Electromotive XDI200 Installation Manual & Users Manual Download Page 2

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XDI200 Manual Version 0.1

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Table of Contents

Terms and Conditions ........................................................ 6

1.1

ELECTROMOTIVE, INC. PRODUCT WARRANTY .......................................... 6

Forward................................................................................ 7

2.1

Improvements of the XDI200 over the TECgt ................................................... 8

2.2

Fundamentals of the System ............................................................................ 8

Installing the Hardware .................................................... 10

3.1

Pre-Installation Checklist ................................................................................ 10

3.2

Mounting the Main Computer and DFU .......................................................... 10

3.3

Trigger Wheel and Sensor Installation ............................................................ 12

3.3.1

Crankshaft Trigger Installation for 60(-2) Tooth Wheel ............................... 12

3.3.2

Hall Effect or Magnetic Crank Sensors ....................................................... 12

3.3.3

Crank Sensor Installation ............................................................................ 13

3.3.4

Wiring a Magnetic Trigger Sensor ............................................................... 15

3.3.5

Verifying Trigger Wheel Timing ................................................................... 16

3.3.6

Camshaft- & Distributor-Mounted Trigger Setups ....................................... 18

3.3.7

Individual Cylinder trim application

– Cam Synchronization ........................ 18

3.3.8

TDC Tooth Setup Software Adjustment Parameters ................................... 20

Wiring the System ............................................................ 23

4.1

Introduction ..................................................................................................... 23

4.1.1

Suggestions on Crimp Terminals… ............................................................. 23

4.2

Wiring ECU & Main Power .............................................................................. 24

4.2.1

Power Harness Installation ......................................................................... 24

4.3

Wiring Ignition Coil Primary Sides................................................................... 25

4.3.1

Introduction ................................................................................................. 25

4.3.2

Standard Direct Fire Units, DFU’s ............................................................... 26

4.3.3

Wiring Standard DFU’s Coils ...................................................................... 26

4.3.4

Spark Plug Wiring High Voltage Side .......................................................... 28

4.4

Ignition Firing Order ........................................................................................ 30

4.4.1

Common Engine Sparkplug Wiring ............................................................. 31

4.5

Coil Firing Schemes ........................................................................................ 32

4.5.1

Coil Firing Patterns for EVEN-FIRE Engines .............................................. 32

4.5.2

Coil Firing Patterns for ROTARY Engines ................................................... 33

4.5.3

Coil Firing Patterns for 2-CYCLE Engines .................................................. 33

4.5.4

Coil Firing Patterns for ODD-FIRE Engines ................................................ 34

4.5.5

Examples of Typical Engine Setups ............................................................ 34

4.5.6

Common Firing Orders ................................................................................ 37

4.5.7

How to find the TDC Event Order : .............................................................. 38

4.5.8

TDC Tooth for DFU “2” needed for an Odd-Fire Engine: ............................ 38

4.5.9

Harley-Davidson Applications ..................................................................... 38

4.5.10

Rotary Engines............................................................................................ 38

4.5.11

Dual Plug Engines ....................................................................................... 39

4.6

Spark Plug Wire Selection .............................................................................. 39

4.7

Spark Plug Selection ...................................................................................... 40

4.8

Driver on Coil Logic Driven Coils .................................................................... 42

Wiring Sensors & Other Inputs ....................................... 43

5.1

The Manifold Air Pressure (MAP) Sensor ....................................................... 43

Summary of Contents for XDI200

Page 1: ...XDI200 Product Installation Manual User s Guide V 01 Electromotive Inc 703 331 0100 9131 Centreville Road 703 331 0100 fax Manassas VA 20110 support electromotive com ...

Page 2: ...the System 23 4 1 Introduction 23 4 1 1 Suggestions on Crimp Terminals 23 4 2 Wiring ECU Main Power 24 4 2 1 Power Harness Installation 24 4 3 Wiring Ignition Coil Primary Sides 25 4 3 1 Introduction 25 4 3 2 Standard Direct Fire Units DFU s 26 4 3 3 Wiring Standard DFU s Coils 26 4 3 4 Spark Plug Wiring High Voltage Side 28 4 4 Ignition Firing Order 30 4 4 1 Common Engine Sparkplug Wiring 31 4 5 ...

