Electro motive XDI200 Guía

XDI200

Product Installation Manual

& User’s Guide

V 01

Electromotive, Inc. 703-331-0100

9131 Centreville Road 703-331-0100 fax

Manassas, VA 20110 support@electromotive.com

________________________________________________________________________

Table of Contents

1Terms and Conditions........................................................6

1.1 ELECTROMOTIVE, INC. PRODUCT WARRANTY..........................................6

2Forward................................................................................7

2.1 Improvements of the XDI200 over the TECgt...................................................8

2.2 Fundamentals of the System............................................................................8

3Installing the Hardware....................................................10

3.1 Pre-Installation Checklist................................................................................10

3.2 Mounting the Main Computer and DFU..........................................................10

3.3 Trigger Wheel and Sensor Installation............................................................12

3.3.1 Crankshaft Trigger Installation for 60(-2) Tooth Wheel ...............................12

3.3.2 Hall Effect or Magnetic Crank Sensors .......................................................12

3.3.3 Crank Sensor Installation............................................................................13

3.3.4 Wiring a Magnetic Trigger Sensor...............................................................15

3.3.5 Verifying Trigger Wheel Timing...................................................................16

3.3.6 Camshaft- & Distributor-Mounted Trigger Setups .......................................18

3.3.7 Individual Cylinder trim application –Cam Synchronization........................18

3.3.8 TDC Tooth Setup Software Adjustment Parameters...................................20

4Wiring the System ............................................................23

4.1 Introduction.....................................................................................................23

4.1.1 Suggestions on Crimp Terminals….............................................................23

4.2 Wiring ECU & Main Power..............................................................................24

4.2.1 Power Harness Installation .........................................................................24

4.3 Wiring Ignition Coil Primary Sides...................................................................25

4.3.1 Introduction .................................................................................................25

4.3.2 Standard Direct Fire Units, DFU’s ...............................................................26

4.3.3 Wiring Standard DFU’s Coils ......................................................................26

4.3.4 Spark Plug Wiring High Voltage Side..........................................................28

4.4 Ignition Firing Order........................................................................................30

4.4.1 Common Engine Sparkplug Wiring.............................................................31

4.5 Coil Firing Schemes........................................................................................32

4.5.1 Coil Firing Patterns for EVEN-FIRE Engines ..............................................32

4.5.2 Coil Firing Patterns for ROTARY Engines...................................................33

4.5.3 Coil Firing Patterns for 2-CYCLE Engines ..................................................33

4.5.4 Coil Firing Patterns for ODD-FIRE Engines ................................................34

4.5.5 Examples of Typical Engine Setups............................................................34

4.5.6 Common Firing Orders................................................................................37

4.5.7 How to find the TDC Event Order :..............................................................38

4.5.8 TDC Tooth for DFU “2” needed for an Odd-Fire Engine: ............................38

4.5.9 Harley-Davidson Applications .....................................................................38

4.5.10 Rotary Engines............................................................................................38

4.5.11 Dual Plug Engines.......................................................................................39

4.6 Spark Plug Wire Selection..............................................................................39

4.7 Spark Plug Selection ......................................................................................40

4.8 Driver on Coil Logic Driven Coils....................................................................42

5Wiring Sensors & Other Inputs .......................................43

5.1 The Manifold Air Pressure (MAP) Sensor.......................................................43

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5.1.1 MAP Sensor Data .......................................................................................44

