2-Stage Progressive Switch INSTALLATION AND USER MANUAL
Contents
1. S S Q a KVS0020 rev E 2 Stage Progressive Switch INSTALLATION AND USER MANUAL 204 254 5b6e3 204 25 7 3190 Winnipeg MB CANADA info fjoracing com Table of Contents Page l ODOR VIC W 922920 AN PRO RITE DONES EE EE JET FETA ECO UE TENIR CIE ARPA e Tee EE IE PERI ROC IO TE 1 ds SONA Installa COM ceeccdsccwccscasccacsasteeddatuscceectunsecdscsissncasswenssaceneceusesaswndscuhedueusubeedacsenncacsceucaccacumeseeueeesssacaccnsedaeascaceceasenonsteceusenccenaatecs 1 3 IT 1 TCL TN Osia Tr CI Cm TR ere rt Eo EP eC EO cen 2 3 1 Throtile Position Sensor TPS TH bl enemics estoc dl be dr T sals edats 2 JZ GEM ANI UT RR oct SO RRR eI A V SU AR es Da AAR E ateneus A IA A EA JL A diaca A AV Srs tent aA A des 3 3 3 DO CO DUIS APRE E R rae tte sera 222 P ees ENE anf era C2228220 EAC Oa a a CE 20002290 ad E70 EA CO AAA E20 Sn 3 3 3 1 Progressive O archaea acta AN AN a te tanta aa Be ee N ac TC PAU AA n trata a TA AAA T TA RAD ties 3 35 32 Trio Ef TN PU aure ccf St A E EE tee EE aU eects NANS s E A AU O A N ATE NU e D D A e AOS A Taa taments 3 3 33 121991 OAE IE 1 E 3 ARO E ean es EE E E EIE E ETE ENEE ETENA E en cat star st 4 3 3 4 PWM ETE QUE n Van ceo ctt a SA A OA a t TA A A dn A O L COL A TO A ANT c OAT T AA TAUT A AL MSS A TEIT E VT A 4 3 3 5 FEM TRR R CS OI Eee Se te delata sta nen PN Tenia dat trad boia Tenia data ei ADS st EA daten PB 4 3 3 6 Relay Output mon proestessive mode OD Nieto metetedetemettt2. With this set up the controller will automatically trigger the ignition retard function when it turns on the nitrous oxide WARNING Failure to set the options correctly will result in engine damage due to the ignition not being retarded when the nitrous oxide is on des EKS lt Q S M O 5 Q ao 93 9 3 Fiererrinog ca JE DO D lt a z EE 0 Sr D DS o O O D D O sys MS DU wuy AG LF lemod QE m e e e e e e e e e e JOS USS LOUS Cd 8Iy01U OL mc ea a JSA plouelos 86015 Sn 186614 Di Die UOILLUBI OL TA 1 COU OOS UOWUD OL UDOM Mep O O JOAUP plouajos UO anols 18d Sduup OP PS95XO ION Od KV60020 rev E
3. diagram KV60020 rev E 3 2 RPM Input 2 Stage Progressive Switch FJO Racing ai xi File View Controller Help Upload Download Controller Info Connected Throttle Position Sensor TPS From idle to wide open throttle the TPS voltage Rises FPM The RPM Multipher is 1 9 Stage 2 Progressive Solenoid D Config Downloaded RPM Multiplier selects the correct pulse count for the RPM counter Use the following as a guide to determine the correct setting a Using a TACH signal TACH signals will typically have 1 pulse per cylinder during 2 revolutions of the crankshaft 1 full cycle and therefore the correct setting would be 2 the number of cylinders Example When using a TACH signal 4cylinder setting would be 2 6 cylinder setting would be 3 8 cylinder setting would be 4 b Using a trigger signal from a coil first determine how often it fires per revolution of the crankshaft The correct setting would be x1 for a waste spark since it fires each revolution of the crankshaft x2 for a full sequential since it fires every other revolution This setting must be verified prior to operation Verifying this setting will require the unit to be installed on the vehicle see installation instructions later in the manual 3 3 Stage Outputs The following applies to both Stage 1 and Stage 2 3 3 1 Progressive Output Stage 1 Progressive Solenoid Driver Connected W The Trigg
4. x The config was uploaded to the corto Clicking on the UPLOAD button will store your settings in the controller The Config Uploaded window will appear following a successful upload You are now ready to install the 2 STAGE PROGRESSIVE SWITCH on the vehicle KV60020 rev E 4 Installation The 2 STAGE PROGRESSIVE SWITCH is designed to be installed almost anywhere on the vehicle Select a location that is away from heat sources that can damage the wires Before permanently installing the device we recommend that you complete the installation procedure below as you will need access to the potentiometer and have a clear view of the LEDs for the final steps Using the wiring diagram applicable to your application connect the harness as illustrated Power Input should be connected to the arming switch and fused for 5 amps Ground should be connected to chassis ground as close as possible to the battery and preferably not to the same location that the FJO HIGH CURRENT SOLENOID DRIVER is grounded to TACH input is designed to work with a 12 volt signal but will work with signals down to 3 5 Volts Trigger switch input requires a 12 volt signal to activate it TPS signal input is designed to work with all analog TPS signals or with a 12 volt WOT switch Stage 1 amp 2 Control Outputs are designed to trigger the FJO HIGH CURRENT SOLENOID DRIVER or the groundside of a relay coil FJO HIGH CURRENT SOLENOID DRIVER is designed to hand
