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User Guide - Formula Ford Zetec

1. 120 Pressure measurement 128 Temperature 130 Eremina Tio 132 Optional sensors and interface 136 6 System 2 User Guide ABS sensor interface box sseHRH Hee 137 Waterspeed sensor menn 139 Wheelspeed selector box 141 Turbo carburettor pressure 143 Rotary Potentiometer seeeee 144 hrottle Sensor i inerte kt eka be a n eka MR k 146 Linear potentiometers 147 Potentiometer interface box 148 Thermocouple sensor essen 150 Part B Fitting the wiring loom eere 152 Connect the loom to the dash 152 Lay the loomiun the car eoim eee 152 Secure unwanted sensor wires 153 Cut the 1 812 154 Fit the Sure Seal connectors 155 Repeat the process for each sensor
2. m 87 Turbo and carburettor pressure measurement 88 System 2 video data link 90 DAYS kd sets loue tute tte eft uec 93 Bah lighting wes iiie teret ROREM 94 External buttons act te co e ede e boe 94 Engine speed RPM 95 Speed caes UL ae e t Le a ede ts 98 Lap times Beacor eee eee 101 Sensor readings General 103 TemperatUfres 22 itai Wad e pet a eret kiy 103 PresSur6s 5 ud aa 104 Steering position n eh tet ence dee Dee dde 105 Throttle pen ak eoa e rete cetera ir ee po bek 105 Battery aif PRA AAA one am ek miu 106 Accelerometer annin ena eiit iriti 106 Data loss or data corruption 107 Telltales HEREDI 108 PANNAN ui vi tes asie kan E 109 The installation 111 Part A Fitting the dash and sensors eene 112 Wiring not s EN ee etas v eet ee ect 112 Wiring colour codes 112 Power supply piki eo ai kn fk on pan e DA Se ae AR tene 113 Mounting the dash seem 114 Wheelspeed measurement 117 RPM
3. 157 Fit the Spade connectors ssssm 158 Fit thie Ammrring tags ertet 158 Fit the 8mm ring 159 Fit the spiralwrap irsinin araen r 159 Reinstall the loom tm ito D eibi eet 159 Waterproof the multiway 159 Part C System checks and Power up 160 Check the installation 160 dash on per 160 Configure the dash ssssseeseeeeenen nennen 161 Part D The Auxiliary Connector 162 AUX Connector pin outs eeseeeeneenneen 162 Examples Of O E ideni eol RR RAE 163 Part E Wiring details eeeeeeeeeeeeee eene nennen 165 Dash wiring Information eseen 165 Connector aiti ede 167 Contact information eeeeeeeeeseeee eene nennen nennen nnns 170 Introduction Welcome to the Pi System 2 User Guide This Guide is the core documentation for the installation and use of Pi System 2 References are made in this Guide to the Club Expert PC Personal Computer software which can be used with most laptop computers The Club Expert software allows you to compare the performance of both the car and the driver to previous outings or outings from another car This Guide has been divided int
4. Press and Hold CHANNEL and LAP MODE buttons together Step through Configuration groups D D 2 Click Inspect or alter a Configuration group Press and Hold Step through Parameter values Click Increment values Click Auto adjust values Press and Hold LAP MODE Save the current settings within each Configuration group Press and Hold CHANNEL Save all current settings O eO oe eo Press and Hold CHANNEL and LAP MODE buttons together 37 Entering Configuration mode 38 The car must be powered up stationary and in Real time mode You cannot access Configuration mode from Telltale mode 1 Press and Hold the CHANNEL and buttons for two seconds The dash flashes SETUP on the display and shows the first Configuration Group Alarms Selecting a Group 1 Clickthe button to cycle through the Configuration Groups Stop on the one you want to view or change alarm thresholds RPM speed etc 2 Hold the CHANNEL button Selecting a Parameter 1 Clickthe button to cycle through the parameters until you reach the one required You can either Alter or Inspect a parameter System 2 User Guide Altering a parameter There are two ways to change the value of a parameter once you have selected it Step mode and Auto adjust mode Step mode Step mode is most suited to values that
5. 67 A few moments later the display gives you the option of erasing the logging memory Click the button YES to erase the data in the dash Click the button AU or wait for 10 seconds to leave the data in the dash The Next Outing If you chose not to erase the logging memory new data will be added to the data already collected If you continue to do this and do not download data to a printer or computer the dash will eventually fill up and be unable to log any more data Retrieving data Even if the dash has been reset it is still possible to print out data or download data to a laptop computer You can recall un erase data at any time until the car leaves on the next outing by gt 1 repeating the Reset procedure and choosing the option You may wish to do this if you have downloaded data to a computer which resets the dash but want to use the dash to inspect the data from the last outing 68 System 2 User Guide Data Loss Auto reset Dash versions 3 49 or higher If case you forget to reset the dash at the start of a day s racing the dash is programmed to reset itself if the engine is cold To avoid accidental data loss switch to Manual mode when using the Club Expert PC software see the Configuring the Dash section In certain situations data may be lost The two most likely causes of data loss are Switching off the ignition when entering the Pit lane The dash
6. Flashing telltale Switches the flashing marker on the bar graph On or Off Spike Filter Although normally unnecessary the dash can filter out spikes on tacho signals from ignition systems Overrev Light Duration Sets how long the over rev light stays on Tyre diameter Sets the tyre diameter on which the wheel speed trigger is mounted in millimetres or inches NOTE Take special care in measuring the tyre diameter since this setting affects the accuracy of all speed readings Triggers Sets the number of speed triggers that are fitted on the wheel 42 System 2 User Guide Outing start speed Sets the speed that must be exceeded before logging starts This will vary according to your car but should be greater than the speed reached when you drive around the pits or garage areas Wheel trigger indicator Dash version 3 49 or higher When on Speed settings the alarm light will flash when the wheel speed sensor detects its trigger This feature will help you check the setting of the sensor The following parameters may be measured in various units Select the ones you prefer when configuring the dash for the first time D c 2 Speed Set the Speed units to either miles per hour mph or kilometres per hour kph Oil Water Temperature Set the Temperature units to either Celsius C or Fahrenheit F Fuel Pressure Set the Pressure units to either pounds per square inch psi 100 00
7. Problem The wheelspeed reading seems inaccurate e g by 5 percent Cause The Tyre diameter setting is wrong Action Check and adjust the value in Configuration mode This should be the actual rolling diameter of the tyre when it is under load 99 Problem Cause Action Speed and RPM Graphs on the PC Software don t line up This is actually a Beacon problem the data logged by the dash is synchronised by the Beacon position Put the transmitter at the same place on the pit wall each time you race at a track use a name marker or sticky tape Using an ABS speed sensor Problem Cause Action Problem Cause Action Cause Action The wheelspeed appears incorrect when using an ABS sensor interface box The number of triggers and or the tyre diameter set in the dash may be wrong Check the number of triggers on the ABS sensor wheel and re configure the dash The wheelspeed trace shown by the Club Expert is corrupted with spikes or dropouts The interface box is earthing to the chassis Do not connect any of the wires from the interface box directly to the chassis The ABS sensor is also trying to drive the car s ABS system Isolate the interface box wiring from the ABS system with 100uF capacitors as described in the Installation Notes section Using the waterspeed sensor 100 Problem Cause Action Problem Cause Action The water speed appears incorrect The number of triggers and or
8. System 2 User Guide Contents Overview At the Track 7 About this User Guide 5 inopem vnb utiles 8 What is System 2 es oti kantik dola ain do eesti eter ds 10 TASDASM zung eee dtes 11 The Beacon klt e ct e pee P nai pe ee EL taux 12 The Club Expert PC software sene 13 Conventions And 14 2 00 5 kaye oo pepe e ase se oo n bed 15 Configuration 15 Power p Mode ppt io epi ode de asime 16 Real time mode iiie et eee e Mere zr Pan AA IHE 17 Race mode t Be mU aetates 19 Telltal tode secet prt hee an eaten 20 Initial checks 22 Kit IST ge 22 Ghecklists 2e ee utm ei t in S 23 A typical 25 Preparing for an outing 26 Dtrivingrthie Caria uet e bd ieu etg OE da seat 27 Returning to the pits 29 Switching off the car sssssssseeeneeeeennennne 31 Configuring the dash Settable parameters 33 Contiguration det i b is 33 Configuration mode eeeseeeeeeeeeeeeeeeeenne enne nnns nnn nnn nnnm ann 36 Entering Configuration mode sess 38 PAIN ETE 41 RPM enamel 41
9. Speed anh tu ke ai teat ka na desde idee e 42 UPS zin itis o ite niece EAAS 43 Nares RERO 44 Printer ah a So etes 44 usse aat MUR 44 Engine Logbook ete teet i de iit 45 Graph loggirig erit ti e pe aet ebbe hex 45 Outing tyD6e kai ei REED GER EE FREUEN EO Rann pwa 46 Using System 2 Real time mode eene nennen anne nnn annee 48 Null Value iad ee ei 53 TURD Ost PEE 53 iuum aaia aar ason 54 AANIMS E EI ba veb ead ae 56 Telltale mode ipaa aa rnea nnne Na Enas 57 Lap Telltales itn Net nt eee 58 Outing Telltales si vote meter hr terret ht 62 Printing Reports eeeeseeeeeeee nnnm 63 Outings and resetting the dash eene 66 D ataiL0sS 5 nus eno D LS 69 New track New map seseeee 70 Application Notes eeeeeeeeeeeeeeeee nennen enne nennen nnn nnne 71 BMW M System 1995 71 Mazdaspeed Zytech ECM link eee 77 Lola F3000 1994 5 ebur ees 81 4 System 2 User Guide Troubleshooting Installation Notes Rally and Hillclimb applications 84 Karting applications
10. System 2 has a free running timer configure Beacon to RUN which when used in conjunction with the standing start feature displays the elapsed stage time to the driver The time freezes on the display for 10 seconds when an end of stage Beacon transmitter is detected Telltales When driving road stages drivers prefer that the dash does not switch into telltale mode whenever the car stops Rally mode switches this feature off Club Expert plus Features Stage Maps Club Expert plus can draw point to point stage maps from data that starts and or finishes with zero wheel speed Beacon transmitters should be used to trigger end of stage timing wherever possible 85 Slip indicator The effective gear ratio of the car is calculated by dividing engine RPM by the wheel speed and can be graphed by Club Expert PC software This gives a clear graphical representation of wheel spin or lock along the stage In line acceleration In line acceleration is calculated as the rate of change of wheel speed and provides teams with an indication of how well the car is accelerating from the start line or out of corners Allocating data to Up Down laps Rally cars often run up and down a stage during testing creating an outing with laps and maps from both directions Club Expert allows you to tag each lap as a PIT UP or DOWN lap and to select which set of laps are viewed This helps to prevent analysing UP data on a DOWN map 86 Sys
11. Thermocouple sensor 300 0 mm 12 0 nominal length K type thermocouple connector Thermocouple amplifier box metal braiding SureSeal plug to loom thermocouple sensor 50 0 50 0 1 96 1 96 d lt Thermocouple Sensor 150 System 2 User Guide Thermocouple probe and amplifier Probe Operating range 100 C to 999 C Mounting With lock nuts Connector K type Connections Blue ve White ve Amplifier Mounting Velcro Sensor connector K type System 2 connector 3 pin Cannon Sure Seal Connections Pin 1 Green Ground 0V Pin 2 Blue Signal Pin 3 Red Power 12V The thermocouple is used to measure exhaust gas temperature EGT on vehicles with 2 stroke or 4 stroke engines On 2 stroke karts EGT is a good indicator of fuel mixture Extension leads can be used in conjunction with the sensor but they must have the same metals and polarity t5 151 Part B Fitting the wiring loom By this stage you should have mounted the dash and all the sensors on the car You are now ready to connect everything together Connect the loom to the dash Take the loom and plug the multiway connector into the back of the dash Lay the loom in the car The wires for each of the sensors are grouped colour coded and tagged with their identity Run the wires to each of the sensors on the car Take care to avoid sharp metal edges an
12. Club Expert series of software 11 The dash normally logs for up to 42 minutes However by reducing the logging rate a maximum of 105 minutes can be logged before the memory in the dash fills up See the section Configuring the dash for details The User channels can be used to measure a range of parameters Thermocouples for measuring Exhaust Gas Temperature EGT Temperatures for additional gearbox or differential temps Potentiometers for steering or throttle position The fuel and oil pressure channels can also be configured to measure lower turbo or carburettor pressures 0 40psi The Beacon kit The Beacon kit provides the following benefits Fixed lap times or elapsed stage times Lap counter Lap time telltales Lap markers for the Club Expert series of software The Beacon kit allows an accurate registration of each lap passed The kit consists of an infrared detector mounted on the car and an infrared transmitter mounted on the pit wall As the car passes the transmitter the infrared signal is picked up by the detector on the car The dash immediately displays the lap time for the driver as well as storing information for each lap for later analysis with the Club Expert series software As well as displaying the time and count for each lap the Beacon kit enables System 2 to store and display the maximum minimum readings for each of the sensors per lap the telltales If you are intending to use the Cl
13. Configuration mode The Redline needs to be adjusted The Redline setting in the dash needs to be adjusted Check and adjust the value in Configuration mode The whole RPM bargraph blanks out Intermittent power failure on the dash You will see the dash going through Power up mode each time Check the connector on the back of the dash and the connections on the car battery and master switch Part of the RPM bargraph is blank Faulty LCD connection inside the display or damaged LCD try pressing the screen gently to see if it comes on again Return the dash to Pi Research DO NOT ATTEMPT to fix the dash yourself Unstable or absent RPM Bar graph reading The dash has not been set up to the correct RPM Type With the dash in Configuration mode RPM settings change the setting for RPM Type until the bargraph stabilises If none of the settings work contact Pi Research after obtaining a technical specification for the tachometer signal from your supplier e D The wiring is picking up noise from other sources on the car Check whether the tachometer wiring runs close to other ignition circuits and re route it if necessary 95 Cause Action Cause Action Cause Action The tachometer signal from the ignition box is noisy Set the Filter setting on the dash to 3 or 7 The dash is not compatible with your tachometer signal Use the RPM Box instead of your tachometer signal
14. Crimping a contact onto each wire Take one wire for example the yellow wire for the Oil Temp 1 Strip approximately 8mm of insulation off the wire taking care not to cut the wire itself 2 Twistthe strands of wire together 3 Fold the stripped portion of the wire in half to form a tight loop 155 4 Take a contact socket for yellow wire 34 from the plastic bag and place it in aperture 3 of the crimp tool provided The two smaller clamping prongs should be facing the W shaped part of the tool Before crimping After crimping C2 Waterproof connector crimp connections 5 Push the looped end of the wire right into the contact and crimp it by squeezing the handles all the way together 6 Fold in the cable grip wings one at a time Use the flat front end section of the crimp tool or a small pair of pliers to fold in the cable grip wings one at a time to hold the cable insulation 7 Crimp the cable grip wings Finally using aperture 3 of the crimp tool crimp the cable grip wings so that they actually grip the insulation on the wire 8 Repeat this process to crimp a pin contact onto the red wire for the oil temperature connector 156 System 2 User Guide Insert the contact into the connector AN AN e Pins Cannon Sure Seal connectors viewed from rear 1 Take one of the rubber 2 way connectors from the bag and locate the contact insertion tool
