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Appendix VII. TECgt Wiring Harness Layout

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TECgt Manual Version 2.0

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Summary of Contents for TECgt

Page 1: ... Synchronization 17 A 4 g TDC Tooth Setup Software Adjustment Parameters 19 A 5 Wiring the TECgt 21 A 5 a TECgt Main Power Connections 21 A 5 b Power Harness Installation 21 A 5 c Wiring the Fuel Injectors 23 A 5 d Wiring the DFU s 24 A 5 e Wiring the Engine Sensors 24 B Tuning Guide 25 Introduction 25 B 1 Adjusting the Timing Advance 25 B 2 Establishing Proper Starting Enrichments 26 B 3 Getting ...

Page 2: ...7 C 6 Rotary Engines 47 C 7 Dual Plug Engines 48 C 8 Spark Plug Wire Selection 48 C 9 Spark Plug Selection 49 D Fuel Injector Configurations 50 D 1 High vs Low Impedance Injectors 50 D 2 Injector Firing Schemes 52 D 2 a Staged Injection 52 D 2 b Throttle Body Injection TBI 53 D 2 c Phase Sequential Injection 54 D 2 d Full Sequential Injection 55 D 2 e Rotary Engine Injection 56 D 3 Injector Wiring...

Page 3: ...neral Purpose Input GPI Functions 98 H 1 b Wiring the GPI s 99 H 1 c GP I O Wiring Harness Layout 100 H 2 General Purpose Output GPO functions 101 H 2 a Available GPO Functions 101 H 2 b Wiring the GPO s 102 I Diagnostics 104 I 1 Trouble Codes from the LED s Mounted on the TECgt 104 I 2 Trouble Codes from the Check Engine Output 105 Trouble Code Descriptions 106 I 2 a Using the Trouble Codes 107 I...

Page 4: ...uning Features 116 Supported Engine Management Configurations 117 Data logging Features 117 Physical Dimensions 117 Environmental Considerations 118 PC Requirements 118 Appendix II Electromotive Trigger Wheel Availability 118 Appendix III Secondary Coil Polarity for Redundant Ignition Applications 120 Appendix IV TECgt Custom Harness Specification Sheet 121 Appendix V TECgt Custom Harness Spec She...

Page 5: ... The customer must have the serial number and original proof of purchase available Electromotive s Technical Support staff will attempt to help you correct any minor issues that might be causing the problem If we are unable to fix the issue to your satisfaction a return merchandise authorization RMA number will be issued Under our Warranty program Electromotive will typically ship the customer a r...

Page 6: ...eyond the description on the face of this document 7 There are no warranties of fitness for a particular purpose except as stated on the face of this Electromotive Product Warranty 8 Any and all oral warranties are excluded and will not be honored 9 Consequential damages will not be covered by this warranty How to Obtain Warranty Service 1 For information on warranty service contact your Electromo...

Page 7: ...ER PROPERTY CAUSED BY ANY DEFECTS IN THE PRODUCT DAMAGES BASED UPON INCONVENIENCE LOSS OF USE OF THE PRODUCT LOSS OF TIME LOSS OF PROFITS LOSS OF BUSINESS OPPURTUNITY LOSS OF GOODWILL INTERFERENCE WITH BUSINESS RELATIONSHIPS OR OTHER COMMERCIAL LOSS EVEN IF ADVISED OF THEIR POSSIBILITY OF SUCH DAMAGES 2 ANY OTHER DAMAGES WHETHER INCIDENTAL CONSEQUENTIAL OR OTHERWISE 3 ANY CLAIM AGAINST THE CUSTOME...

Page 8: ...rough the use of a cam position sensor but sequential operation is not available for the 8 cylinder engine option on the TECgt There are Nine dedicated user definable general purpose inputs outputs GP I O s included with the TECgt to make your high tech engine setup a snap The GP I O s can be used to control anything from wastegates for turbo setups to simple electric radiator or intercooler fans ...

Page 9: ... 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 400kPa Choose the appropriate sensor for the application and you are done Ignition Advance Control Once the MAP sensor and crank sensor are installed the TECgt has inputs for RPM and load U...

Page 10: ...S 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 the software is tuned the engine will run quite well However to further refine the control of the engine a few additional features are included The idle air control motor IAC is used to meter air into the engine at idle This he...

Page 11: ... 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 TECgt might get hot under prolonged high rpm operation As long as air is moving around the ECU there is no risk of damage to the TECgt just be careful not to burn yourself on the unit Secure ...

Page 12: ... a Crankshaft Trigger Installation for 60 2 Tooth Wheel ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 12 2008 Electromotive Inc For a crankshaft mounted trigger wheel setup an appropriate place must be found to mount the wheel and trigger Typically the easiest place to mount a trigger wheel is on the harmonic damper or pulley I...