5. 6 Watch the YELLOW LED If you set the correct RPM multiplier it will come on just as you reach the target RPM 7 Now repeat steps 5 and 6 and watch the RED LED and use the Turn On At RPM setting that you downloaded for stage 2 8 Ifthe LEDs come on at the right RPM then you selected the correct multiplier 9 Ifthe LEDs come on too late then the RPM multiplier is too high and you need to set the multiplier to 1 2 the previous setting and repeat the RPM set up verification 10 If the LEDs come on too soon then the RPM multiplier is too low and you need to set the multiplier to 2x the previous setting and repeat the RPM set up verification Note DO NOT use the half step multipliers unless this ts a 3 or 10 cylinder application The installation is complete 5 Software and Firmware Updates Please take a moment to register your product online at http www fjoracing com Registered owners are entitled to download the free updates for the 2 Stage Progressive Switch and related software 6 Disclaimer FJO Racing Electronics shall not be held responsible for any damages howsoever caused to any persons or equipment during the installation or operation of its products FJO Racing Electronics products are meant for off road use only and make no claims as to the units ability to meet local safety or emissions laws 7 Warranty FJO Enterprises Inc FJO warrants the material and workmanship of the equipment components and parts
6. Turn On At sets the lower threshold of the RPM window To change the value click on the small up and down arrows To quickly scroll up or down click and hold the large down arrow while moving the mouse right or left Turn Off At sets the upper threshold of the RPM window To change the value click on the small up and down arrows To quickly scroll up or down click and hold the large down arrow while moving the mouse right or left 3 3 6 Relay Output non progressive mode only stage 1 Frogressive solenoid Driver Connected L Toru Turn On Off the Relay non progressive mode H A Tur On S only allows you to set whether the relay is Ta Cnet 3000 RPM SB Tum Dp At ERM e EF turned on or off during the RPM window 3 4 Upload Download Configuration DO NOT connect the controller to your PC until you have installed the software To connect the controller to your PC use the USB cable supplied with the kit The controller is powered by the USB port on your computer and as such does not require any additional power sources Plug the USB cable into an available port on your PC Note If you are using a USB hub it must be capable of providing 100mA of current to power the controller File View Controller Help Once the software has identified the FJO 2 STAGE SWITCH the buttons will become fully visible and um T L 1 3 Cas vs ZE the connected ICON will be green Upload Download Controller Info Connected
7. manufactured by FJO against defects under normal use and service This warranty shall extend for 180 days from the date of manufacture provided that the customer first returns the defective part or component through an authorized distributor shipping costs prepaid Prior to returning a product for warranty inspection the customer must contact FJO s service department with the product serial number to receive a WARRANTY CLAIM NUMBER Units returned without this number will be refused FJO may at its option repair or replace without cost for parts and labour the defective product This warranty does not cover finishes normal wear and tear nor does it cover damage resulting from accident misuse dirt tampering unreasonable use service attempted or performed by unauthorized service agencies failure to provide reasonable maintenance or FJO products that have been modified or used for commercial reasons FJO specifically does not warrant equipment parts or components purchased by FJO or the customer from any third party manufacturers or suppliers Rather for any defect in respect of equipment parts and components purchased from third party manufacturers and suppliers the customer shall have recourse only to the terms of the warranty of that particular manufacturer or supplier Any recommendations made by the third party manufacturer or suppliers concerning the use or application of their products are those of the manufacturer or supplier and F