15. ONO 11 12 13 14 15 16 17 Logged yes yes yes yes yes option option option option option option option option option option option option option option option Configuration The Mazdaspeed ECM version has the following settings Parameter Setting Alarms Oil press 2 5 bar Fuel press 2 5 bar Oil temp 110 C Water temp 110 C Battery 11 0 volts RPM Redline 8 500 Max scale 9 500 Speed Wheel diameter 645 mm Units Pressures bar Beacon Yes Pinouts Custom pinouts Pin Description 13 ECM ground 32 ECM data in 79 Features The User channels are available for monitoring for instance steering and throttle position The low power warning feature has been disabled to enable the dash to be tested without the ECM connected 80 System 2 User Guide Lola F3000 1994 5 Description The Lola F3000 System 2 variant has a defined User channel for monitoring the position of the sequential gearbox Consiructor Lola Cars Ltd Glebe Road St Peter s Hill Huntingdon CAMBS UK PE18 7DS Dash specification Pi dash code ref Dash descriptor Version s Club Expert PC software System 2 PC software Club Expert PC software 30G 0018 LOLA 3 70 July 94 Version 1 13 or higher Version 3 55 or higher 81 Channels User 2 is used for the gear position input Parameter User 2 Calibration Mnemonic 5 Configuratio
16. Speed Problem Cause Action Problem Cause Action Cause Action Problem Cause Action Cause Action The speed reading doesn t work at all If it has never worked the wheel speed sensor may need adjusting The sensor must be set within 0 4 to 0 8 mm from the triggers on the wheel WARNING DO NOT OVER TIGHTEN THE WHEELSPEED SENSOR it will break Nip the lock nuts up with a spanner You are advised not to use a socket set IMPORTANT Although the wheelspeed sensor may appear to work at low speeds unless the sensor is set within 0 4 and 0 8 mm the sensor may not work at high speed The sensor has been adjusted but it won t work Faulty sensor Visually inspect the wheelspeed sensor for any damage to the head too close to trigger or body over tightened Replace if necessary Faulty wiring See the Installation Notes section for details on how to check the wiring for damage The wheelspeed is wrong e g by a factor of 2 or 4 The sensor is not picking up all the triggers on the wheel Check that all the triggers are set within 0 4 and 0 8mm from the sensor NOTE Because of the tolerance on the suspension of some saloon cars it is very hard to set up multiple targets within 0 5 mm In this case it is best to use a single trigger The wheelspeed Pulse setting is wrong Check and adjust the value in Configuration mode 98 System 2 User Guide NOTE There are various ways to tell if the wheelspeed sen
17. White 300 Red 3000 Red 2000 Red 2000 Red 2000 Black 2000 Red 2000 Yellow 2500 Violet 2500 Violet 300 Blue 300 Yellow 3000 Green 2000 Blue 3000 White 3000 U gt gt gt 0 U 22 UU00002 UU UU Over rev LED ve 12V via 570R Left button sense ve Right button sense ve Wheelspeed power 12Vsw out Beacon power 12Vsw out User channel 1 12Vsw out User channel 2 12Vsw out System supply ground OV in System supply power 12V in Data to printer PC Data from printer PC Data from ECM Data to ECM Oil temperature sense ve Beacon pulse in Water temperature sense ve Wheelspeed pulse in CON J pin 4 CON J pin 6 CON J pin 8 CON B pin 3 CON C pin 3 CON L pin 3 CON M pin 3 CON D 8mm ring CON D 8mm ring CON A pin 2 CON A pin 3 CON J pin 9 CON J pin 10 CON F pin 1 CON C pin 2 CON E pin 1 CON B pin 2 NOTE Wheelspeed Power and Beacon Power are connected together and sleeved A single wire is then crimped into pin 27 The wires are grouped into the following bundles to alleviate strain Bundle A exit 19 wires 19 amp 37 side of 37D Bundle B exit 17 wires 1 8 20 side of 37D Bundle C exit 6 wires System 2 User Guide Connector wiring AUX connector Pin Colour Ident Function Length mm 1 Black 4 Alarm LED ve drive 300 2 Violet 23 Alarm LED ve 12V via 570R 300 3 Black 5 Over rev LED ve drive 300 4 Yellow 24 Over rev LED ve 12V v
18. can either be mounted in a threaded block or with a sheet metal bracket Make sure the sensor does not vibrate or touch the trigger when the car is driven System 2 can be used with a wide variety of cars so the details of mounting the sensor will vary installation data sheets for each type are available from Pi Research Three examples of mounting configurations are shown in the following diagrams Wheelspeed Sensor N Gap 0 4 to 0 8mm X gt 0 015 to 0 31 YW Steel trigger plate Top mounted configuration Wheelspeed sensor Gap O 4 to 0 8mm 0 015 to 0 31 Side mounted configuration 118 System 2 User Guide 2 0 mm 0 078 Gap 0 4 to 0 8mm minimum clearance E 0 015 to 0 31 E E 2 0 mm 0 078 spacer Wheel stud mounted configuration Wheelspeed sensors 1 Make a bracket for the wheelspeed sensor and mount the sensor on the car The sensor is normally mounted on the front nearside wheel since this experiences the least wheel lift or lockup Do not over tighten the wheelspeed sensor and avoid mounting the sensor too close to the brake disc to avoid superheating 2 Secure the cable of the sensor on the wishbone and into the front nose cone on a formula car or through to the engine bay on a saloon car 3 Cover the wheelspeed sensor cable with spiralwrap Make sure the cable is not tight when the wheel moves or the wishbone is lowered 4 Mount the wheelspeed trigger on the
19. dash is faulty If the fault does not move with the connector the pressure sensor needs replacing System 2 User Guide When using the turbo carburettor pressure sensor Problem The dash appears to display the wrong turbo or carburettor pressure Cause Action The dash and pressure sensor may be incompatible If you are using the low range pressure sensor 0 to 2 5 bar you must have dash code version 3 66 or higher and the pressure channel units must be configured as TBAR under the UNITS menu in configuration mode Contact your Pi representative for information on dash upgrades Steering position Problem The steering trace on Club Expert is erratic and switches from very high to Cause Action very low The rotary steering sensor may not have been set up correctly or may have gone out of alignment and is going off scale during use While viewing the potentiometer reading on the relevant user channel align the steering pot so that it reads 2 5 volts when the steering is dead centre When viewed on Club Expertthe steering trace should now be centred on 2 5 volts Throttle position Problem The throttle trace does not show full throttle or subtle movements of the Cause Action throttle The 10 mm throttle sensor is not aligned properly with the throttle pedal and as a result is not picking up certain parts of the pedal movement Ensure that the stroke of the throttle sensor picks up the final on power 10 mm of
20. each branch point to hold the loom in shape The individual sensor groups are now ready to be cut to length Use tape to mark the length required untwist the wires and slide the ident sleeve AND individual wire idents to the marked point Be sure to leave enough length so that connections are not under stress Cut the branches to length and tie the lose ends to prevents the idents sliding off Cut all the wires to the same length for each sensor Fit the connectors and spiralwrap In most cases you can do this more easily if you remove the loom from the car 154 System 2 User Guide Fit the Sure Seal connectors The Oil temperature Water temperature RPM Wheelspeed Beacon sensors and User channels are connected to the loom via 2 or 3 pin Cannon Sure Seal connectors The loom is connected to the dash via a 37 way D connector The connections for each sensor wire are given in the tables below Note that on the loom pin 1 is always a socket pins 2 and 3 are always pin contacts 2 pin Cannon Sure Seal Pin1 socket Pin2 pin Oil Temperature Yellow 34 Red 14 Water Temperature Blue 36 Red 15 3 pin Cannon Sure Seal Pin1 socket Pin2 pin Pin3 pin RPM Black 3 Violet 20 Red 9 Wheelspeed Black 7 White 37 Red 27 Beacon Black 8 Green 35 Red 27 User 1 Black 8 Yellow 11 Red 27 User 2 Black 8 Blue 10 Red 27 The pin connections of the 37 way D connector are given in square brackets
21. guide Switching off the car Once the car has come into the pits and the dash has stored its data i e when the Alarm LED flashes it is safe to turn off the dash Data from the outing is retained in the dash by a small internal battery and may be printed or downloaded to a computer at any time before the next outing A note on Outings In general an Outing is defined as the time a car spends between leaving the pits and returning to the pits at the end of the race or practice e lt To avoid the dash being reset if your car spins off and stops on the track data continues to be logged until either the dash fills up with data the data is downloaded to a laptop PC the data is printed out or the dash is manually reset Data logging is triggered by exceeding a preset road speed for example 40 mph This avoids filling up the dash with unwanted data before you start the race or practice laps 31 Configuring the dash Settable parameters This section describes in detail how to configure the dash You will need to do this when you first install System 2 You may also wish to adjust alarm thresholds when you are more familiar with the System To allow System 2 to be used on a wide range of cars there are a number of parameters that can be adjusted to your particular requirements Some of these parameters only need to be set once when System 2 is installed However you may w
22. have a small range or only switch from Yes to No 1 Clickthe button to increment the value of a parameter one step at a time Auto adjust mode This mode is most suited to values that have a wide range of values such as temperatures tyre sizes or user channel name 1 FirstPress and Hold the MODE LAP button If auto adjust is available for a parameter the digits will start to flash between 0 and 9 2 Click the button to freeze each digit at its correct value starting with the left most digit Once all the digits have been frozen auto adjust mode ends automatically NOTE In Auto adjust mode if you try to set a value below the minimum permitted value it will be set at the minimum Similarly any value set above the maximum value will be set to the maximum permitted value 39 c D 2 To Inspect or Change other parameters in the Group 1 Clickthe CHaNNeL button To Return to the Configuration Groups 1 Press and Hold the button to return to the Configuration Groups You can then select another Group of parameters or leave Configuration mode To Leave Configuration mode To save the parameters and exit from Configuration mode 1 Return to the main Configuration Groups 2 PressandHoldthe CHANNEL and buttons fortwo seconds The dash momentarily displays the word SAVED To Exit without saving changes If you make a mistake or change your mind you can restore the previ
23. how they should be connected see Part B Fitting the wiring loom The connections on the sensor are spade terminals and are unpolarised They can be connected either way around 128 System 2 User Guide Pressure sensor for blue coloured dashes from serial number 4000 onwards Operating Range 5 to 200 psi 0 to 14 07 Kgf Oto 13 78 bar Mounting 7mm 1 8 NPTF thread Connector 2 off 4mm ring tag Connections non polarized Explosion rating 35 bar The same sensors are used for fuel and oil pressure measurement The colour coded wiring on the loom determines how they should be connected see Part B Fitting the wiring loom The connections to the sensor are made using 4mm ring tags They are unpolarised and can be connected either way around Mounting the pressure sensors Indirect fitting Mount the pressure sensors on a side pod near to the fuel oil pumps using tie wraps and rubber pads ud Pressure sensor Connected to System 2 loom IN Oil fuel pipe Indirect fitting of pressure sensors ao t 129 Temperature measurement Hex 12 6 A F 1 8 NPTF thread 10 0 28 0 inani Jo a 125 0 4 92 Imperial thread Temperature Sensor Temperature sensor Imperial Operating Range 0 to 150 32 to 302 F Accuracy 2 5 C 4 5 F Mounting 7mm 1 8 NPTF thread 17mm extending past thread Connector 2 pin Cannon Sure Seal Connections Pin 1 White Sign
24. printer with serial interface provides a cost effective and portable method of getting Telltale reports at the track Dash and Club Expert PC software Printing If you use the Club Expert PC software you will not need to print directly from the dash If you wish to print from either the dash or your computer you will need a printer with a serial interface e g HP Paintjet However printing from the computer using a serial interface may be much slower than the usual parallel interface Emulation Modes Most printers e g Panasonic can emulate other printers Any printer that can emulate the Epson FX 80 or IBM Proprinter can be used with System 2 If you do not have one of the printers supported by System 2 consult your printer manual NOTE System 2 dash kits are not supplied with a printer lead as standard For information on accessories please contact your Pi representative 65 Outings and resetting the dash 66 Outings In general an outing is defined as the time a car spends between leaving the pits and returning at the end of the race or practice Starting an Outing Data logging is triggered by exceeding a preset minimum Outing Speed for example 40 mph This prevents the dash from filling up with unnecessary data before you start the race or practice laps The minimum Outing Speed can be changed when the dash is in Configuration mode see the Configuring the dash section Ending an Outing Normally
25. provided 2 Slide the slot in the tool over the yellow wire for example and push the tool up to the neck on the contact 3 Pickup the connector and push the contact firmly into hole 1 in the body until it is flush with the mating face on the inside of the connector 4 Check that the contact is correctly located in the body then withdraw the tool 5 Repeat this process for the red wire pushing it into hole 2 on the connector Repeat the process for each sensor After the Oil temperature sensor has been connected repeat the entire crimping and insertion process for the Water temperature sensor RPM sensor Wheelspeed sensor Beacon sensors User 1 and User 2 WARNING Failure to terminate any of the wires could lead to a short circuit of the dash ao t 157 Fit the spade connectors Use the spade connectors for 0 120 psi and 5 120 psi pressure sensors Unpolarised blade connections Oil Pressure Black 16 Green 18 Fuel Pressure Black 17 White 19 1 Once cut to length strip about 5mm of insulation off each wire DO NOT LOOP the wire 2 Take a spade connector and grip it gently in the crimp tool Slide the wire into the connector until it hits the small stop 3 Squeeze the tool to crimp the connector making sure that the bare wire is crimped securely 4 Repeat this process for the remaining wires Fit the 4mm ring tags Use the 4mm ring tags for 1 200 psi pressur
26. the coil Dash O RPM box annee Ignition Control Ignition coil Original Unit wiring The RPM Box connected using LT leads Notes The wires coming from the RPM box are two ends of a piece of wire there are no electrical connections inside the box The ignition signal is unchanged as long as the connections are good The RPM Box can be sensitive to the direction of the current pulse it receives If this causes a problem try connecting it into the other terminal of the ignition coil This reverses the direction of the current flowing in the wire and should resolve the problem If the spade connectors on the RPM Box do not fit the terminals on your car we suggest you replace the connectors on our box You can then remove the RPM box at a later date if you wish 122 System 2 User Guide RPM Box HT connection The HT High Tension voltage connection consists of a single wire running from the bullet connector in the RPM Box and wrapped around the HT lead of the car A piece of wire high temperature rated with a bullet connector has been included with the RPM Box for this purpose Wire from bullet connector wound and taped to master HT lead Ignition Control Unit By AN Original Ignition wiring coil The RPM Box connected to HT lead The wire should be wrapped around the master HT lead about five times any excess can be clipped off and then secured with tape The RPM box LT connections are not
27. the tyre diameter settings in the dash may not be providing a correct calibration with the boat speed Adjust the value used for tyre size to change the speed displayed by the dash try 650mm and 20 pulses per rev The speed can be calibrated against a hand held GPS unit The waterspeed trace is very noisy even when the boat is in smooth water The sensor may have been mounted on the hull in such a way that it picks up turbulence from the prop or fins on the hull Try mounting the sensor in a different position on the hull as indicated in the installation section System 2 User Guide Cause Action Problem Cause Action The sensor may be mounted too high on the hull and is being driven by the air flow under the hull Move the sensor lower on the hull The waterspeed trace is noisy during rough water racing The sensor may be out of the water for long periods of time The pickup may be mounted too high so it is being driven by air flowing under the hull You might be able to remount the sensor lower on the hull to reduce turbulence otherwise you can smooth the trace with the Club Expert PC software Using the wheelspeed selector box Problem Cause Action Cause Action The speed information is corrupted The wheelspeed selector box is picking up noise from the chassis Do not connect the supply OV Pin G on the selector box if the ABS sensors are earthed to the chassis The power supply is being tak