Page 3: ...e Input GPI Functons 56 5 11 2 Wiring the GPI s 57 6 Wiring Outputs 59 6 1 Idle Air Control Motor 59 6 1 1 Wiring a 2 wire IAC 60 6 1 2 Wiring a 3 wire IAC 60 6 2 Tachometer Output 62 6 3 Fuel Pump Relay Output 62 6 4 General Purpose Output GPO functions 63 6 4 1 Outputs 64 6 4 2 Available GPO Functions 64 6 4 3 Wiring the GPO s 65 7 Communications Ports on the XDI200 67 7 1 1 PC communications US...

Page 4: ...arting Problems 83 12 2 1 Air Related Starting Problems 83 12 2 2 Fuel Related Starting Problems 83 12 2 3 Spark Related Starting Problems 83 12 3 Idling Problems 84 12 3 1 Air Related Idling Problems 84 12 3 2 Fuel Related Idling Problems 84 12 3 3 Spark Related Idling Problems 85 12 4 Low Medium and High Load Problems 85 12 4 1 Air Related Load Problems 85 12 4 2 Fuel Related Load Problems 85 12...

Page 5: ... 6 Physical Dimensions 88 13 7 Environmental Considerations 88 13 8 PC Requirements 88 14 Appendix II Trigger Wheel Availability 89 15 Appendix III Secondary Coil Polarity for Redundant Ignition Applications 90 16 Software Firmware Support 91 16 1 1 Software Coding Information 91 16 1 2 Firmware Coding Information 91 16 1 3 Software Upgrade Procedure 91 16 1 4 Firmware Upgrade Procedure 92 17 Appe...

Page 6: ...er Warranty Exclusions If You Need 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 note 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 purchase receipt and it must clearly show name of t...

Page 7: ...e of the product loss of time loss of profits loss of business opportunity loss of goodwill interference with business relationships or other commercial loss even if advised of their possibility of such damages Any other damages whether incidental consequential or otherwise Any claim against the customer by another part Certain shipping charges 2 Forward The XDI200 Distributorless Ignition system ...

Page 8: ... Improvements of the XDI200 over the TECgt The XDI200 has the added features of 1 Water resistant case and connector system 2 6 high current ignition coil drivers to operate 12 cylinder or dual plug 6 cylinder engines 3 6 separate ignition coil logic outputs to operate up to 12 Driver On Coil DOC coils 4 User selected fixed coil dwell time or standard coil current control 5 General Purpose Inputs ...

Page 9: ...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 XDI200 has inputs for RPM and load Under steady state conditions on a fully warmed up engine these are the only necessary inputs for the XDI200 to control the fuel and ignition curves Control of the ignition advance curve is quite simple there is...

Page 10: ...Cam Trigger Wheel 9 Coolant Temperature Sensor CLT OPTIONAL 10 Manifold Air Temperature Sensor MAT OPTIONAL 11 Manifold Air Pressure Sensor MAP OPTIONAL 12 Throttle Position Sensor TPS OPTIONAL 13 Exhaust Gas Oxygen Sensor EGO OPTIONAL 14 Idle Air Control Motor IAC OPTIONAL 15 Knock Sensor KNK OPTIONAL 16 Wire Terminal Crimping Tool available from Electromotive 17 Shrink Tubing 18 Assorted Wire Cr...

Page 11: ...mperatures are below 250oF 120oC Since they are entirely sealed exposure to the elements is not an issue The DFU Ground Wire MUST be installed to vehicle ground It is recommended that the ECU and DFU be separated by at least six inches for the purpose of reducing electrical noise in the ECU Figure 1 Electromotive Direct Fire Units Mounting bolt pattern is 3 375 x 6 88 2 Coil DFU Dimensions 3 Coil ...

Page 12: ...ilable See Appendix II for a listing of applications Universal trigger wheels are also available in a variety of sizes and are listed in Appendix II as well Electromotive can custom make trigger wheels in nearly any configuration for a one time tooling fee To choose the proper size trigger wheel find the diameter of the pulley or damper on which the wheel is to be mounted The trigger wheel diamete...

Page 13: ...he two always stays the same Variations in sensor gap may cause erratic timing or false triggering of the ignition This is the reason for not mounting the trigger wheel to the outer ring of a harmonic damper As such any custom magnetic sensor bracket should be very rigid The sensor can be secured with either a set screw or a clamping arrangement as long as the 1 2 sensor is utilized part number 25...

