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Electromotive XDI200 Installation Manual & Users Manual

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Electromotive, Inc.
9131 Centreville Road
Manassas, VA 20110
XDI200
Product Installation Manual
& User's Guide
V 01
703-331-0100
703-331-0100 fax
support@electromotive.com

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Summary of Contents for Electromotive XDI200

  • Page 1 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...

  • Page 2: Table Of Contents

    Table of Contents Terms and Conditions ............6 ELECTROMOTIVE, INC. PRODUCT WARRANTY .......... 6 Forward................7 Improvements of the XDI200 over the TECgt ........... 8 Fundamentals of the System ................8 Installing the Hardware ............ 10 Pre-Installation Checklist ................10 Mounting the Main Computer and DFU ............
  • Page 3 Adjusting the Timing Advance ................ 68 Getting the Engine to Idle ................69 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...
  • Page 4 Trouble Codes from the LED’s Mounted on the XDI200 ......... 75 Trouble Codes from the Check Engine Output ..........76 Trouble Code Descriptions ................77 9.3.1 Using the Trouble Codes ................78 9.3.2 Wiring the Check Engine Light ..............79 Tuning the Knock Control ................
  • Page 5 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 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 5 - ©2017 Electromotive, Inc.

  • Page 6: Terms And Conditions

    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.

  • Page 7: Forward

    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.

  • Page 8: Improvements Of The Xdi200 Over The Tecgt

    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)
  • Page 9 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.

  • Page 10: Installing The Hardware

    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.
  • Page 11 It is recommended that the ECU and DFU be separated by at least six inches for the purpose of reducing electrical noise in the ECU. 2-Coil DFU Dimensions 3-Coil DFU Dimensions Figure 1. Electromotive Direct Fire Units Mounting bolt pattern is 3.375” x 6.88” ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 11 - ©2017 Electromotive, Inc.

  • Page 12: Trigger Wheel And Sensor Installation

    Appendix II for a listing of applications. Universal trigger wheels are also available in a variety of sizes, and are listed in Appendix II as well. Electromotive can custom-make trigger wheels in nearly any configuration for a one-time tooling fee.

  • Page 13: Crank Sensor Installation

    ½” diameter. See Table 2 for the appropriate magnetic sensor/trigger wheel combinations. Once a sensor and trigger wheel are installed, they must be aligned such that the XDI200 computer knows where to locate Top Dead Center of the #1 cylinder (referred to as TDC #1).
  • Page 14 Make sure that the Mag. Sensor harness is NOT routed near battery cables or other high current leads or devices such as cooling fans, starter or alternator. Locating close to coil wires or other power leads should be avoided. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 14 - ©2017 Electromotive, Inc.

  • Page 15: Wiring A Magnetic Trigger Sensor

    3-1/2” 60 (-2) Tooth (Above 6000rpm) Greater than 3-1/2” 60 (-2) Tooth wheels 1 tooth Cam Wheel Figure 4. Electromotive ½” (12.7mm) crank sensor Figure 5. Electromotive 3/8” (9.53mm) crank sensor 3.3.4 Wiring a Magnetic Trigger Sensor The magnetic sensor has three wires. The red wire is the signal from the sensor, the black wire is the signal ground, and the bare wire is the shield.

  • Page 16: Verifying Trigger Wheel Timing

    DOUBLE the actual desired timing value due to the waste-spark firing of the DFU coils. They are fooled into thinking that the timing is twice as advanced as it actually is. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 16 - ©2017 Electromotive, Inc.
  • Page 17 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 17 - ©2017 Electromotive, Inc.

  • Page 18: Camshaft- & Distributor-Mounted Trigger Setups

    120(-4) tooth trigger wheel is necessary. This wheel has two sets of two missing teeth, spaced 180 degrees apart. As such, the input to the XDI200 is identical to that of the crank-mounted 60(-2) tooth trigger wheel. Electromotive offers 120 (-4) tooth wheels in 3.25”...
  • Page 19 39. Keep in mind that when adapting an OEM cam trigger setup to a XDI200, the wheel may need to be rotated to place the rising edge in the appropriate degree window for the XDI200.

  • Page 20: Tdc Tooth Setup Software Adjustment Parameters

    Some applications may require less “mechanical timing” (some rotary users may wish to do this). Assuming the crank sensor is aligned with the 11 tooth at TDC, this can be done by ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 20 - ©2017 Electromotive, Inc.
  • Page 21 (the displayed values will be 6 degrees lower than the actual advance). Note: In the past, aligning the sensor with the 12 tooth would advance the mechanical timing by 6 degrees. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 21 - ©2017 Electromotive, Inc.
  • Page 22 Figure 13 - TDC tooth for two possible scenarios. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 22 - ©2017 Electromotive, Inc.

