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G4 Wiring and Installation Manual

46

© 2009 Link

Inlet RH

DI 2

Aux 2

Exhaust or Exhaust LH

DI 3

Aux 3

Exhaust RH

DI 4

Aux 4

Solenoids MUST be wired directly to an auxiliary output channel DO NOT wire continuously
variable valve timing solenoids through a relay as high frequency switching is used.

Some factory systems use 12V switching to control VVT solenoids. These solenoids must
be rewired to be ground switching.

8.7

Electronic Throttle Control

At the time of writing this manual G4 Xtreme ECUs are equipped with tested Electronic
Throttle Control hardware but not released with this feature enabled.

This section of the manual will be updated once the feature is enabled.

E-Throttle Wiring

9

Rotary Engine Wiring

This section outlines wiring of G4 ECU's to Rotary engines. Wiring of Injection, Ignition and
Metering Oil Pump control is covered. This applies to two, three and four rotor engines.

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Содержание G4 Storm

Страница 1: ...Link G4 Storm Link G4 Xtreme Copyright 2009 Link ElectroSystems Ltd Wiring Installation Manual...

Страница 2: ...12 2 Ignition Component Placement 13 3 MAP Sensor Location Part IV Storm Header Pinout 13 Part V Xtreme Header Pinout 14 Part VI Power and Ground Wiring 15 15 1 Power Supplies 16 2 14V In 16 3 14V Aux...

Страница 3: ...wer Supply 40 Switching Through a Relay 41 Switching an LED 41 4 Idle Speed Control 42 Two Terminal ISC Solenoid 43 Three Terminal ISC Solenoid 43 Four Terminal ISC Stepper Motor 44 Six Terminal ISC S...

Страница 4: ...fter market engine management systems in the world can provide While every effort has been made to keep G4 ECU s as user friendly as possible it should be recognised that added features bring added co...

Страница 5: ...ge Inputs 3 4 Internal MAP 11 Temperature Inputs 2 4 Knock Sensor Inputs 0 2 Regulated Outputs 8V 5V 8V 5V Trigger Inputs 2 2 Storm shares one header pin for DI4 and An Volt 2 2 1 Injector Outputs The...

Страница 6: ...th Modulated PWM above 300Hz Note that PWM frequencies above 300 Hz may be required to drive a tachometer for a V8 above 4500 RPM An electronic throttle motor must only be wired to Aux 9 and Aux 10 Sp...

Страница 7: ...re from 0 5V transducer Temperature channels are designed to be used only with PTC or NTC thermistor sensors Almost all factory temperature sensors fit this category Do not wire the output of a 0 5V t...

Страница 8: ...ses Trigger 1 will need to be used In many cases Trigger 2 must also be used Engines with Variable Valve Timing may also require Digital Inputs be wired to cam shaft position sensors Refer to the Trig...

Страница 9: ...ction 3 Injector 3 Cylinder 3 Injection 4 Injector 4 Cylinder 4 Injection 5 Injector 5 Cylinder 5 Injection 6 Injector 6 Cylinder 6 Injection 7 Fuel Pump Speed Control 1 Injection 8 Fuel Pump Speed Co...

Страница 10: ...ity Optical or Hall Trigger 2 Analogue Temp Input 1 NTC Thermistor sensors Only Analogue Temp Input 2 Analogue Temp Input 3 Analogue Temp Input 4 Analogue Volt 1 0 5V Input from sensor or external con...

Страница 11: ...tput 2 Auxiliary Output 3 Auxiliary Output 4 Auxiliary Output 5 PWM less than 300 Hz or general switching functions ISC Stepper Auxiliary Output 6 Auxiliary Output 7 Auxiliary Output 8 Auxiliary Outpu...

Страница 12: ...r tuning cable 3 If water immersion or spray is likely particularly for marine applications additional protection may be necessary A sealed plastic container may be employed here 4 Allow sufficient sp...

Страница 13: ...should be installed in a location near the engine but away from excessive heat vibration and moisture It is not recommended to mount the MAP sensor directly on the engine Refer to Input Wiring sectio...

Страница 14: ...G4 Wiring and Installation Manual 14 2009 Link 5 Xtreme Header Pinout Viewed looking into ECU header or wire side of loom connector...

Страница 15: ...The switch labelled ignition switch is usually the key The wire that is used to turn on the main relay should be energised when the key is in the ON position Do not use a source that provides power w...

Страница 16: ...e 14V In wire must remain above 7 Volts at all times This is especially important while the starter motor is being cranked A significant drop in voltage will result in the ECU undergoing a reset that...

Страница 17: ...that require a ground e g throttle position sensor water temperature sensor etc Failure to do this may result in unstable sensor readings causing erratic ECU operation Do NOT be tempted to ground sen...

