Electro motive Tec3r Guida

Product Installation Manual

& User’s Guide

V1.11

Electromotive, Inc 703-331-0100

9131 Centreville Road 703-331-0100 fax

Manassas,VA 20110 support@electromotive.com

Table of Contents

Term and Conditions....................................................................................7

Electromotive, Inc. Limited Product Warranty......................................................................... 7

New Product Limited Warranty:..............................................Error! Bookmark not defined.

If You Need Warranty Service:................................................................................................. 7

Out-of-Warranty Product Repair .............................................................................................. 7

Third Party Products and Parts: ................................................................................................ 7

Warranty Exclusions................................................................................................................. 7

Determinations:......................................................................................................................... 8

Disclaimer of Implied Warranties:............................................................................................ 8

Exclusion of Damages: ............................................................................................................. 8

Forward..................................................................................................9

A. Installing the Tec3-r System.........................................................10

A.1. How it All Works: The Two Pages You Need to Read ........................10

A.2. Pre-Installation Checklist.......................................................................11

A.3. Mounting the Main Computer and DFU ..............................................12

A.4. Trigger Wheel and Sensor Installation .................................................13

A.4.a. Crankshaft Trigger Installation for 60(-2) Tooth Wheel............................................. 14

A.4.b. Magnetic Crank Sensor Installation............................................................................ 14

A.4.d. Verifying Trigger Wheel Timing................................................................................ 16

A.4.e. Camshaft- & Distributor-Mounted Trigger Setups ..................................................... 18

A.4.f. Full Sequential Applications –Cam Synchronization................................................. 18

A.4.g. TDC Tooth Setup Software Adjustment Parameters .................................................. 19

A.5. Wiring the Tec3-r....................................................................................22

A.5.a. Tec3-r Main Power Connections............................................................................... 22

A.5.b. Power Harness Installation.......................................................................................... 22

A.5.c. Wiring the Fuel Injectors............................................................................................. 23

A.5.d. Wiring the DFU’s........................................................................................................ 24

A.5.e. Wiring the Engine Sensors.......................................................................................... 24

B. Tuning Guide .................................................................................25

Introduction ......................................................................................................25

B.1. Adjusting the Timing Advance...............................................................25

B.2. Establishing Proper Starting Enrichments...........................................26

B.3. Getting the Engine to Idle.......................................................................27

B.4. Establishing Proper Acceleration Enrichments ...................................27

B.5. Adjusting the VE Table...........................................................................28

B.6. Using TPS/MAP Blend............................................................................29

B.7. Tuning for Cold Engines and Cold Weather........................................29

B.8. Tuning the Idle Air Control Motor........................................................30

B.8.a Configuring the New Electromotive Idle Speed Control ............................................ 30

B.8.b. Idle Speed primer ........................................................................................................ 31

B.8.c Getting Started.............................................................................................................. 31

B.8.d Error Sensitivity ........................................................................................................... 32

B.8.e. RPM Rate-of-Change Sensitivity................................................................................ 32

B.8.f. Wiring a 2-wire IAC:................................................................................................... 33

B.8.g. Wiring a 3-wire IAC: .................................................................................................. 34

B.9. Tuning the Knock Control......................................................................34

B.10. Using the Injector Trims.......................................................................34

B.11. Using the Ignition Advance Trims.......................................................35

B.12. Tuning the EGO Sensor........................................................................35

C. Direct Fire Units (DFU’s) .............................................................36

Introduction ......................................................................................................36

C.1. Wiring the DFU’s ....................................................................................36

C.2. DFU to Spark Plugs.................................................................................37

C.3. Spark Plug Wire Routing .......................................................................40

C.3.a. Common Engine Setups .............................................................................................. 40

C.3.b. Special Note for Coil-Per-Plug Applications.............................................................. 41

C.4. Coil and Injector Firing Schemes ..........................................................43

C.4.a. Injector and Coil Firing Patterns for EVEN-FIRE Engines ........................................ 43

C.4.a. Injector and Coil Firing Patterns for EVEN-FIRE Engines (continued)..................... 44

C.4.b. Injector and Coil Firing Patterns for ROTARY Engines ............................................ 45

C.4.c. Injector and Coil Firing Patterns for 2-CYCLE Engines ............................................ 45

C.4.c. Injector and Coil Firing Patterns for 2-CYCLE Engine (continued)........................... 46