Page 13: ...ble A 4 1 Crank Trigger Specifications Trigger Wheel Size Air Gap Maximum Out of Round 2 5 0 025 max 0 002 3 5 0 035 max 0 003 5 0 050 max 0 005 6 0 060 max 0 006 7 25 0 070 max 0 007 8 25 0 080 max 0 008 A 4 b Magnetic Crank Sensor Installation When installing the magnetic sensor an appropriate bracket must be made to aim the sensor at the trigger wheel A good starting point for a magnetic sensor...

Page 14: ...vent that the sensor is not aligned correctly the WinTec software can be made to compensate by manipulating the Tooth Offset Parameter as outlined in Section A 4 g of this manual IMPORTANT NOTE Make sure that the Mag Sensor harness is NOT routed near battery cables or other high current leads or devices such as cooling fans starter or alternator Coil wires injector leads also should be avoided Tab...

Page 15: ...ions 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 the engine block and it should point at a line on the crankshaft pulley or trigger wheel when the...

Page 16: ...______________________________________________________________________________________ TECgt Manual Version 2 0 Page 16 2008 Electromotive Inc ...

Page 17: ...ite 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 the number 10 was set for the Tooth Offset the mechanical timing would be ADVANCED by 6 degrees 6 d...

Page 18: ...nal from the sensor is going into terminal G23 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 G23 Keep in mind that when adapting an OEM cam trigger setup to a TECgt the wheel may need to be rotated to place the rising edge in the appropriate degree window for the TECgt Figure A 4 8 Proper cam ...

Page 19: ... Trigger Wheel TDC that is LESS than 11 Each tooth less than 11 represents 6 degrees of advance that is added to 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 too...

Page 20: ...nstead of the 11th Solution Enter in the number 11 to the TDC Tooth Alignment Parameter The timing 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 Figure A 4 9 TDC to...

Page 21: ... ground wire is 10awg The reason for the larger thicker size of the wire is that the ECU is mainly in charge of switching the GROUNDS not the 12 Volt power As an example the fuel injector and coil outputs are all pull to grounds The 12 Volt power is supplied on a harness that is external to the TECgt The red 12awg wire in position A on the 2 position connector should be connected to Switched 12 Vo...

Page 22: ...ors EGO sensor heater and Fuel Pump The switched voltage input is used to turn on the TECgt ECU and should be wired to a 12Volt source that is activated with the ignition key Purple White Stripe 16awg Injector Power runs to all injectors Red White Stripe DFU Power pin D on DFU s Green 16awg Fuel Pump Positive and EGO Sensor Heater Positive Yellow 18awg Switched 12 Volt Input for TECgt turn on requ...

Page 23: ... To summarize the main wiring points from Section D Injector drivers 1 4 use a Yellow base color The stripe color indicates the channel Black Red Green Blue Channel 1 2 3 4 Injector drivers 5 6 use a Light Blue base color The stripe color indicates the channel Black Red Channel 1 2 All injectors need a 12Volt connection on one terminal and a TECgt Injector Output on the other terminal ____________...

Page 24: ...econd 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 A 5 e Wiring the Engine Sensors The TECgt harness has provisions to connect all of the engine devices outlined in Sections G and F of this manual Refer t...

Page 25: ...ion advance An engine with too much timing will detonate regardless of how much fuel is thrown at it An engine with too little timing will 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 ...

Page 26: ...tart it is most likely not getting enough fuel For engines that will not start when cold look to SE0 the Temperature Based One Second Starting Enrichment If the engine is flooding out during cold starting decrease this number If this number is already zeroed out and the engine is flooding look to SE1 the Constant One Second Starting Enrichment If SE1 is too high the engine will flood out during co...

Page 27: ...e IOT number until the engine stops misfiring Timing also plays a big role in idle quality Most piston engines idle well with at least 10 degrees of advance at idle Rotary engines require less timing at idle try zero degrees If an engine is not responding well to IOT adjustments and adjusting the timing does not help either make sure the coils are wired correctly Also check that the spark plug wir...

Page 28: ...now you are ready to jump into that big table with all the numbers to fine tune your engine Be forewarned however that most engines even throttle per cylinder setups can run quite well with 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 IOT and or TOG UAP settings Radically cammed h...

Page 29: ... reading and therefore smooth out the pulse width fluctuation To accomplish this enter a small amount of Blend Percentage 25 50 near the idle point Raise the TPS Offset Voltage to increase the pulse width to the desired level Lower the TPS Offset Voltage if the engine is running too rich The pulse width should stabilize once the proper settings are established B 7 Tuning for Cold Engines and Cold ...

Page 30: ... volts at idle the TPS Voltage at Closed Throttle will need to be set to 1 55 volts in the software in order for the IAC function to turn on To begin tuning the IAC motor parameters turn the engine OFF Define your desired idle speed as a function of coolant temperature This is the target speed that the IAC motor will attempt to reach Start the engine and watch the idle speed and coolant temperatur...

Page 31: ...ally begin to open to prevent idle droop or a stall Below are some graphic examples of how these parts work B 8 c Getting Started Attempt 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 o...

Page 32: ...ropping slowly as in example A in Figure 2 the Rate of Change sensitivity 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 a...