5.2 Throttle Position Sensor .................................................................................45

5.3 TPS Wiring .....................................................................................................46

5.4 Coolant Temperature Sensor .........................................................................47

5.5 Manifold Air Temperature Sensor...................................................................49

5.6 The Exhaust Gas Oxygen Sensor ..................................................................50

5.6.1 Mounting the EGO Sensor..........................................................................50

5.6.2 Wiring the EGO Sensor...............................................................................50

5.6.3 EGO Functionality.......................................................................................51

5.6.4 About One-Wire EGO Sensors ...................................................................52

5.7 Wideband O2 Sensor .....................................................................................52

5.7.1 Wideband EGO Information and Installation Instructions............................52

5.8 Secondary EGO sensor input.........................................................................53

5.8.1 EGO FAQ’s and Troubleshooting Tips:.......................................................53

5.9 Knock Sensor .................................................................................................53

5.10 Auxillary Temperature Sensor Input............................................................55

5.11 General Purpose Inputs (GPI’s) ..................................................................55

5.11.1 Available General Purpose Input (GPI) Functons ......................................56

5.11.2 Wiring the GPI’s ..........................................................................................57

6Wiring Outputs..................................................................59

6.1 Idle Air Control Motor......................................................................................59

6.1.1 Wiring a 2-wire IAC:....................................................................................60

6.1.2 Wiring a 3-wire IAC:....................................................................................60

6.2 Tachometer Output.........................................................................................62

6.3 Fuel Pump Relay Output ................................................................................62

6.4 General Purpose Output (GPO) functions :....................................................63

6.4.1 Outputs .......................................................................................................64

6.4.2 Available GPO Functions............................................................................64

6.4.3 Wiring the GPO’s: .......................................................................................65

7Communications Ports on the XDI200 ...........................67

7.1.1 PC communications, USB port....................................................................67

7.1.2 PC communications, RS232 Serial port......................................................67

7.1.3 CAN bus serial port.....................................................................................67

8Tuning Guide.....................................................................68

8.1 Introduction.....................................................................................................68

8.2 Adjusting the Timing Advance ........................................................................68

8.3 Getting the Engine to Idle ...............................................................................69

8.4 Tuning the Idle Air Control Motor....................................................................69

8.4.1 Configuring the New Electromotive Idle Speed Control ..............................69

8.4.2 Idle Speed primer........................................................................................70

8.4.3 Getting the IAC Started...............................................................................70

8.4.4 Error Sensitivity...........................................................................................71

8.4.5 RPM Rate-of-Change Sensitivity.................................................................71

8.5 Tuning Tips:....................................................................................................72

8.5.1 Other tips: ...................................................................................................72

8.5.2 Absolute vs. Gage Pressure .......................................................................73

8.5.3 Units of Measurement.................................................................................73

9Diagnostics .......................................................................75

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9.1 Trouble Codes from the LED’s Mounted on the XDI200.................................75

9.2 Trouble Codes from the Check Engine Output...............................................76

9.3 Trouble Code Descriptions.............................................................................77

9.3.1 Using the Trouble Codes ............................................................................78

9.3.2 Wiring the Check Engine Light....................................................................79

9.4 Tuning the Knock Control ...............................................................................80

9.5 Using the Ignition Advance Trims...................................................................80

10 Data logging with the XDI200 ..........................................80

10.1 PC-Based Data logging...............................................................................80

10.2 On-Board Data logging ...............................................................................81

11 Rev Limiters......................................................................81

11.1 Valet Mode Rev Limiter...............................................................................81

11.2 Secondary Rev Limiter :..............................................................................81

11.3 Primary Rev Limiter :...................................................................................82

11.4 Zero degree advance..................................................................................82

11.5 3-stage coil cut............................................................................................82

