FuelTech FTSPARK 1500mJ Owner'S Manual Download Page 7

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FTSPARK

Wiring Harness

Wire harness length: 59 in. at power outputs
connected to coils and 118 in. at the other
cables.

Cylinders

Sequential

Wasted spark / 2 Stroke

22.500 RPM

11.250 RPM

4 (EXTREME)

11.250 RPM

NOT COMPATIBLE

15.000 RPM

NOT COMPATIBLE

15.000 RPM

NOT COMPATIBLE

11.250 RPM

NOT COMPATIBLE

8 (EXTREME)

11.250 RPM

NOT COMPATIBLE

Rotors

Rotary

Units

11.250 RPM

1 x FTSPARK-4

15.000 RPM

2 x FTSPARK-4

11.250 RPM

2 x FTSPARK-4

Maximum rotary engine speed (with 16V battery)

Maximum piston engine speed (with 16V battery)

FTSPARK-4 (4 Coils)

20A @ 10000RPM

FTSPARK-6 (6 Coils)

30A @ 10000RPM

FTSPARK-8 (8 Coils)

40A @ 10000RPM

FTSPARK-4 EXTREME (4 Coils) 1500mJ

40A @ 10000RPM

FTSPARK-8 EXTREME (8 Coils) 1500mJ

(using 2 FTSPARK ignition module)

FTSPARK(A) - 40A @ 10000RPM
FTSPARK(B) - 40A @ 10000RPM

FTSPARK-4 (4 Coils):

23 Wires

FTSPARK-6 (6 Coils):

29 Wires

FTSPARK-8 (8 Coils):

35 Wires

FTSPARK-8 EXTREME (4 Coils): 21 Wires
FTSPARK-8 EXTREME (8 Coils): 42 Wires

IMPORTANT

FTSPARK EXTREME is not compatible with rotary engines.

Maximum Current Consumption

Summary of Contents for FTSPARK 1500mJ

Page 1: ...OWNER S MANUAL ...

Page 2: ......

Page 3: ...trol 23 6 1 Individual triggering 23 6 2 Serial bus triggering 23 6 3 Input signal trigger edge 24 6 4 CAN network 24 6 5 Energy level selection 25 6 6 Wasted spark operation 750mJ Only 26 6 7 Safety Features 26 6 8 Ignition delay time 27 7 Recalibrating ignition and fuel map 27 8 LED operation indicator 27 9 FTSPARK settings and operation 28 9 1 FTSPARK settings 28 9 2 Ignition energy 29 9 3 Usin...

Page 4: ...4 FTSPARK 9 6 Status Events Information 33 10 FTCAN 2 0 protocol 34 10 1 Physical layer 35 10 2 Features 35 10 3 IDENTIFICATION 35 10 4 DATA FIELD 36 10 5 Attachments 37 11 Dimensions 42 ...

Page 5: ...rimary coil circuit using FuelTech CDI Racing Ignition Coil Up to 175Amps in the primary coil circuit using FuelTech CDI Racing Ignition Coil and FTSPARK 1500mJ FTSPARK EXTREME CAN communication with FuelTech Power FT product line for diagnostics and data logging Anodized aluminum housing Automotive connector with gold plated terminals Serial bus 1 wire allows the use of only one ECU output to tri...

Page 6: ...s may create an antenna that captures electromagnetic interference that may generate product malfunction Limited Warranty This product warranty is limited to one year from the purchase date only covering manufacturing defects and requiring purchase invoice presentation Damages caused by misuse of the unit are not covered by the warranty Warranty void analysis is done exclusively by FuelTech techni...

Page 7: ...K 4 4 11 250 RPM 2 x FTSPARK 4 Maximum rotary engine speed with 16V battery Maximum piston engine speed with 16V battery FTSPARK 4 4 Coils 20A 10000RPM FTSPARK 6 6 Coils 30A 10000RPM FTSPARK 8 8 Coils 40A 10000RPM FTSPARK 4 EXTREME 4 Coils 1500mJ 40A 10000RPM FTSPARK 8 EXTREME 8 Coils 1500mJ using 2 FTSPARK ignition module FTSPARK A 40A 10000RPM FTSPARK B 40A 10000RPM FTSPARK 4 4 Coils 23 Wires FT...

