperature Sensor CLT so they are much more accurate and reliable than an external thermo switch The output of the GPO is a pull to ground so you would run the appropriate GPO wire for the channel you defined as Radiator Fan to a standard 4 position automotive relay pin 85 on the relay The opposite side of the relay pin 86 would be wired to 12 volts and the relay would b...

Page 86: ...uel Pump Control That is they activate as a function of RPM and MAP value Note that the Nitrous Control should not be used to turn on the nitrous directly Instead it should be thought of as a nitrous enable This essentially replaces the wide open throttle switch Use Figure F 4 4 for similar wiring F 4 b The Spare Output Function and Harness Layout The spare output is configured as a pull to ground...

Page 87: ...1 Electric radiator fan wiring Fig F 4 3 Air conditioner control wiring Note that the relay simply splices into either of the two wires on the A C clutch with terminals 30 and 87a When activated the A C control will break the normally closed connection between 30 and 87a by grounding pin 85 Fig F 4 2 Shift light wiring ...

Page 88: ... a MAP sensor is a 0 to 5 Volt signal When the intake manifold pressure is low high vacuum the sensor reading is low approaching 0 Volts This would occur during part throttle cruising or decelerating engine braking When the intake manifold pressure is high low vacuum the sensor reading is high approaching 5 Volts This would occur during full throttle operation Absolute vs Gauge Pressure A MAP sens...

Page 89: ...ilopascal kPa is the standard unit of measurement The distinction must be made to whether the measurement is in absolute kPa or gauge kPa Typically this is done by writing kPa abs for the former and kPa gauge for the latter For the purposes of this section we will treat all kPa reading as absolute readings Table G 1 1 gives conversion data for US and metric units Remember Ambient atmospheric Press...

Page 90: ...y 4 80 Volts 2 Bar approximately 2 30 Volts 3 Bar approximately 1 55 Volts Note that the output voltage should be measured between pin B output and pin A ground If the sensor does not output a voltage near the above numbers the sensor is likely defective Refer to Figure G 1 1 for MAP sensor wiring instructions Refer to Figures G 1 2 through 4 for MAP sensor voltage as a function of manifold pressu...

Page 91: ...hly from a low voltage approaching 0V at idle to a high voltage approaching 5V at full throttle Switch type TPS s will NOT work with a Tec3 r since they do not output a smooth voltage transition from closed to opened throttle The throttle position sensor should have a resistance of roughly 10k measured across the 5V and Ground terminals To determine the pin out of an unknown TPS follow the instruc...

Page 92: ...e note that the TPS must use a roughly 10k potentiometer Failure to do so will result in improper impedance matching for the Tec3 r and a false sensor reading will result Fortunately most TPS s are of the 10k variety TPS Functionality and Wiring The TPS allows the Tec3 r to provide fuel enrichments for various throttle movement situations like an accelerator pump on a carburetor For high rpm close...

Page 93: ...le coolant temperature sensors These sensors are sold by Electromotive under part number 305 71210 They are threaded for a 3 8 NPT hole Liquid cooled engines should have the CLT sensor installed somewhere in the coolant passages Ideally it should be installed toward the outlet of the engine or the entry of the radiator so that the highest temperature reading will be seen For air cooled engines the...

Page 94: ...ter Match the resistance of the sensor to the operating temperature using Table G 3 1 As a guideline use the following specs Cold engine 70F 20C 3300 Hot Engine 180F 80C 350 Temp o C Temp o F Resistance ohms 40 40 100700 18 0 25000 7 19 13500 4 39 7500 20 68 3400 38 100 1800 70 158 450 100 212 185 110 230 133 120 248 102 140 284 62 Resistance Curve for MAT CLT Sensors 10 100 1000 10000 100000 40 0...

Page 95: ...sometimes better to install the sensor upstream a bit particularly if the air intake or filter box is made of a material that does not conduct heat very well like plastic This will give the MAT sensor a more appropriate reading for intake air temperature The MAT sensor resistance curve is identical to that of the CLT sensor See Figure G 3 1 and Table G 3 1 for details The sensor resistance test ca...

Page 96: ...ss for the Tec3 r is not being used for the EGO heater element the EGO heater should be wired to a switched voltage source If it is wired to a full time voltage source it will drain the battery in short order See Figure G 5 1 for proper wiring Figure G 5 1 Wiring details for Electromotive s EGO sensor PN 315 72120 Functionality When using an EGO sensor it must be realized that AFR s that are not n...