11.6 Full coil cut..................................................................................................82

12 Troubleshooting ...............................................................82

12.1.1 Air, Fuel, and Spark ....................................................................................83

12.2 Starting Problems........................................................................................83

12.2.1 Air-Related Starting Problems.....................................................................83

12.2.2 Fuel-Related Starting Problems..................................................................83

12.2.3 Spark-Related Starting Problems................................................................83

12.3 Idling Problems ...........................................................................................84

12.3.1 Air-Related Idling Problems ........................................................................84

12.3.2 Fuel-Related Idling Problems......................................................................84

12.3.3 Spark-Related Idling Problems ...................................................................85

12.4 Low-, Medium-, and High-Load Problems...................................................85

12.4.1 Air-Related Load Problems.........................................................................85

12.4.2 Fuel-Related Load Problems ......................................................................85

12.4.3 Spark-Related Load Problems....................................................................85

13 Appendix I. ECU Specifications .....................................86

13.1 OUTPUTS...................................................................................................86

13.1.1 Coil Outputs ................................................................................................86

13.1.2 Idle Air Control (IAC) Motor.........................................................................86

13.1.3 General Purpose s (GPO’s) ........................................................................86

13.1.4 Fuel Pump Control......................................................................................86

13.1.5 Tachometer Output.....................................................................................86

13.1.6 Check Engine Light Output .........................................................................86

13.1.7 ECU Diagnostic Check engine Lamp..........................................................86

13.2 INPUTS.......................................................................................................86

13.2.1 General Purpose Inputs (GPI’s) ..................................................................86

13.2.2 Engine Sensor Inputs..................................................................................86

13.2.3 Angle Based Timing Control .......................................................................87

13.2.4 Feedback Charging Control........................................................................87

13.3 Tuning Features..........................................................................................87

13.3.1 Ignition Timing Map.....................................................................................87

13.3.2 Rev Limiters................................................................................................87

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13.3.3 On-Fly Tuning .............................................................................................87

13.3.4 Compensation Features..............................................................................87

13.4 Supported Engine Configurations ...............................................................88

13.4.1 4-Stroke ......................................................................................................88

13.4.2 2-Stroke ......................................................................................................88

13.4.3 Rotary .........................................................................................................88

13.5 Data logging Features.................................................................................88

13.5.1 Laptop Data logging....................................................................................88

13.6 Physical Dimensions...................................................................................88

13.7 Environmental Considerations ....................................................................88

13.8 PC Requirements........................................................................................88

14 Appendix II. Trigger Wheel Availability .........................89

15 Appendix III. Secondary Coil Polarity for Redundant Ignition

Applications.............................................................................90

16 Software & Firmware Support.........................................91

16.1.1 Software Coding Information.......................................................................91

16.1.2 Firmware Coding Information......................................................................91

16.1.3 Software Upgrade Procedure......................................................................91

16.1.4 Firmware Upgrade Procedure.....................................................................92

17 Appendix IV. ECU Connector Pin Out List.....................93

18 Appendix V. ECU Connector Drawing...........................94

19 Appendix VII. Driver on Coil Schematic ........................96

20 Glossary of Terms............................................................97

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1 Terms and Conditions

1.1 ELECTROMOTIVE, INC. PRODUCT WARRANTY

Products manufactured by Electromotive (XDi Ignitions and TEC ECUs) are built to last. Many of

our products have been in service for multiple decades. Products sold, but not manufactured, by

Electromotive are warranted as described under Other Products and Parts We Sell.

Should your product not be functioning properly during the warranty period, please first check

Tech Support information available at www.electromotive-inc.com under the Support tab. You

may find that the issue is due to something other than unit malfunction.

Our warranty period is 1 year as of January 1, 2017.

New Product Warranty:

With a 1 year limited warranty, Electromotive offers, by far, one of the best warranties in the

business on all new XDi and TEC units, for the original purchaser only, from the original purchase

date. We warrant our products to free of defects in materials and workmanship during the

warranty period. The replacement product will, in turn, be warranted for 1year from the date of

replacement. Electromotive will pay for standard shipping to return the repaired/replacement unit

to the customer, if a defect covered under warranty is found.

Note: At Electromotive’s discretion, products that show evidence of tampering, abuse, accident

damage, or other unusual wear and tear conditions may not be eligible for warranty coverage.

See details under Warranty Exclusions.

If You Need Warranty Service:

Notify us at [email protected] or 703/ 331-0100 M-F 8:30 to 5:00 EST. Then, send

(1) a note with a summary of the issues you are experiencing, (2) a copy of your sales receipt,

and (3) the XDi or TEC unit. Ship to: Electromotive Repairs, 9131 Centreville Road, Manassas,

VA 20110. You must include the purchase receipt and it must clearly show name of the

seller, date of purchase and purchase amount.