Page 33: ...h 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 prevent this If the engine falls below the idle target and almost stalls a larger reset value will help B 8 f Wiring a 2 wire IAC A 2 wire IAC should be wired as shown in Figure 3 The diode shown is required on all idle motors ...

Page 34: ...m Retard Allowed parameter is met It is important to realize that the TECgt will NEVER add ignition timing over and above the value set in the Ignition Advance Table when the Knock Control is adding advance back to the engine B 10 Using the Injector Trims To compensate for fuel injector variations or cylinder to cylinder inconsistencies advanced users of the TECgt may wish to adjust the fuel deliv...

Page 35: ...ing and including 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 tu...

Page 36: ... connector Here is the pin out Terminal A Ground Pulse for Coil A Terminal B Ground Pulse for Coil B Terminal C Unused Terminal D Full Time 12 Volt Source 9 amps On a standard inline 4 cylinder four stroke application this DFU will be used On dual plug 4 cylinders two of these DFU s will be used Refer to Figure C 1 2 for terminal locations 3 Coil DFU s Part Number 070 33600 The 3 coil DFU s utiliz...

Page 37: ...routed in a separate shielded cable housing These are all 9amp pull to ground outputs that is they create a ground path every time a coil charges When the coils fire the outputs float with no connection to ground or power If the wires need to be spliced 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 ...

Page 38: ...he letter is 1 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 A1 you can connect your spark plug wires for the respective cylinders to EITHER tower Figure C 2 1 Coil notation Fi...

Page 39: ...nd 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 ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 39 2008 Electromotive Inc ...

Page 40: ...chosen in the software setup coil channels A and B will be fired alternately every 180o of crankshaft rotation The firing goes A 180 o B 180 o A 180 o B etc When a 3 or 6 cylinder engine is chosen in the setup coils A B and C will fire every 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 Coil...

Page 41: ... 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 Firing Order 1 2 3 4 Coil Firing Order A1 A2 B1 B2 Engine Fi...

Page 42: ...ent injection and ignition firing patterns that are available on the TECgt 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 C 4 a Injector and Coil Firing Patterns for EVEN FIRE Engi...

Page 43: ... 4 c Injector and Coil Firing Patterns for 2 CYCLE Engines C 4 d Injector and Coil Firing Patterns for ODD FIRE Engines ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 43 2008 Electromotive Inc ...

Page 44: ...r 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 ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 44 2008 Electromotive Inc ...

Page 45: ... and trailing plugs Leading plugs will go to TECgt gray connector pin G25 white wire first rotor leading TECgt pin G24 red wire second rotor leading Trailing plugs will go to TECgt pin G1 black wire first rotor trailing TECgt pin G2 red wire second rotor trailing Refer to the wiring diagram layout for signal wire hookup ______________________________________________________________________________...

Page 46: ... Cadillac Northstar 1 2 7 3 4 5 6 8 1 4 2 5 7 6 3 8 Audi 4 2 V8 Mercedes Benz 1 5 4 8 6 3 7 2 1 6 5 3 4 7 8 2 Coil 6 cylinder 3 coil 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...

Page 47: ...TDC A 45o TDC B For the TDC Setup Set the DFU 1 Trigger Wheel TDC to the 11th tooth Set the DFU 2 Trigger Wheel TDC to the 18th tooth In the Dual Plug Timing Split set the values to 3 degrees for all RPM s Wire DFU 1 Coil A1 output to pin A of a 4 cylinder DFU This will fire cylinder A s spark plug Wire DFU 2 Coil A2 output to pin B not pin C of a 4 cylinder DFU This will fire cylinder B s spark p...

Page 48: ...fferent areas of the cylinder at different times resulting in an uneven flame propagation Consequently it is recommended that most dual plug applications NOT use the Dual Plug Timing Split C 8 Spark Plug Wire Selection The TECgt outputs an extremely high energy charge for the ignition coils Resistor carbon core wires work best with this charging method since they absorb electrical noise generated ...

Page 49: ...an spark plug wires Most spark plugs exhibit failure when exposed to a large load Failure usually consists of either intermittent sparking or arc over Arc over is when the spark occurs between the spark plug wire and the engine block instead of at the plug tip Arc over is exacerbated by the use of low quality wires or wires that have cuts in the insulation The load at which a spark plug fails is d...

Page 50: ... be the 1 2ohm injectors found in throttle body injection TBI setups These injectors should be wired with only one injector per driver in the 4amp mode High impedance injectors can be used in place of low impedance injectors at any time as a rule use the same logic to adjust your outputs When the injectors are wired such that the circuit will flow more than 5 amps the TECgt fires them in peak and ...

Page 51: ...r is used on a channel see Figure D 1 1 When two injectors are used on a channel the current flow through each individual injector will be half of the flow through the injector circuit When three injectors are used on a channel the current flow through each individual injector will be one third of the flow through the injector circuit however more than 2 injectors per driver should never be necess...