Страница 18: ...red through the relays now and run as normal 4 When the ignition switch is turned off the ECU senses this through its Digital Input 5 The ECU resets the stepper motor to its default position then shut...

Страница 19: ...required information Trigger 1 is used to determine crankshaft position Trigger 2 is used to determine the engines position in the firing order cam position Often called the sync signal Digital Inputs...

Страница 20: ...tely different 7 1 1 Reluctor Magnetic Sensors Reluctor Magnetic sensors have a toothed trigger wheel that passes across the face of the sensor The movement of the teeth past the sensor generates a vo...

Страница 21: ...lses These sensors require a power supply and typically have three wires The 8V Supply offers a regulated 8V for optical or hall sensors These wires are not used for reluctor sensors Note many hall se...

Страница 22: ...P sensor an external MAP sensor can be wired to an Analogue Volt input To use the internal MAP sensor connect the MAP pressure hose to the barbed fitting on the ECU s end plate Xtreme ECU s require th...

Страница 23: ...ires the connection of three wires 1 Signal The MAP signal must be wired to an Analogue Volt input Configure this input as MAP sensor and select the appropriate calibration in PCLink Tuning Software 2...

Страница 24: ...ttle to move through its full range of motion The TPS should be adjusted so that it is not reaching the end of its movement at either closed throttle or full throttle An ideal output voltage range is...

Страница 25: ...air entering the engine The air temperature sensor must be set up to most accurately measure the temperature of the air entering the engines combustion chambers On a naturally aspirated engine this no...

Страница 26: ...antly improve the probe performance at idle and during warm up phases of operation This is because the probe temperature must exceed 300 C before accurate readings are possible An Auxiliary Output can...

Страница 27: ...tuning purposes A wideband sensor can be used to run Closed Loop Lambda CLL for improved economy and emission A wideband sensor is a necessity if Quick Tune refer to the PCLink Tuning Software online...

Страница 28: ...variable valve timing Switches and Controllers The diagrams below show the two methods of wiring Digital Inputs to a switch When wiring other devices such as controllers it will be necessary to determ...

Страница 29: ...uts is recommended for VVT wiring Note that in practice any Digital Input Auxiliary Output combination can be used Cam Shaft Digital Input Auxiliary Output Inlet or Inlet LH DI 1 Aux 1 Inlet RH DI 2 A...

Страница 30: ...ing high impedance injectors When driving low impedance injectors directly it is essential that before running the engine the correct Injection Mode Peak and Hold and Peak and Hold Currents are config...

Страница 31: ...ector drives This means that for most engines sequential injection can be used Depending on the number of Injection Drives the following Injection Modes may available Single Point Group Sequential Mul...

Страница 32: ...quirements that would normally require extremely large injectors Very large injectors make tuning difficult at low loads idle and low power operation With staged injection one smaller set of injectors...

Страница 33: ...p Staged Injection Set the Injection Mode to Sequential Staged when using this configuration 8 2 Ignition Drives Note For information on wiring Ignition Outputs as additional Auxiliary Outputs refer t...

Страница 34: ...onventional igniters begin to charge the coil when their input is high Spark occurs when the input goes low This is known as a Rising Dwell Edge Some factory igniters eg some Ford and Honda MSD igniti...

Страница 35: ...her sensitive devices especially the ECU Do not run non ignition related wiring close to igniters coils or HT leads wherever possible Maintain maximum distance from radio transmitters and coaxial cabl...

Страница 36: ...der is fired conventionally on the compression stroke while the other cylinder has its piston in the same position but on the exhaust stroke One crankshaft rotation later these two cylinders are two w...

Страница 37: ...ch ignition drive is matched to the correct cylinder the firing sequence will need to be determined Note this option is only possible when the engine has an even number of cylinders When using a waste...

Страница 38: ...ition Therefore a second sensor mounted on the camshaft or driven at camshaft speed is required to send a sync pulse If an engine does not have an appropriate sensor then either one will need to be fa...

Страница 39: ...should be used DO NOT connect 12V directly to any auxiliary output The following list shows only some of the devices that can be controlled by Auxiliary Outputs Idle Speed control ISC Solenoids and St...

Страница 40: ...a solenoid If Auxiliary Outputs 5 to 8 are already used then it will be necessary to wire a relay to control the solenoids power supply Aux 5 to 8 high side drivers can supply up to 0 5 Amps this mean...

Страница 41: ...l ISC is required to provide an acceptable idle speed when the engine is cold or when loads AC etc are applied Without idle speed control an engine will idle too slowly when cold Often the cold idle s...