  • Page 23: Wiring The System

    4 Wiring the System 4.1 Introduction The task of installing a XDI200 wiring harness may seem a bit intimidating at first. However, by dividing the wiring installation into a few small jobs, it can be accomplished by most installers in a reasonable amount of time.

  • Page 24: Wiring Ecu & Main Power

    The power outputs provide power for the DFU’s, EGO sensor heater, and Fuel Pump. The switched voltage input is used to turn on the XDI200 ECU, and should be wired to a +12Volt source that is activated with the ignition key.

  • Page 25: Wiring Ignition Coil Primary Sides

    4.3 Wiring Ignition Coil Primary Sides 4.3.1 Introduction The XDI200 has the ability to operate either the older style standard ignition coils or more recent Driver on Coil (DOC) coils. If DOC coils are selected, the customer must set a fixed dwell time in the calibration.

  • Page 26: Standard Direct Fire Units, Dfu's

    4 single tower coil units. Two cycle applications will use single tower coils as well. The DFU’s are driven by a 12-volt charging system housed in the XDI200 ECU. For the Electromotive DFU wiring requirements, refer to Figures 25 below.
  • Page 27 The XDI200 has both standard DFU coil outputs and logic outputs. When using the Standard DFU outputs showed below, remove or tape off the DOC wires [5,6,7 and 10,11,12]. Figure 25: ECU Coil Output Wires (note: shield wire is connected inside the XDI200 unit, not connected at the coils).

  • Page 28: Spark Plug Wiring High Voltage Side

    Figure 26 shows a configuration using two 3-coil DFU’s. If you are using 2-coil DFU’s the numbering is the same except there is not C1 and C2. If your application requires only one DFU, then A2, B2, and C2 will not be needed. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 28 - ©2017 Electromotive, Inc.
  • Page 29 Figure 28: 8-Cyl and 4-cyl Dual Plug DFU Setup. Note that the 2 DFU coils will not be DFU is wired as shown, the coil labeled “A” labeled C and D from Electromotive. When the 2 will fire coil output “A2.” The coil labeled “B” will fire coil output “B2.” ________________________________________________________________________ XDI200 Manual Version 0.1...

  • Page 30: Ignition Firing Order

    For the engine to run correctly, the coils must be connected to the appropriate cylinders. Since the Electromotive DFU’s utilize waste-spark coils, it is necessary to know the firing order of an engine to determine which cylinders should be paired together.

  • Page 31: Common Engine Sparkplug Wiring

    Leading or Trailing: Leading Trailing Leading Trailing Note: In the software, the timing split between the leading and trailing spark plugs can be set for different engine speeds. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 31 - ©2017 Electromotive, Inc.

  • Page 32: Coil Firing Schemes

    The following pages outline the different ignition firing patterns that are available on the XDI200. It will be necessary to know the firing order for your engine before using the engine configuration tables (some common firing orders are given in the following section).

  • Page 33: Coil Firing Patterns For Rotary Engines

    4.5.2 Coil Firing Patterns for ROTARY Engines Coil Firing Patterns for 2-CYCLE Engines 4.5.3 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 33 - ©2017 Electromotive, Inc.

  • Page 34: Coil Firing Patterns For Odd-Fire Engines

    4.5.4 Coil Firing Patterns for ODD-FIRE Engines 4.5.5 Examples of Typical Engine Setups Figure 32. Typical In-Line 4-cylinder DFU wiring. Firing Order 1-3-4-2 depicted here. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 34 - ©2017 Electromotive, Inc.
  • Page 35 Firing Order 1-5-3-6-2-4 depicted here. 8 Cylinder Figure 35. Typical GM 8-cylinder DFU wiring. Firing Order 1-8-4-3-6-5-7-2 depicted here. Remember, 8-cylinder setups fire the coil channels in the order of A ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 35 - ©2017 Electromotive, Inc.
  • Page 36 [2] (white wire) = first rotor, leading. XDI200 pin [3] (red wire) = second rotor, leading. Trailing plugs will go to XDI200 pin [14] (white wire) = first rotor, trailing. XDI200 pin [15] (red wire) = second rotor, trailing.