Page 52: ...motive 60 2 tooth trigger wheel on the crankshaft No cam sensor is required For an outline of the various firing options available with the TECgt see the tables in Section C 3 Regardless of engine firing order the TECgt fires its injector output channels in numerical order 1 2 3 4 5 6 Injector channels must be wired appropriately to match an engine s firing order If an injection mode does not use ...

Page 53: ...eously Channel A Drivers 1 2 The other two injectors should be fired simultaneously as well but phased 180o Channel B Drivers 3 4 Drivers 5 and 6 would then be left over for staged injectors if any This firing option could also be used with a rail fire setup on a V8 though rail fire is not a recommended practice with the current level of Technology See Figure D 2 1 for a TBI wiring schematic Figur...

Page 54: ...nder 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 sequential injector wiring schematic Figure D 2 2 8 cylinder phase sequential injector wiring for firing order 1 8 4 3 6 5 7 2...

Page 55: ...t 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 reference since their engine cycles occur in only one revolution Consequently rotaries and 2 strokes...

Page 56: ...th 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 Injector Pulse Width Table in the software Figure D 2 4 shows the necessary wiring for a rotary injection application Figure D 2 4 Rotary ...

Page 57: ...od on a carburetor That is the TOG has a large effect on the high load injector pulsewidths while the IOT has a large effect on the light load injector pulsewidths TOG dynamically manipulates the raw fuel curve as a function of load while IOT 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 TOG and IOT correlat...

Page 58: ...hat 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 TECgt software has a Volumetric Efficiency VE table This table allows corrections to the raw fuel curve at all rpm and load points This...

Page 59: ... cycle injection schemes i e full sequential Note that the result from these equations is in SECONDS not milliseconds Theoretical TOG once per rev injection Calculated Injector Size Actual Injector Size 60 Max Engine RPM Injector Recovery Time IOT Theoretical TOG once per engine cycle injection Calculated Injector Size Actual Injector Size 120 Max Engine RPM Injector Recovery Time IOT Where Your I...

Page 60: ...ge kPa relationship 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 62 118 174 60 3 00 67 128 190 65 3 25 72 138 206 70 3 50 77 148 222 75 3 75 81 158 237 80 4 00 86 168 253 85 4 25 91 178 2...

Page 61: ...s Theoretical TOG 7 04ms Scaled TOG 7 04 4 5 Scaled TOG 8 80ms The TECgt generates a straight line for the pulse width curve from the TOG value at 5 Volts on the MAP sensor to zero pulse width at 0 Volts on the MAP sensor See Figure D 4 1 for a graphical representation of this Figure D 4 1 Effect of TOG on injector pulse width Note TOG 7ms IOT 0ms __________________________________________________...

Page 62: ...d conditions Due to the fact that IOT is added or subtracted to the fuel curve at all points the TOG 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 TOG of 7 milliseconds and a IOT of 0 milliseconds it would be necessary to decrease the TOG by 1ms if the IOT was increased by 1ms in order for the full ...

Page 63: ...l curve Changing TOG by itself results in adding or subtracting a percentage to the entire fuel curve Changing TOG and IOT together affects the slope of the fuel curve Select TOG and IOT such that the Volumetric Efficiency table corrections are at a minimum See next section for more details on this ______________________________________________________________________________________ TECgt Manual ...

Page 64: ...te view mode will display 100 when the fuel curve is unmodified A number less than 100 will lean out the fuel curve while a number greater than 100 will richen up the fuel curve The Pulse width view mode shows the injector pulse width values that the TECgt will use throughout the operating range The numbers in the Duty Cycle view mode should not exceed the maximum value for an RPM when taking the ...

Page 65: ...ons When the TECgt software is set up to use the TPS Blend function it takes the reading from the TPS and the MAP and combines them into one number This number is then used as the MAP sensor reading Consequently when TPS MAP Blend is being used the displayed MAP sensor value when the engine is running will not be the output of the MAP sensor it will be the Modified MAP Value from the TPS MAP Blend...

Page 66: ...es into the Blend routine This is useful for placing the Modified MAP Value at the desired point Generally this parameter is used when the TPS output is not at the desired point In practice if an engine needs more fuel the TPS Offset should be increased If it needs less fuel the TPS Offset should be decreased TPS Offset is not used for anything other than the TPS Blend calculation i e it will not ...

Page 67: ...haust For gasoline this number is 14 64 parts air to 1 part fuel by mass Thus for gasoline the stoichiometric air fuel ratio is 14 64 1 Different fuels have radically different stoichiometric ratios Lambda The ratio of actual air fuel ratio to stoichiometric air fuel ratio For a gasoline engine running at 14 64 1 lambda is 14 64 14 64 1 For an engine running at 12 5 1 lambda is 12 5 14 64 0 85 Thu...

Page 68: ...r to be engaged This parameter is used for exhaust systems that cannot create enough heat at idle for the EGO sensor to be accurate A few things to remember Standard oxygen sensors are designed to provide a switch point for stoichiometric air fuel operation They are NOT designed to be able to tell you the exact air fuel ratio when you are outside the stoichiometric amount 14 64 1 AFR Oxygen sensor...