Page 14: ... event that the sensor is not aligned correctly the WinTec software can be made to compensate by manipulating the Tooth Offset Parameter as outlined in the tuning section 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 Locating close to coil wires or other power l...

Page 15: ...from the sensor the black wire is the signal ground and the bare wire is the shield The harness has provisions for both a crank and a cam sensor The crank sensor cable must be used for all 60 2 or 120 4 tooth trigger wheel inputs It is not recommended to use a magnetic sensor on the cam trigger wheel 3 8 Diameter Chisel Point Sensor PN 250 72212 1 2 Diameter Flat Tip Sensor PN 255 72218 Diameter F...

Page 16: ...g 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 engine is at TDC 1 When running the engine verify that the timing value read by the timing light corresponds to the timing value in the software s engine monitor screen Use of a good quality inductive timing light is recommended DO NOT use a timing light that ...

Page 17: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 17 2017 Electromotive Inc ...

Page 18: ...the intake valves beginning to open on the exhaust stroke Since the spark plugs fire on both the compression and the exhaust 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...

Page 19: ...flying magnet sensors As long as the sensor outputs a rising voltage to the XDI200 between 180o and 6o before TDC compression for the number one cylinder it should work perfectly Terminal 39 on the ECU is used for cam sync inputs as shown in Figure 6 If using a Hall effect or other sensor type that is powered by 5Volts be sure that the output signal from the sensor is going into terminal 39 Keep i...

Page 20: ...these setups are referenced to the 14th tooth for TDC but you MUST confirm this on your application since Bosch used a few different offsets through the years Odd Fire applications have the ability to move the TDC reference for the second DFU using the parameter DFU B Trigger Wheel TDC This allows the user to define the odd fire ignition split that is present on the engine Refer to the Tuning Guid...

Page 21: ...the TDC Tooth Alignment Parameter The timing will be shifted to make the Ignition Advance Table accurate Method The software will automatically RETARD the timing when a number GREATER THAN 11 is entered into the TDC Tooth Alignment Parameter The timing will be automatically ADVANCED when a number LESS THAN 11 is entered Situation B Problem The engine needs less mechanical advance and the crank sen...

Page 22: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 22 2017 Electromotive Inc Figure 13 TDC tooth for two possible scenarios ...

Page 23: ...erminal failure and wire fatigue To crimp properly we recommend using a high quality ratcheting crimp tool such a tool is available from Electromotive In the absence of a good crimp tool the terminals can be soldered Care should be taken to make absolutely certain that the solder penetrates the terminal and gets to the wire There are two main crimp styles used with the XDI200 sensors Metri Pack an...

Page 24: ...er and fuel pump Included in the harness is a fuse block with four fuses ignition DFU s and Fuel Pump are fused and two relays to switch the power Our custom harnesses are all built with the power harness pre installed so wiring them is even more straightforward Figure 15 gives an example of a typical Power Harness installation There are three breakouts in the Power Harness ECU Connections Power I...

Page 25: ...connections are already fused Figure 15 XDI200 Power Harness PN 070 40000 4 3 Wiring Ignition Coil Primary Sides 4 3 1 Introduction The XDI200 has the ability to operate either the older style standard ignition coils or more recent Driver on Coil DOC coils If DOC coils are selected the customer must set a fixed dwell time in the calibration Failure to select DOC and set a dwell time will cause dam...

Page 26: ...rminal D Full Time 12 Volt Source 9 amps On a standard inline 4 cylinder four stroke application this DFU will be used On 8 cylinder or dual plug 4 cylinders two of these DFU s will be used 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...

Page 27: ...ng 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 25 for details on the coil outputs in the wiring harness The XDI200 has both standard DFU coil outputs and logic outputs When using the ...

Page 28: ... DFU The coil located closest to the connector is Coil A The coil next to it is Coil B If the DFU contains three coils the last coil is Coil C The number identifies the DFU that the coils are on In an engine configuration using only one DFU the number following the letter is 1 Coil notation is shown in Figure 26 Note Each coil has two towers for spark plug wires The towers are identical and should...

Page 29: ...2017 Electromotive Inc Figure 27 4 Cyl DFU Setup 1st DFU 2nd DFU Figure 28 8 Cyl and 4 cyl Dual Plug 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 ...