Our policy is to provide a new or factory refurbished replacement unit rather than repair units

under warranty, at our discretion. If the issue is something very minor, we may opt to repair

rather than replace. Replacement products may include remanufactured or refurbished products

or components.

If your product is shown to be in complete working order when we receive it, you may be

charged a small fee for handling and return shipping.

Out-of-Warranty Product Repair

Should your product be out of warranty, we offer factory diagnosis and repair services. There is a

small fee for diagnosis and estimation of repair costs. Check with us for the current diagnosis

fee. You will have options including (1) repair, (2) (if available) purchasing a refurbished unit, or

(3) trading your old unit for a discount off a new unit. We strive to keep our repair times to within

5 business days, plus shipping days.

Other Products And Parts We Sell:

We make every attempt to source products that live up to our quality standards. In the rare

occasion that one of these products/parts fails within 90 days of purchase, return it to us along

with a copy of your sales receipt and we will replace it if, at our discretion, the malfunction is not

due to the same exclusions listed under Warranty Exclusions.

________________________________________________________________________

Warranty Exclusions:

Any product, on which the serial number has been defaced, modified or removed or doesn’t

appear in the Electromotive serial number registry.

Damage, deterioration, or malfunction deemed to be from:

Accident, misuse, neglect, fire, water, lightning, or other acts of nature, unauthorized product

modification, tampering, or failure to follow instructions supplied with the product/available for

download from www.electromotive-inc.com

Repair or attempted repair by anyone not authorized by Electromotive.

Any damage due to shipment.

Removal or installation of the product.

Causes external to the product such as electric power fluctuations or failure

Use of supplies or parts not meeting Electromotive specifications.

Any other cause, which does not relate to a product defect.

Limitation of Implied Warranties:

There are no warranties, expressed or implied, which extend beyond the description contained

herein including the implied warranty or merchantability and fitness for a particular purpose.

Exclusion of Damages:

Electromotive’s liability is limited to the cost of repair or replacement of the product.

Electromotive shall not be liable for:

Any costs for removal, installation, tuning or set up of the unit before or after the malfunction.

Damage to other property caused by any defects in the product.

Damages based upon inconvenience, loss of use of the product, loss of time, loss of profits, loss

of business opportunity, loss of goodwill, interference with business relationships, or other

commercial loss, even if advised of their possibility of such damages.

Any other damages, whether incidental, consequential or otherwise

Any claim against the customer by another part.

Certain shipping charges.

2 Forward

The XDI200 Distributorless Ignition system is the latest ignition system in the expanded

line of ultra-high resolution engine management systems from the company that revolutionized

engine management over twenty years ago. The XDI200 can be configured to control the

ignition of virtually any 1, 2, 3, 4, 6, 8 or 12 cylinder engine, as well as 1 or 2-rotor rotary engines,

and dual plug 4 or 6 cylinders. The heart of the XDI systems has always been a high-resolution

ignition, which offers incredibly precise ignition timing even at the highest acceleration rates. The

XDI200 continues this tradition; only what was once done with an analog ignition circuit is now

done with a high-speed microprocessor. Direct Fire Units (DFU’s) with twin-tower coils are

available from Electromotive in 2- and 3-coil versions. Single tower coils are available as well.

These DFU’s are completely weather proof, and feature sealed electrical connectors.

Additionally, the DFU’s are impedance matched for optimum performance with our XDI200.

There are Nine dedicated, user-definable, general-purpose inputs / outputs (GP I/O’s)

included with the XDI200 to make your high-tech engine setup a snap. The GP I/O’s can be used

to control anything from wastegates for turbo setups to simple electric radiator or intercooler fans.

The possibilities are nearly limitless.

________________________________________________________________________

One of the GPI’s has a frequency-based input capability, which can process data from

wheel a speed sensor or similar device. The other GPI’s are analog inputs only, and do not

feature frequency-based capabilities. These channels can perform timing trims, and many other

functions.