  • Page 37: Common Firing Orders

    1&4 6&3 2&5 Lowers Coil 4 cylinder - Firing Order Most Inline 4-cyl Engines: 1-3-4-2 1&4 3&2 VW Flat 4 (air-cooled): 1-4-3-2 1&3 4&2 Dual Plug 4-cyl: 1-3-4-2 1&4 3&2 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 37 - ©2017 Electromotive, Inc.

  • Page 38: How To Find The Tdc Event Order

    References to DFU #1 in the software will correspond to the 2 primary spark plug coils (coil outputs A1 and B1), and will fire the leading spark plugs on rotors 1 and 2, respectively. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 38 - ©2017 Electromotive, Inc.

  • Page 39: Dual Plug Engines

    Split. 4.6 Spark Plug Wire Selection The XDI200 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.

  • Page 40: Spark Plug Selection

    The load at which a spark plug fails is different for all spark plugs. With the XDI200’s charging circuit, the more load you put on an engine, then more voltage will be applied to the plug.
  • Page 41 MUST be used. The bottom line is this: the XDI200 system uses an inductive (long duration charge at battery voltage) charging method for the coils, which is completely different than the capacitive (short duration charge at higher-than-battery voltage) charging method used by several other aftermarket manufacturers.

  • Page 42: Driver On Coil Logic Driven Coils

    DOC coil and set a fixed dwell time. If you do not know the exact dwell time to use for the coil you have, start with 1.8 mSec. Failure to make this calibration change may cause extreme damage to the coils. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 42 - ©2017 Electromotive, Inc.

  • Page 43: Wiring Sensors & Other Inputs

    5 Wiring Sensors & Other Inputs The XDI200 harness has provisions to connect all of the engine devices described in this section. Refer to this section to wire your sensors appropriately.  The following sensors use pull-to-seat connectors (feed the wire through the connector before...

  • Page 44: Map Sensor Data

    MAP sensor voltage as a function of manifold pressure for the three MAP sensors. Since the XDI200 does NOT know whether the MAP voltage is from a 1-, 2-, or 3-Bar MAP sensor (that is, it only knows the voltage), it is necessary to enter the MAP sensor that is being used into the software.

  • Page 45: Throttle Position Sensor

    (approaching 0V) at idle to a high voltage (approaching 5V) at full throttle. Switch-type TPS’s will NOT work with a XDI200 since they do not output a smooth voltage transition from closed to opened throttle.

  • Page 46: Tps Wiring

    Please note that the TPS must use a (roughly) 10k potentiometer! Failure to do so will result in improper impedance matching for the XDI200, and a false sensor reading will result. Fortunately, most TPS’s are of the 10k variety.

  • Page 47: Coolant Temperature Sensor

    PN 310-71330 Fig. 44 Fig. 45 The TPS connects to three wires from the XDI200 harness: +5 Volt, Ground, and TPS Signal. See Figure 46 for proper wiring instructions. Figure 46: Proper throttle position sensor wiring 5.4 Coolant Temperature Sensor The XDI200 is compatible with negative temperature coefficient (NTC) thermistor-type coolant temperature sensors.
  • Page 48 A and B with an ohmmeter. Match the resistance of the sensor to the operating temperature using Table 5. As a guideline, use the following specs: Cold engine (70F, 20C): ~3300 Hot Engine (180F, 80C): ~350 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 48 - ©2017 Electromotive, Inc.

  • Page 49: Manifold Air Temperature Sensor

    Sensor is an NTC thermistor. The MAT input is used for data logging purposes. The XDI200 is set up to use the GM-style MAT sensors. These sensors are sold by Electromotive under part number 305-71220. They are threaded for a 3/8”...

  • Page 50: The Exhaust Gas Oxygen Sensor

    5.6.2 Wiring the EGO Sensor Virtually all 4-wire EGO sensors on the market are compatible with the XDI200. Most universal EGO sensors available from the auto parts store have a color code as follows:...

  • Page 51: Ego Functionality

    The positive wire for the heater can be spliced to the Fuel Pump output on the XDI200 Power Harness (PN 070-40000). This is the 16awg light green wire. This is NOT the same as the Fuel Pump Relay Ground output of the XDI200, which is a 20awg light green wire from pin [57].

  • Page 52: About One-Wire Ego Sensors

    20awg wire in the XDI200 Harness – Pin [49]).  Connect the EGO- line on the XDI200 (this is the tan 20awg wire going to Pin [8]) to the Sensor Ground line (this is black w/ white stripe 18awg wire going to ground).