Page 30: ...ure is from a twin plug 6 Cyl if running a V8 the first DFU will have coils A1 B1 the second DFU will have coils A2 B2 4 4 Ignition Firing Order For the engine to run correctly the coils must be connected to the appropriate cylinders Since the Electromotive DFU s utilize waste spark coils it is necessary to know the firing order of an engine to determine which cylinders should be paired together ...

Page 31: ...Note To clarify these seemingly complex firing patterns write your firing order into the appropriate engine setups found below and wire them accordingly 4 4 1 Common Engine Sparkplug Wiring 4 4 1 1 Chevy V8 Firing Order 1 8 4 3 6 5 7 2 Coil Firing Order A1 A2 B1 B2 A1 A2 B1 B2 Engine Firing Order 1 8 4 3 6 5 7 2 As can be seen Coil A1 will be used for cylinders 1 6 Coil B1 for cylinders 4 7 Coil A...

Page 32: ...s shown in Figure 36 4 5 Coil Firing Schemes The XDI200 software is able to run a multitude of different engine configurations To determine the proper wiring of coils for a given engine it is necessary to understand the points at which the coils are fired as functions of engine position The following pages outline the different ignition firing patterns that are available on the XDI200 It will be n...

Page 33: ...______________________________________________________________ XDI200 Manual Version 0 1 Page 33 2017 Electromotive Inc 4 5 2 Coil Firing Patterns for ROTARY Engines 4 5 3 Coil Firing Patterns for 2 CYCLE Engines ...

Page 34: ..._______________________ XDI200 Manual Version 0 1 Page 34 2017 Electromotive Inc 4 5 4 Coil Firing Patterns for ODD FIRE Engines 4 5 5 Examples of Typical Engine Setups Figure 32 Typical In Line 4 cylinder DFU wiring Firing Order 1 3 4 2 depicted here ...

Page 35: ...0 1 Page 35 2017 Electromotive Inc 8 Cylinder Figure 35 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 33 Typical In Line 6 cylinder DFU wiring Firing Order 1 5 3 6 2 4 depicted here ...

Page 36: ...il setup 4 of these coils will be required for leading and trailing plugs Leading plugs will go to XDI200 connector pin 2 white wire first rotor leading XDI200 pin 3 red wire second rotor leading Trailing plugs will go to XDI200 pin 14 white wire first rotor trailing XDI200 pin 15 red wire second rotor trailing Refer to the wiring diagram layout for signal wire hookup ...

Page 37: ... 4 8 1 6 3 5 7 4 2 8 Cadillac 368 425 472 500 1 5 6 3 4 2 7 8 1 4 5 2 6 7 3 8 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 ...

Page 38: ...V Twin is the result of an odd uneven firing pattern between the two cylinders To run this engine select 2 cylinder Odd Fire for the engine setup Since this is a 45o V Twin with one connecting rod lobe the TDC events occur in the following fashion for one complete engine cycle TDC A 45o TDC B 315o TDC A 45o TDC B For the TDC Setup Set the DFU 1 Trigger Wheel TDC to the 11th tooth Set the DFU 2 Tri...

Page 39: ...dual cylinder should occur at the same instant for optimum flame front propagation However with non hemispherical dual plug heads it may be desired to experiment with staggering the spark timing from one plug to the next To do this the Dual Plug Timing Split Table can be used The values entered into this table represent the timing split in degrees between the two spark plugs on a particular cylind...

Page 40: ...tremely high quality wire with excellent noise suppression we recommend the Magnecor brand Specifically their Electrosports 80 8mm wire is very good with our system Custom wire lengths and ends are available from them so you will not need to crimp the wires yourself They can be reached at 248 669 6688 or on the web at www magnecor com Taylor Pro Wire Silicon Resistor wires also work well 4 7 Spark...

Page 41: ... plug wire a resistor plug MUST be used The bottom line is this the XDI200 system uses an inductive long duration charge at battery voltage charging method for the coils which is completely different than the capacitive short duration charge at higher than battery voltage charging method used by several other aftermarket manufacturers What may work well for these systems may not work well for ours...