28. up the engine Use the dash to monitor temperatures and pressures whilst you warm the car up in the pits 2 Click the button to cycle through the different Pages The dash does not log data at this point Resetting the dash If you want to log data make sure the dash has been reset the first time you go out on a new track 1 Double Click the button 2 Click the button to erase data NOTE If you use a laptop computer the dash is reset automatically whenever you download logged data 26 System 2 User guide Driving the car The car is now ready to drive 1 Press and Hold the button to switch to Page 1 As you leave the pits and pass the outing speed the dash starts logging Page 1 shows the RPM the maximum straight line speed the minimum cornering speed and lap times 2 Click the button to display Page 2 Page 2 shows the RPM the lap number the lap time e To return to Page 1 at any time 3 Press and Hold the button The RPM bar graph The RPM bar graph appears on all of the Pages and has some useful features An adjustable red line marker Some drivers use this as a gear change indicator When the RPM exceeds the red line both the bar graph and the over rev light flash A telltale marker shows the highest RPM reached This can be cleared by Clicking the button while the car is being driven Lap Times As you drive past the Beacon transmitter o
29. wrong Cause Action Cause Action Water in the sensor connector or dash connector Inspect and dry where necessary Seal temperature connectors with Silicone sealant The temperatures are correct but different from previous readings Check where temperature sensors were previously mounted for example oil sumps may be hotter than filler pipes If possible confirm temperature readings at the sensor location with a thermocouple probe When measuring temperatures with a thermocouple Problem The thermocouple readings are noisy Cause Action Cause Action Pressures 104 Problem Cause Action Cause Action The amplifier is picking up electrical noise from the chassis Make sure the thermocouple amplifier box is not electrically connected to the chassis The amplifier is picking up electrical noise from the chassis Make sure the leads for the thermocouple probe and amplifier do not pass close to high voltage sources such as the ignition coil or magneto The pressure readings are wrong The sensor is faulty Check that the connectors on the pressure sensors are correctly fitted and going to the right sensor If necessary change the pressure sensor The pressure sensor wiring is damaged Check the wiring on the car for visible damage and repair where necessary NOTE If one pressure sensor seems wrong try putting its connector onto the other sensor If the fault moves with the connector then the wiring or
30. you from having to manually reset the dash and will prevent the MAX indicator flashing when the dash is full On the Rally setting the dash behaves as in Auto but also the dash does not automatically enter Telltale mode when the car stops the start logging criteria change to outing speed and 2096 of RPM redline as opposed to 4096 to stop logging the dash must see zero speed for 10 seconds as opposed to 3 seconds Using System 2 SYSTEM 2 USER GUIDE Real time mode This section gives you step by step instructions on how to use the dash It can be used for reference once you have understood the concepts described in the sections Overview and At the Track Real time mode displays the same information as Race mode except that the data is not stored Once you exceed the outing speed the system automatically switches to Race mode and begins logging data CHANNEL button The button is used to move through the different Pages to display the values recorded by the various sensors Click the button to cycle through the Pages Press and Hold the button to return to Page 1 MODE LAP button Press and Hold the button to switch to Telltale mode Note this only works after the car has been driven and is stationary Double Click the button for Reset options The 12 Real time mode Pages display data as follows 48 System 2 User Guide Page 1 Lap time max and min speed Q Q Click CHANNEL
31. 0 rotary Electrical travel 338 rotary Mounting mount with a custom bracket Connector 3 pin Cannon Sure Seal Connections Pin 1 Green Ground 0V Pin 2 Blue Signal Pin 3 Red Power 5V 144 System 2 User Guide The rotary potentiometer can be used to measure steering position on a car or other mechanical movements such as on throttle or suspension components A System 2 potentiometer interface box must be used and the appropriate User channel must be configured for volts D 145 Throttle sensor throttle pedal Throttle sensor Mechanical travel Electrical travel Mounting Connector Connections linear potentiometer 12mm linear 10mm Industrial Velcro 3 pin Cannon Sure Seal Pin 1 Yellow Pin 2 Red Pin 3 Green 100 0 mm 3 93 approx SureSeal plug to interface box Throttle sensor using linear potentiometer Ground 0V Signal Power 5V This sensor is a short stroke linear potentiometer which is typically used to measure throttle pedal movement It may be difficult to monitor full pedal movement with the sensor The sensor should be mounted in such a way as to monitor the latter part of the throttle movement so that you can monitor when the driver lifts from full power You must use a System 2 potentiometer interface box and configure the appropriate User channel for volts 146 System 2 User Guide Linear potentio
32. 0N m bar kilogram force kgf or Tbar bar for turbo sensors 0 to 2 5 bar Oil Pressure Set the Pressure units to either pounds per square inch psi 100 000N m bar kilogram force kgf or Tbar bar for turbo sensors 0 to 2 5 bar User 1 Set the User 1 channel to measure either temperature C or F voltage VLT or thermocouple temperature CT 43 Name Printer Beacon User 2 Set the User 2 channel to measure either temperature C or F voltage VLT or thermocouple temperature CT Tyre diameter Set the tyre diameter units to either millimetres mm or inches inches You can assign your own names to channels User 1 and User 2 Using Auto adjust mode you can set each digit to be A Z 0 9 or blank Printer type If you intend to print data directly from the dash you will require a printer with a serial interface Set the Printer type to be the same as the make or emulation mode of the printer Beacon fitted If you have the Beacon kit installed set this option to YES to detect Beacon pulses Mode The lap timer can be configured to show the lap time for the previous lap Fix or as a running timer Run 44 System 2 User Guide Engine Logbook The Logbook records the history of an engine from the time it is reset This data is only available by using the Club Expert PC software If you change the engine in your car select Reset with the button Graph logging R
33. 1 Make sure that the dash is configured for your printer This will vary according to the type of printer you have Some printers require that you select Emulation Mode see below 2 Turn the printer on and feed the paper in 3 Plug the 25 way connector of the System 2 printer lead into the printer When the car has been driven and returns to the pits 1 Plug the 5 way connector of the System 2 printer lead into the car s communication port When the dash detects the printer is connected it starts printing out the Telltale report Printing out the Telltale report resets the dash To get another copy of the printout 1 Retrieve the data in the dash This is done by using the manual reset routine and selecting NZ 2 Select Telltale Mode 3 Pressand Hold the MODELAP and buttons at the same time for two seconds Notes on selecting a printer Due to the wide variety of printers on the market System 2 has been designed for use with four popular printer types Basic Epson FX 80 Paintjet HP Paintjet Diconix Kodak Diconix IBM IBM Proprinter Select the printer you are using while in Configuration mode see the Configuring the dash section Printing directly from the dash The dash has a serial printer interface and is supplied with a 25 way D type printer lead If you intend to print directly from the dash you will need a printer with a serial interface 64 System 2 User Guide A Kodak Diconix
34. 27 3000 User channel 1 L 3 Black 8 Yellow 11 Red 27 2000 User channel 2 M 3 Black 8 Blue 10 Red 27 2000 169 Contact information 170 For more information about Pi products and details of worldwide authorised agents please contact Pi Research Brookfield Motorsports Centre Twentypence Road Cottenham CAMBRIDGE UK Customer Support Tel 44 0 1954 253600 CB4 8PS Fax 44 0 1954 251196 Pi Research Inc 8250 Haverstick Suite 275 Indianapolis IN 46240 Tel 1 317 259 8900 USA Fax 1 317 259 0137 System 2 User Guide
35. 3 option UPOT ECM 14 option Battery dash 15 option Dash temp dash 16 Lateral g dash option 72 System 2 User Guide Configuration The M System has been preconfigured with the following settings Parameter Alarms Water temp Oil temp Axle temp Gear temp Water press Oil press Fuel press Fuel level RPM Red line Cylinders Max scale Type Speed Wheel diameter Pulses Start Beacon Outing Fuel Fuel full Period for average Setting 95 C 125 C 140 140 C 1 40 bar 2 00 bar 3 5 bar 10 litres 8 400 4 not accessible 9 500 C not accessible 648 mm 48 40 kph Yes Rally 512 litres 1 lap 73 Parameter Setting Page list Fuel calc No RPM No Speed No Water temp yes Oil temp yes Axle temp No Gear temp No Water press No Oil press Yes Fuel press No Fuel left No UPOT No Battery No Dash temp No Pinouts Custom pinouts Pin Description 13 ECM ground 16 Page up ve 18 Page up 32 data from ECM 33 data to ECM 74 System 2 User Guide Features ECM interface The M System receives a serial data stream from the ECM on the car The data is converted into the correct units by the dash and can be displayed or logged as required Page select Within Configuration mode you can select which parameters to display using the Page List Logging select Within Configuration mode you can select which parameters to log using the Page Up Down selecti
36. 99 pulses per wheel revolution Connector Unterminated Connections Foil Screen do NOT connect Red Signal Black Reference a 137 System 2 connections Connector unterminated or 3 pin Canon Sure Seal Connections Pin 1 Green Ground 0V Pin 2 Blue Signal Pin 3 Red Power 12V The ABS sensor interface box enables System 2 to take wheelspeed information from an existing ABS Anti lock Brake System speed sensor ABS speed sensors provide a robust wheelspeed measurement on touring and rally cars where mounting of the standard System 2 wheelspeed sensor might provide difficult The interface box has been designed for use with two wire ABS speed sensors passive type WARNING If the ABS speed sensor is also used by the ABS system on the car the two wires from the System 2 interface box should be connected to the sensor connections via 100uF 16V capacitors with the negative side of the capacitor going to the sensor If in doubt please contact your Pi representative Do not connect any wires directly to the chassis of the car 138 System 2 User Guide Waterspeed sensor 2 010 3 0 metres 6 5 101 1 SureSeal plug wheelspeed sensor _ boat hull MT Waterspeed Sensor attachment Waterspeed sensor Sensing type Hall effect pickup off 6 point paddle wheel Mounting Via two 5mm mounting slots Mounting position On boat s transom in smooth water flow Co
37. EL buttons to clear an Alam signal Page 1 Lap time max and min speed O O Click CHANNEL LAP TIME 49 21 ww System 2 User Guide Page 2 Lap time lap number and current speed Click CHANNEL qu 9 e 7 SPEED Page 4 Speed Clicking the button on the Speed Page latches the current road speed Q Click mon SPEED i 59 Alarms System 2 has been specially designed to trigger an alarm if any of the following parameters are exceeded Max Water temperature Max Cil temperature Min Oil or turbo pressure Min Fuel or turbo pressure Max User 1 or User 2 values Min Battery voltage After an Alarm has been generated the thresholds are adjusted until the dash has been reset preventing alarms from retriggering after a spin Temperature 5 C Pressures 5 psi Voltage 0 5 volts Alarm prevention To prevent alarms being set off unnecessarily they are only triggered when the RPM goes above 40 of the red line i e the engine attains 3600 RPM for a car with a red line set at 9000 RPM or the car has been moving for more than 30 seconds Adjusting Alarms You can adjust the Alarm thresholds when the dash is in Configuration mode see the Configuring the dash section User channels User channels are alarmed for use with temperature or thermocouple sensors If you are using voltage readings for steering or throttle position you should set alarm thresholds in excess of 5 5 vo
38. Hz If the RPM reading on the dash starts to flash at high RPM try increasing the setting by one or two positions Do not be afraid of experimenting until you find the correct setting for your car as an incorrect setting will not damage the unit Example Setups 4 cylinder 4 stroke A 4 cylinder 4 stroke engine generating 2 sparks revolution at 7500 RPM maximum requires the RPM Box to respond to 15 000 sparks min The switch then needs to be set to 1 for LT pickup or 9 for HT pickup 1 LT 9 HT a Dash RPM Settings TYPE D for RPM box e PULSE 4CYL pulses per cycle 125 126 1 cylinder 2 stroke A single cylinder 2 stroke engine generating 1 spark revolution at 11 000 RPM maximum requires the RPM Box to respond to 11 000 sparks min The switch on the RPM Box needs to be set to 0 for LT pickup or 8 for HT pickup RPM Box 1 LT 8 HT Dash RPM Settings TYPE D PULSE 2CYL The dash assumes a normal 4 stroke engine that runs from one ignition coil 1 cylinder 2 stroke engines fire on every rotation and appear as 2 cylinder engines 4 cylinder 4 stroke with double coils A 4 cylinder 4 stroke engine with double coils generating 1 double spark revolution per coil at 13 500 RPM maximum requires the RPM Box to respond to 13 500 sparks min The switch then needs to be set to 1 for LT pickup or 9 for HT pickup Care must be taken to ensure that the RPM Box only picks up signals from one of the
39. LAP TIME SPEED 24 29 i Page 2 Lap time lap number and current speed click CHANNEL LAP TIME eed Page 3 RPM O O Click CHANNEL 49 Page 4 Speed Q Click CHANNEL SPEED 5 Click CHANNEL NOW AT WATER Page 6 Oil Temp O Click CHANNEL 50 System 2 User Guide Page 7 Oil Pressure Q Click CHANNEL Page 8 Fuel Pressure Q Click CHANNEL Page 9 User 1 Steer Q Q Click CHANNEL 51 Page 10 User 2 EGT Q Q Click CHANNEL Page 11 Battery Voltage Q Click CHANNEL Page 12 Box Temperature 52 System 2 User Guide Null Value If a sensor has not been connected a null value is displayed In the example below the fuel pressure sensor is not connected No Fuel pressure Turbo If the oil or fuel pressure channels are configured for a turbo sensor they are displayed as follows Turbo 53 94 Race mode Race mode is similar to Real time mode except that data logging takes place during Race mode this is triggered by driving the car above its outing speed The CHANNEL button Click the button to cycle through the Pages Press and Hold the button to return to Page 1 The MODE LAP button Click the button to reset the RPM telltale Click the button to latch the current road speed when on Page 4 Alarms Click the MODELAP Or CHANN
40. Rate Fast Slow Fast Accel Yes No Yes User 1 Yes No No User 2 Yes No No Oil pressure or Turbo 1 Yes No No Fuel pressure or Turbo 2 Yes No No Water temperature Yes No No Oil temperature Yes No No Battery voltage Yes No No Outing type Outing Type Auto Manual Rally Auto 35 Configuration mode The table below shows how Parameter values are organised in Configuration groups The table on the facing page summarises the dash button operations for editing parameter values in Configuration mode Configuration groups Parameter values Oil pressure Oil temp Water temp Fuel pressure User 1 User 2 Battery Redline Pulses Max scale Pulse type Flashing telltale Filter Light SPEED Tyre diameter Triggers Outing speed UNITS Speed Temperature Fuel Pressure Oil Pressure User 1 User 2 Tyre diameter NAMES User 1 User 2 PRINTER Printer type BEACON Beacon fitted Mode LOGBOOK Reset LOGGING Rate Accelerometer User 1 User 2 Oil pressure Fuel pressure Water temp Oil temp Battery OUTING Type 36 System 2 User Guide NOTE Repeat the steps for configuring parameter values as often as necessary before saving the current settings We suggest you configure the Unit parameters first WARNING Changing configurations may cause data to be erased Only enter Configuration mode after you have inspected or downloaded data from any previous outings To do this Enter Configuration mode Do this