8. TPS signals as low as 2 volts in either rising or falling formats The manual trigger input allows the driver to over ride the controller and disable stages manually 2 Software Installation ReadMe txt this file provides basic instructions on installing softvvare the PC installer file run this program to install the softvvare on your PC driver files on your PC Note For Windows 98SE the driver files will not be automatically installed Once you have installed the software and connect the controller you will be prompted for the location of the driver files by the windows new hardware wizard The files are located on the CD in the USB Drivers subdirectory If you require additional information please refer to the Installation User manual provided with the kit For your convenience an electronic copy of this document can be found on this CDROM KWS0020 rev 2 Stage Progressive Switch Manual pdf KV60020 rev E 3 Configuration DO NOT connect the controller to your PC until you have installed the software The following settings do not require that the controller be connected to the PC until you are ready to UPLOAD All changes made to the set up require that you UPLOAD to the controller before installing it in the vehicle See Upload Download section 2 Stage Progressive Switch FJO Racing 0 lt File View Controller Help an ta f Upload SO Controller Info Connected Throttle Positio
9. Em R Wiring Diagram 2 Stage Progressive Switch On Off Mode 9 KV60020 rev E 10 VViring Diagram 2 Stage Progressive Svvitch Progressive Mode Om 23 632 gOS 062 D L lt A DOR 5 5 ui lt l l Le que l lt zl 8 OB Oa NES 3 Oa 3 S La 3 S 2 5 g 5 gt el Q Q m 3 FT z JoAN Y 1 Q D NO KK SOQ n Q O 82 SR 3 5 OIE 2 UUOU 2 0 p QO x G OF V d 2 D ej lt Q O s gt S O 100000 O lt Co RV60020 rev E 11 Progressive Nitrous Oxide and Ignition Retard Control If you have an ignition system with a retard trigger the 2 STAGE PROGRESSIVE SWITCH can provide a progressive nitrous channel and automatically retard your timing First you must determine if your ignition system s retard function is triggered when the input has a 12 volt signal applied to it or when it is grounded Now connect your 2 STAGE PROGRESSIVE SWITCH according to the correct wiring diagram below ENABLE the Progressive Solenoid Driver Connected option for Channel 7 only Set the desired parameters in Channel 1 s menu DISABLE the Progressive Solenoid Driver Connected option for Channel 2 only Set the Turn On Off the Relay option to TURN ON Set the Channel 2 Turn On At and Turn Off At parameters to the same settings you selected for Channel 1 diaca DI
10. JO extends no warranty with respect to the results obtained for their use FJO does not warranty those products in any way beyond the term of the warranty extended by the manufacturer or supplier The warranty provided above FJO s obligations and liabilities hereafter and the rights and remedies of the customer are exclusive and in substitution for and the customer waives all other warranties guarantees obligations liabilities rights and remedies expressed or implied arising by law or otherwise including without limitation the implied warranties of merchantability or fitness of purpose and any obligations or liability of FJO arising from tort or loss of use revenue or profit or for incidental or consequential damage KV60020 rev E 8 Wiring Diagram 2 Stage Progressive Switch 2 G ELECTRONICS Floracing com AN White White Red Yellow Orange Black 5A Fuse Power 12V ee a hrottle position sensor input Trigger switch input RPM input stage 1 control output stage 2 control output Ground KV60020 rev E Arming SW T BA Fuse Power 12V e Wide open Throttle SW m I i A ane Trigger Switch S Witeled _ _ _J 5 39 E Red E S Y to TACH signal Sal 5 Ka Stage 1 Relay T a Nitrous Oxide Yellow Orange N y Black L Ground Nitrous Oxide Stage 2 Relay AN Required if no throttle position sensor is present
11. emecmentmudemitatuemesteudaerests 4 9 41 Upload Download Con oural OM cemetamymysLeemosmmsmemsmlaseemmsmmnlesmemtstmmtanemyisauiesss 4 v NS E 11 E Ona a AEAEE E E00 SENAN tades itin E At ERA A Ee IE 0 Ae SN EANAN INNA 5 4 1 Wide ORC ERO CS T eres ters a J 2 1 AFMS ON TIE A O TTT 5 5 Soitware and Firmware Updefes ti RG Gisela Gas 6 6 Disclaimer mis mama mesa rails 6 r Warranty cat a a 6 8 Wiring Diagram 2 Stage Progressive Switch vececonaoonssssasonssonansonsioson nsos6nsssssisnsia ss sanes a insisiesisn ss sinsissosin 7 9 Wiring Diagram 2 Stage Progressive Switch On Off Mode cccccccssssssscccccccssssssssccccccccssscscccccesceesssssccccsseeessssccccesseeeeeees 8 10 Wiring Diagram 2 Stage Progressive Switch Progressive Mode ccccccccccccrsssssccsccccccccsccscsccccccceesssscccccscceessssccceseeeeees 9 11 Progressive Nitrous Oxide and Ignition Retard Control cccccccccccccssssscscccccccccscsssscccccccesssssccccccccccssscccccssceecsssccccseeees 10 KV60020 rev E 1 Overview The 2 STAGE PROGRESSIVE SWITCH is a digital controller that combines the functions of a throttle position sensing switch two RPM window switches and two progressive timers all into a very compact module With the optional FJO high current driver module it can drive up to 40 amps per channel The device also supports low voltage OEM V10 or 3 cylinder TACH signals without the need for additional adapters It also works with
