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ECOTRONS DLE120 Installation Manual

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UAV engine EFI installation manual-DLE120-V1.4
UAV engine EFI
installation manual
-DLE120 engine
Installation Manual
V1.4
COPY RIGHTS ECOTRONS LLC
ALL RIGHTS RESERVED
Http://www.ecotrons.com
Copy right ECOTRONS LLC
http://www.ecotrons.com
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  • Page 1 UAV engine EFI installation manual-DLE120-V1.4 UAV engine EFI installation manual -DLE120 engine Installation Manual V1.4 COPY RIGHTS ECOTRONS LLC ALL RIGHTS RESERVED Http://www.ecotrons.com Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 2 UAV engine EFI installation manual-DLE120-V1.4 Note: If you are not sure about any specific details, please contact us at info@ecotrons.com. Index Page Revision Date Note First Edition 5.3.2015 V1.1 Second Edition 6.12.2015 V1.2 Third Edition 9.5.2016 V1.3  Fourth Edition 23.6.2016...

  • Page 3: Table Of Contents

    UAV engine EFI installation manual-DLE120-V1.4 Content Introduction ........................5 Chapter 1 EFI installation ....................8 1.1 Remove the stock carburetor and install the throttle body ........8 1.2 Install the fuel supply system ................10 1.3 Install the cylinder head temperature sensor (CHT) .......... 12 1.4 Install the intake air temperature sensor (IAT) ..........
  • Page 4 UAV engine EFI installation manual-DLE120-V1.4 1.13 Optional prime switch function ................ 38 Chapter 2 ALM-ECU integration for tuning ..............40 2.1 Install the wideband O2 sensor ................ 40 2.2 Connect the ALM to ECU ................. 40 2.2.1 Connect the ALM to ECU via ANOUT ............ 40 2.2.2 Connect ALM-CAN to ECU via CAN channel .........

  • Page 5: Introduction

    Rotary fuel pump with pressure regulator (outside of the tank, 25L/h)) 5. Baro sensor (integrated in ECU) 6. Engine temperature sensor 7. Intake air temperature sensor 8. Ecotrons CDI - ECU controlled (optional, you can use your own CDI). Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 6 UAV engine EFI installation manual-DLE120-V1.4 9. Serial communication cable (to a computer) 10. USB adaptor - included 11. CD for tuning software (downloadable from our website) Note: The kit requires a 12V battery by default. 37-pin ECU and Harness Fuel pump group Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 7 UAV engine EFI installation manual-DLE120-V1.4 Throttle body with TPS and Servo motor Throttle body with Servo motor Engine temperature and intake air temperature Ecotrons CDI Unit Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 8: Chapter 1 Efi Installation

    1.1 Remove the stock carburetor and install the throttle body Note: the stock DLE 120 carburetor is about 22mm diameter outlet. The Ecotrons throttle body is also 22mm diameter. So it is a bolt-on replacement. Note: Ecotrons Small throttle body is designed to replace the stock carburetor and has the same or similar spacing as the carburetor, so that you can bolt on the throttle body.
  • Page 9 UAV engine EFI installation manual-DLE120-V1.4 And we also have 14mm, 18mm, 22mm, 28mm throttle body for UAV engines, so we can provide the UAV EFI kit for different engines with different displacement. Some engines, you can use the throttle body to replace the carburetor completely, and for some engines, you need make the adapter to bolt on the throttle body.

  • Page 10: Install The Fuel Supply System

    UAV engine EFI installation manual-DLE120-V1.4 1.2 Install the fuel supply system Customers have to find a good location to install the fuel pump. By default, the fuel pump should be lower than the fuel tank. The fuel feed inlet in the tank should be submerged in the fuel all the time.
  • Page 11 UAV engine EFI installation manual-DLE120-V1.4 Note: The fuel pump is a rotor type, has 25L/h flow rate. It has only limited sucking power. If there are too many air bubbles in the fuel lines, the pump will not work. Connect the connector to the fuel pump Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 12: Install The Cylinder Head Temperature Sensor (Cht)

    UAV engine EFI installation manual-DLE120-V1.4 1.3 Install the cylinder head temperature sensor (CHT) Note: The CHT sensor must be installed at the cylinder head, closed to spark plug. If you can place it under the spark plug, it is also OK.