Page 69: ...e engine is operating substantially above the thermostat value the coolant temperature enrichment can be used to add fuel to help cool down the engine If a cold engine is running rough misfiring but not blowing black smoke from the exhaust the coolant temperature enrichment likely needs to be increased If a cold engine is blowing black smoke out the exhaust the coolant temperature enrichments shou...

Page 70: ...eliminates one more variable from the tuning process on a fully warmed up engine Please note that the MAT enrichment increases at very high MAT readings in Figure D 4 10 This is a safety precaution that is in place to reduce the tendency for an engine to detonate with excessive air temperatures Turbocharged engines should definitely use the high air temperature enrichments Naturally aspirated engi...

Page 71: ...enrichment is added when the Acceleration Mode is engaged and the coolant temperature is 40C The enrichment ramps down to zero once the coolant temperature has reached 80C This enrichment only adds fuel for a period of 1 second once the Acceleration Mode is engaged The enrichment value is added to the VE Absolute number Use this parameter only after ACE 3 has been established on a fully warmed up ...

Page 72: ...ed at 40C coolant temperature The enrichment ramps down linearly to zero when the coolant reaches 80C The enrichment value entered here is added to the VE Absolute value Constant One Second Starting Enrichment SE 1 This enrichment adds to the injector pulse width for a period of one second after the TECgt detecs engine cranking The enrichment value entered here is added to the VE Absolute value Fi...

Page 73: ...s to add or subtract to calculated open time based on the current battery voltage The compensation value is specified in microseconds per volt When the voltage is at 10 volts 2 volts low and value in the software voltage compensation specifies 65 microseconds per volt the value added to the final injector pulse time will be 130 microseconds 65 microseconds per volt x 2 volts low 1 ms 1000 microsec...

Page 74: ...s 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 This value is an absolute reading so when the engine is operating at 100 TFP it is running at the pulse width defined by the raw fuel curve with no other enrichments When the TFP value is less than 100 the fuel injector ...

Page 75: ... 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 of the pressure at which the flow rating was obtained must be realized As an example an injector that was rated at 40 lbs hr at 43 5psi pr...

Page 76: ...w 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 Injector Size The above calculation assumes an injection scenario in which an injector is held open for a maximum of one engine revolution typical phase sequential setup For other...

Page 77: ...be at least 1 0ms is practice Consequently the values given in Table E 1 1 should have 1 0ms subtracted from them to determine the actual pulse width peak Time for One Revolution vs RPM 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 RPM Time milliseconds Fig...

Page 78: ... 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 0 8 0 15500 3 9 7 7 16000 3 8 7 5 16500 3 6 7 3 17000 3 5 7 1 17500 3 4 6 9 18000 3 3 6 7 18500 3 2 6 5 19000 3 2 6 3 19500 3 ...

Page 79: ...an adjustable fuel pressure regulator The reason for this is quite simple the TECgt 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 re...

Page 80: ...ings to make your search as easy as possible F TECgt Output Functions and Wiring F 1 Idle Air Control Motor The Idle Air Control IAC Motor is responsible for maintaining a smooth engine idle Using the WinTec software the IAC motor can be made to increase idle speeds during cold engine operation or air conditioner turn on The IAC motor control built into the TECgt can be used with four wire stepper...

Page 81: ...iversal PN 325 81112 Ford PN 325 81114 This allows the installation of rubber hose onto the housing One hose can then be run to the intake plenum with the other hose going to filtered air With all Idle Air Control Motor setups always make sure that the engine is receiving filtered air from the air bypass passages The IAC will not be activated unless the TPS voltage is BELOW the TPS Closed Throttle...

Page 82: ...meter 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 Figure F 2 1 Typical tachometer wiring 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 directly See Figure F 3 1 ...

Page 83: ... cause an excessive amount of current to be drawn through the circuit and may result in damage to your TECgt Figure F 3 1 Fuel pump relay wiring ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 83 2008 Electromotive Inc ...

Page 84: ...ient atmospheric pressure When we say that an engine is running 15psi 103kPa of boost it means that the intake manifold is seeing 15psi of positive pressure Since standard atmospheric pressure is approximately 14 7psi 101 3kPa the absolute manifold pressure for this engine would be 29 7psi 205kPa or about 2 Bar Thus a 2 Bar sensor is necessary for this engine Refer to the formula below if you are ...

Page 85: ...0 5 61 psi 310 30 3 psi 150 7 06 psi 320 31 7 psi 160 8 51 psi 330 33 2 psi MAP Sensor Data To check that the MAP sensor is working correctly and to check for the MAP sensor Bar number 1 2 or 3 Bar it is necessary to know the output voltage from the sensor as a function of pressure With the TECgt turned on but the engine NOT running the MAP sensors will output the voltage for atmospheric pressure ...