12. er Switch ill Mot Change This Stage Progressive Solenoid Driver Connected sets the mode of the output stages Blank means that the output is configured to drive a relay With a checkmark in this box the controller is On Ramp Time 1 0 sec PWM Frequency 14Hz del Hz configured to drive the FJO SOLENOID DRIVER in progressive mode DO NOT use Tum Qn Aar 7340 RPM ee Tum OFF Ab 12873 RPM El 9 the progressive mode unless you have the 3 3 2 Trigger Input FJO SOLENOID DRIVER module as you will damage the controller and or the engine Trigger Switch will setting determines if the trigger switch will enable disable or have no effect on the applicable stage The trigger switch input can be used to control the output stages manually such as disabling them when the Transmission brake is engaged or as a driver over ride KV60020 rev E 3 3 3 Ramp Time On Ramp Time progressive mode only sets the time period for the controller to ramp from 0 to 100 DO NOT use the progressive mode unless you have the FJO HIGH CURRENT SOLENOID DRIVER module as you will damage the controller and or the engine 3 3 4 PWM Frequency PWM Frequency is the rate at which the controller cycles the solenoids This number is determined by the solenoid manufacturer DO NOT use the progressive mode unless you have the FJO HIGH CURRENT SOLENOID DRIVER module as you will damage the controller and or the engine 3 3 5 RPM On Off Thresholds
13. le a maximum load of 40 amps per stage Exceeding this rating will cause permanent damage 4 1 Wide Open Throttle Setup 1 Before connecting the 2 STAGE PROGRESSIVE SWITCH adjust the potentiometer to the initial position by turning it 25 turns clockwise for a rising voltage TPS or 25 turns counterclockwise for a falling voltage TPS 2 Disconnect the solenoids from the relays to prevent them from firing 3 Turn on the ignition power and arm the 2 STAGE PROGRESSIVE SWITCH 4 Verify that the RED YELLOW GREEN LEDs are off with the throttle in the idle position 5 Push the throttle to the wide open position WOT and hold it 6 Ifthe GREEN LED is on adjust the potentiometer to turn it off by turning it clockwise for a rising voltage TPS or counterclockwise for a falling voltage TPS Once the GREEN LED goes out proceed to the next step 7 Now turn the potentiometer the other way until it just comes back on and then one additional turn 8 Verify that the GREEN LED goes off at IDLE and on at WOT Repeat steps 4 6 as necessary 4 2 RPM Setup Verification 1 Disconnect the solenoids from the relays to prevent them from firing 2 Turn on the ignition power and start the engine 3 Arm the 2 STAGE PROGRESSIVE SWITCH 4 Verify that the RED YELLOW GREEN LEDs are off with the throttle in the idle position 5 Slowly increase the throttle until you reach the Turn On At RPM setting that you downloaded for stage 1 KV60020 rev E
14. n Sensor TPS From idle to wide open throttle the TPS voltage Rises HPM The RPM Multiplier is a Stage 1 Progressive Solenoid Driver Connected M The Trigger Switch will Not Change This Stage Un Ramp Time PYM Frequency 14 Hz Turn On AL 2404 APM Turn Off At 18618 RPM The Trigger Switch will Change J This Stage FM Frequency 14 Hz Turn On at 3000 FPM El Turn Of At 6000 RPM On Ramp Time 1 0sec lt RAC ING DUCTS Pro 3 1 Throttle Position Sensor TPS Input 2 Stage Progressive Switch FJO Racing Ioj xi File View Controller Help an ONAN F TI Upload ea Controller Info Connected Throttle Position Sensor TPS From idle to wide open throttle the TPS voltage Rises RFM The RPM Multiplier is 11 9 The Trigger Switch Will Change El This Stage During the RPM Window Tum Off The Relay Tum On At 3404 RFM H Turn Dit At 18618 APM El Stage 2 Progressive Solenoid Driver Connected The Trigger Switch Will Not Change This Stage During the RPM Window Tum Off The Relay Turn On t 3000 RPH H Turn oit At 6000 RFM Throttle Position Sensor TPS allows you to select if the output voltage from the throttle position sensor increases Rises or decreases Falls at wide open throttle WOT Note If used with a WOT switch set to Rises and connect the switch as shown in the wiring
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