  • Page 13: Install The Intake Air Temperature Sensor (Iat)

    For DLE series engine, Ecotrons CDI is compatible and can be installed directly. So the EFI will control both fuel and spark in standard EFI kit. If you want the ECU to control the CDI ignition timing, and if you have Ecotrons CDI included in the kit, you need to do this.
  • Page 14 UAV engine EFI installation manual-DLE120-V1.4 Ecotrons CDI Unit Connect the “CDI Power” from ECU harness to the red connector of Ecotrons CDI. Connect the “CDI Ctrl” from ECU harness to the black connector of Ecotrons CDI. The connector which is labeled “Tachometer” can be connected to your own Tachometer.
  • Page 15 UAV engine EFI installation manual-DLE120-V1.4 Note: 1) CDI Power: it gives Ecotrons CDI power. 2) CDI Ctrl: ECU outputs to control Ecotrons CDI. 3) Do NOT plug the connectors in the wrong direction. Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 16: Connect The Hall-Sensor Connector To The Stock Hall Sensor

    UAV engine EFI installation manual-DLE120-V1.4 1.5.2 Connect the Hall-Sensor connector to the stock Hall sensor. 1.6 Servo motor installation 1.6.1 Parameters of servo motor The servo motor is installed on the throttle body for an UAV EFI system by default. It is to open and close the throttle valve, as the throttle actuator.
  • Page 17 UAV engine EFI installation manual-DLE120-V1.4 Futaba servo S3016: Type Analog Servo Torque 4.8V: 47.0 oz-in(3.38kg-cm) 6.0V: 58.0oz-in(4.18kg-cm) Speed 4.8V: 0.25 sec/60 6.0V: 0.20 sec/60 Weight 1.20 oz(34.0 g) Size length: 1.22 in(31.0 mm) width: 0.63 in(16.0 mm) height:1.21 in(30.7mm) There are three wires in servo. The black is ground, the white is the control signal line, and the red is the power line, which is 5V.

  • Page 18: Installation Of Servo Motor

    UAV engine EFI installation manual-DLE120-V1.4 1.6.2 Installation of servo motor Note: Usually we install the Servo motor on the throttle body, you don’t need re-install it. If you need install the servo motor, please see the following information as reference.
  • Page 19 UAV engine EFI installation manual-DLE120-V1.4 Note: You would assume the total rotation angle of a servo motor is 0-180 degrees; but actually, the servo rotation angle is about 90 degrees when used to control the throttle. Copy right ECOTRONS LLC...
  • Page 20 UAV engine EFI installation manual-DLE120-V1.4 As shown in the above picture, the servo angular positions of -45 degree to 45 degree are corresponding to throttle position of 0 to 180 degrees. Example of installation: We use the Futaba S3016 servo motor in our EFI system.
  • Page 21 UAV engine EFI installation manual-DLE120-V1.4 About 180 degree position of the servo arm: 1. Make sure the servo can rotate freely between 0-180 degrees, then position the reference point (The purple circle) in the middle of the 180 degree range. That means, from that position, it can go 90 degrees either way.
  • Page 22 UAV engine EFI installation manual-DLE120-V1.4 2. Install the servo on the throttle body. Before you connect the servo and the throttle, open the throttle valve about 40 degree, where the throttle opening is about 50%. Note: the total throttle valve turning angle might be only 80 degrees.
  • Page 23 UAV engine EFI installation manual-DLE120-V1.4 3. After linking the servo to the throttle valve, try to move the servo both ways, and make sure the throttle valve is opening and closing. You shall notice that the servo is about -40 degrees when throttle valve is fully closed, and it is about 40 degrees when the throttle valve is fully opened.
  • Page 24 UAV engine EFI installation manual-DLE120-V1.4 Throttle Valve is fully opened Note: the throttle idle position can be adjusted by the mechanical idle stop. Finally, fix and tighten everything. Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 25: The Connection Of Tps Signal

    UAV engine EFI installation manual-DLE120-V1.4 Warning: For the servo installation, you have to make sure the throttle and servo are both synchronous with one another. When the servo arm moves, the throttle valve arm also should moves. If the servo arm moves, but the throttle valve arm doesn’t move, the throttle valve will not be opened;...