41. Seal plug connector supplied pin 2 Ignition System e ro System 2 loom 3 way Sure Seal plug Tachometer connections System 2 User Guide When the loom is installed the tacho signal will be connected to the signal input on the RPM connector The RPM Box Switch 350 0 selection 13 77 aperture m gt LTb LR e 85 uo LTa 5 40 0 ST way Sure 57 Seal plug a 278 t RPM Box Mounting Industrial Velcro Connector 3 pin Cannon Sure Seal Connections Pin 1 Green Ground Pin 2 Blue Signal Pin 3 Red Power The RPM box either picks up current pulses from the LT side of the coil or voltage pulses from the master HT lead WARNING To prevent damage neither of these sources should be directly connected to a System 2 dash The RPM Box should be fixed using Industrial Velcro near the ignition coil but not mounted to it A suitable mounting position can usually be found which allows the LT connection to be made without extending the wiring provided ao t 121 RPM Box LT connection The LT Low Tension voltage connection on the RPM Box has two flying leads 1 Remove the connection from the coil to the ignition unit and connect one of the flying leads on RPM Box to the free end of this wire 2 Connect the other lead from the RPM Box to
42. System 2 USER GUIDE Pi System 2 User Guide Part Number 29K 071089 3E Version 3 0 January 1999 Pi and the Pi logo are trademarks of Pi Group Limited Pi Research 1999 WWW piresearch com Disclaimer Pi Research makes no representation or warranties of any kind whatsoever with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose Pi Research shall not be liable for any errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of the software associated hardware or this written material Pi Research reserves the right to revise this publication from time to time and to make changes in the content hereof without obligation to notify any person of such revision or changes A copy of the Pi Research Terms and Conditions of Sale is available on request and includes a declaration of the warranty and limitation of liability which apply to all Pi Research products and services Health and Safety information Under the terms of European and UK Health and Safety Legislation Pi Research is required to classify any hazardous materials in the products it supplies and to provide relevant safety information to users Any hazardous materials in Pi products are clearly marked with appropriate symbols Product Safety Data Sheets relating to these materials are available on request 2
43. Wheelspeed RPM Beacon User channels 1 amp 2 2 way Sure Seal socket connectors for temperatures 3 way Sure Seal plug connector for tacho RPM inputs Sure Seal socket crimps Sure Seal pin crimps 8mm crimp terminals for power connections Female spade connectors for 5 120 psi and 0 120 psi pressure sensors 4mm ring tag connectors for 0 200 psi pressure sensor Molex connector options Molex pin crimps 3mm spiralwrap 6mm spiralwrap M3 x 10 pan head screws for panel mounted comms connector M3 brass nuts Shakeproof washers Sure Seal insertion tool Sure Seal crimp tool Tube silicone sealant 2 LZ 111 Part A Fitting the dash and sensors Wiring notes The wire used in System 2 is abrasion resistant and rated to 150 C The spiralwrap is rated 10 to 120 C and is used to further protect the wiring and keep itin a neat bundle When a bundle passes through a sheet metal bulkhead make sure that there is no risk of the edge cutting into the bundle Cables should not be run next to sources of interference i e ignition coils plug leads alternators fuel pumps radios and ECUS If it is absolutely necessary to run the cables near any of these avoid parallel runs if at all possible Care should be taken in the routing of the cables around the engine or brake areas as localised heating when the car is stationary can cause damage to the wiring All cars should be wired
44. Wiring fault Check that the tachometer signal from the ignition box NOT the HT or LT ignition signals is connected to pin 2 of the 3 way RPM connector on the System 2 loom RPM Box HT or LT mode Problem Cause Action Cause Action Problem Cause Action Cause Action The RPM Bar graph is blank or intermittent The dash has not been set up to run with the RPM Box Under the RPM settings set the RPM TYPE to D The loom connection to the RPM Box may be faulty Inspect the 3 way connector on the RPM Box or System 2 loom and repair if necessary The RPM reading is occasionally spiky and the PC Software shows small spikes The wiring is picking up noise from other sources on the car Check whether the RPM wiring runs close to other ignition circuits and re route it if necessary The RPM signal from the RPM Box is noisy Set the Filter setting on the dash to 3 or 7 RPM Box HT High Tension Connection 96 Problem The RPM bargraph cuts out or flashes at high RPM Cause Action The RPM Box is not setup correctly Check that the RPM Box is set for HT positions 8 to F and for the maximum sparks per minute that can be emitted by the ignition system System 2 User Guide Problem Cause Action Problem Cause Action The RPM Bar graph is unstable The HT connection on the RPM Box may be faulty Inspect the wiring on the HT lead and repair if necessary The RPM reading is obviously too low The HT picku
45. ace boxes can be used on which channels Please note that System 2 channels are pre calibrated and cannot be used with alternative sensors unless they appear in the table Standard Channel Wheelspeed RPM Oil temperature Water temperature Oil pressure Fuel pressure User 1 and 2 Alternative Use ABS wheelspeed Boat speed Fastest slowest wheel speed RPM Turbo pressure Carburettor pressure Turbo pressure Carburettor pressure Gearbox temperature Differential temperature Steering position Throttle sensor Suspension movement Exhaust gas temperature Sequential gear position Optional sensors ABS sensor interface box Waterspeed sensor Wheelspeed selector box Tacho pulse input Pressure sensor low Pressure sensor low Pressure sensor low Pressure sensor low Standard temperature sensor Standard temperature sensor Rotary potentiometer 360 Linear sensor 10mm Linear potentiometer 50 150mm Thermocouple probe and amp Depends on gearbox design Potentiometer interface box required 136 System 2 User Guide ABS sensor interface box green to System 2 loom blue red ABS sensor earth bare interface box from ABS sensor red black ABS sensor Interface Grey lead connects to ABS sensor Black lead connects to the wheelspeed connector on System 2 loom ABS sensor interface box Mounting Industrial Velcro ABS sensor connections Maximum input freq
46. ack run the software and enter the track name Remember to enter the driver and outing details once you have downloaded data from an outing Wait for the dash to power up about three seconds before plugging in the computer lead If you do not want to download a certain outing to the computer reset the dash to avoid it filling up with data The data you get from the car may be valuable and you should back up the outings onto floppy discs on a regular basis see the Club Expert PC Software Guide on the subject of archiving data A typical day Once you have completed the check lists you are now ready to go The diagram below shows a typical day s use of System 2 The unit will normally have been correctly installed and configured for your car Install the dash e Configure the dash Prepare for outing Alarms Drive the car Battery failure Spin off Return to the pits Download to PC Print telltales Inspect telltales a a Another outing No Switch off the car N 5 Preparing for an outing Powering up the dash Turn on the master switch and ignition switch if necessary to power up the dash The dash changes from Power up mode to Real time mode Check configuration The first time you use the dash check that it is correctly configured see the Configuring the dash section Warming up the car 1 Press the starter button to fire
47. al Pin 2 Red Power WARNING The sensors can be adversely affected by water Waterproof connectors have been supplied but it is essential to use the silicone sealing compound to prevent water reaching the connectors from the loom wiring If water penetrates the connector dry it out reconnect then seal using a silicone sealant The sensors for water and oil temperature are exactly the same The colour coded wiring on the loom determines how they should be connected see Part B Fitting the wiring loom 130 System 2 User Guide Mounting the temperature sensors Mount the oil and water temperature sensors in the piping of the engine The water temperature sensor is normally mounted in the piping of the cooling system either in an existing mounting point or by braising and threading an extra one The oil temperature sensor is normally mounted either in the sump area or in the piping of the oil pump NOTE The sensors have their own earth so earthing the body of the sensor or isolating it from the car will have no adverse effect t5 131 Lap timing 132 15 0 0 59 Channel kt selector 70 0 d 2 75 j Nw l TI 10 0 59 0 350 0 0 39 2 32 19 77 gt gt gt 10 channel Beacon Detector The Beacon detector Mounting Industrial Velcro Channels 0 to 9 Connector 3 pin Cannon Sure Seal Connections Pin 1 Green Ground Notes The Beacon detector s
48. also ask your race car supplier how the system has been integrated into your particular vehicle For further information please contact your Pi representative BMW M System 1995 Description The M System e g System 2 dash accepts engine data from the ECM via a serial data link and uses standard inputs for monitoring wheel speed and lap times Its fuel calculation feature can estimate the amount of fuel used time to go and laps to go The driver can move up or down through the display pages and the team can configure which channels are to be displayed and or logged Constructor BMW M GmbH ZS M 6 Daimlerstr 19 D 8046 Garching bei M nchen GERMANY Dash specification Pi dash code ref 30G 0019 Dash descriptor BMW Version s 3 73 Feb 95 Backlighting yes Buttons black Logo BMW M logo 71 PC Software System 2 Version 1 13 or higher Club Expert Version 3 55 or higher Channels The following channels are available Parameter Input Page s Logged Race Pages RPM bar ECM 1 2 Lap times sensor 1 2 yes Min speed calculated 1 Max speed calculated 1 Speed sensor 2 Lap number sensor 2 yes Fuel Page Time to go calculated 3 Laps to go calculated 3 B Speed sensor 3 Monitor Pages RPM ECM 4 yes Speed sensor 5 yes Water temp ECM 6 option Oil temp ECM 7 option Axle temp ECM 8 option Gear temp ECM 9 option Water press ECM 10 option Oil press ECM 11 option Fuel press ECM 12 option Fuel left ECM 1
49. an outing is considered to end when the car comes into the pits and is stationary for three seconds or more At this point the Alarm light flashes dash versions 3 49 or higher and the dash switches to Telltale mode However to avoid the dash being reset and data lost if your car spins off and stops on the track data continues to be logged until any of the following takes place the dash fills up with data the data is downloaded to a PC the data is printed out or the dash is manually reset WARNING Do not switch off the dash until the car has been stationary for more than three seconds or data will be lost System 2 User Guide Maximum Logging Time The dash has enough memory to log data for a total of 42 minutes Over this period the high frequency logging rates are RPM 20 times a second Speed 10 times a second The other parameters are also logged ten times a second By reducing the logging rates the maximum logging time can be increased see the Configuring the Dash section When the dash is full When the dash fills up the word MAX flashes in the centre of the display When this happens the dash stops logging data However alarms may still be triggered and lap times and sensor readings are still displayed Inspecting Resetting the logging memory To check how much logging time is left in the dash when the car is stationary 1 Double Clickthe MoDELAP button The time left is then displayed
50. and Using the dash sections For a typical day using System 2 If you have a Beacon kit you will need the Beacon transmitter and power lead a 12V battery to run the Beacon transmitter If you use a printer you will need the printer printer paper a power lead or battery the System 2 printer lead If you have the Club Expert PC software you will need your laptop computer with Club Expert installed a recharger or a spare battery the System 2 computer lead some formatted floppy discs for backing up data In case of accident damage we suggest you have a basic toolkit including crimping tool and System 2 insertion tool some spare System 2 connectors a spare wheel speed sensor a spare temperature sensor a spare pressure sensor 22 System 2 User guide Checklists Before each outing check that the dash is powered up the dash has been reset the dash has been configured properly for the car the sensors are working properly Click the button to check each sensor value e g car battery voltage or steering position the wheel speed sensor is adjusted correctly spin the wheel the sensor wiring has not been damaged if you ve been working on the car p lt If you have a Beacon kit check that the Beacon transmitter is wired up and working check the front light on the transmitter the transmitter and detector are set to the same channel the Beacon detector is worki
51. ansmitter are the same The transmitter should be mounted at the same height as the detector on the car with the transmitter beam pointing horizontally and aimed straight across the track Make sure the detector is not pointing into the sun when it passes the transmitter 30m 100ft maximum 3m 10ft minimum wr Position transmiter same height from ground as receiver Pit wall 2 Siting a Beacon transmitter driver s view 134 System 2 User Guide If several Beacon transmitters are in use at a track do not place them so close together that their beams interfere with one another as this could give rise to spurious lap times The following diagram shows the minimum separation distances to be observed Pit _ wall _ A e Se p SE i Nominal beam angle 26 Ma Hi Ze Tane Se ES ian E E knn ERE YO p Nominal beam angle 26 a __ _ Pit wall Minimum separation of transmitter Beacons plan view 135 t Optional sensors and interface boxes There are range of sensors and interface boxes available for use with your System 2 These can either replace some of the standard sensors supplied or used on the User channels to add further data logging and display capability The table below details which sensors and interf
52. ate This selects a fast or slow logging rate for the speed and RPM data Fast logging gives better resolution on the Club Expert PC software slow logging doubles the logging time Rate Samples per second Speed RPM Fast 10 20 Slow 5 10 NOTE Other parameters i e Oil pressure are sampled at the same rate as speed e g 5 or 10 samples per second Accel Once you have made a map of a track with the Club Expert PC software there is no longer any need to log lateral acceleration cornering g force unless you are using the Cornering Analysis Program CAP If are using CAP you must log Accel all the time To increase logging time you can stop the dash from logging data from its internal accelerometer Acceleration Logging time minutes Fast Slow Yes 42 84 No 52 104 45 Graph Logging When used with Club Expert plus you have the option of being able to produce graphs for any of the following channels Outing type 46 User 1 User 2 Oil pressure or Turbo 1 Fuel pressure or Turbo 2 Water temperature Oil temperature Battery voltage Type System 2 User Guide On Manual setting the dash is reset as normal e g when a printer or PC is plugged into the computer or when the dash is manually reset Use this mode if you are using the Club Expert software on a regular basis On Auto setting the dash is also reset at the beginning of the day when the engine temperatures are cold This saves
53. ater P 159 Part C System checks and Power up Check the installation Before turning the dash on check the clearance on the wheelspeed sensor the freedom of wires from moving parts the silicone sealant on the multiway connectors the connector on the back of the dash and no wires have been left unterminated Turn the dash on When you turn on the Master switch the display powers up Note that on some installations the ignition must also be turned on By clicking the button you can step through the values being measured on each sensor The road wheel can be rotated backwards and forwards to get the wheelspeed sensor to trigger On Dashes with software versions later than 3 33 there is a wheelspeed indicator in the section Configuring the Dash The RPM display remains blank until the engine is running Temperature sensors indicate the ambient temperature If a sensor is not connected properly the word COLD appears on the dash display The pressure sensors require engine pressures before showing a value If a sensor is not properly connected dashes appear on the display The battery voltage of the car is displayed along with the ambient temperature of the dash itself Once the dash has been configured to use a Beacon see below waving a powered transmitter in front of the detector causes lap times on the display to change Make sure the channel settings on both
