Electromotive xdi, Installation Manual & Users Manual

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XDI Manual Version 1.8 Page 10
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2017 Electromotive, Inc.
3.0 Hardware Installation
The minimum installation of an XDI requires three main components. These include an XDI, a Direct
Fire Unit (DFU), and crank trigger wheel with a sensor.
3.1 Pre-Installation Checklist
To perform a complete XDI installation, the following items are required:
1.
XDI Controller
2. DFU(s)
3. Wire Harness (additional harness required for configurations requiring 2 DFU’s)
4. Resistor Core Spark Plug Wires (see notes on Spark Plug Wires)
5. XDI Wiring Harness
6. Crank Position Sensor (Magnetic Sensor)
7. 60 (-2) Tooth Crank Trigger Wheel
8. Drill
9.
¼” Bolts for DFU(s) & XDI Controller
10. Wire Stripper
11. Wire Crimper
3.2 Cautions and Warnings
1. DANGER! The XDI generates high voltages that can be lethal. Do not ever touch a coil tower or spark
plug wire when there is a chance of a spark. Without the spark plug wires on the coils and spark plugs,
the system will generate dangerous levels of voltage that can damage the XDI. This can also lead to fatal
electrocution.
2. Do not let the spark plug wires touch the block, head, frame or body. The power of this ignition can burn
through most spark plug wire insulation. Use a quality 8mm (or larger) wire with two-piece spring-
loaded contacts and wire separators.
3. Replace spark plugs wires every year (recommended).
4. Remove any series (ballast) resistance in both the +12 volt power (red) and the ground (black) wires. All
connections must be clean and tight.
5. A fully charged battery is necessary for optimum performance of the system. During cranking, the
battery voltage should not fall below 6 volts. If the battery is old, replace it.
6. Do not operate the standard XDI continuously at more than 18 volts. 24V units are available for special
applications.
7. Double battery jump-starts can damage the XDI.
Never disconnect the alternator while the engine is running. This may cause destructive high voltage spikes.
3.3 Installing the Direct Fire Unit (DFU)
The DFU(s) can be placed nearly anywhere under the hood of the vehicle where the temperatures are
below 250
o
F (120
o
C). Since they are entirely sealed, exposure to the elements is not an issue. The DFU
Ground Wire MUST be installed to vehicle ground.