Page 8: ... block to ground the FTSPARK Use the negative battery terminal To turn the FTSPARK on and off use a 12V switch connected to the analog input on pin 12 Do not connect the FTSPARK to a voltage booster it demands current peaks of more than 100A and will cause the system to malfunction Do not use the The FTSPARK on systems with over 20V power supply Do not use FTSPARK on systems with power supply volt...

Page 9: ...ange Black COIL D 17 Orange Black COIL E 18 Orange Black COIL F 19 Orange Black COIL G 20 Orange Black COIL H 21 Black BAT Power ground Connect to battery 22 Black BAT 23 Black BAT 24 Gray Ignition Input A Ignition trigger input A or Serial bus 1 wire 25 Gray Ignition Input B Ignition trigger input B 26 Gray Ignition Input C Ignition trigger input C 27 Gray Ignition Input D Ignition trigger input ...

Page 10: ...erial input Ignition Input B Ignition Input C Ignition Input D Ignition Input E Ignition Input F Ignition Input H Ignition Input G Coil B Coil C Coil D Coil E Coil F Coil H Coil G CANBUS Coil A Energy Level CAN LOW CAN HI BAT A BAT A Battery Ground Signal Reference Fus 50A e 12V Switched FTSPARK activation A CANBUS CAN LOW A CAN HI Ignition Input A Serial input Ignition Input B Ignition Input C Ig...

Page 11: ...Red Switched 12V FTSPARK Switch ON OFF 13 Orange Black COIL A Coil primary output 750V wire Twisted Power ground side 14 Orange Black COIL B 15 Orange Black COIL C 16 Orange Black COIL D 17 Not Used Not Used 18 Not Used 19 Not Used 20 Not Used 21 Black BAT Power ground Connect to battery 22 Black BAT 23 Black BAT 24 Gray Ignition Input A Ignition trigger input A or Serial bus 1 wire 25 Gray Igniti...

Page 12: ...TSPARK 4 Connector Diagram BAT A BAT A Fus 50A e 4 Cylinder engine FTSPARK EXTREME Connector diagram Pin Wire Label Function 1 Orange COIL A Coil primary output High voltage Positive side 2 Not Used 3 Not Used 4 Orange COIL D 5 Not Used 6 Orange COIL F 7 Orange COIL G 8 Not Used 9 Yellow Energy level Energy level selection ground trigger NOTE If the FTSPARK is connected via the CAN network it is n...

Page 13: ...t Used 27 Gray Ignition Input D Ignition trigger input D 28 Not Used Not Used 29 Gray Ignition Input F Ignition trigger input F 30 Gray Ignition Input G Ignition trigger input G 31 Not Used Not Used 32 Black GND Battery ground Trigger signal reference 33 Red BAT Power supply for FTSPARK Connect to battery positive or main switch when required 34 Red BAT 35 Red BAT Bobina B Bobina H Bobina G Igniti...

Page 14: ...rness CANBUS CAN LOW 11 Yellow White Wiring harness CANBUS CAN HI 12 Red Switched 12V FTSPARK Switch ON OFF 13 14 Orange Black COIL B Coil primary output 750V wire Twisted Power ground side 15 Orange Black COIL C 16 Not Used 17 Orange Black COIL E 18 Not Used 19 Not Used 20 Orange Black COIL H 21 Black BAT Power ground Connect to battery 22 Black BAT 23 Black BAT 24 Gray Ignition Input A Ignition ...

Page 15: ... Fus 50A e 5 4 Connection diagrams Individual FuelTech CDI Racing Ignition Coil Bobina H Bobina A Bobina A ABC ABC ABC ABC ABC ABC ABC ABC FTSPARK 4 A A ABC ABC ABC ABC ABC ABC ABC ABC Cylinder 7 Cylinder 8 Cylinder 1 C 2 ylinder C 3 ylinder C 4 ylinder Gray Output 5 Gray Output 6 Ignition input E Ignition input F Cylinder 5 Cylinder 6 Gray Output 1 Gray Output 2 Gray Output 3 Gray Output 4 Fus 50...