54. attery Failure System 2 requires a minimum battery voltage 9V in order to operate If the car battery delivers less than this the dash will anticipate a power failure and will save the data logged so far The Battery Alarm will alert you when the battery is running low From then on until the car stops the dash will display information as usual but will not attempt to log it 28 System 2 User guide Returning to the pits NOTE Each time you come into the pits YOU MUST ALLOW THE CAR TO STOP FOR 3 SECONDS before killing the power to the dash otherwise data will not be recorded On dash versions 3 49 and above the Alarm light flashes twice when it is safe to switch off the dash e Inspecting telltales When you stop and have the dash powered up the lap number and time for the fastest lap are displayed NOTE Depending on the way the dash is configured you may have to Press and Hold the button to manually select Telltale mode 1 Click the button This cycles through the following telltales for the fastest lap Lap time Max RPM Max Speed Max Water temperature Max Cil temperature Min Oil pressure Min Fuel pressure Min Battery voltage Max User 1 Max User 2 Max dash temperature 29 2 Click the button to change the lap This cycles through the telltales maximum and minimum values for each lap and for the outing as a whole in the following sequ
55. coils Then set the RPM PULSE to 2 RPM spike filtering In cases where there are noise spikes on the RPM trace or telltale the dash can be set to filter them out Under the RPM settings in Configuration mode there is a parameter called SPIKE FILTER It has three settings OFF 3 and 7 OFF the normal unvalidated RPM mode which works in most situations 3 should be used for 1 or 2 cylinder engines that give spiky traces 7 should be used for engines with 3 cylinders or more System 2 User Guide Notes Because of the filtering method used clutch slip over rev on down shifting etc are not masked Filtering is only intended to remove the odd spike and cannot clean up a consistently bad signal It can only remove single spikes double spikes will be displayed For this reason the installation should be checked for sources of interference before using the filter t5 127 Pressure measurement 1 8 NPTF thread 075 0 02 95 connector terminals Hex 17 A F Pressure Sensors dimensions in millimetres and inches Standard Pressure sensor for black coloured dashes up to serial number 3006 Operating Range 5 to 120 psi 0 35 to 8 44 Kgf 0 34 to 8 27 bar Mounting 7mm 1 8 NPTF thread Connector 2 off 1 4 female blade Connections non polarized Explosion rating 35 bar The same sensors are used for fuel and oil pressure measurement The colour coded wiring on the loom determines
56. d Black Black Green White Violet Red White Violet The connections on the back of the dash are as follows 300 300 3000 300 300 300 3000 2000 2000 2000 3000 2000 2000 2500 300 3000 3000 2000 2000 2000 2000 3000 2500 2500 300 Bundle U 25252525 252525 25U 00 005UUUU U U Description Backlight ve 0V Backlight ve 12V RPM ground Alarm LED ve drive Over rev LED ve drive Left Right button ground Wheelspeed ground Beacon ground User channel 2 ground User channel 1 ground RPM power 12Vsw User channel 2 signal User channel 1 signal Printer PC port ground Ground from ECM Oil temperature ve 8V Water temperature ve 8V Oil pressure ve Fuel pressure ve Oil pressure ve 8V unloaded Fuel pressure ve 8V unloaded RPM pulse in Programming volts in Printer detect Alarm LED ve 12V via 570R Connector CON J pin 11 CON J pin 12 CON I pin 1 CON J pin 1 CON J pin 3 CON J pin 5 CON B pin 1 CON C pin 1 CON M pin 1 CON L pin 1 CON I pin 3 CON M pin 2 CON L pin 2 CON A pin 5 CON J pin 7 CON F pin 2 CON E pin 2 CON G 1 4 F blade CON K 1 4 F blade CON G 1 4 F blade CON K 1 4 F blade CON I pin 2 CON A pin 4 CON A pin 1 CON J pin 2 165 2 LZ 24 25 26 27a 27b 27 27 28 29 30 31 32 33 34 35 36 37 166 Yellow 300 Blue 300
57. d cables carrying high voltages e g ignition circuits System supply You may need to untwist the power and ground supply wires if the battery is at the front of the car connect red wire from loom and the Master switch is towards the rear connect black wire from loom Beacon Run the Beacon connections to a suitable position e g by the roll hoop even if you do not yet have a Beacon kit 152 System 2 User Guide Printer Comms connection 16 0 The Printer Comms port The printer cable is already terminated with a 5 pin panel mounting DIN socket You should mount the socket so it is accessible when the car comes into the pits e g somewhere near the driver The AUX connector The AUX connector provides for optional accessories such as external buttons or lights and should be fixed behind the dash Secure unwanted sensor wires Isolate any wires you are not using near the dash e g fuel pressure and insulate the ends with tape Keep the sleeve and wire idents on the loom to facilitate identification at a later date 153 ao t Cut the Loom to size Now that the loom is lying in the car you can determine how long each group needs to be Before cutting the wires the loom should be consolidated by grouping sensor wires together and taking branches where particular sensors require it Dash The wiring loom The final loom will look like a tree You should use tape at
58. devices are the same 160 System 2 User Guide Configure the dash Before using the dash you must configure it to show the correct RPM Speed and Units etc If you are using a Beacon this must also be set on the dash WARNING When you configure your System 2 dash please take time to write down the settings and have them available when seeking technical support from Pi Research Troubleshooting All the troubleshooting hints are in a separate chapter If you have any problems with your System 2 refer to the section Troubleshooting 161 Part D The Auxiliary Connector System 2 has a number of features that can be accessed from the auxiliary AUX connector Standard features External CHANNEL and MODE LAP buttons External Alarm or Over rev lights Factory fitted options Backlighting Data links to Electronic Control Units ECUs Backlighting fitted to a dash is powered externally either from the ignition circuit or from an instrument lighting circuit e g in a saloon car If you have a custom dash that has had ECU software written for it the data stream from the ECU is linked to System 2 through the AUX connector AUX Connector pin outs 162 Function Colour Molex pin D Type ID Backlight Power Red 12 2 Backlight Ground Black 11 1 Left Button Blue 6 25 Right Button White 8 26 Left Right Button Ground Black 5 6 Alarm LED ve drive Violet 2 23 Alar
59. e 5 Q Q Click CHANNEL Max User 1 value Steering 5 Q Click CHANNEL 60 System 2 User Guide Max User 2 value EGT Q Click CHANNEL Min Battery voltage Q Q Click CHANNEL Max Box temperature LC P mn BXTAP 259r x om 61 Outing Telltales On the Outing Pages maximum and minimum values are shown for the whole outing OUTING Q e Press and Hold CHANNEL Notes Times are not shown for Out or In laps since they are not generally useful A lap time cannot be shown for an Outing only for a given lap If a Beacon is not used maximum and minimum values are shown for the whole outing and not for each lap 62 System 2 User Guide Printing Reports Telltale values stored in the dash can be printed out for reference purposes All printouts show the following values for the outing max RPM max Speed max Oil temperature max Water temperature min Oil pressure min Fuel pressure max User 1 or User 2 values min Battery voltage max Box temperature If a Beacon was used the printout also includes an Engine Report with RPM and Speed values for each lap a Pressure Report with Oil and Fuel pressures for each lap a Temperature Report with Water and Oil temperatures for each lap and a Miscellaneous Report with Battery voltage and Box temperature for each lap 63 Getting a printout Before you drive the car
60. e full use of the rally and hill climb features on System 2 configure your dash as follows Parameter Setting Speed START speed 0 Beacon LAP RUN Outing RALLY Dash Features Start logging criteria By setting the outing speed to zero the dash can log data from standing starts As soon as a wheel trigger is detected and the RPM threshold is exceeded logging begins RPM threshold Due to the loose surface on rally stages the RPM threshold for logging to commence is reduced to 20 percent of the redline when the dash is configured to Rally mode 84 System 2 User Guide Stop Logging criteria During left foot braking it is possible for one or two of the rear wheels to lock for more than three seconds This would normally cause the dash to stop logging and insert a pit Beacon but in Rally mode zero speed must be seen for 10 seconds before a pit Beacon is inserted Distance measurement Because of the risk of wheel lock for prolonged periods the dash will estimate the distance travelled during such periods based on the vehicle speed prior to the wheel locking Wheel speed selection To help reduce the risk of prolonged periods where the dash sees a speed of zero a Wheel speed Selector box Part Number 01F 152119 can be used to sample two wheel speeds and output the highest value at any time If wheel spin is a concern the Selector box can also select the lowest speed of the two input signals Free running stage timer
61. e sensors Unpolarised 4mm ring tags Oil Pressure Black 16 Green 18 Fuel Pressure Black 17 White 19 Repeat the procedure for the spade connectors detailed above Use the knurled finger nut and split washer to secure the ring tag to the sensor Note Ensure that the spit washer is between the ring tag and the knurled finger nut 158 System 2 User Guide Fit the 8mm ring tags Battery connections System supply power 12V Red 29 System supply ground Black 28 Repeat the procedure for the spade connectors detailed above Fit the spiralwrap Starting at the sensor branch ends fit the spiralwrap to the loom using the small size for 2 or 3 wire groups and the larger size for 4 or more Wrap all the way back to the connector at the dash end of the loom Once the loom has been wrapped it is finished and can be reinstalled in the car Reinstall the loom 1 Connect the display sensors and the power connections to the loom 2 Checkthat the polarity of the power connections are correct Waterproof the multiway connectors Once you are satisfied with the installation the multiway connectors must be fully waterproofed This is done by sealing the rear of the loom connectors with the silicone sealer provided to stop water penetration Once applied leave the silicone to cure for one hour WARNING Failure to waterproof the multiway connectors will not damage your System 2 but certain readings can be affected by w
62. en directly from the battery The 12V supply Pin J on the selector box should come from System 2 and not directly from the vehicle battery Lap times Beacon Problem Cause Action If you have not purchased a Beacon kit for your System 2 the dash cannot show lap times on the screen To test the Beacon system turn on the dash and transmitter and wave the transmitter in front of the detector on the car The lap times on the display should change Lap times don t appear on the display The dash must be configured to use a Beacon Check and adjust the setting in Configuration mode 101 o D Problem Cause Action Cause Action Cause Action Cause Action Problem Cause Action Problem Cause Action Cause Action Lap times aren t working dash shows 0 00 The Beacon transmitter isn t being powered the LED on the Beacon transmitter isn t on Make sure the battery wiring is secure and that the battery is fully charged 12V NOTE Although a lit LED on the transmitter indicates a good connection to the battery only a fully recharged battery will supply a strong signal to the car Make sure you recharge the battery before a day at the track The channels are not correctly set Make sure that the Beacon transmitter on the pit wall and detector on the car are set to the same channel They both have a switch with positions 0 to 9 The transmitte
63. ence the Out lap Lap 1 lap 2 lap 3 the In lap the outing except that no lap time is given for the outing as a whole 3 Press and Hold the button to select the outing values Printing telltales directly from the dash 1 Make sure your printer is powered up and is loaded with sufficient paper 2 Ifthe dash is in Real time mode Press and Hold the button to return to Telltale mode 3 Plug the System 2 printer cable into the Communication port on the car After a short delay the data is printed out Refer to the section Using the System 2 for details on printing Downloading to a laptop PC To download data from the dash to a laptop computer 1 your laptop powered up and running the Club Expert PC software 2 Select the track from the existing list or enter the name for a new track 3 Plug the computer lead into the 9 pin serial port on the back of the laptop 4 Plug the other end of the computer lead into the communication port on the car A bar graph is displayed on the bottom of the computer screen to indicate the proportion of data transferred so far DO NOT REMOVE THE LEAD from the car until the bar graph has completely filled up You can now exit the program and turn off the laptop or analyse the data further Because you have downloaded the data the dash resets itself for the next outing See the Club Expert PC Software Guide for details of how to use the analysis software 30 System 2 User
64. eters such as the RPM over rev light or the battery voltage alarm level more frequently Details of how to configure System 2 are given in the Configuring the dash section of this guide together with a list of the parameters you can change 15 Power up mode When power is first switched on information is displayed for about three seconds This includes the dash serial number and the version of the software installed On Mk II Dashes the readings will be similar to these Dash Serial Number IUS 1 Software Version 316 FI You should make a note of the version number displayed on your dash and have it ready if you ever need technical support 16 System 2 User Guide Real time mode LAP TIME nnnm LI LILI LILI After powering up the dash goes into Real time mode Page 1 and remains there until the car is driven As the name suggests Real time mode is used to show the readings of the sensors on the car in real time i e continuously as they happen The word Page is used to describe a single screen display on the dash All Pages in Real time mode include the RPM bar graph red line marker and max rev marker in addition to the particular information listed in the following table 17 18 Real time Pages Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 System 2 User Guide Lap time Beacon kit required Max Speed Min Speed Lap time Lap
65. for the Beacon kit communications port and User channels 1 amp 2 even if you do not intend to use them immediately If your car does not have fuel injection you should coil up the wiring for the fuel pressure sensor behind the dash you may need it if you install your System 2 on another car Wiring colour codes The wires in the loom are colour coded black for ground red for power and a different colour for signal However this does not mean that all black or red wires are the same To avoid any problems System 2 unit should be treated as a separate system and only connected to the car at the battery and Master switch It should not share its wiring with other systems or items on the car 112 System 2 User Guide Power supply On racing cars the negative side of the supply battery is conventionally connected to the vehicle chassis through a Master switch This allows total disconnection of all electrical power in an emergency and is required by the regulations governing all motor sports System 2 should be connected directly to the safe side of the Master switch to ensure the safety of the installation The positive supply to the display should be fed directly from the battery live terminal or optionally through a separate switch which allows the display to remain powered up while the ignition systems are off This prevents data loss when the engine is stopped by switching off the ignition Data will be lost if
