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KMS 06.001-1, Manual

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KMS 06.001-1 Manual Download Page 54

 

      

 KMS MA-5 manual 

       Version 5.1     

 

54    

 
 

5  Hardware installation 

 
 
To guarantee that the system functions properly, it is of utmost importance to adhere to the 
instructions given below. 
 
 
Fitting the ECU 
 
 
It is important that the ECU should be fitted in a dry and not too hot place. When fitting it, make sure 
that the USB-C panel mount connector can be installed/ reachable. This is needed for communication 
with the ECU 
 
 
Connecting the communication cable 
 
 
Installed in the basic loom is a USB-C panel mount connector. Use a standard USB-C cable to 
connect the ECU to your computer. 
 
 

Summary of Contents for 06.001-1

Page 1: ...MA5 Manual V5 1 ...

Page 2: ...ambda control 25 3 4 1 9 Boost control 32 3 4 1 10 A L S 37 3 4 1 11 AUX 1 38 3 4 1 12 AUX 2 38 3 4 1 13 AUX 3 38 3 4 1 14 External Dashboard 39 3 4 1 15 Remarks 40 3 4 1 16 Communication port 40 3 4 2 Output test 41 3 4 3 Crankshaft sensor test 41 3 4 4 Motor system diagnostics 42 3 4 5 Change user access level 45 3 5 Correction tables 46 3 6 Idle control 48 3 7 Up down load function 49 3 8 Lambd...

Page 3: ... The same way the ignition spreadsheet can be setup By modifying these values while monitoring the exhaust gas composition best way is using a wide band lambda sensor you can see if the engine runs rich or lean This way you can find the optimal amount of fuel and optimal ignition moment needed for all possible combinations of RPM and throttle position manifold absolute pressure This process can be...

Page 4: ...and fuel system components must be mounted away from heat sources or shielded if necessary Do not use a batterybooster or a 24V charger Do not reverse the polarity of the battery or the charging unit Do not change the battery with the engine running The peak power supply could severely damage the KMS ECU and other electrical devices Avoid open sparks and flames near flammable substances Do not use...

Page 5: ... found on our download section kms vankronenburg nl downloads Once installed the program is set to work via communication port COM1 If this port is already being used or not available another communication port can be used For the procedure to change the communication port see Communicationport USB connections have the most various numbers of communication ports so make sure you ve got the communi...

Page 6: ...een When the program is started the main screen will appear which is composed of three parts The Injection table can be switched to the Ignition table The function bar The communication bar These sections describe the possibilities and functions of the system ...

Page 7: ...m to 12 500 rpm This however can be changed see RPM pickup The RPM range is divided over 25 boxes The engine load range is sub divided into 16 boxes dividing the range that has been set for the engine load sensor The rows and columns are shown in graphs in the form of bar charts when the left mouse button is clicked on an engine speed or a load value For further information see section Programming...

Page 8: ...ition characteristic diagram In the ignition spreadsheet figures can be entered that indicate the ignition advance in crankshaft degrees before TDC This means that for any engine speed and any engine load the desired ignition moment can be entered ...

Page 9: ...tputs The following readings will show These readings can be used to check whether the right sensors are being used and all settings are correct There is an option to get an enlarged picture of the lambda sensor reading by clicking on the display bar An extra reading window will appear at the top of the screen 3 1 3 The function bar The vertical bar on the right hand side of the screen shows sever...

Page 10: ...d by a crown icon MA5 files have the extension m06 3 3 Save file This function key is used to save modified files The names of these files automatically receive the extension MA5 files have the extension m06 3 4 Options When this function key is activated a menu will appear on the screen which gives the option of several settings and tests The options will be explained in the following sections ...

Page 11: ...KMS MA 5 manual Version 5 1 11 3 4 1 Options If Options is selected a menu appears which lists several possible settings These settings are described below ...