Page 42: ...lows the plug wiring as noted in the standard DFU wiring above Where a coil spark plug wire connection is indicated substitute the DOC logic output for that cylinders DOC coil One DOC logic output is wired to two DOC coils SIGNAL CONNECTION EXAMPLES VERIFY THE FIRING ORDER 4 Cylinder 6 Cylinder and Dual Plug 8 Cylinder Firing Order 1 3 4 2 1 6 2 4 3 5 1 8 4 3 6 5 7 2 Standard Coil DOC Pin Wire Col...

Page 43: ...r 5 1 The Manifold Air Pressure MAP Sensor The MAP sensor determines the operating load of the engine To do so it measures the intake manifold absolute pressure Since the intake manifold pressure has a direct effect on the amount of air that the cylinders can ingest the use of a MAP sensor as a load determining device is well justified MAP sensors are available from Electromotive in three varietie...

Page 44: ... 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 pressure for the three MAP sensors Since the XDI200 does NOT know whether the MAP voltage is from a 1 2 or 3 Bar MAP sensor that is it only knows the voltage it is necessary to enter the MAP sensor that is being used into the softwar...

Page 45: ...f roughly 10k 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 the same three resistances Two of the read...

Page 46: ...e note that the TPS must use a roughly 10k potentiometer Failure to do so will result in improper impedance matching for the XDI200 and a false sensor reading will result Fortunately most TPS s are of the 10k variety Figure 41 Potentiometer functionality for closed and open throttle conditions 5 3 TPS Wiring Many different TPS s have been used by OEM s in the past few decades The most common types...

Page 47: ...advance timing as a function of engine temperature The XDI200 is set up to use the 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...

Page 48: ...51 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 the operating temperature using Table 5 As a guideline use the following specs Cold engine 70F 20C 3300 Hot Engine 180F 80C 350 Resistance...

Page 49: ...e MAT sensor is very easy See Figure 52 for 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 on...

Page 50: ...ted after the collector Failure to mount the EGO sensor close to the engine will result in poor performance due to under heating 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...

Page 51: ...sing an EGO sensor it must be realized that AFR s that are not near the stoichiometric value are not accurate The stoichiometric value is the AFR that results in complete combustion with no excess fuel gas alcohol etc or excess air oxygen In simple terms the stoichiometric value is AFR at which the incoming mixture is neither lean nor rich Read the section on Oxygen Sensor Corrections for more inf...

Page 52: ...nstructions The XDI200 supports an input from most wideband sensor controllers The wideband controller must have an analog 5 volt output signal A typical configuration is shown in Figure 57 Figure 57 Typical Wideband Configuration The installation of the oxygen sensor and controller should follow the wideband controller manufacturer s instructions The analog 5 volt output signal connects to pin 49...

Page 53: ...the analog monitor screen in the box labeled WBS The XDI200 uses this voltage and the corresponding values you entered in the calibration to determine the AFR For example if the manufacturer states 2 volts is an AFR of 12 6 and the XDI200 WBS is displaying 2 volts but the XDI200 AFR reads 13 6 then you entered the calibration values incorrectly Repeat the procedure detailed above to correct the ca...

Page 54: ...phone that is designed to be very sensitive to the frequency of detonation When the XDI200 senses detonation from the knock sensor it will begin to retard the timing on all subsequent spark events Once knock has dropped a sufficient amount the timing will then begin to increase to the desired advance setting When the XDI200 starts to increase the advance it will not add any more timing than what i...

Page 55: ... sensors A speed input is defined as a frequency signal When using a magnetic sensor 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 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 curv...

Page 56: ...iagram Speed Input The speed input is on pin 34 Orange Black 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 XDI200 speed input Depending on the location of the speed input trigger wheel you must configure the software to calibrate the spe...

Page 57: ...Inc 5 11 2 Wiring the GPI s Figure 60 Potentiometer wiring for Fuel Ignition and GP I O Trim Inputs Figure 62 Alternate air conditioner idle speed increase wiring Note that the A C clutch solenoid polarity MUST be known for this method Figure 61 Air conditioner idle speed increase wiring Figure 63 Nitrous timing retard wiring ...

Page 58: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 58 2017 Electromotive Inc Figure 64 Valet mode on off wiring Figure 65 Typical speed sensor wiring ...

Page 59: ...can be used with four wire stepper motor style 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 69 for an IAC motor plumbing diagram See Figure 68 or 71 for IAC wiring instructions The Tuning Guide...