66. h software version 3 53 and above the Alarm LED flashes after this three second period The wheelspeed signal which triggers logging was not working Refer to wheelspeed troubleshooting The Outing speed was set higher than the maximum speed reached during the outing Check and adjust the Outing speed in Configuration mode You may have reset the dash by trying to access Configuration mode from Telltale mode this forces the dash to print out its data and then reset On Dashes with software version 3 53 and above the dash is only reset if a printer is actually connected to the communication port on the car You can retrieve the data using the manual reset feature at any time before the car is driven again refer to the section Using System 2 Only part of the outing has been logged The dash is full The MAX indicator will be flashing Download data to a PC or printer or manually reset the dash to clear the memory The dash experienced a low battery alarm while the car was being driven and stopped logging data Inspect the Outing battery telltale to verify low battery voltage Check and recharge the battery on the car e D Too much data appears to have been logged The dash was not reset before the last outing Remember to reset the dash before each outing especially the first time you run at a new track 107 Action Check and adjust the wheelspeed sensor Proble
67. her Channels The following parameters are transmitted from the ECM port Parameter RPM Wheel speed Lateral g Alarm status Beacon status RPM redline segment User 1 User 2 Lap time minutes Lap time thousandths Lap number 90 System 2 User Guide Pinouts Custom pinouts Pin Description 13 ECM ground 33 ECM data out Installation A complete installation requires the following components System 2 dash Parameter readings are transmitted from the ECM port Modem A modem converts the digital signals from the dash into audio signals which are recorded During playback at a studio the audio signal is played back through the modem and the digital signals fed into the serial port of a PC In car video The audio signal is recorded on the spare sound channel of a video 8 camera inside the vehicle PC simulation During playback of the in car video the Club Expert PC software produces a VGA image of the dash An IBM compatible PC with a 486 processor is required Mixing The VGA image on the PC is converted to PAL and overlaid onto the original in car video shot and in car sound Available from your Pi representative 91 Troubleshooting Dash Problem Cause Action Cause Action Cause Action Cause Action Problem Cause Action Problem Cause Action Until you are completely familiar with your System 2 you may encounter certain difficulties This Section li
68. hould be mounted at right angles to the ground and at right angles to the direction of the car in motion Where possible the detector should be mounted flush to the skin of the car or recessed less than 25mm Where possible the receiving head should not face directly into the sun while detecting System 2 User Guide Pin 2 Blue Signal Pin 3 Red Power Mounting the Beacon detector The Beacon detector should be mounted so that it can point at either side of the track It is often placed by the roll hoop or above the driver s headrest The detector is fixed to the car with Industrial Velcro supplied by Pi Research Side wall of car aperture 33mm minimum or 10mm if flush mounted Detector s field of view is approx 20 Position receiver at same height above ground as Beacon 25 0mm transmitter 1 0 max Beacon detector placement Front view Side view Power on LED Channel selector cover 80 0 3 14 Transparent 55 0 2 16 82 0 24 0 3 22 0 94 a gt Beacon transmitter 133 2 2 Beacon transmitter Mounting Industrial Velcro or tape Channels 0 to 9 Connector 2 screw posts Connections Red post 12V Black post OV Notes A fully charged 12V car battery or rechargeable dry cell battery can be used to run the Beacon transmitter Make sure that the channels selected on the detector and tr
69. ia 570R 300 5 Black 6 Left Right button ground 300 6 Blue 25 Left button sense ve 300 7 Yellow 13 Ground from ECM 300 8 White 26 Right button sense ve 300 9 Violet 32 Data from ECM 300 10 Blue 33 Data to ECM 300 11 Black 1 Backlight ground 300 12 Red 2 Backlight power 300 Printer Comms Port Pin Colour Ident Function Length mm 1 White 22 Printer detect 2500 2 Yellow 30 Data to printer PC 2500 3 Violet 31 Data from printer PC 2500 4 Red 21 Programming volts in 2500 5 Black 12 Printer PC ground 2500 a 167 168 Female Blade connectors for 5 120 and 0 120 psi pressure connection Sensors Connector Pins Colours Oil Pressure G 2 Black 16 Green 18 Fuel Pressure K 2 Black 17 White 19 4mm Ring Tags for 0 200 psi pressure connection Sensors Connector Pins Colours Oil Pressure G 2 Black 16 Green 18 Fuel Pressure K 2 Black 17 White 19 8mm Ring Tags for power connection Function Connector Colour Length mm System power D Red 29 2000 System ground D Black 28 2000 System 2 User Guide Length mm 2000 2000 Length mm 2000 2000 Waterproof ITT Cannon Sure Seal connectors Sensor Connector Pins 1 2 3 Length mm Oil Temp F 2 Yellow 34 Red 14 3000 Water Temp E 2 Blue 36 Red 15 3000 Beacon C 3 Black 8 Green 35 Red 27 2000 RPM 3 Black 3 Violet 20 Red 9 3000 Wheelspeed B 3 Black 7 White 37 Red
70. ion The dash won t print out its Telltale report There isn t any data in the dash Drive the car first The printer isn t plugged into the communication port correctly or the printer lead isn t plugged into the printer correctly Check the printer lead connections The printer isn t turned on or the batteries mains are not connected Turn on the printer and check the power supply There isn t any paper in the printer or the printer isn t on line Check the paper and switch the printer on line The dash can t communicate with the printer Make sure your printer is correctly set up NOTE The dash has the following hardware characteristics Interface Serial RS232 Baud rate 9600 Protocol XON XOFF The printout is corrupted or incomplete The printer and dash may not be set up to communicate with each other Check the dash Printer type in Configuration mode and the printer Emulation Mode refer to your printer manual 109 o D Installation Notes The Installation Notes section covers the installation procedure for System 2 This section will also be useful to you If you need to fit external switches or backlighting to a car with System 2 already installed The installation kit System 2 comes complete with an installation kit which includes all the connectors tools and components you will need Quantity 5 11 17 Description 3 way Sure Seal socket connectors
71. ish to adjust parameters such as the RPM over rev light or battery voltage alarm level more frequently Configuration c z e The parameters their range and defaults are listed in the following table Setup Min Max Default Alarms Oil pressure psi or TURB1 0 200 20 Oil temperature C 10 150 105 Water temperature C 10 150 105 Fuel pressure psi or TURB2 0 200 20 User 1 10 999 105 User 2 10 999 105 Battery voltage volts 9 20 10 5 33 34 Setup RPM Red line rpm Pulse 4 stroke Max scale rpm Pulse type Flashing telltale Spike filter Over rev light duration Speed Tyre diameter mm Triggers per rev Outing start speed Units Speed Oil Water temperature Fuel pressure Oil pressure User 1 User 2 Tyre diameter Name User 1 User 2 System 2 User Guide Min Options 0 1 3 500 A B C D Yes No Off 3 7 0 01 30 1 0 2 20 40 80 112 KPH MPH C F psi KGF bar Tbar psi KGF bar Tbar C F VLT CT C F VLT CT mm inches Max 20 000 16 19 500 2 0 999 100 5 character alphanumeric 5 character alphanumeric Default 6 500 7 500 Yes Off 0 01 535 112 KPH C psi psi C C USER1 USER2 Setup Options Default Printer Printer type Basic Paintjet Diconix IBM Basic Beacon Beacon fitted No Yes No Mode Fix Run Fix Engine logbook Reset Keep Reset Keep 2 Logging
72. lts to prevent the alarms being triggered 56 System 2 User Guide Telltale mode The dash automatically enters Telltale mode after the car has been driven and has come to a standstill for more than three seconds NOTE Dash version 3 33 and below also require zero RPM before entering Telltale mode automatically On these dashes you can select Telltale mode with the button while the engine is still running The CHANNEL button Click the button to cycle through max and min values for the current lap or outing Press and hold the button to see the telltales for the whole outing The MODE LAP button Click the button to move to the next lap or outing Press and hold the button to switch between Real time and Telltale mode Double Click the button for Reset options NOTE The first lap driven in an outing is always called the Out lap The last lap driven in an outing is always called the In lap Version 3 49 and above If a car enters and leaves the pits in the middle of an outing the entry lap is called the Pit lap and the exit lap is the Start lap 57 Lap Telitales Default Page Fastest lap time Click em Max RPM LAP O Click CHANNEL 58 System 2 User Guide Max Speed Q Click CHANNEL Max Water temperature Q Q Click CHANNEL Max Cil temperature Q Click CHANNEL 59 Min Oil pressure Q Click CHANNEL Min Fuel pressur
73. m LED ve drive Black 1 4 Over rev LED ve drive Yellow 4 24 Over rev LED ve drive Black 3 5 Data from ECM Violet 9 32 Data to ECM Blue 10 33 ECM Ground Yellow 7 13 System 2 User Guide 10 12 The AUX connector Customer part viewed from rear of connector Examples of use Backlighting Use two pieces of wire preferably red and black that are long enough to run from the AUX connector to the power or lighting circuits 1 Strip and crimp the two wires Using the pin contacts provided for the Molex connector strip and crimp the two wires Follow the instructions for making up the Cannon connectors detailed in part C 2 Push the crimped black and red wires into the AUX connector positions 11 and 12 respectively 3 With the Master switch off connect the red wire to a positive supply and the black wire to earth ao t 163 External push buttons The external buttons can duplicate the buttons on the dash where access to the dash is constrained The buttons are normally open momentary buttons which pull an input on the dash to ground when pressed Contact Pi Research to obtain the external button LED kit 6 Left 8 Right 5 Ground External push buttons 164 System 2 User Guide Part E Wiring details Dash wiring Information Colour Length mm Black Red Black Black Black Black Black Black Black Black Red Blue Yellow Black Yellow Red Re
74. m The dash had data in it when the car came in but after turning the dash off and on again the data was lost Cause On software versions 3 49 and above there is an Auto reset mode which resets the dash if the dash temperature is within 10 of the engine temperature when it is turned on Action You can retrieve the data in the dash using the manual reset feature at any time until the car is driven Alternatively change the Outing parameter in Configuration mode to Manual Cause If the data was logged and hasn t been downloaded to a PC or printer the back up battery may be flat Action Return the dash to Pi Research to have the internal battery replaced DO NOT ATTEMPT TO REPLACE THE BATTERY YOURSELF NOTE Internal Battery failure is not a common fault make sure you have checked everything else before returning the dash Telltales Problem The dash won t go into Telltale mode Cause The dash cannot go into Telltale mode until the dash has logged an outing Action Drive the car first Problem The telltales are incorrect or corrupted Cause Incorrect set up or operation of the dash Action Refer to the Troubleshooting section on Data loss or data corruption 108 System 2 User Guide Cause The wheelspeed sensor is not working correctly and is inserting pit stops into the data e g when it reads zero speed Printing Problem Cause Action Cause Action Cause Action Cause Action Cause Action Problem Cause Act
75. med when pressure falls below the preset threshold In the case of turbo measurement the alarm can be set to come on when the turbo drops below a preferred value Dash specification Dash descriptor F3 Version s 3 66 or higher 88 System 2 User Guide Configuration To use the low pressure sensors on both channels the dash would be configured as follows Parameter Setting Units OIL P TBR FUELP TBR Installation A System 2 low pressure sensor can be ordered from your Pi representative Part Number 21A 0050 The sensor can be used to measure turbo pressure or carburettor pressure Features The dash displays the chosen pressure channel as TURB1 oil pressure or TURB2 fuel pressure and will issue an alarm to the driver if the turbo or carburettor pressure falls below the preset threshold The alarm will cancel if the value rises above the limit for one second Club Expert plus features The pressure values can be recorded if configured in Graph Logging and graphed in the Club Expert plus PC software 89 System 2 video data link Description All new non ECM System 2 dashes have the ability to support the data link to an in car video 8 camera The dash transmits a data stream at 1200 baud via the ECM Tx port Data packets are transmitted at intervals of 10 milliseconds i e 100 Hz Details of the data format are available on request Dash specification Dash descriptor F3 Version s 3 66 or hig
76. ment ECM Shutdown If the ECM is powered down while the M System is running information on the data link may be invalid If unusual values for max RPM are seen on the dash or with Club Expert PC software then the power down sequence may have been recorded by the dash Contact your BMW M or Pi representative for further information 76 System 2 User Guide Mazdaspeed Zytech ECM link Description This application provides an ECM link for taking engine data from a Zytech engine management system The User channels are still available for use if required Constructor Mazdaspeed Co Ltd 5 23 Kachidoki 6 chome Chuo ku TOKYO 104 Japan Dash Specification Pi dash code ref Dash descriptor Version s Backlighting Logo Club Expert PC software System 2 PC software Club Expert PC software 30G 0017 MAZDA 3 70 Nov 94 Yes Pi Version 1 13 or higher Version 3 55 or higher 77 78 Channels The following channels are available Race Pages Parameter RPM bar Lap times Min speed Max speed Speed Lap number Monitor Pages System 2 User Guide RPM Speed Fuel used Throttle Battery Water temp Air temp Fuel temp Oil temp Fuel press Oil press Lambda Diagnostics User 1 User 2 Air pressure Lateral g Driver trim Input ECM sensor calculated calculated sensor sensor ECM sensor ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM sensor sensor ECM sensor ECM Page s
77. meters clear 50 0 heatshrink 01 96 8 5 nominal length heatshrink SureSeal plug Linear potentiometer Linear potentiometers Mechanical travel 50 75 100 125 or 150mm Electrical travel 50 75 100 125 or 150mm Mounting rose joints Connector 3 pin Cannon Sure Seal Connections Pin 1 Black Ground 0V Pin 2 Yellow Signal Pin 3 Red Power 5V These linear potentiometers are typically used for measuring suspension travel on cars or bikes You must use a System 2 potentiometer interface box with each one and configure the appropriate User channel s for volts ao t 147 Potentiometer interface box SureSeal socket to sensor Lin Rot Sensor Interface Box SureSeal plug to loom Potentiometer Interface box Potentiometer interface box Mounting Industrial Velcro Sensor connections Connector 3 pin Cannon Sure Seal socket Connections Pin 1 Green Ground 0V Pin 2 Blue Signal Pin 3 Red Power 45V 148 System 2 User Guide System 2 connections Connector 3 pin Cannon Sure Seal plug Pin 1 Green Ground 0V Pin 2 Blue Signal Pin 3 Red Power 12V The potentiometer interface box is used to convert the voltage signal from a linear or rotary potentiometer into the signal type required by System 2 The box goes between the 3 pin connector on the loom and the 3 pin connector on the sensor 149
78. miliar with the system System 2 is an integrated digital dashboard and data logger Each System 2 includes a dash a car loom a wheel speed sensor an RPM box two temperature sensors two pressure sensors an installation kit and a System 2 User Guide The following options are available backlighting external buttons and warning lights ECM links to Engine Management Systems a Beacon kit Club Expert series of software for data analysis Additional sensors for the two User channels and an interface for monitoring sequential gearbox position 10 System 2 User Guide The dash The dash itself forms the central part of System 2 Included in the dash is the digital display logging memory two control buttons back up battery accelerometer for g force dash temperature sensor and a power supply for the sensors The dash has been designed to monitor display and log the following parameters Speed RPM Lap times Beacon kit required Oil temperature Water temperature Dash temperature Oil pressure Fuel pressure Car battery voltage Cornering g force User channel 1 amp 2 The dash also has two lights on the front panel an over rev light or gear change light that comes on when the RPM goes over the red line and an Alarm light that flashes if any of the sensors exceed preset alarm thresholds Logged data can be viewed on the dash or downloaded to a printer or to a computer with optional