Page 86: ...ure G 1 2 1 Bar MAP sensor output voltage 2 Bar MAP Sensor 0 20 40 60 80 100 120 140 160 180 200 220 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 Output Voltage Absolute Pressure kPa Figure G 1 3 2 Bar MAP sensor output voltage ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 86 2008 Electromotive Inc ...

Page 87: ...ition sensor should have a resistance of roughly 10kΩ measured across the 5V and Ground terminals To determine the pin out of an unknown TPS follow the instructions below you will need an ohmmeter 1 With the TPS in the closed throttle position measure the resistance of the following three positions referenced to Figure G 2 1 A B A C and B C 2 With the TPS in the opened throttle position measure th...

Page 88: ...reading will result Fortunately most TPS s are of the 10kΩ variety Fig G 2 2 Potentiometer functionality for closed and open throttle conditions TPS Functionality and Wiring The TPS allows the TECgt to provide fuel enrichments for various throttle movement situations like an accelerator pump on a carburetor For high rpm closed throttle situations like deceleration or engine braking it can be used ...

Page 89: ...he GM style 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 en...

Page 90: ...r CLT and MAT sensor Fig G 3 2 Coolant temperature sensor wiring Wiring the Coolant temperature sensor is straightforward See Figure G 3 2 for details Since the sensor is just a resistor wires A and B can be switched with no adverse results To test for faulty coolant temperature sensors simply measure the resistance across terminals A and B with an ohmmeter Match the resistance of the sensor to th...

Page 91: ...or details Install the MAT sensor in an area that is representative of the air temperature entering the engine If it is mounted directly in the intake manifold particularly in aluminum and iron manifolds it may be getting a slightly warmer reading than the actual air temperature due to the conduction of heat through the manifold and the radiation of heat onto the sensor tip It is sometimes better ...

Page 92: ...g the sensor The EGO sensor needs plenty of heat to operate properly Mild steel threaded bungs for the EGO sensor are available from Electromotive under PN 315 72111 When installing the sensor take care not to run the wires on the exhaust This will obviously melt the wires once exhaust temperatures rise Wiring the Sensor Virtually all 4 wire EGO sensors on the market are compatible with the TECgt ...

Page 93: ...uracies when away from the stoichiometric AFR is simple EGO sensors are only designed to provide a switch point at the stoichiometric AFR The voltage goes from a low reading approaching 0 volts when lean to a high reading approaching 1 volt when rich Note that the TECgt software multiplies the EGO input voltage by a factor of 5 when displayed on the engine monitor and datalog screens Thus the maxi...

Page 94: ...t do not have a built in heater or ground reference Wire the sensor as follows Connect the wire from the EGO sensor to the EGO line on the TECgt this is the Purple 20awg wire in the TECgt Harness Pin G33 Connect the EGO line on the TECgt this is the tan 20awg wire going to Pin G32 to the Sensor Ground line this is black w white stripe 18awg wire going to Pin G6 One wire sensors are typically not a...

Page 95: ...tal monitor screen the monitor screen at the bottom of the window will change from EGO Sensor to Wideband Sensor On the analog monitor screen the label under the AFR bar will change from EGO Sensor to Wideband Sensor 2 The TECgt AFR changes but it doesn t match my controller s display unit The analog voltage from the wideband controller can be read on the analog monitor screen in the box labeled W...

Page 96: ...int of spontaneous ignition This results in a pressure shock wave that is akin to beating the upward moving cylinder with a downward moving hammer It also results in a noise resonance through the engine block just as a noise would resonate through the block if you hit the piston with a hammer Piston ring and rod bearing damage is typical when an engine is detonating too much To obtain an accurate ...

Page 97: ... dedicated GPI channel 2 input only and also one dedicated GPO channel 1 output only The remaining seven channels 3 9 9 GP I O s total can be configured to be either Input or Output A few facts that should be remembered when using the GP I O s All the GPO s regardless of their function are pull to ground when they are activated That is they create a connection to ground when turned on A MAXIMUM of...

Page 98: ...peed limit on the vehicle The rev limiter will be activated when the desired speed is reached See Figure H 1 5 for wiring diagram Nitrous Retard Provides a set amount of ignition timing retard when nitrous is activated When used with the Electromotive 4 stage timing retard module the NOS Retard should be set to 30o consult the 4 Stage Nitrous Retard Instructions for wiring When used with a potenti...

Page 99: ... of time before ignition can be cut again Finally there is an option to pull to 12v activate high or pull to 0v activate low Additionally the line must be released before the channel can be activated again H 1 b Wiring the GPI s Fig H 1 1 Potentiometer wiring for Fuel Ignition and GP I O Trim Inputs Fig H 1 2 Air conditioner idle speed increase wiring Fig H 1 3 Alternate air conditioner idle speed...

Page 100: ...l speed sensor wiring H 1 c GP I O Wiring Harness Layout GP O 1 Terminal G10 White w Black Stripe 18awg GP I 2 Terminal G20 Orange w Blue Stripe 18awg ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 100 2008 Electromotive Inc ...