C.4.d. Injector and Coil Firing Patterns for ODD-FIRE Engines.......................................... 46

C.4.d. Injector and Coil Firing Patterns for ODD-FIRE Engines (continued)....................... 47

C.4.e. Examples of Typical Engine Setups :......................................................................... 47

C.5. Common Firing Orders ..........................................................................49

C.6. Odd-Fire Engines.....................................................................................49

C.6.a. To find the TDC Event Order:..................................................................................... 50

C.6.b. TDC Tooth for DFU “2” needed for an Odd-Fire Engine: ......................................... 50

C.6.c. Harley-Davidson Applications .................................................................................... 50

C.7. Rotary Engines.........................................................................................51

C.8. Dual Plug Engines....................................................................................51

C.9. Spark Plug Wire Selection......................................................................52

C.10. Spark Plug Selection..............................................................................52

D. Fuel Injector Configurations........................................................53

D.1. High vs. Low Impedance Injectors........................................................53

D.2. Injector Firing Schemes..........................................................................55

D.2.a. Staged Injection........................................................................................................... 56

D.2.b. Throttle Body Injection (TBI)..................................................................................... 56

D.2.c. Phase-Sequential Injection .......................................................................................... 57

D.2.d. Full Sequential Injection ............................................................................................. 58

D.2.e. Rotary Engine Injection............................................................................................... 59

D.3. Injector Wiring........................................................................................60

D.4. Fuel Injector Pulse Width Derivation ...................................................61

D.4.a. Introduction ................................................................................................................. 61

D.4.b. User Adjustable Pulse Width (UAP)........................................................................... 63

D.4.c. Pulse Width Offset Time (POT).................................................................................. 65

D.4.d. Volumetric Efficiency Table Corrections................................................................... 66

D.4.e. TPS/MAP Blend Corrections...................................................................................... 67

D.4.f. Oxygen Sensor Corrections ......................................................................................... 69

D.4.g. Warm-Up Enrichments (Coolant Temperature-Based)............................................... 71

D.4.h. Manifold Air Temperature Enrichments..................................................................... 72

D.4.i. Throttle Position Sensor and MAP Enrichments......................................................... 73

D.4.j. Starting Enrichments.................................................................................................... 74

D.4.k. Battery Voltage Compensation ................................................................................... 75

D.4.l. Deceleration Fuel Cut-Off ........................................................................................... 75

D.4.m. Summary.................................................................................................................... 76

E. Fuel System..................................................................................................76

E.1. Injector Sizing..........................................................................................77

E.2. Fuel Pump Selection................................................................................81

E.3. Fuel Pressure Regulator Selection .........................................................81

F. Tec3-r Output Functions and Wiring........................................82

F.1 Idle Air Control Motor.............................................................................82

F.2. Tachometer Output .................................................................................84

F.3. The Fuel Pump Relay Output.................................................................84

CAUTION:........................................................................................................84

F.4. The General Purpose Outputs (GPO’s) and the Spare Output ..........85

F.4.a. Available GPO Functions ............................................................................................ 85

F.4.b. The Spare Output Function and Harness Layout......................................................... 86

F.4.c. Wiring the GPO’s and the Spare Output...................................................................... 86

F.4.d. GPO Wiring Harness Layout....................................................................................... 88

G. Tec3-r Input Functions and Wiring.........................................88

G.1. The Manifold Air Pressure (MAP) Sensor ...........................................88

G.2. Throttle Position Sensor .........................................................................91

G.3. Coolant Temperature Sensor.................................................................93

G.4. Manifold Air Temperature Sensor........................................................95

G.5. The Exhaust Gas Oxygen Sensor...........................................................95

Mounting the Sensor............................................................................................................... 95

G.6. Wideband O2 Sensor ..............................................................................97

FAQ’s and Troubleshooting Tips: .......................................................................................... 98

G.7. Knock Sensor...........................................................................................99

G.8. The General Purpose Inputs (GPI’s)...................................................100

G.8.a. Available GPI Functions ........................................................................................... 100

G.8.b. Wiring the GPI’s ....................................................................................................... 101

G.8.c. GPI Wiring Harness Layout...................................................................................... 103

H. Diagnostics ...................................................................................103

H.1. Trouble Codes from the LED Mounted on the Tec3-r......................103

H.2. Trouble Codes from the Check Engine Output.................................104

Trouble Code Descriptions............................................................................105

