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MegaSquirt DBWX2, Abridged User Manual, Page: 5 / 24

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MegaSquirt DBWX2 Abridged User Manual Download Page 5

 

 

Wiring 

Steps to take for a good install with custom wiring 

1. Make sure that you have the proper crimping tools 
2. Use proper gauge wire 

 

Connector and pin part numbers: 

Molex MX150 Black connector:

33472-1201 

Molex MX150 Gray connector:

33472-1202 

Molex MX150 Pins for 22AWG:

33012-2003 

Molex MX150 Pins for 18-20AWG:

33012-2002 

Molex MX150 Pins for 14-16AWG:

33012-2001 

 

Wire gauge: 

Use 14AWG or 16AWG wire as the power input and ground input to the controller. Motor wires to 
the throttlebodies can be smaller but recommendation is 16AWG. Sensor wires do not carry large 
currents so they can be freely selected by the installer / loom maker. Use correct pin sizing to the 
wiring as per Molex connector specifications.  

 

Proper crimping: 

As the currents that flow through the controller are large, it is extremely important to have the 
best possible connections from the wires to the controller, battery and throttlebody. If a 
connection exceeds the nominal connection resistance (read: badly crimped), it will reap havoc to 
the analog signals and cause unstable operation! 

 

4 

Summary of Contents for DBWX2

Page 1: ...Users manual DBWX2 Controller Not For Release BETA ...

Page 2: ...lt codes 7 PID Settings a Operating modes b Throttlebody specific settings 8 Configuring fault output 9 Step by step initial configuration guide a Setting up DBW throttle to MegaSquirt 3 Trademark Legal Notice All product names trademarks and registered trademarks are property of their respective owners All company product and service names used in this document are for identification purposes onl...

Page 3: ...ependent PID controller that is user configurable Safety is handled by using dual cpus The redundant cpu architecture makes the controller one of the safest in the industry Both cpus monitor the pedal and throttle butterfly positions independently and will disable the throttle if a malfunction in the system is detected 2 ...

Page 4: ...puts to be used to drive the brushed DC motors in DBW throttlebodies These outputs are protected from short to ground and 12V Gray connector 1 DBW1 motor 2 DBW1 motor 3 DBW1 ref 5v out 4 DBW2 ref 5v out 5 DBW2 motor 6 DBW2 motor 7 DBW1 ref gnd 8 DBW1 main sense in 9 DBW1 secondary sense in 10 DBW2 ref gnd 11 DBW2 main sense 12 DBW2 secondary sense Black connector 1 12V IN 2 12V in 3 Pedal main 5v ...

Page 5: ...und input to the controller Motor wires to the throttlebodies can be smaller but recommendation is 16AWG Sensor wires do not carry large currents so they can be freely selected by the installer loom maker Use correct pin sizing to the wiring as per Molex connector specifications Proper crimping As the currents that flow through the controller are large it is extremely important to have the best po...

Page 6: ... be slightly longer than the tab that will be crimped over it Step 2 Crimp the tab that holds the wires copper strands in place Note how the copper protrudes from the crimped portion If no copper is showing the crimp is faulty and must be dismissed Tug on the wire to verify proper crimp The wire should not be loose 5 ...

Page 7: ... are affordable even for the hobbyist Added bonus is that the crimpers can be utilized with most of the open barrel automotive connectors Soldering Do not solder Soldering the connectors may result in the wires cracking at the connector end Also if solder gets inside the pin it will lock the spring in the pin connector resulting intermittent failures This type of failure is especially nasty becaus...

Page 8: ... sure that the white plastic part from inside the connector is pulled out This can be verified by making sure that the plastic piece is protruding from the connector If the plastic is not showing you can use a small screwdriver to pry it out from the connector 7 ...

Page 9: ...on of the pin Top row has the dimple on top and bottom row at bottom You can hear an audible click as the connector is seated Tug on the wire to confirm proper pin seating After all pins have been inserted push the white plastic piece in to the connector to lock all the pins in place Now the wiring of the connector is complete 8 ...