Page 101: ...pin 86 would be wired to 12 volts and the relay would be switching the power or the ground to the fan with pins 30 and 87 A few facts that must be remembered when using a channel for a GP I O function All the GP I O s regardless of their function are pull to ground outputs when they are activated That is they create a connection to ground when turned on A MAXIMUM of 1 amp may be drawn from each GP...

Page 102: ...Custom and Custom or Custom and uses both ranges RPM and MAP values It requires RPM below which GPO comes on and MAP minimum turn on value Custom or functions only inside either RPM or MAP values set OR both H 2 b Wiring the GPO s This section covers the wiring that is necessary to use the various GP I O controls With one exception A C turn off the relays depicted in the schematics are all simple ...

Page 103: ...her 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 ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 103 2008 Electromotive Inc ...

Page 104: ...ECgt is operating Here are the readings from the LED s Turn ignition key on but do not start engine Upper LED goes steady green Good the processors are getting power Upper LED does not turn on at all Either the TECgt is not receiving 12V power from pin A or the ECU has an issue Engine cranking below 400 rpm Lower LED changes color from red to green every other revolution Good the crank sensor is w...

Page 105: ... are related to the engine sensors If the check engine output wire is connected to a light bulb it will display a sequence of flashes depending on the problem The diagnostic codes are arranged such that there are two digits for each code The check engine light will give long duration flashes for the first digit of the code and short duration flashes for the second digit See Figure H 2 1 for a grap...

Page 106: ...range This can be useful for a boosted application to trigger a check engine signal when an over boost situation has occurred Alternately it can be used to detect a short in the wires When this code is displayed the TECgt will be using the MAP Failure Default value for MAP calculations As such there will be no load input to the TECgt s ECU and the computer will enter into a limp home mode Codes 25...

Page 107: ...lt Code 58 Tachometer Output Failure The tachometer output has seen an over current situation or is shorted to power or ground Code 61 Idle Speed Control Thermal Shutdown The driver for the idle speed motor has been overheated The 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...

Page 108: ...e Default Value is useful for applications using the TPS MAP Blend feature because it defines a fixed amount of TPS to blend with the MAP sensor during a TPS failure I 2 b Wiring the Check Engine Light The check engine light output gives a pull to ground for a light bulb Terminal 2 on the TECgt s gray connector is the pink wire for the check engine light The circuit should not be allowed to flow m...

Page 109: ...the GP I O switch back on and the previous file will be erased This is an important fact whenever the GP I O switch is turned off the data will remain in the Tec s memory even if the engine is shut off When the switch is turned back on the previous data will ALWAYS be erased There is the option to engage the OBD function only above a specified RPM point When this is chosen the OBD will be engaged ...

Page 110: ... be set slightly higher than zero volts to counteract this effect This will cause the MAT reading to go to the Failure Default Value The easiest way to wire the Secondary Rev Limiter is to use a standard 4 position relay Using the relay Pins 30 and 87 will short to each other when 86 goes to 12 volts Relay Pin 30 MAT Sensor Signal White 20awg TECgt Pin 21 from the connector AND from the TECgt Rela...

Page 111: ...en the RPMs are above the rev limit and below the delay RPM the number of cylinder events skipped will stay the same If the revs drop below the rev limit and remain above the hysteresis value the number of injector events will be increased This will help to maintain a smooth consistent RPM when holding against the rev limiter M Troubleshooting Troubleshooting an engine management system is actuall...

Page 112: ...hat are wet with fuel o Too little starting enrichment will keep an engine from starting and running properly o A coolant temperature enrichment that is too low or too high will cause an engine to have cold starting problems M 2 c Spark Related Starting Problems The crank sensor is the first thing to check when an engine will not start o Crank the engine The LED on the TECgt ECU should flash red g...

Page 113: ... Related Idling Problems Check for stuck injectors and fuel pressure problems if the idling characteristics cannot be improved through tuning see Section M 1 b on Fuel Related Starting Problems to see if the fuel injectors are functioning properly If the engine is blowing black smoke out the exhaust during idling the mixture is too rich Decrease the IOT or decrease the VE Table values at the probl...

Page 114: ...enough fuel An engine that is not performing well may have too little timing or too much timing Try adding timing until detonation is detected then back off a bit Rotary engines do not make a loud pinging sound so do not attempt to run a rotary into detonation o Secondary Ignition failure is often blamed for ignition problems under load The secondary ignition includes the spark plugs and spark plu...

Page 115: ...lable for high voltage triggered tachometers Check Engine Light Output o Pull to ground output for instrument panel light 1 amp max current draw ECU Diagnostic LED o Warns of crank trigger problems o Multi code diagnostics INPUTS General Purpose Inputs or Outputs GP I O s o 9 channels low amp pull to ground I O s o Channel 2 may be used for speed inputs magnetic optical and hall effect sensors are...