  • Page 53: Secondary Ego Sensor Input

    AFR. For example, if the manufacturer states 2 volts is an AFR of 12.6, and the XDI200 WBS is displaying 2 volts but the XDI200 AFR reads 13.6, then you entered the calibration values incorrectly. Repeat the procedure detailed above to correct the calibration file.
  • Page 54 Once knock has dropped a sufficient amount, the timing will then begin to increase to the desired advance setting. When the XDI200 starts to increase the advance, it will not add any more timing than what is set in the Ignition Advance table.

  • Page 55: Auxillary Temperature Sensor Input

    Analog Voltage 0-5 VDC 29 Orange/Gray Analog Voltage 0-5 VDC Speed 34 Orange/Black Road Speed Pulses EG RTD 48 Orange/White Resistive Temperature Sensor EGO Sec. 50 Purple/Tan Analog Voltage 0-5 VDC ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 55 - ©2017 Electromotive, Inc.

  • Page 56: Available General Purpose Input (Gpi) Functons

    1, GPO Trim #2 only effects table 2. See Figure 60 for wiring diagram. A/C Idle Speed Increase: On XDI200 installations with an idle air control motor, this feature allows the idle speed to be increased when the air conditioner is turned on. See Figures 61 and 62 for recommended wiring.

  • Page 57: Wiring The Gpi's

    Figure 62: Alternate air conditioner idle speed increase wiring. Note that the A/C clutch solenoid polarity MUST be known for this method. Figure 63: Nitrous timing retard wiring. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 57 - ©2017 Electromotive, Inc.
  • Page 58 Figure 64: Valet mode on/off wiring. Figure 65: Typical speed sensor wiring ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 58 - ©2017 Electromotive, Inc.

  • Page 59: Wiring Outputs

    WinTec software, the IAC motor can be made to increase idle speeds during cold engine operation or air conditioner turn-on. The IAC motor control built into the XDI200 can be used with four-wire stepper motor-style IAC’s. The stepper motor allows the pintle of the IAC motor to move in and out very quickly to allow varying amounts of air into the intake manifold.

  • Page 60: Wiring A 2-Wire Iac

    IAC motor. Switched +12v must also be connected to the IAC adapter pin B. The case of the adapter MUST be grounded. Pin A from the IAC adapter connects to the signal wire from the XDI200 unit. This setup does not require any diodes.
  • Page 61 Fig 71: Common 4-wire idle air control motor wiring. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 61 - ©2017 Electromotive, Inc.

  • Page 62: Tachometer Output

    XDI200 is first turned on. This ensures adequate fuel rail pressure on start-up. When the XDI200 is first turned on, the fuel pump will run for the amount of time defined in the software. If the engine is not cranked during or after this time, the fuel pump will turn off.

  • Page 63: General Purpose Output (Gpo) Functions

    XDI200’s GPO functions. To accomplish this task, you would first select the Radiator Fan option from the GPO menu. Then, you would input the temperature at which the fan should turn on, and the temperature at which it should turn off.

  • Page 64: Outputs

    RPM and MAP values. See Figure 82 for wiring diagram. Auxiliary Fuel Pump: This GPO turns on an auxiliary fuel pump at a desired RPM and MAP value. See Figure 83 for wiring diagram. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 64 - ©2017 Electromotive, Inc.

  • Page 65: Wiring The Gpo's

    30 or 40 amps, which should be more than adequate for most applications. High quality relays and relay sockets are available from Electromotive under part numbers 340-91200 and 340-91201, respectively. Part number 340-91200 is a 5-position relay, so it can be used for all applications depicted below.
  • Page 66 A/C clutch with terminals 30 and 87a. When activated, the A/C control will break the (normally-closed) connection between 30 and 87a by grounding pin 85. Figure 83: Auxiliary fuel pump wiring. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 66 - ©2017 Electromotive, Inc.

  • Page 67: Communications Ports On The Xdi200

    The XDI200 also has the old style RS232 serial port that some PC computers still have. The XDI200 functions will work identically for either USB or RS232. Do not use both ports at the same time. Make sure the Wintec4 software finds the right port number, usually 1 or 2.

  • Page 68: Tuning Guide

    Always confirm your timing values in the software with a timing light! Remember that dial-type timing lights will not read correctly with the XDI200 due to the waste- spark. To avoid potential engine damage, it is best to check engine timing with a timing light when first starting the tuning process.

  • Page 69: Getting The Engine To Idle

    This can help achieve the desired idle RPM, even on applications not using the IAC motor. 8.4.1 Configuring the New Electromotive Idle Speed Control For information on wiring the 2-wire IAC, refer to the drawings at the end of this section.