Besides the GP I/O’s, several functions are built-in to the XDI200 that are quite useful on

most applications. The following outputs are standard on the XDI200:

Tachometer (configurable to drive most modern tachs)

Check Engine Light

Fuel Pump Relay Ground (activated at appropriate times by the XDI200

Idle Speed Motor control (stepper motor style or 2-wire style)

The XDI200 uses the following inputs to perform engine management:

Crank Trigger

Cam Trigger (optional)

Manifold Air Pressure

Coolant Temperature Sensor

Manifold Air Temperature Sensor

Throttle Position Sensor

Knock Sensor (optional)

Exhaust Gas Oxygen Sensor (O2sensor)

2.1 Improvements of the XDI200 over the TECgt

The XDI200 has the added features of:

1. Water resistant case and connector system

2. 6 high current ignition coil drivers to operate 12 cylinder or dual plug 6 cylinder

engines.

3. 6 separate ignition coil logic outputs to operate up to 12 Driver On Coil (DOC) coils.

4. User selected fixed coil dwell time or standard coil current control.

5. General Purpose Inputs(GPI) separated from General Purpose Outputs(GPO)

6. On board USB port for direct connection to Laptop PCs.

7. Retained RS232 Serial port like older TECs with same functionality

8. New Second Oxygen sensor input

9. New Third temperature sensor input

10.High power Tach signal driver

11.Two range knock sensor sensitivity

12.Added 2 more GPO outputs

13.Dedicated road speed frequency input

14.Future Twin Variable Valve Timing cam input and output control

2.2 Fundamentals of the System

The goal behind Electromotive’s Total Engine Control product line is to provide complete, high-

resolution control of all functions of the modern engine, and to do so with a user-friendly interface.

Consequently, the XDI200 is designed to easily control a huge number of complex engine

management functions through the hands of a user who is new at the game.

________________________________________________________________________

Engine Speed & Position = Crank Sensor…

What separates our engine management systems from those of our competitors is the fact

that our products are all designed around an ultra high-resolution ignition. For this reason, we

use a 60(-2) tooth crank trigger wheel to give the computer an extremely accurate engine position

input. This is also the reason that we do not support any other types of trigger inputs. Take, for

instance, the flying magnet trigger input used by some manufacturers: 8 cylinder engines have 4

magnets mounted to the crank trigger wheel. Our 60(-2) tooth trigger has 15 TIMES MORE

RESOLUTION! From a magnetic sensor aimed at the trigger wheel, the XDI200 receives its

input for engine speed and position.

Engine Load = MAP Sensor…

As nice as the 60(-2) tooth trigger wheel is for determining engine speed and position,

more is necessary to perform ignition and fuel control; namely a load input. While many OEM’s

use Mass Airflow (MAF) sensors to determine the airflow (and thus the load) of an engine,

Electromotive systems are designed around Manifold Air Pressure (MAP) sensors as the load-

determining device. MAP sensors simply plug into the intake manifold of the engine (after the

throttle), and are inherently easier to install than MAF sensors since they are not sensitive to

vacuum leaks or engine airflow requirements. A 1-Bar MAP sensor is designed for naturally

aspirated engines. A 2-Bar sensor is used for turbo/supercharged engines with up to 15psi

(about 200kPa absolute) manifold boost. A 3-Bar sensor is good for up to 30psi (300kPa), while

a 4-Bar is good for up to 45psi (400kPa). Choose the appropriate sensor for the application, and

you are done.

Ignition Advance Control…

Once the MAP sensor and crank sensor are installed, the XDI200 has inputs for RPM and

load. Under steady-state conditions on a fully warmed-up engine, these are the only necessary

inputs for the XDI200 to control the fuel and ignition curves. Control of the ignition advance curve

is quite simple: there is a table of RPM vs. MAP in which the desired ignition advance angle is

entered for every point. The table can be made in any size from 8x8 to 16x16 data points.