Page 12: ...n the function you can set the rpm range for the main parameter maps minimum rpm is 500 and maximum is 20 000 Standard the 25 rows are divided over a rpm range 12 500 rpm example see left figure below If your engine doesn t make more than 6 500 rpm you can devide the 25 rows over this 6 500 rpm example see right figure below So the mapping will be more fine tuned for this engine rpm range ...

Page 13: ...patible with all engine types Possible combinations are listed in this table Some trigger patterns are shown in Appendix 1 Trigger pattern drawings When using a 60 2 trigger pattern the maximum engine speed is limited to 12 500 rpm We have for example a 150mm 60 2 trigger wheel available on our webshop KMS partnumber KMI 01 602 When using a Hall sensor it is nescessary to use a convertor that will...

Page 14: ...ure a built in driver stage However if a coil without an integrated driver stage is used the separate KMS ignition driver module with part number KAC 05 002 will be needed Dis coil The choice is between dis coil wasted spark and single coil control rotor and distributor cap If you have a dis coil and also when using coil per plug wasted spark the box has to be ticked If you use a rotor with distri...

Page 15: ...le to prevent backfiring when the engine is started For engines with a high compression ratio it is recommended not to set this to a number higher than 1 Injection in x stroke mode The injection frequency x can be set to 2 times per crankshaft revolution x 1 1 time per crankshaft revolution x 2 1 time per two crankshaft revolutions x 4 Normally it is recommended to select the 4 stroke setting ...

Page 16: ...ntiometer signal to the analog aux input which can be configured for this function see Hardware configuration The potentiometer must have a range between 1 kΩ and 47 kΩ The 5V and ground for the potentiometer are available from the 5V ground sensor supply The signal of the potentiometer must be connected to the Analog Aux 1 Advanced settings This can be used to build up boost pressure before start...

Page 17: ...mmended or NC the NC box should be ticked If the use advance settings control box is selected the advanced settings menu must be set Advanced settings In this menu you can adjust the shift time for each gear However a position sensor must be present on the transmission housing for this purpose In this menu you can then specify the ascending output voltages corresponding to the various gears This c...

Page 18: ...on the side you can see all the possible combinations The possible combinations are explained below Engine load 1 Throttle Position Sensor All the load tables included lambda target are linked to TPS value This is normally used for N A engines with throttle bodies Engine load 2 MAP or MAF All the load tables included lambda target are linked to MAP or MAF value This is normally used for turbo supe...

Page 19: ...gine running smooth with changing the complete fuel map all cells at once with positive or negative percentage using the edit menu If lambda control is active and the engine is at normal operating temperature you can start programming the separated cells in the fuel map with the boost pressure set as low as possible After the injection table is mapped at low boost the next step is to raise the boo...

Page 20: ...throttle positions will now be shown A warning will appear if automatic calibration cannot be finished correctly For possible causes see Troubleshooting Manual calibration When a map sensor or an air mass sensor is used automatic calibration is not easy because the minimum and maximum output signals of the sensor are not known before the engine has run We recommend filling in the figures by hand m...

Page 21: ...ided in proportion to the signal MAP sensor Logarithmic At lower loads the load signal is divided over a smaller number of steps and at higher loads it is divided over a larger number of steps Air mass sensor e log The action is opposite to that of the logarithmic parabola Single Throttle body setup ...

Page 22: ... pulse can be filled in for four coolant temperature ranges Above the highest temperature the normal startup pulse will be used 3 4 1 5 Throttle pump effect When the throttle valve is opened the engine will draw in more air and therefore need more fuel to keep the mix ratio at a constant level As air is a gaseous substance it will reach the inlet valve earlier than the liquid fuel which because of...

Page 23: ...nal enrichment is needed The amount of extra fuel will slowly decrease during these rotations Sensitivity and the amplifier function the same as they do with the initial burst The additional enrichment can be increased by a percentage for the water temperature More enrichment is needed with a low water temperature The figure on the right gives an indication of how these two types of enrichments af...

Page 24: ... air pressure External using a 75 120kPa KMS pressure sensor on the MAP input Internal if available this can be selected to use the ECU internal pressure sensor With the Air pressure compensation is set to active External or Internal the correction table for Air pressure in Mbar is active See Correction tables Diagnostic output This is an option to check whether the lambda control is still active ...