H.2.a. Reading the Trouble Codes....................................................................................... 106

H.2.b. Using the Trouble Codes........................................................................................... 107

H.2.c. Wiring the Check Engine Light................................................................................. 107

I. Data logging with the Tec3-r.....................................................................108

I.1. PC-Based Data logging...........................................................................108

I.2. On-Board Data logging ..........................................................................108

J. Rev Limiters..................................................................................109

J.1. The Primary Rev Limiter......................................................................109

J.2. The Secondary Rev Limiter...................................................................109

J.3. Valet Mode Rev Limiter ........................................................................109

K. TIMING CONTROL...................................................................110

K.1. Zero degree advance .............................................................................110

K.2. 3-stage coil cut........................................................................................110

K.3. FUEL CONTROL.................................................................................110

K.3.a. No Fuel Cut ............................................................................................................... 110

K.3.b. Fuel Cut..................................................................................................................... 110

K.3.c. Progressive Fuel Cut.................................................................................................. 110

L. Troubleshooting...........................................................................110

Air, Fuel, and Spark.............................................................................................................. 111

L.1. Starting Problems..................................................................................111

L.1.a. Air-Related Starting Problems................................................................................... 111

L.1.b. Fuel-Related Starting Problems................................................................................. 111

L.1.c. Spark-Related Starting Problems............................................................................... 111

M.1. Idling Problems.....................................................................................112

M.1.a. Air-Related Idling Problems..................................................................................... 112

M.1.b. Fuel-Related Idling Problems................................................................................... 112

M.1.c. Spark-Related Idling Problems................................................................................. 112

N.1. Low-, Medium-, and High-Load Problems.........................................113

N.1.a. Air-Related Load Problems....................................................................................... 113

N.1.b. Fuel-Related Load Problems..................................................................................... 113

N.1.c. Spark-Related Load Problems................................................................................... 113

O.1. Summary of Troubleshooting Topics..................................................113

Appendix I. Electromotive Tec3-r ECU Specifications..........................114

Outputs............................................................................................................114

Inputs...............................................................................................................114

Tuning Features..............................................................................................115

Supported Engine Management Configurations.........................................116

Data logging Features.....................................................................................117

Physical Dimensions.......................................................................................117

Environmental Considerations .....................................................................117

PC Requirements............................................................................................117

Appendix II. Electromotive Trigger Wheel Availability...........................118

Appendix III. Coil Polarity for Redundant Ignition Applications...........119

Appendix IV. Tec3-r Custom Harness Specification Sheet.................120

Appendix V. Firmware Upgrade Procedure...............................................121

Appendix VI. Tec3-r Connector Pin Out Summary................................123

Gray Connector..................................................................................................................... 123

Appendix VII. Tec3-r Connector Pin Out Summary ................................124

White Connector ................................................................................................................... 124

Appendix VIII. Tec3-r Wiring Harness Layout.......................................125

Appendix IX. Tec3-r Power Harness Schematic...................................126

Terms and Conditions

Electromotive, Inc. Limited 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 Third Party Products and Parts.

Should your product fail to function 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:

Electromotive offers a 1 year warranty 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 support@electromotive-inc.com or 703/ 331-0100 M-F 8:30 to 5:00 EST. Then, send (1) a

completed Electromotive Diagnostic & Repair Request Form, 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 sales receipt, and it must clearly

show name of the seller, date of purchase and purchase amount.

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) purchasing a refurbished unit (if available), or (3) trading your old unit for a

discount on a new unit. We strive to keep our repair times to within 5 business days, plus shipping days.

Third Party Products and Parts:

We make every attempt to source third party products and parts that live up to our quality standards. In the

rare instance that one of these third party 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 with a new, remanufactured, or refurbished product,

unless an exclusion listed under Warranty Exclusions applies.

Warranty Exclusions

The following conditions are excluded from warranty coverage:

1. Any product, on which the serial number has been defaced, modified or removed or does not

appear in the Electromotive serial number registry.

2. Damage, deterioration, or malfunction resulting from:

A. Accident, misuse, neglect, contamination, 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

B. Repair or attempted repair by anyone not authorized by Electromotive.

C. Removal or installation of the product.

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

E. Use of supplies or parts not meeting Electromotive specifications.

F. Shipment.

G. Any cause other than a defect in a product sold or provided by Electromotive.

Determinations:

All determinations as to warranty coverage, warranty exclusion, and appropriate remedy will be made in the

reasonable discretion of Electromotive.