Page 60: ...losed 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 6 1 1 Wiring a 2 wire IAC A 2 wire IAC should be wired as shown in Figure 68 The diode shown is required on all idle motors except some Ford motors If the Ford IAC you are using had ...

Page 61: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 61 2017 Electromotive Inc Fig 71 Common 4 wire idle air control motor wiring ...

Page 62: ...wever some older tachometers trigger off the high voltage signal from the ignition 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 Figure 76 Typical tachometer wiring 6 3 Fuel Pump Relay Output The fuel pump output is desig...

Page 63: ...f the XDI200 s GPO functions To accomplish this task you would first select the Radiator Fan option from the GPO menu Then you would input the temperature at which the fan should turn on and the temperature at which it should turn off The temperature readings are all obtained from the Coolant Temperature Sensor CLT so they are much more accurate and reliable than an external thermo switch The outp...

Page 64: ...unctionality See Figure 80 for wiring diagram Shift Light Turns on a shift light or any other rpm activated object at a user definable RPM See Figure 81 for wiring diagram Torque Converter Control Use this GPO to control a lock up torque converter You are able to define the MAP and Speed points at which the torque converter clutch is activated Since there is a multitude of different lock up transm...

Page 65: ...below which GPO comes on and MAP minimum turn on value Custom or functions only inside either RPM or MAP values set OR both 6 4 3 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 automotive 4 position relays The air conditioner turn off request needs a 5 position...

Page 66: ...nc Figure 82 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 Figure 83 Auxiliary fuel pump wiring Figure 81 Shift light wiring ...

Page 67: ...ontrol panel and select hardware device manager Then look at Ports If the USB port number shows a number higher than 12 select that port and then select advanced Change the port number to one that is less than 12 Close that and go to Wintec4 control options and change the communications to that new port number 7 1 2 PC communications RS232 Serial port The XDI200 also has the old style RS232 serial...

Page 68: ...gines regardless of compression ratio will require anywhere from 8 20 degrees of advance when the engine is idling Rotary engines require little or no timing at idle some even idle with negative advance so an ignition advance of zero may work best at low engine speeds Less timing makes the combustion process occur later and thus makes the exhaust temperatures higher It also usually makes an engine...

Page 69: ...AC motor has a few settings to establish the proper idle speed without oscillation Also the IAC motor has the ability to provide increased air to the engine during cranking without opening the throttle The IAC motor will only work if the TPS voltage is below that which is defined in the TPS Parameters section So if the TPS voltage is 1 5 volts at idle the TPS Voltage at Closed Throttle will need t...

Page 70: ...vity to the difference between the current RPM and the desired RPM In order to prevent stalling the rate at which the engine slows down must also be monitored so that the RPMs can be caught to prevent stalling This is done with the Rate of Change Sensitivities A large value should generally be used with falling RPM and a smaller value should be used with the rising gain The Error Sensitivities and...

Page 71: ...dle speed the car should then be drivable Little if any adjustments should be required to finalize the idle settings 8 4 4 Error Sensitivity Error Sensitivity controls how rapidly the idle motor will move in reaction to the error of RPM at any given time The picture below shows how the XDI200 unit finds error 8 4 5 RPM Rate of Change Sensitivity Rate of Change sensitivity controls how rapidly the ...

Page 72: ...cause the idle motor is properly sized for the engine Regardless of engine idle motor combination the default configuration should be close 8 5 1 Other tips If your engine starts and maintains idle but the idle drops too low when lifting off the gas and then rises slowly to the target RPM a likely solution is to increase the Reset position This will help to slow the rate that the RPM drops when li...

Page 73: ...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 confused about the difference between gauge and absolute pressure Ambient atmospheric Pressure Gauge Pressure Absolute Pressure When discussing absolute pressure there is no distinction made between vacuum and pressure When discussing gauge or relative pressure vacuum readings will ...

Page 74: ...180 11 4 psi 20 24 0 in Hg 190 12 9 psi 30 21 1 in Hg 200 14 3 psi 40 18 1 in Hg 210 15 8 psi 50 15 2 in Hg 220 17 2 psi 60 12 2 in Hg 230 18 6 psi 70 9 28 in Hg 240 20 1 psi 80 6 31 in Hg 250 21 6 psi 90 3 35 in Hg 260 23 0 psi 100 0 39 in Hg 270 24 4 psi 110 1 26 psi 280 25 9 psi 120 2 71 psi 290 27 4 psi 130 4 16 psi 300 28 8 psi 140 5 61 psi 310 30 3 psi 150 7 06 psi 320 31 7 psi 160 8 51 psi ...