  • Page 26: Connect The Servo Motor Wires To Ecu Harness

    UAV engine EFI installation manual-DLE120-V1.4 If there is no TPS sensor when you order the EFI kit, and you add the TPS sensor by yourself later, you need to do some tuning (usually, we will pre-set the setting when you order the EFI system with TPS sensor, or send the Calibration data file to you by emails).
  • Page 27 UAV engine EFI installation manual-DLE120-V1.4 the EFI system without TPS sensor, or send the Calibration data file to you by emails). Please set “VAL_TpsSource “ to be 1. There are three wires on servo. The black wire is ground, the white wire is the control signal, and the red is the power line, which need DC6V.
  • Page 28 The below picture is the connections of harness, connector adaptor, and servo motor. Note: Ecotrons ECU can control the servo with a PWM duty cycle output. But the Auto-Pilot needs to send the command to ECU via serial communication or CAN bus.
  • Page 29 UAV engine EFI installation manual-DLE120-V1.4 There are two calibration variables and one measured variable that you need to add. Calibration variables: to find the two variables and add Go to menu->Variables-> Calibration Selection them. VAL_ServoPWM2VoltSlope: slope parameter VAL_ServoPWM2VoltOffset: offset parameter Measured Variable: OnTime_ServoPWM_In –...
  • Page 30 UAV engine EFI installation manual-DLE120-V1.4 Right click on the window, choose “Add Variables”, and find the variable” OnTime_ServoPWM_In “, and add it to 20ms, then click “OK”, you can see the variable on the list window. Copy right ECOTRONS LLC...
  • Page 31 UAV engine EFI installation manual-DLE120-V1.4 Step 3: Connect the ECU to laptop via EcoCAL. Use the remoter / auto-pilot to control the servo motor, move the throttle to the idle position. Read and record the “OnTime_ServoPWM_In” value, marked PWM1. Copy right ECOTRONS LLC...
  • Page 32 UAV engine EFI installation manual-DLE120-V1.4 Then adjust the servo motor to move the throttle wide-open, read and record the “OnTime_ServoPWM_In” value, marked PWM1. Step 4: Calculate the offset and slope, to convert the signal of servo PWM to throttle position.

  • Page 33: Control Servo Motor

    UAV engine EFI installation manual-DLE120-V1.4 Verify the TPS signal is changing from 0 to 100% by controlling the servo from idle to “WOT” position. Warring: The reading of OnTime_ServoPWM_In should be from 0.6 to 2.3ms for the Futaba S3016 which comes from Ecotros’ EFI.

  • Page 34: Install The Fuel Injector And Connect The Connector

    UAV engine EFI installation manual-DLE120-V1.4 1.9 Install the fuel injector and connect the connector 1.10 Connect the harness to 12v battery Note: the red is to the positive of battery; the black is to the negative of battery. There is one manual switch on the power wire; you can use this switch to power on EFI, or power off.

  • Page 35: Mount The Ecu

    UAV engine EFI installation manual-DLE120-V1.4 Note: connect the negative of battery to the engine block. All ground wires should be common. Note: The black wire goes to negative of battery. 1.11 Mount the ECU Find a safe place to mount the ECU, avoid the severe vibration and severe hot conditions.
  • Page 36 UAV engine EFI installation manual-DLE120-V1.4 Parameters of ECU • Aluminum case, light weight: 120 gram total; • Mini size: 78x64x20mm dimensions; • mini-D connector (37 pin); • built-in baro sensor, automatic altitude compensation; • controlling 1 or 2 cylinder engines, both fuel injection and ignition controls;...
  • Page 37 UAV engine EFI installation manual-DLE120-V1.4 Definition of pins: Number Define Color instructions INJ1 White Fuel injector # 1 low side driver output KEYSW Blue Fuel injector # 1 power output Black Power ground Black Power ground Rout White Relay low side driver output...