Page 116: ...adjustment increments o 1 4o spark timing accuracy worst case Fuel Map o Two numbers define slope of fuel curve o 16 x 16 tables of RPM vs MAP for volumetric efficiency corrections o 65535 point interpolation between data points o 1 adjustment increments up to 0 001millisecond resolution Load Sensing Three Options o MAP sensor based o TPS MAP based using TPS MAP Blend feature o TPS Based using 100...

Page 117: ...yl o Phase sequential and TBI injection on all applications o Staged injection available for most setups o Waste spark ignition control for all applications 2 Stroke o 1 2 3 4 cylinder engines o Full sequential fuel injection or TBI o Staged injection available for all setups o Coil per plug for all applications Rotary o 1 2 rotor engines o Full sequential fuel injection w staged injection or TBI ...

Page 118: ...Outer Diameter PN 230 72650 3 5 Outer Diameter PN 230 72635 2 5 OD 1 5 Center Hole PN 230 72625 2 375 OD 0 25 center Hole PN 230 72624 Universal 120 4 Tooth Wheels Cam Trigger Wheels 2 75 Outer Diameter PN 230 72128 3 25 Outer Diameter PN 230 72133 Custom Bolt On Trigger Wheel Kits All custom kits include everything necessary to install a trigger setup Kits with a 220 Part Number reuse the stock s...

Page 119: ... generation SOHC DOHC PN 200 73001 VW Type 1 PN 200 72401 Jeep 4 2 Liter PN 205 72780 2nd Generation MR2 Turbo NA Coming Soon Please note that most common engines have trigger kits made by our various dealers Porsche Mazda Toyota Acura Honda and Subaru applications are currently covered extensively ______________________________________________________________________________________ TECgt Manual ...

Page 120: ...ndant Ignition Applications Figure X DFU Secondary Voltage Polarity for Redundant Ignition Applications ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 120 2008 Electromotive Inc ...

Page 121: ...m Harness Specification Sheet Note All unspecified wire lengths are 6 ft from ECU ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 121 2008 Electromotive Inc ...

Page 122: ... _____________________________________________________ Telephone __________________________________________________ E mail _______________________________________________________ ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 122 2008 Electromotive Inc ...

Page 123: ...4 1 0 software version WILL NOT run with a 4 0 0 firmware version Always use the PC SOFTWARE version for which the FIRMWARE is designed The X digit of the PC software must always match the X digit of the Firmware Firmware Coding Information The Firmware version is displayed in the Engine Monitor Screen The firmware code is 4 X 0 T3 The X digit must match the X digit of the software version see abo...

Page 124: ...ext to the serial port and press the button behind it You may need to disconnect the serial cable to do this 7 While pressing this button power ON the TEC The top LED should light RED and the bottom LED should be GREEN If this does not occur try again Once the LED lights RED you may remove the screwdriver and re connect the serial cable 8 Now that the TEC is in upgrade mode click on Tools Options ...

Page 125: ...nnel 2 Yellow w Red Stripe 18awg G12 Injector Channel 1 Yellow w Black Stripe 18awg G13 DFU Shield Bare 22awg G14 IAC pin A or GP I O 3 Dark Blue w Black Stripe 18awg G15 IAC pin B or GP I O 4 Dark Blue w White Stripe 18awg G16 Data Log Status Light White w Orange Stripe 18awg G17 Fuel Pump Relay Ground Light Green 18awg G18 Check Engine Light Pink 18awg G19 Tachometer Output Brown 18awg G20 Speed...

Page 126: ...S Input Dark Blue 18awg G30 MAP Input Dark Green 18awg G31 Knock Sensor Input Orange 18awg G32 Oxygen Sensor Tan 18awg G33 Oxygen Sensor Purple 18awg Normal O2 and Wideband Input G34 Injector Channel 3 Yellow w Green Stripe 18awg G35 Injector Channel 4 Yellow w Blue Stripe 18awg ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 126...

Page 127: ...Appendix VII TECgt Wiring Harness Layout ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 127 2008 Electromotive Inc ...

Page 128: ...Appendix VIII TECgt Power Harness Schematic ______________________________________________________________________________________ TECgt Manual Version 2 0 Page 128 2008 Electromotive Inc ...

Page 129: ...e 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 position and speed typically composed of a crank trigger wheel and a crank sensor Detonation When the air f...

Page 130: ...ing The amount of degrees before Top Dead Center that a spark plug fires IOT POT Injector Offset Time a k a Pulse width offset time This number adds or subtracts a fixed pulse width from the raw fuel curve The value of IOT POT is the amount of time in milliseconds that will be added or subtracted Knock Sensor A device used to measure detonation Knocking see Detonation Lean Mixture An air fuel mixt...

Page 131: ...r 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 pressure For example a rising rate regulator may be used to supply 2psi of fuel pressure increase with every 1psi of manifold boost Spark Knock See De...

Page 132: ...nes 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 TOG User Adjustable Pulse Width a k a Time on for One Gama This number defines the slope of the raw fuel curve When UAP TOG is zero the raw fuel curve will have zero pulse width at zero MAP sensor volts When the M...

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