79. movement of the pedal e D E 105 Battery Accelerometer 106 Problem Cause Action Problem Cause Action Problem Cause Action Cause Action The Low Power warning came up on the dash The car battery is delivering less than 9V Recharge the battery before running the car again NOTE When the voltage drops below 9V the dash stops logging data To make sure the dash logs data again switch it off and on again with a recharged battery before driving the car The PC Software does not show an accelerometer trace Early Mark Dashes did not have an accelerometer fitted Return the dash to Pi to be upgraded The accelerometer trace on the PC Software does not show zero along the straight The dash is not mounted horizontally which distorts the g force measured by the dash Check and adjust the mounting of the dash The dash is incorrectly calibrated The dash needs to be re calibrated Return the dash to Pi for investigation and re programming System 2 User Guide Data loss or data corruption Problem Cause Action Cause Action Cause Action Cause Action Problem Cause Action Cause Action Problem Cause Action The dash does not appear to have logged any data The dash did not have time to shut down before it was switched off Make sure the car stops for three seconds before turning the dash off On Dashes wit
80. n The LOLA F3000 version has the following settings Input sensor Description reverse park first neutral second third fourth fifth sixth Parameter Setting Alarms User 2 Names User 2 Units User 2 82 System 2 User Guide Page s 1 10 voltage 0 0 19 0 20 0 72 0 73 1 32 1 33 1 70 1 71 2 27 2 28 3 04 3 05 3 90 3 81 4 56 4 57 5 11 de activated GEARP volts Logged option graphed Pinouts Custom pinouts Pin Description 8b GEARP ground 10 GEARP signal 27d GEARP power A System 2 potentiometer interface box is required between the gearbox sensor and the System 2 inputs Installation A 360 degree rotary sensor is mounted on the gear box selector drive The sensor provides a different voltage depending on which gear and hence the position of the shaft the driver has selected System 2 uses a look up table to correlate the voltage against actual gear position Features The calculated gear position is displayed in the centre of page 1 The voltage from the sensor is also displayed on a separate page to enable calibration to be carried out easily User Channel 1 is still available for use by teams 83 Rally and Hillclimb applications Description System 2 is widely used is rally and Hill climb applications There are a number of new features that have been developed specifically for the data logging requirements of leading teams Configuration To mak
81. n the pit wall the time for your last lap appears on the display Page 2 also shows a lap count Latched Speed With the current road speed displayed on Page 4 Click the button This latches the current speed 27 NOTE External buttons can be fitted to the steering wheel as an option Spinning off If you spin off the track and restart quickly System 2 continues to log data If you spin off and stop for more than three seconds the display switches into Telltale mode the system cannot distinguish between a pit stop and a spin When you get back onto the track the display switches back into Race mode automatically and adds data to that already logged Alarms An important feature of System 2 is its ability to warn you if there is anything wrong with the parameters it is monitoring e g loss of oil pressure The thresholds at which the alarms go off are set in Configuration mode If an alarm condition is detected the Alarm light goes on and a message appears on the screen If the alarm comes on and stays on e g there is an oil leak 1 Click either button to reset the alarm The alarm thresholds are adjusted for the remainder of the outing to prevent them from re triggering immediately If the problem e g low fuel pressure is temporary the alarm will reset itself and the threshold will not be adjusted NOTE After a manual reset alarm thresholds are reset to their original value only when the dash is reset B
82. nd lights can be obtained from Pi Research The driver should look straight at or slightly down at the display Jre Dash viewing angle Wheelspeed measurement Wheelspeed sensor M8 x 1 thread T2 30 0 1 18 max 1800 00 DENN le 70 86 Ji Wheelspeed Sensor Sensing Distance 0 4mm to 0 8mm Clearance Distance 8mm from any steel object Mounting 30mm of M8 x 1 thread DO NOT OVER TIGHTEN Connector 3 pin Cannon Sure Seal Sensor connections Pin 1 Blue Ground Pin 2 Black Signal Pin 3 Brown Power Failure to have the minimum clearance from other steel objects causes the sensor to register a rotation even though the trigger target has moved out of range On the other hand if the working distance is too great the sensor will miss triggers especially at slow speeds WARNING The sensor should only be tightened with a small spanner Over tightening the sensor will cause it to fracture 2 2 117 Wheelspeed Trigger Type ferrous metal object Number 1 to 30 per wheel revolution typically 2 or 4 Size nominally 8 x 8 x 4mm The trigger used to activate the wheelspeed sensor should have a surface approximately the same size as the head of the sensor and be at least 4mm away from other metal objects On saloon cars tolerances of 0 5mm on can be hard to achieve so we suggest you use only one trigger The sensor
83. ng wave the transmitter in front of it and make sure the lap times change the transmitter is placed on the pit wall at the same height as the detector the battery is fully charged you ve remembered to pick up the transmitter after the race NOTE The lap times are stored in the dash not in the Beacon transmitter This means that all the cars in your team can use the same Beacon channel with a single transmitter Each time you visit a circuit try to place the transmitter at exactly the same place on the pit wall This will ensure that graphs produced by the Club Expert PC software from different visits to the same track align A master Beacon transmitter is installed at major tracks in the UK The beacon transmitter is set to channel 0 To use this transmitter you must set your beacon detector to channel 0 You do not then need to use your own beacon transmitter 23 24 If you use a printer check that the printer is turned on paper has been loaded the System 2 printer lead has been plugged in the dash has been properly configured for your particular printer the printer has been properly configured for use with System 2 see the Configuring the dash section If you have the Club Expert PC software System 2 User guide Before you leave for the track make sure that the laptop has been fully recharged Most monochrome laptops can run on batteries for about two hours If this is your first visit to a particular tr
84. nnector 3 pin Cannon Sure Seal Connections Pin 1 Shield Ground Pin 2 Orange Signal Pin 3 Blue Power 5 12V Yellow n c The waterspeed sensor can be used to measure boat speed through the water Although it relies on contact with the water by using analysis features in System 2 the sensor can measure the effective speed of offshore boats which may be out of the water up to 50 percent of the time The sensor should be mounted on the boat s transom where the flow of water is least turbulent The left port side of the transom is preferable if it is impractical to mount it 139 ao t there the right side can be used Don t mount the sensor behind strakes or ribs as these disturb the water flow to the speed sensor Also make certain that the sensor will remain in the water even when the boat is on plane The sensor is generally mounted about one foot from the boat s centre line boat hull cross section poor location good locations Positioning the Sensor on the hull When viewing waterspeed on the Club Expert PC software a smoothing filter can be used to reduce spikes in the speed trace When setting tyre size and triggers on the dash try using 650mm and 20 pulses rev A hand held Global Positioning System can be used to check the calibration If you experience any problems contact your Pi representative 140 System 2 User Guide Wheelspeed selector box peg Wheel
85. number Current speed RPM digital Current Speed Latched speed Water temperature Oil temperature Oil pressure Fuel pressure User 1 User 2 Box dash temperature Battery voltage Race mode LAP TIME 15 91 Race mode has the same display Pages as Real time mode but differs in that the dash is also logging data The dash enters Race mode when the car exceeds its minimum outing speed for example 40 mph Once the car starts moving it automatically switches to Page 1 and starts displaying maximum and minimum speeds 19 Telltale mode When you return to the pits after driving the car around the track the dash detects that you have come to a stop Three seconds later the dash switches to Telltale mode to show you the most important information about the outing you ve just completed In Telltale mode the lap number and lap time for the fastest lap assuming a Beacon is being used are displayed Telltale mode displays the following information for each lap Lap time Max RPM Max Speed Max Water temperature Max Cil temperature Min Oil pressure Min Fuel pressure Max User 1 Max User 2 Min Battery voltage Max Box temperature 20 System 2 User Guide At the Track SYSTEM 2 USER GUIDE At the Track Initial checks This section takes you through a typical day of using System 2 If you have not used System 2 before you may need to refer to the Configuring the dash
86. o sections to help you become familiar with the system quickly and easily If System 2 has already been fitted to your car you can get a general idea of the features available within each operating mode Race mode Telltale mode etc by looking at the Overview section A summary of how System 2 is likely to be used in practice is given in the section At the track If you are installing System 2 yourself you will need to follow the instructions given in the Installation notes section before proceeding The User Guide is divided into the following sections Overview At the track Configuring the dash Using System 2 Troubleshooting Installation notes About this User Guide This version of the System 2 User Guide covers dash features up to dash version 3 80 It includes details of sensors available for use on the two User channels The User Guide also includes application notes for a number of specific racing applications such as rallying and karting There are also notes for cars that have sequential gearboxes or with serial data streams available on their engine management systems 8 System 2 User Guide Overview What is System 2 This section gives an overview of System 2 its features variants and configuration modes Read this section before you use System 2 as an engineer or driver You will also find it useful to refer to it at the beginning of each race until you are thoroughly fa
87. on An additional page up button is supplied to facilitate scrolling up or down through the display pages Fuel Calculations Fuel left The ECM provides a value for the amount of fuel left in the tank in litres Time to go The M System calculates the rate of use of fuel over a fixed time period or a lap if a Beacon is used The M System then divides the amount of fuel remaining by the rate of use to estimate a time to go Laps to Go The M System divides the time to go by a lap time averaged over the last three laps to estimate the number of complete laps to go based on the amount of fuel remaining in the tank If the M System is not configured to run with a Beacon the Laps to go parameter is not displayed on the dash Fuel alarm The low fuel alarm is only available if the fuel page is selected in the page list Fuel Page If a Beacon is not used the second race page page 2 would only display real time speed To minimise the number of pages the Fuel page page 3 if selected replaces the second race page 75 Special Issues Wheel speed Selector Box A wheel speed selector box has been developed to monitor two wheel speeds and select the highest measured speed This is to overcome problems with one wheel lifting during severe cornering and providing erroneous speed readings to the M System Rally Mode We recommend that Rally mode is selected on the M System to ensure accurate distance measure
88. ously stored settings by switching off the dash e g with the master switch before exiting Configuration mode 40 System 2 User Guide Alarms RPM You must set the values for the following parameters as the highest value allowable before an alarm is triggered Oil temperature Water temperature User 1 User 2 You must set the values for the following parameters as the owest value allowable before an alarm is triggered Oil pressure or Turbo 1 Fuel pressure or Turbo 2 Battery voltage NOTE If either pressure channel is configured as a turbo channel the alarm LED can be set to come on when the turbo drops below a given value c 2 Detailed instructions on setting up the RPM are included in the Installation Notes Red line The RPM for the red line marker on the display This should be less than the SCALE setting see below Pulse The number of ignition pulses per TWO revolutions of the engine Max Scale This parameter is generally fixed by the markings on the display However it can be adjusted in steps of 1000 RPM by using adhesive overlays 41 Speed Pulse type The Pulse type can take values A B C or D Use type D with the Pi RPM box If you are using a signal directly from an ECM Engine Control Module you may need to select a different type If you are having problems with the RPM check the setting on the RPM Box as well see the Installation Notes section
89. p has been wrapped around an HT lead to an individual cylinder instead of the main HT lead and is not picking up the sparks for the other cylinders Wire the HT pick up around the main HT lead NOTE Some engines now have multi coil systems where each cylinder has its own coil In these cases you can use the HT lead from one coil if the PULSE value on the dash is adjusted accordingly see the Installation Notes section alternatively you could use the LT signal from the ignition box and drive the RPM Box in LT mode RPM Box LT Low Tension Connection Problem Cause Action Problem Cause Action Problem Cause Action The RPM bargraph cuts out or flashes at high RPM The RPM Box is not set up correctly Check that the RPM Box is set for LT positions O to 7 and for the maximum sparks per minute that can be emitted by the ignition system The RPM Bar graph is unstable The LT connection on the RPM Box may be faulty Inspect the wiring on the LT connections and repair if necessary The RPM Bar graph is unstable The polarity of the LT connection may be wrong There are normally three connections on the coil HT supply and trigger The trigger can either be switched to ground or switched to 12V Connect the RPM Box in line with the other low tension side of the coil e g supply or trigger This will reverse the polarity of the signal going through the box e D 97
90. purchased a car with the dash fitted ask your supplier which sensors were fitted to the car For example you may not have a fuel injection system which requires monitoring The sensor is fitted but is not connected to the dash Check the sensor connector and the wiring loom for any obvious damage Mark I Dashes 5 000 to 099 Problem The temperature readings are wrong Cause Action On the Mark Dashes black and steel buttons on the dash the temperature sensors were single pole and required an earth path through the chassis of the car If installed wrongly the sensors can give incorrect readings If the sensors are mounted in a metal block the earth path is through the sensor body Make sure that the oil or water piping is connected to the chassis Water pipes are often insulated by rubber hosing so run a link wire between from the bracket holding the sensor to a point on the chassis If the sensor is earthed through the chassis DO NOT CONNECT THE SENSOR EARTH WIRE IN THE LOOM This will cause an earth loop Leave the earth wire unconnected If the sensor has been mounted in a plastic thread the earth path will be through the earth wire run with the signal wire With a ring connector connect the earth wire to the body of the sensor The sensor is now running from its own signal and earth lines e D E 103 Mark II Dashes 5 1000 and above Problem The temperatures appear
91. r and detector are not lined up correctly As the car passes the transmitter make sure that there is a clear line of sight between the two Sunlight is dazzling the detector The sun a large infrared Beacon transmitter should not shine into the detector as it passes the pits Place the detector on the other side of the car and move the transmitter to the other side of the track Lap times are being corrupted If the wheelspeed sensor is not set up properly the dash will occasionally read zero road speed and insert pit stops in its data This shows up with very short lap times e g 2 seconds and corrupted graph data on the PC Software Check and adjust the wheelspeed sensor see section on wheel speed troubleshooting The lap times seem wrong The car may be picking up someone else s Beacon signal Check if any other teams are running with a System 2 Beacon transmitter on the same channel and agree to use different channels The wheel providing speed information to System 2 is locking up for more than three seconds and is causing extra pit Beacons you will see split laps 1 Use a different wheel for speed measurement or 2 Select Rally mode to prevent premature pit Beacons 102 System 2 User Guide Sensor readings General Problem A sensor does not appear to register on the dash It shows for a value Cause Action Cause Action Temperatures A sensor isn t fitted to your car If you have