Page 97: ...uel Ratio will be altered from the reading in the Desired Air Fuel Ratio Table The target Air Fuel Ratio is changed by the following equation Target AFR Desired AFR Table Value 4 34 Coolant Enrichment 100 Therefore when a 10 Coolant Temperature Enrichment is in the Coolant Enrichment Table the target AFR would be about 14 2 1 if the Desired Air Fuel Ratio Table value was 14 64 1 A Note on One Wire...

Page 98: ...to the Tec3 r You are now ready to use the wideband EGO input FAQ s and Troubleshooting Tips 1 How do I know the Tec3 r is using the wideband sensor There are several indications that you are using the wideband option for your EGO input The label for EGO voltage on the digital monitor screen the monitor screen at the bottom of the window will change from EGO Sensor to Wideband Sensor On the analog...

Page 99: ...me front Typically detonation is caused by ignition timing that is too advanced poor fuel quality low octane or poor combustion chamber design Engines with large combustion chambers and poor air swirl characteristics are especially prone to detonation During detonation the spark plug initiates the flame front but the flame front moves so slowly that there is time to compress and heat the unburned ...

Page 100: ...as a speed sensor its output will be an AC sine wave When using a Hall effect sensor the output will be a 0 5 volt square wave One of the most useful functions of the GPI s is trimming Using a simple potentiometer referenced to 5 volts and ground it is possible to configure the inputs to trim the fuel and spark curves based on the potentiometer knob position This is configured quite easily in the ...

Page 101: ...provide a datalog on light See previous section for details Speed Input Only available on GPI channels 3 and 4 the speed input allows the input of a frequency based signal Many late model vehicles use electric speedometers that use either Hall effect or reluctor triggering mechanisms These are both compatible with the Tec3 r s speed input Depending on the location of the speed input trigger wheel ...

Page 102: ...________________________ Tec3r Manual Version 1 11 Page 102 2017 Electromotive Inc Fig G 8 4 Nitrous timing retard wiring Fig G 8 5 Valet mode on off wiring Fig G 8 6 Data log on off wiring Figure G 8 7 Typical speed sensor wiring ...

Page 103: ...ng power LED turns red or does not turn on at all Either the Tec3 r is not receiving 12V power from pin G5 or the ECU is damaged Engine cranking below 400 rpm LED changes color from red to green every other revolution Good the crank sensor is working correctly LED does not change colors The crank sensor is not functioning properly Engine running over 400 rpm LED is steady green Good the crank trig...

Page 104: ...odes asterisked items are not available with the first software release 12 Crank Trigger Error 13 Cam Trigger Error 14 ECU Internal Failure 21 Throttle Position Sensor High 22 Throttle Position Sensor Low 23 Manifold Air Pressure Sensor High 24 Manifold Air Pressure Sensor Low 25 Coolant Temperature Sensor High 26 Coolant Temperature Sensor Low 31 Manifold Air Temperature Sensor High 32 Manifold A...

Page 105: ... set when the coolant temperature reading is outside its specified range Use this light to warn of coolant temperatures that are too high When this code is displayed the TEC will be using the CLT Failure Default value for coolant based calculations As such there will be no engine temperature input to the TEC s ECU Codes 31 32 Manifold Air Temperature Sensor High Low Works identically to codes 25 2...

Page 106: ... can be caused by incorrect IAC motor wiring or from a broken motor Code 62 Idle Speed Control Short to Battery or Open Load This code is set when the IAC driver has been shorted to voltage or the motor has been unplugged Code 63 Idle Speed Control Short to Ground The IAC driver has been shorted to ground H 2 a Reading the Trouble Codes When reading the trouble codes the first digit will operate t...

Page 107: ...the Idle Speed Control will only start working when the TPS reading is below the Fully Closed Throttle Voltage setting The Low Voltage Failure setting is made a few tenths of a volt lower than the actual closed throttle voltage 1 0V 0 8V This is done to display code 22 for throttle position sensors that have either rotated in their mount or have failed completely by outputting a lower than expecte...