Страница 42: ...gine is cold 8 4 1 Two Terminal ISC Solenoid A two terminal ISC solenoid may be wired to Auxiliary Channels 1 to 8 Injection channels can not be used for ISC control Ignition Channels 1 to 8 can also...

Страница 43: ...ct the terminal to Auxiliary Output 1 and note that this output should be configured as ISC Solenoid Slave Three terminal ISC Solenoid Wiring 8 4 3 Four Terminal ISC Stepper Motor An ISC Stepper Motor...

Страница 44: ...stepper motor after key off This avoids extended cranking periods caused by resetting the stepper at key on The diagram below shows a schematic of a six terminal stepper motor These are similar to a f...

Страница 45: ...l signal 8 6 Variable Valve Timing VVT Solenoids Continuously Variable Valve timing CVVT VVT VVTi AVCS Cam Position solenoids can only be connected to Auxiliary Outputs 1 to 4 It is recommended to eas...

Страница 46: ...VVT solenoids These solenoids must be rewired to be ground switching 8 7 Electronic Throttle Control At the time of writing this manual G4 Xtreme ECUs are equipped with tested Electronic Throttle Cont...

Страница 47: ...s directly to a Xtreme ECU make sure Injector Driver Mode is set to Peak and Hold and the correct peak and hold currents have been set Spare Injection drives can be used as additional auxiliary output...

Страница 48: ...lve so no oil enters the engine Likewise setting Stepper Calibration to Fully Open should cause the motor to completely open the valve Once finished tested set Stepper Calibration to Off If the motor...

Страница 49: ...CU to your laptop the USB drivers must be installed Failure to install the drivers on your laptop first may result in windows assigning incorrect drivers These drivers will not work with the G4 ECU an...

Страница 50: ...en prompted if you wan to install drivers select Continue Anyway 3 Start PCLink Tuning Software by double clicking on the PCLink Tuning Software icon on the windows desktop 4 Switch the key to the ON...

Страница 51: ...the set up procedure 3 Check all oil and water levels are correct Connecting to PCLink Tuning Software Use the following procedure to establish a connection between your Link ECU and PCLink Tuning So...

Страница 52: ...ection is to be used and an air temperature sensor is fitted select the required IAT Mode e g 2D Table or 3D Table Note that the default 2D Table is recommended for the majority of applications b Turn...

Страница 53: ...to OFF for now 4 Click on Ignition Advanced then Individual Cyl Ign Trim a Set Individual Ign Mode to OFF for now 5 Click on Dual Ign Table a Set Dual Table Mode to OFF for now 6 Click on 4D Ign Table...

Страница 54: ...anual will greatly simplify set up of Auxiliary Outputs Note that one auxiliary channel should always be wired and configured for the fuel pump relay drive 1 Click on Auxiliary Outputs then select the...

Страница 55: ...uts tab of the runtime values lower area of PCLink Tuning Software screen 2 Configure each additional Digital Input channel Ensure unused channels have their Function set to OFF 3 Perform a Store to p...

Страница 56: ...he An Temp channel wired to the engine coolant temperature ECT sensor a Set the channels function to ECT b Select Temp Sensor Type If a custom type sensor is to be used then the resistance vs temperat...

Страница 57: ...ntrol a Set Launch Control Mode to OFF 3 Click on Flat Shifting a Set Flat Shifting Mode to OFF 4 Click on Boost Control only visible if an Auxiliary Output is configured for a Boost Control Solenoid...

Страница 58: ...ress F1 Note that trigger calibration must be performed again once the engine is running Due to the acceleration and deceleration of the crankshaft at low speeds an inaccurate measurement of engine ti...

Страница 59: ...k on the Fuel heading then Fuel Set up a Locate the Master setting This will need to be adjusted during or just after start up 6 Crank the engine until it starts Some throttle may be required for firs...

Страница 60: ...closing time however the overall result is that less fuel will flow for a given pulse width than would be expected with an ideal injector To compensate for this the injector pulse widths are increase...

Страница 61: ...air fuel ratios change while the battery voltage drops the dead time table can be trimmed to maintain the same stable air fuel ratio Injector Dead Time can be viewed as a row graph A smooth curve need...

Страница 62: ...29 G Getting Help 4 H Hall Sensor Wiring 20 High Impedance Injectors 30 High Side Driver Wiring 40 I IAT Wiring 25 Idle Speed Control Wiring 41 Igniter Requirements 33 Ignition Component Placement 12...

Страница 63: ...minal Stepper Wiring 44 Storm Pinout 13 14 Support Options 4 Switching an LED 41 Switching Through a Relay 40 T Tachometer Wiring 45 Temperature Inputs Wiring 7 Three Terminal ISC Solenoid Wiring 43 T...

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