92. sor is working depending on the dash version you have The version number is displayed when the dash is powering up Dash version up to 3 0 On the early Dashes the only indicator of wheelspeed is the Speed Page on the dash The speed will be shown if it is greater than 10 mph 1 Lift the wheel with the sensor on it so that it can spin 2 Spin the wheel and see if you are getting a reading Dash versions 3 0 and above These Dashes have a Debug mode which can be used to help diagnose wheelspeed problems To access Debug mode 1 Power up the dash 2 Press and Hold both buttons on the dash 3 When SETUP appears release one button momentarily then press it again The dash will go blank you are now in Debug mode 4 Click the button The word RAW will be displayed with a 0 reading 5 Spin the wheel or move the trigger back and forth across the sensor The reading should go to 1 This indicates that the sensor is working 6 Press and Hold both buttons to exit Configuration mode Dash version 3 49 and above These Dashes have an indicator to show when the sensor is picking up the trigger 1 Go to the Speed setup page in Configuration mode see the section Configuring the Dash 2 Move the trigger across the sensor This will cause the Alarm LED to go on 3 Make sure all triggers are being seen by the sensor 4 Press and Hold both buttons to exit Configuration mode as normal an e 2
93. speed selector box Mounting Supply voltage Supply current Connector Connections Fastest signal H Slowest signal K ne pin lettering scheme o o o A B o o o 2 9 A Kq 9 oC o O 0 p Wheelspeed selector box connector pinout Industrial Velcro 6 to 18 volts 4 mA KPT 2E 12 10P Cannon or equivalent PinA Wheelspeed 1 sensor signal Pin B Wheelspeed 1 sensor reference Pin C Wheelspeed 1 screen Pin D Wheelspeed 2 sensor signal Pin E Wheelspeed 2 sensor reference Pin F Wheelspeed 2 screen Pin G Supply OV from dash Pin H Fastest wheelspeed signal to dash Pin J Supply 12V from dash Pin K Slowest wheelspeed signal 5V only Open drain output which can be connected to System 2 Open drain output which can be connected to System 2 t 141 The wheelspeed selector box monitors any two ABS speed sensors and outputs the fastest and slowest values The fastest speed should be used in applications where wheels may lock during severe cornering e g touring cars The slowest speed should be used in applications where wheels may spin due to poor traction e g rallying The dash must be set up for the number of triggers on the ABS sensor wheel If the ABS speed sensor wires are long or run through an electrically noisy environment it may be advantageous to use screening braid This should only be connected to the selector box and must not be allowed to earth to any me
94. sts the most common sources of problems and how to correct them If the remedies suggested have no effect please contact Pi Research or your local Pi representative addresses are given at the back of this manual WARNING Do not attempt to repair Pi Research equipment yourself All units must be opened and reassembled in clean conditions by trained personnel The Warranty will be invalidated if any parts of the System have been tampered with The dash doesn t start up No supply voltage Check the car s master switch and ignition switch Flat battery Make sure the car battery is charged up and connected The connector on the dash is not secured Check the D type connector in the back of the dash is properly located and secured with the slide lock or screw lock depending on the dash version Faulty wiring Check that the supply voltage wiring is not damaged or has been shorted out Refer to the Pin connection table in the Installation Notes section The dash blanks out Supply voltage is dropping below 9 volts Check the battery is well charged The dash blanks out during use Excessive electrical noise Check earthing of ignition or contact Pi 93 e D LJ Cause Action Backlighting Problem Cause Action Cause Action Cause Action The power and ground wires on the User channels if unterminated may be short circuiting the dash Check the User channel
95. talwork on the car WARNING The 12V supply Pin J for the selector box should come from System 2 not directly from the vehicle battery Do not connect supply 0V Pin G if the ABS speed sensors are earthed 142 System 2 User Guide Turbo carburettor pressure sensor The low pressure sensor has the same physical dimensions as the standard System 2 pressure sensor Turbo carburettor pressure sensor Operating Range Oto 2 5 bar Mounting 7mm 1 8 NPTF thread Connector 2 off 1 4 inch female blade Connections non polarised Explosion rating 35 bar This low range pressure sensor can be used to measure turbo charger pressure or carburettor fuel pressure The sensor reads down to Opsi as opposed to 5psi for the standard sensor Care must be taken when attempting to measure carburettor pressure pressures caused by lateral or longitudinal g may generate pressure readings to the same level as those caused by draw of the carburettor The System 2 dash must have dash code version 3 66 or higher and the relevant pressure channel must be configured as TBAR under the UNITS menu P 143 Rotary Potentiometer suitable mounting arm rotary potentiometer to interface box 3 0 9011 oi 0 27 8 thread rubber driving band NOT provided steering column 1 plan view Steering Sensor using rotary potentiometer Rotary Potentiometer Mechanical travel 36
96. tem 2 User Guide Karting applications Description System 2 can be used on any Kart from cadet class to 250cc The system is able to show on board lap times minimum corner speeds gear change points oil pressure and temperature and exhaust gas temperature EGT Configuration The rolling circumference of kart tyres vary significantly by batch and as a result of temperature and this will have an effect on the speed calculated by System 2 Measure tyres and re configure System 2 to ensure accurate values Parameter Setting Alarms User 1 XXX CT set to desired EGT alarm value User 2 5 50 volts Units User 1 CT User 2 volts Name User 1 STEER User 2 EGT 87 Installation System 2 can be mounted behind the steering wheel in a cradle The Beacon receiver can be mounted on top of the dash itself or on the Nassau panel The wheel speed sensor is mounted as normal on the front left side wheel You will need to make up a custom bracket for this Depending on your kart you may require engine sensors These are mounted as standard If you are using the Thermocouple set the alarm value to the chosen upper threshold temperature Turbo and carburettor pressure measurement Description System 2 has been updated to enable a low range pressure sensor to be used on either of the standard pressure channels e g oil or water pressure The low pressure sensor is calibrated from 0 to 40 psi The channels are alar
97. the Master switch is used to stop the engine as the System 2 cannot save data in a controlled way under these circumstances You can also power System 2 from a separate 12 volt battery when using it for instance on a kart 2 LZ 113 Mounting the dash You can either adapt your car s existing dash panel or make up a new one specifically for System 2 1 Remove the existing Speed and RPM displays from the car but leave the wiring in place if possible 2 Checkthe clearance available behind the dash to make sure there is room for the System 2 loom 70 0 2 75 Minimum clearance required at rear of dash 114 System 2 User Guide 3 Markup the dash panel with an outline of the cutout 114 0 19 0 ok 4 48 0 75 15 0 Ng 259 Y A A Se 3 on 85 0 35 0 Four Q 4 5 mm holes 3 34 zl 1 37 Recommended cutout for dash viewed from front of display Mark up the dash panel with an outline of the cutout required and the location of the four mounting holes 4 Cutoutthe profile and drill the location holes 5 Mount the dash on the panel using the four screws provided 2 2 115 116 Notes System 2 User Guide The dash should be mounted so that the driver can see the display through the wheel The driver should be able to reach the push buttons on the dash External switches a
98. threshold Corner Analysis Program CAP uses steering speed and acceleration channels to produce a Speed Influence graph Steering Sensitivity Intra corner behaviour graph map report and g g diagram 13 Conventions RPM telltale Redline marker RPM bargraph Overrev LED Alarm LED LAP TIME button ud 5 9 7 button MODE LAP CHANNEL Lap times or parameter names Parameter readings BUTTON PRESS TIME seconds EXAMPLE 0 0 5 1 1 5 2 Click Click to cycle through Pages in Real time mode Press and Hold both Press and Hold and to enter Configuration mode Double click click for Reset Definitions of button presses 14 System 2 User Guide System 2 modes The dash automatically switches into one of four different operating modes depending on whether the car is stationary is being driven or has just returned from an outing These operating modes are Power up mode Real time mode Race mode and Telltale mode In addition to the four normal operating modes a Configuration mode exists for you to adjust alarm thresholds e g for low oil pressure or high oil temperature the RPM red line setting and the other parameters Configuration mode System 2 is preprogrammed with default settings but it may be necessary to alter these values to suit your car Some of these parameters only need to be set once when System 2 is installed However you may wish to adjust param
99. transfers data to its internal memory once the car comes to a standstill To make sure this doesn t happen while you are racing during wheel lock for example the dash waits a few seconds to confirm that you have actually stopped before storing data If you cut the power to the dash BEFORE the car has been stationary for three seconds the data from the last outing will be lost Instantaneous power loss If the battery suddenly fails while the car is moving the dash may not have time to perform a controlled shutdown and data may be lost To minimise the risk of battery failure make sure the car s battery is fully charged before you go out on the track 69 New track New map Once the dash has stored its data you can switch off the power on the car The backup battery in the dash saves the outing data until you download it to a PC or you reset the dash Because outing data is retained in the dash it will still be there when you go to another track If new data is then added to data from the previous track it may be confusing when you use the PC analysis software For example you may create a map using the wrong data For this reason it is good practice to manually reset the dash when you arrive at a new track 70 System 2 User Guide Application Notes These application notes explain how to configure and use your System 2 in a number of common applications Installations can vary from car to car so you should
100. ub Expert range of software you will need a Beacon kit since the software displays data by lap 12 System 2 User Guide The Club Expert PC software A powerful feature of System 2 is the data analysis software that can be run on a laptop PC The Club Expert range of PC software Club Expert plus Club Expert super and Corner Analysis Program CAP offers a wide range of features including Circuit maps Graphs of RPM and speed Lap by lap reports on pressures temperatures voltage and Dash temperature Graphs of lateral g force Information about the track driver and date Speed reports that compare performance with other cars or drivers An RPM logbook kept over the life of the engine An archiving facility for saving logged data on floppy discs for future analysis Full printing facilities When plugged into the car at the end of an outing the software transfers i e downloads all the data stored in the dash This data can then be used as the basis of a series of reports For example while the car prepares for its next outing you can be comparing lap times for different suspension settings tyres or even drivers Club Expert plus can also provide split time reports on power histograms compare elapsed time gear ratio in line g and graphs of analog channels Club Expert super allows the use of Set up and Running sheets multiple graphing beacon move facility overlaid histograms animation and configurable lap
101. used and can be joined together and taped up 123 ao t HT pickup detail NOTE The RPM Box is sensitive to the polarity of the HT pulse it receives If this causes a problem try using the LT pickup method Setting up the RPM Box The dash needs to be set up to use the signal from the RPM Box This is done by setting the RPM Pulse type to D The RPM Box has a small 16 position switch which needs to be set to match the signal received Legends for positions 0 4 8 and C 212 are printed on the box but the intermediate settings are available Settings 0 to 7 should be used with LT ignition coil connections Settings 8 to F should be selected if using the HT connection HT settings E F 0 1 2 LT settings 8 to F D 3 0 to 7 8 6 A 9 9 Switch currently set to 3 RPM box switch settings 124 System 2 User Guide The settings are related to the number of sparks per minute the engine needs at maximum RPM as in the following table I Max sparks min LT Typical example 11 000 0 8 11 000 RPM 2 stroke 11 000 sparks min 19 000 1 9 7 500 RPM 4 stroke 15 000 sparks min 36 000 2 A V8 single coil 4 stroke 30 000 sparks min 45 000 3 B 54 000 4 C 64 000 5 D 85 000 6 E 95 000 7 F Notes RPM measurement is more reliable when unwanted signals are filtered out Setting the box sets the frequency at which signals are filtered out e g Setting 1 filters out signals higher than 19 000
102. wheel See earlier description of trigger types Make sure that the sensor head does not touch any of the triggers 5 Setup the sensor with an approximate gap of 0 7mm ao t 119 RPM measurement 120 System 2 can measure the engine RPM in three ways digital tacho signals e g Vauxhall Junior F3 or F3000 with electronic ignition the System 2 RPM box with Low Tension LT input e g standard contact breaker ignition systems the System 2 RPM box with High Tension HT input e g electronic ignition systems where no tacho signal is available The RPM Box generates its own tacho signal from the LT or HT signals on the car Tachometer Signals The System 2 dash unit can accept a tacho feed from most electronic ignition modules The settings for the dash selected in Configuration mode are A for Open Collector PNP Pull Down 12V B forOpen Collector PNP Pull Down 5V C forOpen Collector NPN Pull Up 12V or 12V pulse feeds D forOpen Collector NPN Pull Up 5V or 5V pulse feeds The RPM Box also requires setting D Connector 3 pin Cannon Sure Seal Connections Pin 2 Violet Signal A spare connector has been included in the installation kit Only pin 2 needs to be connected the ignition system and System 2 must share the same earth If you have a low voltage digital tacho signal on your car from the ignition system locate the wire and connect it to pin 2 of the 3 way Sure
103. wiring is correctly terminated with SureSeals The backlight doesn t work The backlighting is an optional extra and may not be fitted to your dash Send your dash to Pi Research to have backlighting fitted No 12V supply to the backlighting element The backlight is powered from a separate 12V supply via the AUX auxiliary connector It can be connected to the lighting circuit on your car or directly from the battery in which case it will be on all the time Follow the instruction in the Installation Notes to connect up the supply voltage The backlighting element has been damaged Return the dash to Pi Research for repair External buttons and lights Problem Neither external push buttons work Cause The AUX auxiliary connector has come apart Action Check the AUX connector and re join if necessary Problem One external push button doesn t work Cause Faulty wiring Action Refer to the Installation Notes to check the wiring to the AUX connector and in the main loom Cause Faulty push button Action Try swapping the buttons to see if that cures the problem If so replace the faulty one 94 System 2 User Guide Engine speed RPM The dash Problem Cause Action Problem Cause Action Problem Cause Action Problem Cause Action Tacho signal Problem Cause Action Cause Action The dash is reading half the correct RPM value The Pulse setting in the dash is wrong Check and adjust the value in

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