Page 10: ...s in the best operation From electronics revision C onvard controller has a user programmable CAN bus termination resistor that can be enabled from the tuning software Also an open collector output has been added This is a grounding type output This is intended to be used as a main power for the engine to provide an additional layer of safety Installer can configure this output to be normally open...

Page 11: ...Wiring the accelerator pedal 10 ...

Page 12: ...DBW connections 11 ...

Page 13: ...udio if its running After unzipping the firmware update you should see firmwareupdater exe or similar name Double click on it to start the update You can press ENTER for every question so that defaults will be selected Successful update can be verified by connecting to the controller with Tunerstudio 12 ...

Page 14: ... tripped if the input voltage goes momentarily below 11 volts This is an aid to the installer to check the wiring to the controller if this warning is shown Pedal main and secondary sensor error This error is triggered if the input voltage from the accelerator pedal sensor is out of calibrated specification Pedal sync error This error is triggered if the calculated percentage values from main and ...

Page 15: ... makes the main CPU to resend the calibration data to the AVR CPU If a fault condition is not cleared by clear button try to update the avr data to see if the fault condition was caused by calibration data mismatch The sensor fault codes are the same as in the ARM fault code menus Compared to the ARM codes there are a few extras The AVR CPU monitors the H bridge statuses and these can be seen from...

Page 16: ...s message is not received for any reason Selectable options are off or one of the throttle curves Throttlebody specific settings Throttle PWM Frequency This setting selects the operating frequnecy Range is from 750Hz to 20000Hz The H Bridge works at better efficiency if a lower frequency is selected but there will be an audible noise from the DBW throttlebody Throttle motor max dytycycle This sett...

Page 17: ... can limit the maximum PID calculation outputs The PID controllers internal register are logged and can be viewed from the logs These values will clamp the calculated values to the set values BIAS The DBW controller also has a table that is called either bias or feed forward table This is basically an open loop of the control strategy We have found that a well tuned PID control may not need this t...

Page 18: ...User can configure the outputs PWM frequency and dutycycle in normal and fault operation Also the configuration makes possible to ignore faults in channels that are used as auxiliary channels that does not require the fault output to be tripped Default state of the channel is high impedance 0 duty It is recommended to make the connected external circuit operate so that fault state is 0 duty 17 ...

Page 19: ...led Disable AVR CPU Click on it and you will see the text in the throttlebody calibration menu change to AVR Protection disabled and change color to blue from yellow Also you will get a faultcode in the AVR indicating that the protection features is disabled Now you can press on the Calibrate DBW button and the controller will automatically drive the DBW throttlebody to the maximum and minimum pos...

Page 20: ...r in anger the driver can stomp on the accelerator and it will read past 100 This will cause an error code and will result in the controller entering limp mode Make sure that the secondary sensor cal is Linear The table is only used with uncommon sensors from the early 2000 era Now we have calibrated all of the sensors You will probably have fault codes registered in the controller Go in to the Fa...

Page 21: ...es You will not get the absolute best possible results but they should result in good operation for most throttlebodies Now is the time to choose the operating mode You can test the throttle in standalone modes but usually the throttlebody is controlled via the ECU Select MS Can if you intend to use DBW throttle on your MegaSquirt 3 project 20 ...

Page 22: ... needs to match with megasquirt and all other devices sharing the CAN bus Enable the MS DBW messaging If this is the last or only device on the CAN bus with megasquirt you can enable the internal bus termination resistor here NOTE If you needed to make changes to the CAN bus id s you will need to restart the controller to the changes to take effect TunerStudio should prompt you to restart after id...

Page 23: ...e Additional throttles You can use the table to set the throttle opening to you liking Avoid 100 and 0 values as they mean that the throttle butterfly is driven to the mechanical endstop Usually the throttlebody is fully open in the 95 range You can verify this visually by looking in the DBW throttlebody Also it is not usually needed to close the throttle completely You should use values such as 1...

Page 24: ... these at 4 for optimal operation and safety This table is the maximum allowed DBW butterly opening mapped to accelerator pedal position This table will overrule any other requests Set the 0 20 area so that in the event of corrupt request via CAN bus won t cause spontaneous acceleration if the throttle is not pressed This table is monitored by both processors It is the responsibility of the instal...

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