XDI Manual Version 1.8
Page 7
2017 Electromotive, Inc.
Built-in timing monitor lets you measure the advance with a voltmeter
Options include: backup sensor, dual rev limiter, and remote timing control
1.3 Choosing Spark Plugs and Wires
1.3.a Spark Plug Wire Selection
The XDI outputs an extremely high-energy charge for the ignition coils. Resistor (carbon) core wires
work best with this charging method, since they absorb electrical noise generated by the coil firing events. Use
8mm or larger RFI and EMI suppression wire with GM boots. We recommend using a carbon core-style
suppression wire with a resistance of 3,000 to 5,000 ohms per foot.
SOLID CORE WIRES SHOULD
NEVER BE USED
. Do not be misled by spark plug wire manufacturers claiming to give you a “power
increase” from their wire. The bottom line is that with our charging method, different spark plug wires simply
do not make a difference in terms of spark energy. However, there is a huge difference in noise generated by
different spark plug wire types (solid core wires generate a very high amount of noise with our system).
Quoted from Magnecor’s Website:
“What is not generally understood (or is ignored) is that the potential 45,000 plus volts (with alternating
current characteristics) from the ignition coil does not flow through the entire length of fine wire used for a
spiral conductor like the 1 volt DC voltage from a test ohmmeter, but flows in a magnetic field surrounding the
outermost surface of the spiral windings (skin effect). The same skin effect applies equally to the same
pulsating flow of current passing through carbon and solid metal conductors. A spiral conductor with a low
electrical resistance measured by a 1 volt DC ohmmeter indicates, in reality, nothing other than less of the
expensive fine wire is used for the conductor windings!
Electrical devices, including spark plugs, use only the electrical energy necessary to perform the function for
which such devices are designed. Spark plug wires are nothing more than conductors, and whereas a bad
ignition wire's inefficient conductor can reduce the flow of electricity to the spark plug, an ignition wire that
reportedly generates an "increase" in spark energy will have no effect on the spark jumping across the spark
plug gap, since the energy consumed at the spark plug gap won't be any more than what is needed to jump
the gap. For a more obvious example of this, a 25watt light bulb won't use any more energy or produce any
more light if it's screwed into a socket wired for a 1000 watt bulb.”
Due to the extremely high energy in the XDI coil charging circuit, spark plug wires may wear out faster
than with a standard ignition. As such, it is recommended that the wires be checked periodically for carbon
tracking caused by a breakdown of the internal conductor element. Looking at the plug wires in a dark area and
wetting them with a spray bottle of water will reveal carbon tracking. Pay close attention to the exposed section
of the spark plug (where the rubber boot ends) during the test. To maximize spark plug wire life, keep the
lengths as short as possible (i.e. mount the DFU as close to the engine as possible). Replacement of the wires
on an annual basis is recommended for high-rpm/high-horsepower applications.
For an extremely 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 on the web
at: www.magnecor.com. Taylor Pro-Wire Silicon Resistor wires also work well.
1.3.b Spark Plug Selection
As was previously stated, spark plugs are generally more important to spark quality than spark plug
wires. Most spark plugs exhibit failure when exposed to a large load. Failure usually consists of either
intermittent sparking or arc-over. Arc-over is when the spark occurs between the spark plug wire and the
engine block, instead of at the plug tip. Arc-over is exacerbated by the use of low-quality wires, or wires that
have cuts in the insulation.
The load at which a spark plug fails is different for all spark plugs. With the XDI’s charging circuit, the
more load you put on an engine, the more voltage will be applied to the plug. This is a beneficial situation: for
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