Page 25: ...pes of output signal type a b and c Always check if the output type is the same as selected in this software Use Lambda sensor 1 with correction on injection group 1 the only option for using a MA5 Remaining options only work for the MA6 or MD35 Lambda scaling In this menu the values of the different types of sensors controllers are visible not adjustable The KMS UEGO display controllers are pre c...

Page 26: ...ue specifies the delay before the ECU reactivates the A F ratio feedback control after an engine has returned to idle In this way idle rpm can stabilize first before the A F feedback control takes effect Recommended value 0 5 1 5 sec Max inc in Fuel Specifies the maximum positive increase injection compensation Max dec In Fuel Specifies the maximum negative decrease injection compensation Overrun ...

Page 27: ...d reduction of the throttle position without entering throttle overrun state the air fuel ratio feedback control has to be deactivated in most engines At a certain deceleration speed the lambda signal is disturbed due to less efficient combustion Here you can specify the decreasing rate that triggers the de activation of the lambda control The value input here represents the decrease in engine loa...

Page 28: ...c in 1 sample Specifies the maximum negative injection compensation between two samples as a percentage If 0 0 is set in here this function is not active For example if the sample rate is set on 10 samples per second The maximum decrease in 1 sample is set on 0 5 Then the lambda control can only compensate 10 x 0 5 5 fuel decrease per second Up to main load Above this main load value there is no l...

Page 29: ...vent the A F ratio feedback control from curtailing supplementary enrichment Min Fluctuation at warm up Before the A F ratio feedback control will activate the oxygen sensor signal first has to fluctuate with the amplitude set here This is a way to recognize if the lambda sensor is connected and working Recommended 0 2 0 5 Max time at max increase Here you can input the maximum permissible time fo...

Page 30: ... map can be selected and send as a correction percentage to the injection map Thus the map can be adapted to minimize percentage of the A F ratio feedback control which ensures optimum driving characteristics Make sure that the engine runs smooth after the correction percentages are send to the injection map After the percentages have been send to the injection map the entire correction map needs ...

Page 31: ...s and engine loads the sample rate can be set higher due to more combustions per second and higher exhaust gasflow If the sample rate is set too low the lambda control does not reach the desired target in time On the other hand when the sample rate is set too high the lambda control will get instable Warm up A F limits At lower engine temperatures you can set an upper limit on air fuel ratio Lambd...

Page 32: ...vated in the hardware configuration the boost pressure will be regulated by the PWM percentages in the PWM table Boost PID control Here you can select to activate the control to not only use the fixed PWM values from the PWM chart but PID control calculates an error value between the measured and the target boost The controller attempts to minimize the error by adjusting the solenoid position unti...

Page 33: ...eration of the solenoid valve at low revs Boost Limit ignition cut off In case the boost pressure exceeds the target value risk of engine damage you can specify a limit with this parameter When the boost pressure reaches this limit ignition and injection will be interrupted Setup pressure To allow the turbo system to respond as quickly as possible but not overshooting the target it is important th...

Page 34: ...pressure to its target value The gain factor can be entered here Only used for the Boost PID control Boost target map Via this menu you can enter target boost pressures for separate engine speeds This target will be used only when PID control is set active and TPS value is higher then 15 Only used for the Boost PID control Boost PWM map In this field you can specify for each throttle opening and r...

Page 35: ... the percentage entered here Only when PID control is activated Overboost PWM map If overboost is active the system will use the overboost PWM map The values in the boost PWM map can be easily copied to the overboost PWM map by selecting the cells and choose copy boost to overboost map So the values in the overboost PWM map can easily be increased by a percentage over the boost PWM map values Enab...

Page 36: ... the feature to reduce boost pressure at each separate gear only possible if the gearbox is calibrated in the system The values which can be set here are correction percentages on the actual used PWM map Boost reduction to speed This function is only available in the MA6 and MD35 ...