  • Page 38: Mount The Harness

    UAV engine EFI installation manual-DLE120-V1.4 Green Ground CDI-PG White Control signal of CDI 1.12 Mount the Harness Please find the suitable place to mount the harness. 1.13 Optional prime switch function There is a prime switch on the EFI harness. The function is to manually trigger the EFI to inject a little fuel before you start the engine by hand.
  • Page 39 UAV engine EFI installation manual-DLE120-V1.4 Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 40: Chapter 2 Alm-Ecu Integration For Tuning

    UAV engine EFI installation manual-DLE120-V1.4 Chapter 2 ALM-ECU integration for tuning 2.1 Install the wideband O2 sensor You need drill the hole and weld the bung in the exhaust and to install the O2 sensor. 2.2 Connect the ALM to ECU 2.2.1 Connect the ALM to ECU via ANOUT...
  • Page 41 UAV engine EFI installation manual-DLE120-V1.4 We use the "Perf-SW", performance switch, wire to connect the ALM input. Most of EFI has this “Perf-SW” switch, you need tap the linear output of wideband controller to the wires of performance switch. Please connect it by using following pictures.

  • Page 42: Connect Alm-Can To Ecu Via Can Channel

    UAV engine EFI installation manual-DLE120-V1.4 2.2.2 Connect ALM-CAN to ECU via CAN channel ALM-CAN units can be connected to ECU. Users should connect the CAN-H and CAN-L to ECU CAN-H and CAN-L. ECU can receive the data from ALM-CAN by broadcasting and analyze the data to get the value about Lambda, AFR and O2%.
  • Page 43 RPM for about 10 seconds.) , ECU-ALM will take care of the rest. First, you need connect the ALM or ALM-S to ECU as above connection method. And you need get special CAL files for auto-tuning, please connect Ecotrons. Warning: Auto-Tuning only works in steady-state driving. Also only use auto-tuning feature after you have a stable running engine.

  • Page 44: Chapter 3 Broadcast Protocol

    The data format is hex, the baud rate is 115200, no parity bit, 8 data bits, 1 stop bit, time interval 100ms. Please go to our website to download the document: http://www.ecotrons.com/support/ Download the Ecotrons Broadcast data list. See the mark of the Ecotrons Broadcast data list as shown below. Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 45: Ecu Broadcast Data List On Can Bus

    UAV engine EFI installation manual-DLE120-V1.4 3.2 ECU broadcast data list on CAN bus 3.2.1 The CAN Baud rate setting of ECU Our ECU and tuning software (EcoCAL) support the CAN communication, you can change the baud rate by yourself. Note: There should be a 120 ohm resistor between the CAN wires, and our ECU doesn’t have the 120 ohm termination resistor, so you need add it by yourself in...

  • Page 46: Can Bus Broadcast

    /* CAN bus baud rate 3--500k, 4--250k, 5--125k, 6--100k, 7--50k, 8--20k, 9--10k, 10--5k */ 3.2.2 Can bus broadcast Please go to our website: http://www.ecotrons.com/support/ Download the Ecotrons UAVCAN Protocol. See the mark of the Ecotrons UAVCAN Protocol as shown below. Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 47 UAV engine EFI installation manual-DLE120-V1.4 Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 48: Chapter 4 Communication Settings

    UAV engine EFI installation manual-DLE120-V1.4 Chapter 4 Communication Settings How to install the provided EcoCAL software to your computer? For details on how to use EcoCAL software, please refer to the EcoCAL Manual, downloadable here: www.ecotrons.com/support Run EcoCAL, you will see below windows:...
  • Page 49 UAV engine EFI installation manual-DLE120-V1.4 Read DTC: Go to Menu à Diagnostics ->ECU Diagnostics Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 50 UAV engine EFI installation manual-DLE120-V1.4 Click "Read DTC": Click "Clear DTC": Copy right ECOTRONS LLC http://www.ecotrons.com...
  • Page 51 UAV engine EFI installation manual-DLE120-V1.4 You should select the communication mode first based on which way you use COM , CAN or Ethernet. In default, we provide the COM RS232 cable and USB adapter, so you can use the COM or USB for communication.

  • Page 52: Com Communication Mode

    UAV engine EFI installation manual-DLE120-V1.4 Note: By default, EcoCAL uses USB communication mode (Note: insert the Ecotrons’ USB adaptor into the laptop first for USB mode). This configuration is consistent with most of the computers. 4.1 COM communication mode If the user is using the COM mode (Note: for this mode, your laptop need to have a built-in COM port).