  • Page 70: Idle Speed Primer

    Mazda: Min = 60, Max = 155, Allow shutdown should not be checked Electromotive Stepper: Min = 50, Max = 185, Allow shutdown does not effect this motor  Pick your idle targets as discussed in Section B.8  Make sure to pick the control motor type (2- or 4-wire).

  • Page 71: Error Sensitivity

    8.4.4 Error Sensitivity Error Sensitivity controls how rapidly the idle motor will move in reaction to the error of RPM at any given time. The picture below shows how the XDI200 unit finds error. Figure 90 8.4.5 RPM Rate-of-Change Sensitivity Rate-of-Change sensitivity controls how rapidly the idle motor moves in reaction to the RPM changing.

  • Page 72: Tuning Tips

    For example, if you have a 302 V-8 and are using the Electromotive stepper idle motor, larger sensitivity values will usually be needed because the idle motor must make larger changes to get the engine to respond. In a case where the factory Idle motor is being used, the starting settings given above will likely work well because the idle motor is properly sized for the engine.

  • Page 73: Absolute Vs. Gage Pressure

    “kPa, abs” for the former, and “kPa, gauge” for the latter. For the purposes of this section, we will treat all kPa reading as absolute readings. Table 11 gives conversion data for US and metric units. Remember: Ambient (atmospheric) Pressure + Gauge Pressure = Absolute Pressure ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 73 - ©2017 Electromotive, Inc.
  • Page 74 4.16 psi 28.8 psi 5.61 psi 30.3 psi 7.06 psi 31.7 psi 8.51 psi 33.2 psi 1 Bar MAP Sensor Figure 106: 1-Bar MAP sensor output voltage. Output Voltage ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 74 - ©2017 Electromotive, Inc.

  • Page 75: Diagnostics

    9.1 Trouble Codes from the LED’s Mounted on the XDI200 The LED’s mounted on the XDI200 are used to alert the user’s attention to electrical and crank trigger problems. They are also used to show the mode (in terms of the rpm range) in which the XDI200 is operating.

  • Page 76: Trouble Codes From The Check Engine Output

    The third (and final) rev limiter stage is occurring. Note: If a misfire occurs during normal engine operation, but the lower LED on the XDI200 was not observed to momentarily flash red, the crank sensor may be at fault. To test for errors in this situation, turn the engine off without removing power from the XDI200 ECU by hitting the letter “K”...

  • Page 77: Trouble Code Descriptions

    Alternately, it can be used to detect a short in the wires. When this code is displayed, the XDI200 will be using the MAP Failure Default value for MAP calculations. As such, there will be no load input to the XDI200’s ECU, and the computer will enter into a “limp-home”...

  • Page 78: Using The Trouble Codes

    The trouble codes are displayed for a sensor when the maximum or minimum value for a sensor has been exceeded. Since the maximum and minimum points are user-definable in the ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 78 - ©2017 Electromotive, Inc.

  • Page 79: Wiring The Check Engine Light

    This will allow code 21 to be displayed in the event of a high voltage failure. The Failure Default Value is the voltage that the XDI200 will use for its TPS- based calculations when the TPS sensor has failed. Since this is a fixed value, there will be no TPS-based acceleration enrichments when the TPS has failed.

  • Page 80: Tuning The Knock Control

    There is a huge amount of data moving between the engine sensors and ECU when using the XDI200 system. The data logging feature of the system allows users to view all of this data in graphical format, thereby simplifying tuning and troubleshooting by a huge amount. Data logging is available in two modes : On-Board Data logging (OBD) and PC-Based Data logging (PCD).

  • Page 81: On-Board Data Logging

    11 Rev Limiters Several different rev limiters are built into the XDI200 system. These rev limiters can be engaged in a few different manners, and can be used for a variety of functions.

  • Page 82: Primary Rev Limiter

    Relay Pin 86 : Switch to +12 Volts to activate Secondary Rev Limiter. 11.3 Primary Rev Limiter : The Electromotive rev limiter is very flexible. For ignition control, the timing can be dropped to 0 degrees on rev limit, or our 3-stage coil cut can be used.

  • Page 83: Air, Fuel, And Spark

     The crank sensor is the first thing to check when an engine will not start. o Crank the engine. The LED on the XDI200 ECU should flash red-green-red-green in a fairly steady fashion. If the light is not functioning in this manner during cranking, and there is no RPM reading when viewed on a laptop, there is likely a trigger problem.