Page 37: ...el can be added To limit the boost pressure also a fixed PWM value can be set The fuel enrichment and PWM boost are both percentages If using variable A L S by connecting a potentiometer signal you can vary the PWM value from 0 to the value set here in the A L S settings The potentiometer must be in the range of 1 kΩ 47 kΩ The variable signal from the potentiometer must be connected analog aux inp...

Page 38: ... is activated when both the values set are exceeded If none is selected this channel will be ignored A hysteresis can be set for each AUX output This means that the switching ON value can be set higher than the switching OFF value The advantage of this is that the output does not need to be switched on and off unnecessarily An example is a cooling fan that activates at 90 degrees and deactivates a...

Page 39: ...ues to an external dashboard data logger or Bluetooth dongle This data is being send over a canbus you can set the speed of the canbus 0 5 MHz 1 MHz You can configure your dashboard or data logger so that it can read the KMS canbus should you have any difficulties please contact our professionals for support ...

Page 40: ...1 16 Communication port Use the AutoSearch Com port to find the correct com port once the correct com port has been found use save this setting by using the Save button The Open device manager can be used to check which port is used by the MA5 Please check the troubleshooting page should you have communication issues ...

Page 41: ...p is switched off 3 4 3 Crankshaft sensor test The crankshaft sensor function is used to check whether the crankshaft position sensor registers the correct number of teeth The number of teeth shown should be 60 for a 60 2 toothed wheel and 36 for a 36 1 version If another reading is shown check whether the sensor is correctly connected and properly mounted Electronic interference can occur when th...

Page 42: ...s of the ECU and engine ECU Indicates how long the ECU was powered 500 rpm 1 Indicates the running time of engine above 500 rpm 500 rpm 2 Indicates the running time of engine above 500 rpm Under reset runtime 500 rpm 2 the runtime 500 rpm 2 can be reset The runtime 500rpm 1 as well as runtime ECU cannot be reset Over revving of the RPM limiters In this part you can see how many crank turns the eng...

Page 43: ...U The management software will automatically ask if you want to save the changes you made when you close the system diagnostics screen The maximum water temperature that was reached is shown Air temperature sensor This part is for the diagnostics of the air temperature sensor or measurements from the sensor The air temperature and engine load have to be setup before because afterwards when the fau...

Page 44: ...w is to narrow Lambda control The total time that the maximum increase or decrease in fuel has been reached is recorded here as MaxIncLambda or MaxDecLambda The values for maximum increase in fuel or maximum decrease in fuel are set in Lambda Control see section Lambda control The time behind MaxIncLambdaError or MaxDecLambdaError is the total time Lambda control was shut down as a result of maxim...

Page 45: ...played Motor system diagnostics resettable Reset from menu possible ECU settings read only Settings are displayed but not adjustable Display dashboard only Only the communication bar is displayed no maps No access to ECU No access to ECU The standard password in the system can be changed to a password you like The standard password is kms To save the changes made click Send tot ECU ...

Page 46: ...esult the mix becomes too weak so that the engine will hesitate To compensate for the loss of fuel at low engine temperatures more fuel will have to be injected There is also an option to completely cut off the injection so no fuel will be injected If you insert exactly 100 in the water temp correction fields fuel will cut off completely In the ignition correction table you can enter percentages f...

Page 47: ...age decreases with the risk of engine damage In this table this effect can be compensated for by matching the injector opening time to the battery voltage The correction values are indicated in ms per injection For instance 0 68 ms will be added to the duration of injection when the battery voltage is 12 6V The table is suitable for injectors with a resistance of 12Ω to 15Ω Atmospheric pressure co...

Page 48: ... temperatures you can increase the idle valve opening You can set up 3 different temperatures between the increase takes place Airco settings The system can compensate extra air and fuel when air conditioning system is activated Tick the box when the airco switch is normally closed The airco activating signal from the pump needs to be connected on the powershift input pin This is pin 20 on the con...