Between each data point, there is a 256 point interpolation occurring. This keeps the advance

curve from “stepping” from point-to-point. Additionally, it means that the engine can be tuned with

only a few input numbers; some other systems on the market rely on the tedious input of

hundreds of numbers to obtain an ignition advance curve that is still not as smooth between data

points as ours.

Compensations…

Having a warmed-up engine running under steady-state conditions is all well and good, but

in the real world, we must deal with cold weather starting, engine accelerations and

decelerations, etc. For these scenarios, engines need fuel and spark compensations. The

coolant temperature sensor (CLT) provides an input for the XDI200 to measure the engine

temperature. Since cold engines need more fuel than hot engines, tables are provided in the

software to allow fuel flow increases as a function of engine temperature. Other parameters

related to the coolant temperature are cold starting (cranking) enrichments and throttle movement

enrichments when cold

Additional Features…

Once all the necessary input sensors are in place, and the software is tuned, the engine

will run quite well. However, to further refine the control of the engine, a few additional features

are included. The idle air control motor (IAC) is used to meter air into the engine at idle. This

________________________________________________________________________

helps maintain a smooth idle, regardless of operating conditions. It can also be used to increase

the idle for cold temperatures, or air conditioner activation. A fuel pump output is also included,

which allows the user to turn on the fuel pump relay for a set amount of time when the ignition is

turned on. This primes the fuel system, and powers the fuel pump once the engine is cranked

and running. A tachometer output is included, which will drive most modern tachometers, and a

check engine output is included to keep track of failed engine sensors. A host of other engine

input and output options are included as well, and are outlined in other areas of this manual.

3 Installing the Hardware

3.1 Pre-Installation Checklist

To perform a complete XDI200 installation, the following items are required:

1. XDI200 Computer

2. DFU(s) or Driver on Coil Ignition Coils.

3. Resistor Core Spark Plug Wires (see notes on Spark Plug Wires)

4. XDI200 Wiring Harness w/ Power Harness

5. Windows-based PC-type Computer (see notes on Computer Requirements)

6. Serial Connector Cable (DB9) for PC or USB Cable

7. Crank Position Sensor (Magnetic Sensor)

8. 60 (-2) Tooth Crank Trigger Wheel or 120 (-4) Tooth Cam Trigger Wheel

9. Coolant Temperature Sensor (CLT) (OPTIONAL)

10.Manifold Air Temperature Sensor (MAT) (OPTIONAL)

11.Manifold Air Pressure Sensor (MAP) (OPTIONAL)

12.Throttle Position Sensor (TPS) (OPTIONAL)

13.Exhaust Gas Oxygen Sensor (EGO) (OPTIONAL)

14.Idle Air Control Motor (IAC) (OPTIONAL)

15.Knock Sensor (KNK) (OPTIONAL)

16.Wire Terminal Crimping Tool (available from Electromotive)

17.Shrink Tubing

18.Assorted Wire Crimp Terminals

19.Drill

20.¼” Bolts for DFU(s) & XDI200 ECU

21.Soldering Gun

3.2 Mounting the Main Computer and DFU

For utmost reliability, install the XDI200 computer where temperatures will not exceed

150oF (65oC). The XDI200 computer should be installed in the passenger compartment of the

vehicle where it will not be exposed to the elements. A good location is in the kick panel of a

vehicle originally equipped with a factory ECU. As a second choice, the XDI200 may be mounted

in an area that is partially exposed to the elements. It must not be mounted above or close to any

exhaust or oil piping. A well vented area is recommended, particularly in engines utilizing most of

the ignition channels and operating at sustained high speeds. It should be noted that the XDI200

might get hot under prolonged high-rpm operation. As long as air is moving around the ECU,

there is no risk of damage to the XDI200; just be careful not to burn yourself on the unit! Secure

the XDI200 ECU with four ¼” socket head cap screws. If the wiring harness goes through the

firewall, a suitable grommet must be used to avoid chafing.

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