Page 16: ...re GND from FTSPARK Orange wire 12 pulse from FTSPARK Coil GND ABC ABC 4 Cylinder with multiple wires Cylinder 1 C 2 ylinder C 3 ylinder C 4 ylinder Bobina H ABC ABC ABC ABC ABC ABC ABC ABC FTSPARK 4 Gray Output 1 Gray Output 2 Gray Output 3 Gray Output 4 A A Fus 50A e Battery Ground Signal Reference Power Supply 12V Switched FTSPARK activation Battery Ground Power Ground Ignition Switched Ignitio...

Page 17: ...nput C Ignition input D CAN Network Connection Orange Black wire GND from FTSPARK Orange wire 12 pulse from FTSPARK Coil GND ABC ABC 6 Cylinder with multiple wires Bobina H Bobina A Bobina A ABC ABC ABC ABC ABC ABC ABC ABC FTSPARK 4 A A ABC ABC ABC ABC Cylinder 1 C 2 ylinder C 3 ylinder C 4 ylinder Cylinder 5 Cylinder 6 Gray Output 1 Fus 50A e Battery Ground Signal Reference Power Supply 12V Switc...

Page 18: ...ivation Battery Ground Power Ground Orange Black wire GND from FTSPARK Orange wire 12 pulse from FTSPARK Coil GND ABC ABC Battery Ground Signal Reference Ignition Switch Ignition Switch Bobina A Bobina A ABC ABC ABC ABC ABC ABC Fus 50A ivel Bobina H Bobina A Bobina A ABC ABC ABC ABC ABC ABC FTSPARK 8 BOX A FTSPARK 8 BOX B ABC ABC ABC ABC Cylinder 1 Cylinder 4 Cylinder 6 Ignition input A Cylinder 2...

Page 19: ... Bobina A Leading rotor 1 L1 Leading rotor 2 L2 ABC ABC ABC ABC ABC ABC Leading rotor 3 L 3 Bobina A ABC ABC ABC ABC ABC ABC Trailing rotor 1 T1 Trailing rotor 2 T 2 Trailing rotor 3 T 3 Gray Output 1 Learding rotor 1 L1 Gray Output 2 Learding rotor 2 L2 Gray Output 3 Learding rotor 3 L3 Fus 50A e Battery Ground Signal Reference Power Supply 12V Switched FTSPARK activation Battery Ground Power Gro...

Page 20: ...GND Ignition input A Ignition input B Ignition input C Ignition input D 1st cylinder on firing order 2nd cylinder on firing order 3rd cylinder on firing order 4th cylinder on firing order ABC ABC Ignition pins assignment After FTSPARK installation follow the steps below if changes on the ignition outputs are needed 1 Open the map on FTManager 2 Click on Sensors and calibration Outputs 3 Check whic...

Page 21: ...will make FTSPARK Ground operate with maximum energy Function Color Wire Gauge Ignition output COILS Orange AWG 16 1 5mm2 isolation 750V Ground ignition COILS Orange Black AWG 16 1 5mm2 isolation 750V BAT Black AWG 16 1 5mm2 Isolation 300V until the splice and after AWG 10 4 5mm2 BAT Red AWG 16 1 5mm2 Isolation 300V until the splice and after AWG 10 4 5mm2 Ignition input Gray AWG 20 0 5mm2 Isolati...

Page 22: ...cables together with the other FTSPARK wires or other electrical wiring in the vehicle The output cables that connect to the coils may induce a high amount of current in surrounding wires which can cause malfunction in other systems of the vehicle and even damage inputs and outputs of other modules It s recommended to keep a distance of at least 4 between the ignition coils wiring and all other wi...

Page 23: ...PARK output 6 FTSPARK control FTSPARK has two operation modes Individual triggering using two or more ignition outputs or through Serial bus 1 wire 6 1 Individual triggering For the Power FT product line it is necessary to enable the FTSPARK option and select multiple outputs in the ignition settings For older modules it s necessary to select SparkPRO 3 wires option with a dwell time of 3 ms Longe...