Disclaimer of Implied Warranties:

Apart from the above Limited Warranty, Electromotive disclaims all warranties, express or implied,

including but not limited to the implied warranties or merchantability and fitness for a particular purpose,

and any warranties that might otherwise arise from usage of trade or course of dealing.

Exclusion of Damages:

Your sole and exclusive remedy, and Electromotive’s entire obligation, for breach of warranty is repair or

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

defective product. In no event will Electromotive be liable for any monetary damages, whether direct,

indirect, consequential, special, incidental, punitive, exemplary, or other damages, arising out of or in

connection with any product (including third party products) sold or provided by Electromotive. This

exclusion applies to all monetary damages of any kind, including but not limited to:

1. Costs of removal, installation, tuning or set up of the product before or after the malfunction.

2. Damage to, or costs of repair to, the engine or vehicle on which the product was installed or to any

other property.

3. Damages for 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.

4. Claims against the customer by third parties.

5. Shipping charges from the customer to Electromotive.

6. Damages or costs resulting from a cause other than a defect in a product sold or provided by

Electromotive.

This exclusion of damages shall apply to the maximum extent permitted by applicable law and shall continue

in effect regardless of whether Electromotive has been advised or should have known of the possibility of

any particular damages, regardless of whether any exclusive remedy provided in this Agreement is deemed

to have failed of its essential purpose, and regardless of whether the customer is deemed to have been left

without an effective remedy.

Forward

The Tec3-r Total Engine Control system is the latest in ultra-high resolution engine management

systems from the company that revolutionized engine management over fifteen years ago. The Tec3-r can

be configured to control virtually any 1-, 2-, 3-, 4-, 6-, 8-, or 12-cylinder engine, as well as 1-, 2-, or 3-rotor

rotary engines, dual plug 4 or 6 cylinder and 6 cylinder odd-fire. The heart of the TEC series of engine

management systems has always been a high-resolution ignition, which offers incredibly precise ignition

timing even at the highest acceleration rates. The Tec3-r 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) are

available from Electromotive in 2- and 3-coil versions. These DFU’s are completely weather proof, and

feature sealed electrical connectors. Additionally, the DFU’s are impedance matched for optimum

performance with our Tec3-r.

The Tec3-r with eight dedicated fuel channels and drivers also covers fuel control. This allows up to

16 low or high impedance injectors to be driven. Staged injector firing is a built-in option on the Tec3-r

for most engine configurations. Sequential operation is also available through the use of a cam position

sensor.

Four dedicated, user-definable, general-purpose outputs (GPO’s) are included with the Tec3-r to

make your high-tech engine setup a snap. The GPO’s can be used to control anything from wast-egates for

turbo setups to simple electric radiator or intercooler fans. The possibilities are nearly limitless.

In addition to the four GPO’s, there are also four GPI’s (General Purpose Inputs). Two of the GPI’s

have frequency-based input capabilities, which can process data from wheel speed sensors or similar devices.

The other two GPI’s are analog inputs only, and do not feature frequency-based capabilities. These channels

can perform fuel trims, timing trims, and many other functions.

Beside the GPO’s and GPI’s, several functions are built-in to the Tec3-r that are quite useful on

most applications. The following outputs are standard on the Tec3-r:

Tachometer (configurable to drive most modern tachs)

Check Engine Light (24 diagnostic codes)

Fuel Pump Relay Ground (activated at appropriate times by the Tec3-r)

Idle Speed Motor control (stepper motor style)

The Tec3-r 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)

A. Installing the Tec3-r System

A.1. How it All Works: The Two Pages You Need to Read

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 Tec3-r 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 Tec3-r 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 Tec3-r has inputs for RPM and load.

Under steady-state conditions on a fully warmed-up engine, these are the only necessary inputs for the Tec3-

r 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.

Fuel Injector Control…

Control of the fuel curve is very simple as well. When the user first sets up a calibration, the Tuning

Wizard is generally used. The Wizard asks for the engine horsepower, peak RPM, number of injectors, and

the amount of manifold boost. From these, a raw fuel curve is established. Most importantly, the User

Adjustable Pulse Width (UAP) is established. UAP is the fuel injector pulse width when the MAP sensor

reading is full-scale (wide-open throttle on a 1-Bar MAP sensor, 15psi boost on a 2-Bar sensor, etc.). The

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