  • Page 53: Usb Communication Mode

    UAV engine EFI installation manual-DLE120-V1.4 Built-in COM port (9-pin) RS232 cable The default baud rate is 115200, which the fastest of the serial comm. rate of the PC. It is not supposed to change. 4.2 USB communication mode 4.3 CAN communication mode Our custom ECU support the CAN communication, if the ECU of EFI system supports the CAN communication, you can use this communication mode to connect ECU.

  • Page 54: Ethernet Communication Mode

    UAV engine EFI installation manual-DLE120-V1.4 And if you don’t want to use the CAN, you also need to click “Close Device” to close the CAN device. 4.4 Ethernet communication mode Our custom ECU also support the Ethernet communication, if the ECU of EFI system supports the Ethernet communication, you can use this communication mode to connect ECU.
  • Page 55 UAV engine EFI installation manual-DLE120-V1.4 Note: when you click the “Open Device”, if the equipment is existed and working, the message will pop up, “Open device successfully!” Then you can connect to ECU. Copy right ECOTRONS LLC http://www.ecotrons.com...

  • Page 56: Chapter 5 Initial Test After The Installation

    UAV engine EFI installation manual-DLE120-V1.4 Chapter 5 Initial test after the installation Before you do the initial test of the EFI kit, make sure the installation is done as the previous section. Key-on and KEY-ON ONLY! You should hear fuel pump noise running for a few seconds, if this is not happening, you must have some wiring problem.
  • Page 57 UAV engine EFI installation manual-DLE120-V1.4 First time you start the engine, there may be still some air bubbles in the fuel supply system needs to be purged. So don’t be surprised that the first start takes longer, or even you need to start multiple times to be successful.
  • Page 58 UAV engine EFI installation manual-DLE120-V1.4 1.2.3) Do you have a fuel return line back to the fuel tank? Our EFI kit currently needs a way to return the fuel to the tank. 1.2.4) is there impurity in the gasoline? Check your fuel filter.
  • Page 59 UAV engine EFI installation manual-DLE120-V1.4 4) With the EcoCAL communicating with ECU, do the below tests: 4.1) Try to start the engine (with the engine spinning), Read the variables in EcoCAL: 4.2) Does the signal "RPM" changing from 0 to some value > 300rpm? 5) To rule out the problem of the ignition pickup sensor, do the below tests: 5.1) disconnect both CKP wire and GND wire from the ignition pickup sensor and tape...

  • Page 60: Chapter 6 How Do We Know The Fuel Injector Flow Rate

    UAV engine EFI installation manual-DLE120-V1.4 Chapter 6 How do we know the fuel injector flow rate See the mark of the fuel injector as shown below, This fuel injector flow rate is 248g/min. Note: It does not recommend removing the injector cap, as it may lead to damage the injector cap.

  • Page 61: Chapter 7 Uav Efi Maintenance

    UAV engine EFI installation manual-DLE120-V1.4 Chapter 7 UAV EFI Maintenance UAV EFI check list before flight: a. 12v power supply i. Before each flight, check the 12V power supply to EFI, and make sure the voltage is 12V or higher.
  • Page 62 UAV engine EFI installation manual-DLE120-V1.4 i. Before each flight, check the brass tube on the ECU is not blocked (which is for the on-board Baro pressure sensor) Before each flight, check the “MAP” gauge reading, in EcoCAL. It shall match the ambient pressure, like 101kPa, or 14psi.
  • Page 63 UAV engine EFI installation manual-DLE120-V1.4 i. Check the servo wires and connector before each flight; ii. Before each flight, visually check the servo assembly, no cracks, and no loose parts. iii. Before each flight, visually check the throttle is synchronized with the servo movement.
  • Page 64 UAV engine EFI installation manual-DLE120-V1.4 you hear the fuel pump running noise but no fuel flowing, you shall check the fuel supply to the pump, or air pocket in the lines. v. Every 50 hours, check the fuel pressure with a fuel pressure gauge, and make sure the fuel pressure can be maintained at 3 bar or 45psi at all RPMs, including the WOT (wide open throttle running).
  • Page 65 UAV engine EFI installation manual-DLE120-V1.4 6. Clean engine i. Need to de-carb engine every 50 hours when using 100LL Fuel; 7. Engine exhaust and muffler i. Mufflers should be soaked in cleaner every 50 hours and dry before use; ii. Exhaust(s) inspected after and before each flight Copy right ECOTRONS LLC http://www.ecotrons.com...

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