Page 49: ... in the system will be lost when the power supply to the system is broken 3 8 Lambda function This function key allows temporary activation deactivation of the air fuel ratio feedback control However the control will resume if the system has been without voltage or if the F8 key is pressed again 3 9 Interpolation function With this key the interpolation between the boxes can be switched on or off ...

Page 50: ...hat the battery of the vehicle supplies more than 10V If the battery doesn t exceed 10V the changes you made to the ECU will not be saved Warning Make sure you press the correct button ECU Pc downloads the data from the ecu connected to the PC Shortcut ALT E or ALT S used in old versions PC ECU downloads the data from the PC to the connected ECU Be careful with using the PC ECU button after downlo...

Page 51: ...is found or selected please use the Autosearch Com port button to find the com port that is used for the connection Remaining shortcuts 3 14Shortcuts To work quicker and easier there are several shortcuts created that can be used find below an overview of all shortcuts ALT H Shortcut overview ALT R Show Row in Graph ALT C Show Column in Graph ALT B Show Battery voltage in Graph ALT I Show Inlettem...

Page 52: ...elated to that engine speed If an engine load value is clicked a bar chart will appear showing all the values related to that engine load value Access to the bar charts can also be obtained by pressing the ALT C keys or the ALT R keys simultaneously The thin yellow line in the graphs of the injection diagram indicates the maximum duration of injection for the engine speed concerned If the yellow l...

Page 53: ...l to properly function Conditions Water temperature above 60 Degrees if installed No faults active that are set up under Lambda control Fault settings Engine speed doesn t fluctuate too much Lambda control switched on under Lambda control Lambda control on Then the lambda control will fill the correction map Lambda control Corr Map1 Opening this map quick key Alt T shows all the adjustments perfor...

Page 54: ... the ECU It is important that the ECU should be fitted in a dry and not too hot place When fitting it make sure that the USB C panel mount connector can be installed reachable This is needed for communication with the ECU Connecting the communication cable Installed in the basic loom is a USB C panel mount connector Use a standard USB C cable to connect the ECU to your computer ...

Page 55: ...perature is suitable for an NTC sensor as standard 2 2kΩ at 25 Celsius Input for engine load is suitable for potentiometers air mass meters and map sensors with an output between 0 and 5V Outputs Injector output can deliver at most 7A at 12V for instance 6 injectors with a resistance of 16Ω Shift lamp AUX cooling fan and fuel pump outputs max 1A at 12V per output Dimensions LxWxH 117 x 86 x 38 mm ...

Page 56: ... change this in the properties compatibly Run this program as an administrator Disconnect the ecu under the Window button you can find Run if windows is in English this opens a command in which you can type devmgmt msc this opens the Device manager Under View select Devices by type and Show hidden devices In the main window open the Ports Com LPT tree and delete all the devices shown here that are...

Page 57: ...ng Engine load Auto calibration gives message warning range too small Auto calibration gives message warning signal reversed Auto calibration gives message engine load sensor not connected Sensor range too small or potentiometer connected incorrectly Throttle valve potentiometer turns in the wrong direction The engine load sensor signal does not change Interruption in potentiometer signal wiring o...

Page 58: ...ning engine Lambda sensor isn t warm fast enough to start measuring while the engine has just started Check the fault settings for example the minimum fluctuation at startup see Lambda control Check the led light indication of the Lambda UEGO controller Adjust the injection ignition timing and air flow Under Lambda control change the delay from start to on to a longer period ...

Page 59: ...tions Minimum system requirements Windows 95 98 2000 NT ME XP Vista 7 8 and 10 Internal memory 32Mb Screen resolution 1024x768 Standard USB port Latest Adobe Acrobat reader can be downloaded from our website https kms vankronenburg nl downloads ...

Page 60: ...KMS MA 5 manual Version 5 1 60 8 Appendix 1 Trigger pattern drawings ...

Page 61: ...KMS MA 5 manual Version 5 1 61 ...

Page 62: ...KMS MA 5 manual Version 5 1 62 ...

Page 63: ...KMS MA 5 manual Version 5 1 63 ...

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