Page 24: ...h FuelTech products 1 Female connector 2 Male connector 3 CAN terminator Plug the male connector from the FTSPARK harness 2 to the female connector on the back of the ECU In case you have other products that are already connected to the CAN network WB O2 Nano for instance then connect the male connector from FTSPARK to the female connector from the WB O2 Nano It may be necessary to remove the CAN ...

Page 25: ...If it s not connected product will operate normally with energy set by the energy setting wire IMPORTANT In order to run on 750mJ of energy when not connected to a FuelTech ECU through CAN network the Energy level selection wire pin 9 yellow wire must be connected to the battery negative If this wire is not connected the FTSPARK will run on 400mJ only Operation without CAN network Select energy le...

Page 26: ...on rotary engines which has the sparks timed very close to each other and wasted spark on engines with up to 4 cylinders IMPORTANT Only engines with 4 cylinders or less can use the wasted spark configuration Engines with 5 to 8 cylinders must use sequential ignition 6 7 Safety Features The FTSPARK has many internal safety protections to avoid damage to the product in case of misuse or improper ins...

Page 27: ...o add 20uS to the ignition delay on the ECU 7 Recalibrating ignition and fuel map The additional energy generated and precise ignition timing related to short spark duration generally require ignition map to be recalibrate when FTSPARK is installed to replace an inductive system The additional spark energy allows the engine to operate with richer mixtures before failure or loss of power It s possi...

Page 28: ...low minimum FTSPARK switches off during this fault condition It may be caused by a power failure on FTSPARK or discharged battery 43 Hardware error FTSPARK can not charge the capacitors Probable output failure Contact FuelTech 44 Hardware error FTSPARK has internal protection fuse ruptured This fuse is not accessible and can not be replaced by the user Contact FuelTech 9 FTSPARK settings and opera...

Page 29: ...uelTech PowerFT ECU 2 Turn ignition ON to power FTSPARK boxes 3 Under the tab Tools in the top of the software select CAN Network 4 In the case that the units are all Box A the product icon in the left column will show up as just one Click on top of the product and select the module you want to identify according to it s serial number to become the Box B and select Identify to blink the desired pr...

Page 30: ...A 1 B 2 C 3 D 4 E 5 F 6 G 7 H 8 4 cylinders FTSPARK 8 EXTREME Output Cylinder A 1 B 2 C 3 D 4 Using FTSPARK EXTREME on 6 and 8 cylinder engines is necessary 2 units select Box B to control cylinder 2 3 5 and 8 This configuration is only possible with FTSPARK Generation 2 750mJ or FTSPARK EXTREME 1500mJ FTSPARK Generation 1 600mJ does not allow this configuration NOTE On step 4 if having difficult ...

Page 31: ... 4 3 Output Cylinder A 1 B 4 C 3 D 2 Subaru 1 3 2 4 Output Cylinder A 1 B 2 C 3 D 4 ROTARY setup engines The order must be altered so that the Leading and Trailing outputs of the same rotor are placed in sequence as shown in the table below WARNING The setup on the following table is mandatory on a ROTARY engine because the Trailing and Leading coils will fire practically at the same time and they...

Page 32: ...connector Supply voltage shows the effective power received by the FTSPARK Supply voltage drop shows the difference of the voltage supply between the FTSPARK and the ECU In case this value is too high there might be a problem on the power harness of the FTSPARK Capacitor voltage 1 and 2 FTSPARK has two banks of capacitors that are charged and discharged alternately on the outputs allowing higher e...

Page 33: ...he shutdown Low voltage on the 12V switch Voltage below 12V Check the battery or a harness problem Low voltage on the 15V power supply Internal problem Send to FuelTech s technical assistance Charging circuit can not load the capacitors This message is always displayed along with the reason that caused the shutdown It may be a hardware problem or the positive power disconnected off Overvoltage on ...