  • Page 84: Idling Problems

     If there is no spark, check the wiring to the DFU and to the XDI200. Pin D on the DFU should have +12volts with the ignition key on.

  • Page 85: Spark-Related Idling Problems

     Make sure the coil screws are very tight! Also, the DFU’s must be grounded for proper operation.  If misfiring occurs under load, loose coil screws or ungrounded DFUs are often the culprit. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 85 - ©2017 Electromotive, Inc.

  • Page 86: Appendix I. Ecu Specifications

    Engine Sensor Inputs o Crank Sensor  2-wire magnetic or Hall sensor (compatible w/ some OEM’s)  Uses Electromotive-spec 60(-2) tooth crank trigger  Ultra-high resolution engine position input o Cam Sensor  Hall effect sensor necessary for full-sequential applications ...

  • Page 87: Angle Based Timing Control

    Manifold air temperature-based advance adjustments  Smooth idle advance control (integrated w/ IAC settings)  Paired-cylinder timing trims (each coil has timing trim)  Individual-cylinder timing trims for full-sequential setups ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 87 - ©2017 Electromotive, Inc.

  • Page 88: Supported Engine Configurations

    10 MB of free hard drive space ommunications o RS-232 9- or 25-pin D connector COM 1-99 (software selectable) USB Optional, use either or RS232 or USB but not both CAN Bus Data Output ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 88 - ©2017 Electromotive, Inc.

  • Page 89: Appendix Ii. Trigger Wheel Availability

    Generation MR2 Turbo & NA Coming Soon Please note that most common engines have trigger kits made by our various dealers. Porsche, Mazda, Toyota, Acura/Honda and Subaru applications are currently covered extensively. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 89 - ©2017 Electromotive, Inc.

  • Page 90: Appendix Iii. Secondary Coil Polarity For Redundant Ignition Applications

    15 Appendix III. Secondary Coil Polarity for Redundant Ignition Applications Figure 120: DFU Secondary Voltage Polarity – for Redundant Ignition Applications. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 90 - ©2017 Electromotive, Inc.

  • Page 91: Software & Firmware Support

    16 Software & Firmware Support The XDI200 is designed to be fully upgradeable with respect to its software and firmware. The software is the operating system that is used to tune the engine. The firmware is the embedded code that is installed in the XDI200’s processors. Small changes in functionality can be covered with software changes.

  • Page 92: Firmware Upgrade Procedure

    2. Install the firmware upgrade on the PC that you will use to tune the engine. 3. Connect the XDI200 to the PC’s serial or USB port and power it ON. 4. Startup the WinTec software, it should show in the System console that the unit was found and display the firmware version.

  • Page 93: Appendix Iv. Ecu Connector Pin Out List

    7cond Red/Wht 18TXL 12 volt in Org/Blk 20TXL Speed In Black/Shield 7cond USB GND 7cond USB PC5V White 7cond USB D- Green 7cond USB D+ 20TXL CAM in ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 93 - ©2017 Electromotive, Inc.

  • Page 94: Appendix V. Ecu Connector Drawing

    Main Gnd 18 Appendix V. ECU Connector Drawing Please go to this internet link and down load this document: http://www.molex.com/pdm_docs/as/AS-34566-001.pdf It has important information on handling the XDI200’s new Molex connector. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 94 -...
  • Page 95 ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 95 - ©2017 Electromotive, Inc.

  • Page 96: Appendix Vii. Driver On Coil Schematic

    19 Appendix VII. Driver on Coil Schematic ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 96 - ©2017 Electromotive, Inc.

  • Page 97: Glossary Of Terms

    BTDC (Before Top Dead Center): When a piston is moving upward, but has not yet reached TDC. Cam Sensor: A device used to provide a once-per-engine cycle pulse to the XDI200. This establishes the stage of engine operation that is occurring for a given TDC.
  • Page 98 Knocking: see ‘Detonation’ Load: The amount of work that an engine must provide at a given instant. Load is measured by using the MAP sensor to estimate the cylinder pressure on XDI200 systems. Higher loads result in higher MAP readings.
  • Page 99 Torque (TQ): A measurement of the work that an engine can perform, typically expressed in pound- feet (lb-ft). Trigger Wheel: A device attached to the crankshaft that provides a moving reference of speed and position of an engine’s crankshaft. ________________________________________________________________________ XDI200 Manual Version 0.1 - Page 99 - ©2017 Electromotive, Inc.

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