Page 108: ...the data logging When wired appropriately the status light will display the following codes Light is Off No OBD is occurring Light is Flashing The OBD function is active and data is being recorded Light is On The OBD memory is full When the OBD memory is full turn the GPI switch off View the data log file with the WinTEC software by selecting the View Data log File button If you do not wish to vie...

Page 109: ... coils are turned off completely A fuel cut will also occur on this final stage if selected No engine will accelerate with a full fuel and spark cut Once the RPM falls below the Rev Limit setting the engine will function normally J 2 The Secondary Rev Limiter The Secondary Rev Limiter is activated when the MAT line White 20awg Pin G13 is connected to ground When activated it will engage the same t...

Page 110: ...n automatic transmission or supercharged applications this can be quite violent This is best used alone in naturally aspirated and turbo charged engines with a manual transmission K 3 FUEL CONTROL K 3 a No Fuel Cut This setting will never cut fuel This option will typically only be used with the 3 stage rev limit K 3 b Fuel Cut This setting will cut fuel completely on rev limit This setting will t...

Page 111: ...st the ear listen to the fuel injectors while cranking the engine A loud clicking sound should be heard If none of the injectors are clicking there is a wiring problem Check for 12volts on one injector terminal with the ignition turned on If 12volts is present on one terminal check the continuity between the other terminal and the injector channels of the Tec3 r If an oscilloscope is available loo...

Page 112: ...AC tuning problem o If the engine still surges it is likely an air fuel mixture problem If using an IAC motor and the engine runs rough at idle it is likely an air fuel mixture problem If the IAC motor does not seem to be functioning at all check the TPS closed throttle voltage This value must be ABOVE the actual TPS reading at closed throttle in order for the IAC motor to be engaged If the engine...

Page 113: ...can contribute to fuel problems under load Consult Section B 12 for EGO tuning recommendations N 1 c Spark Related Load Problems Problems related to spark when under load can be traced to three factors Tuning Secondary Ignition Failure and Improper Wiring Make sure the DFU s are wired correctly before proceeding o Tuning issues sometimes seem like spark related problems An engine that is detonatin...

Page 114: ... pull to ground outputs o Channels 1 2 have pulse width capability o Channels 1 4 on off activation for fan relays torque converters waste gates etc o 4 amps max total current draw for GPO1 4 1 amp per channel if all four are used Spare Output o Provides Datalog status light o 1 amp max current draw Fuel Pump Control o Low current pull to ground output for activation of fuel pump relay o Configura...

Page 115: ...erature Sensor MAT Uses NTC thermister manifold temperature sensor 2 wire o Knock Sensor KNK Provides ability to detect pre ignition Compatible with piezo style knock sensors 1 wire o Oxygen Sensor EGO Compatible with 1 3 and 4 wire oxygen sensors Angle Based Timing Control o Ultra high resolution triggering o Engine position known to within 1 8o Feedback Charging Control o Monitors each coil firi...

Page 116: ...nifold air temperature based advance adjustments Smooth idle advance control integrated w IAC settings Paired cylinder timing trims each coil has timing trim Individual cylinder timing trims for full sequential setups Ignition timing offsets for odd fire applications RPM based timing split for rotary application Supported Engine Management Configurations 20 000rpm capability for all engines 4 Stro...

Page 117: ...ate is approximately 25 samples per second o Total data logging time is dependent only on hard drive space Physical Dimensions Length 5 65 plus 0 65 for connectors 14 35 cm 1 65 cm Width 6 40 16 26 cm Height 1 67 4 24 cm Weight 1 8 lbs 82 kg Bolt Hole Pattern 3 50 x 6 03 use or 6mm fasteners Environmental Considerations Two Sealed 23 Pin AMP Connectors for Inputs Outputs Sealed High Amperage Delph...

Page 118: ... 220 Part Number reuse the stock sensor and mount in the stock location Kits with 205 designations use the 3 8 sensors while 200 kits use the sensors Chevrolet Small Block 8 Damper PN 200 72808 Chevrolet Small Block All Other Dampers PN 200 72707 Chevrolet LT1 PN 205 72828 Chevrolet Big Block all Dampers PN 200 72820 Ford Small Block 351W Based Engines PN 200 72819 Ford 4 6L 5 4L SOHC and DOHC PN ...