Page 34: ...ad connected at output There is nothing connected at the output Check the harness coil and connectors Output with partial discharge The coil is not consuming all energy sent by FTSPARK Check the harness coil and connectors 10 FTCAN 2 0 protocol FTSPARK has an advanced diagnosis system for malfunctions faults and problems This helps a lot to diagnose and monitor the functions of your ignition syste...

Page 35: ...N data field 0x01 Standard CAN data field coming from going to a bus converter 0x02 FTCAN 2 0 data field 0x03 FTCAN 2 0 data field coming from going to a bus converter 10 3 IDENTIFICATION Each product that wants to send data to the CAN bus must have a unique identifier Devices that will only receive data from the CAN bus don t need to have a unique ID IDENTIFICATION 29 bits Bits 28 to 14 15 bits B...

Page 36: ... data layout all 8 bytes of the DATA FIELD will be forwarded by the bus converter The DataFieldID 0x01 is also used to identify packets that are originated outside the CAN bus Bridge examples are Standalone USB CAN converter FT500 s USB CAN bridge etc DATA FIELD 1 to 8 bytes 0 1 2 3 4 5 6 7 PAYLOAD DataFieldID 0x02 FTCAN 2 0 This is the DataFieldID that all FuelTech s devices will use to communica...

Page 37: ...ollowing information SEGMENTATION DATA 2 bytes Bytes 1 2 Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 RFU RFU RFU RFU RFU PAYLOAD total length in bytes RFU Reserved for Future Use DataFieldID 0x03 FTCAN 2 0 Bridge bridge gateway or converter This DataFieldID uses the same data layout from DataFieldID s 0x02 when the data is going to or coming from a BUS converter 10 5 Attachments ProductID s list Si...

Page 38: ...AP TPS etc Values are always transmitted as signed 16 bits in big endian byte order Statuses are transmitted as big endian unsigned 16 bits Each real time data will be composed of 4 bytes REAL TIME DATA 0 1 2 3 Data identifier MeasureID Value or status big endian If a device needs to broadcast more than one reading at the same time it can do so using a segmented packet Segmented packet PAYLOAD MEA...

Page 39: ...ntify the data that is being transmitted MeasureID Bits 15 to 1 Bit 0 Data identifier DataID 0 Data value 1 Data status MeasureID DataID Description Unity Multiplier Broadcast source rate 0x00A4 0x0052 External Ignition output 1 discharge time uS 1 FTSPARK 50Hz 0x00A6 0x0053 External Ignition output 2 discharge time 0x00A8 0x0054 External Ignition output 3 discharge time 0x00AA 0x0055 External Ign...

Page 40: ... 0x00DE 0x006F External Ignition no load outputs Note 2 0x00E0 0x0070 External Ignition partial discharge outputs 0x00E2 0x0071 External Ignition damaged outputs 0x00E4 0x0072 External Ignition disabled outputs 0x00E6 0x0073 External Ignition operation status Note 3 0x022C 0x0116 External Ignition Switch voltage V 0 001 0x022E 0x0117 External Ignition CPU supply voltage 0x0230 0x0118 External Igni...

Page 41: ...C 0x0166 External Ignition Switch voltage B V 0 001 0x02CE 0x0167 External Ignition CPU supply voltage B 0x02D0 0x0168 External Ignition CPU temperature B C 0 1 0x02D2 0x0169 External Ignition operation time B S 0 1 FTSPARK 10Hz Note 1 Bit 0 Unknown pulse width received by the FT Ignition Bus Bit 1 Incorrect ignition order in semi sequential operation Bit 2 Over voltage in the high voltage bus ext...

Page 42: ...42 FTSPARK 111 55 mm 135 00 mm 153 00 mm 125 00 mm F T S P A R K 8 EXTREME EXTREME 1500MJ 1500MJ 11 Dimensions ...

Page 43: ......

Page 44: ...FuelTechUSA USA 455 Wilbanks Dr Ball Ground GA 30107 USA Phone 1 678 493 3835 Toll Free 1 855 595 3835 E mail info FuelTech net www FuelTech net ...

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