Page 75: ...unted on the XDI200 The LED s mounted on the XDI200 are used to alert the user s attention to electrical and crank trigger problems They are also used to show the mode in terms of the rpm range in which the XDI200 is operating Here are the readings from the LED s Turn ignition key on but do not start engine Upper LED goes steady green 0 20 40 60 80 100 120 140 160 180 200 220 0 0 0 5 1 0 1 5 2 0 2...

Page 76: ...bserved to momentarily flash red the crank sensor may be at fault To test for errors in this situation turn the engine off without removing power from the XDI200 ECU by hitting the letter K from the engine monitor screen when using a laptop If the lower LED is flashing red after the engine is shut off there was a crank sensor problem at some point during the run 9 2 Trouble Codes from the Check En...

Page 77: ...cam sensor A broken cam trigger wheel or a bad cam sensor could cause this error This code will only be displayed on sequential applications Code 14 ECU Internal Failure This code is displayed when there has been a substantial failure inside the ECU Call Technical support for further information Codes 21 22 TPS High Low See above description Codes 23 24 Manifold Air Pressure High Low These codes a...

Page 78: ...e the sensor is not shorted to 12 Volts Codes 41 42 43 44 45 46 47 48 all function like Codes 23 24 except they are for the Analog to Digital Inputs Codes 51 54 GP I O 1 9 Failure These codes are set when the GP I O input outputs have been shorted to voltage or have been over drawn too much current Make sure that the total circuit draw for GP I O s 1 9 is less than 10 amps 1 amp per channel Code 5...

Page 79: ...ed 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 expected voltage Likewise the High Voltage Failure setting is made a few tenths of a volt higher t...

Page 80: ... full sequential operation the coils can be trimmed on an individual cylinder basis When the Ignition Advance trim is used a set amount of timing can be added to or subtracted from the Ignition Advance curve Certain engines have the tendency to detonate on certain cylinders more than others To counteract this issue the Ignition Advance Trim can be used to remove timing from the problematic cylinde...

Page 81: ... drag race applications in the following scenario In the software set the RPM point to be about 200 RPM above the staging RPM Do the burnout and stage the car Turn on the OBD feature Make the run and turn the OBD off after crossing the finish line Download the data to the laptop when you are ready to view it The memory will be erased the next time the OBD switch is turned on The OBD has a much hig...

Page 82: ...s very flexible For ignition control the timing can be dropped to 0 degrees on rev limit or our 3 stage coil cut can be used The options are described below 11 4 Zero degree advance This is the simplest rev limiter When the rev limit is reached timing is simply dropped to zero degrees This item is unlikely to do the job by itself in any but the lowest power applications 11 5 3 stage coil cut The 3...

Page 83: ...r spark related problems 12 2 2 Fuel Related Starting Problems Note When diagnosing a fuel system problem a fuel pressure gauge will be needed With the ignition key switched on the fuel pump should run for a few seconds The fuel pressure should then increase to the rating of the fuel pressure regulator typically 43psi o If the pressure does not rise to this pressure there is either air in the line...

Page 84: ...coil firing patterns An engine will not run or will run very rough if the plug wires are not going to the appropriate cylinders If the engine backfires through the throttle check that mechanical timing has not been added or subtracted with an improper trigger wheel installation 12 3Idling Problems Sections on Idle speed control in the Tuning Guide above should be consulted to determine problems wi...

Page 85: ...nctioning properly Fuel pressure should increase by 1psi with every 1psi of boost on turbo or supercharged engines unless a rising rate regulator is installed o If the fuel pressure is good the injectors may be undersized o If the injectors are sized appropriately and the fuel pressure is adequate it is likely a tuning issue Undesired EGO sensor corrections can contribute to fuel problems under lo...

Page 86: ...uel Pump Control o Low current pull to ground output for activation of fuel pump relay o Configurable for fuel system priming 13 1 5 Tachometer Output o Drives modern 0 12 volt tachometers o High side amplifier to drive multiple triggered tachometers and other devices 13 1 6 Check Engine Light Output o Pull to ground output for instrument panel light 1 amp max current draw 13 1 7 ECU Diagnostic Ch...