Page 119: ..._____________________________ Tec3r Manual Version 1 11 Page 119 2017 Electromotive Inc Appendix III Coil Polarity for Redundant Ignition Applications Figure X DFU Secondary Voltage Polarity for Redundant Ignition Applications ...

Page 120: ...____________________ E mail ____________________________________________ Wire Description Desired Cut Length from ECU 2 DFU A DFU B 4 6 cyl do NOT use DFU B Idle Air Control Motor Throttle Position Sensor Manifold Air Pressure Circle One 1 Bar 2 3 Bar Manifold Air Temperature Coolant Temperature Sensor Oxygen Sensor Knock Sensor Crank Sensor Cam Sensor Cyl 1 Injector Cyl 2 Injector Cyl 3 Injector ...

Page 121: ...3 X Y portion of the WinTEC name is the code that is used to tell what the software is made for The 3 means that the software is made for a Tec3 r The X digit states the FIRMWARE version on which the software works The Y digit states the PC SOFTWARE version The software version is displayed when the WinTEC software is opened on a computer Software versions are compatible with the firmware version ...

Page 122: ...r Tec3 r ECU as you normally would Following this step by step procedure should keep everything straightforward during the upgrade process Firmware Upgrade Procedure Care must be taken when installing different firmware versions on your Tec3 r ECU Follow the steps outlined below 1 Download the Firmware upgrade from the Electromotive website 2 Install the firmware upgrade on the PC that you will us...

Page 123: ... Input Red 22awg in 2 wire plus shield G11 Crank Cam Shield Bare 22awg shields both crank cam cables G12 CLT Input Gray 20awg G13 MAT Input White 20awg G14 TPS Input Dark Blue 20awg G15 MAP Input Dark Green 20awg G16 Gen Purpose Input 1 Orange w Black Stripe 20awg G17 Gen Purpose Input 2 Orange w Red Stripe 20awg G18 Gen Purpose Input 3 Orange w Green Stripe 20awg G19 Gen Purpose Input 4 Orange w ...

Page 124: ...8awg W10 Coil Wire Shield Bare 16awg shields coil channel outputs W11 Idle Air Control D Dark Blue w White Stripe 20awg W12 Idle Air Control C Dark Blue w Black Stripe 20awg W13 Idle Air Control B Dark Green w White Stripe 20awg W14 Idle Air Control A Dark Green w Black Stripe 20awg W15 Injector Channel 4 Yellow w Blue Stripe 18awg W16 Injector Channel 7 Light Blue w Green Stripe 18awg W17 Injecto...

Page 125: ...Tec3r Manual Version 1 9 G Page 125 2008 Electromotive Inc Appendix VIII Tec3 r Wiring Harness Layout ...

Page 126: ...Tec3r Manual Version 1 9 G Page 126 2008 Electromotive Inc Appendix IX Tec3 r Power Harness Schematic ...

Page 127: ... used to add fuel when an engine is cold This feature is the electrical equivalent of the choke plate on a carburetor Coolant Temperature Sensor A device that measures the coolant temperature of an engine Crank Sensor A device that can read a crank trigger wheel and output a voltage signal that can be used by an engine management system Crank Trigger A device used to measure the crankshaft positio...

Page 128: ...sed to meter air into an engine at idle Air from the outside of the intake manifold is regulated into the intake plenum by the IAC motor Ignition Timing The amount of degrees before Top Dead Center that a spark plug fires IOT Injector Offset Time This number is normally not used with Tec3 r systems but was used in earlier TEC 1 and TEC 2 systems See POT Knock Sensor A device used to measure detona...

Page 129: ...e will carry no excess air or fuel Retard As applied to ignition timing retarding the timing refers to firing the spark plug comparatively later Rich Mixture An air fuel mixture that carries more fuel than the stoichiometric air fuel ratio Rising Rate Fuel Pressure Regulator A Fuel Pressure Regulator that is adjustable to provide a non 1 to 1 relationship between manifold pressure and fuel pressur...

Page 130: ... throttle per cylinder setups since these engines have poor MAP signals at idle and part throttle Trigger Wheel A device attached to the crankshaft that provides a moving reference of speed and position of an engine s crankshaft UAP User Adjustable Pulse Width formerly Time on for One Gama This number defines the slope of the raw fuel curve When POT is zero the raw fuel curve will have zero pulse ...

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