Page 87: ...a high resolution triggering o Engine position known to within 1 8o 13 2 4 Feedback Charging Control o Monitors each coil firing event o Coil current monitoring Consistent dwell adjustment Full coil charging without overcharging 13 3Tuning Features 13 3 1 Ignition Timing Map o 16 x 16 user definable tables of RPM vs MAP for ignition advance angle o 65535 point interpolation between data points o 1...

Page 88: ...ing Features 13 5 1 Laptop Data logging o Records to hard drive on laptop o Sampling rate is approximately 50 samples per second o Total data logging time is limited only by hard drive space 13 6Physical Dimensions Length 7 5 Width 4 0 Height 1 0 add for connector Weight 1 55 lbs Bolt Hole Pattern 6 88 x 3 375 1 4 6mm bolts 13 7Environmental Considerations One Sealed 73 Pin Molex MX123 Connector f...

Page 89: ...th a 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...

Page 90: ...________________________________ XDI200 Manual Version 0 1 Page 90 2017 Electromotive Inc 15Appendix III Secondary Coil Polarity for Redundant Ignition Applications Figure 120 DFU Secondary Voltage Polarity for Redundant Ignition Applications ...

Page 91: ...versions are compatible with the firmware version for which they are designed For example A 4 0 3 software version is compatible with a 4 0 0 firmware version A 4 1 2 software version is compatible with a 4 1 0 firmware version A 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 mus...

Page 92: ... 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 use to tune the engine 3 Connect the XDI200 to the PC s serial or USB port and power it ON 4 Startup the WinTec software it should show in the System console that the unit was found and display the firmware version 5 Turn OFF power to the TEC un...

Page 93: ... Pink 20TXL DoC B2 12 Blk Org 20TXL DoC C2 13 Bare B 16 TST Coil Shield 14 White B 16 TST Coil A2 15 Red B 16 TST Coil B2 16 Black B 16 TST Coil C2 17 Blk Wht 20TXL Ground 18 Blk Wht 20TXL Ground 19 Gray Red 20TXL 5V Ref 20 Gray Red 20TXL 5V Ref 21 Gray Red 20TXL 5V Ref 22 Org Red 20TXL GPI2 23 Org Grn 20TXL GPI3 24 Org Blue 20TXL GPI4 25 Org Ppl 20TXL GPI5 26 Org Pink 20TXL GPI6 27 Org Tan 20TXL ...

Page 94: ...TXL CAN H 52 Grn Pink 20TXL CAN L 53 Red Wht 18TXL 12 volt in 54 55 56 Wht Org Data log stat 57 L Grn 20TXL FPR 58 White Blk 20TXL GPO1 59 Pink 20TXL CE 60 D Blu Wht 20 IACB GPO4 61 D Blu Blk 20 IACA GPO3 62 Brown 20TXL Tach 63 Wht Ppl 20TXL GPO9 64 Wht Blu 20TXL GPO8 65 D Grn Wht 20 IACD GPO6 66 D Grn Blk 20 IACC GPO5 67 68 69 70 71 72 73 Black 12TXL Main Gnd 18Appendix V ECU Connector Drawing Pl...

Page 95: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 95 2017 Electromotive Inc ...

Page 96: ...________________________________________________________________________ XDI200 Manual Version 0 1 Page 96 2017 Electromotive Inc 19Appendix VII Driver on Coil Schematic ...

Page 97: ...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 fuel mixture is ignited by ...

Page 98: ...n instant Load is measured by using the MAP sensor to estimate the cylinder pressure on XDI200 systems Higher loads result in higher MAP readings Manifold Air Pressure MAP Sensor A device that measures the absolute pressure of the intake charge for an engine Manifold Air Temperature Enrichment An inlet air temperature based enrichment that is used to add fuel when the incoming air is cold and ther...

Page 99: ...ive Inc Throttle Position Sensor TPS A device used to measure the position of the throttle Torque TQ A measurement of the work that an engine can perform typically expressed in pound feet lb ft Trigger Wheel A device attached to the crankshaft that provides a moving reference of speed and position of an engine s crankshaft ...

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