Ontronic User Manual
Contents
1. The realisation of the wiring is an important and delicate process which requires automotive electricity knowledge and experience The wiring process is estimated to 5 hours of work Ontronic is delivered with the electrical contacts pins Figure 2 8 The sensor plugs Figure 2 9 are exclusively provided with sensors ordered from http www ontronic ch Itis recommended to weld all connections Figure 2 8 Electrical contacts pins Figure 2 9 Sensor connection plug Page 9 Ontronic user s manual English The main electrical connector of Ontronic is divided in 3 parts high medium and weak currents Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 The connection diagram is shows in Table 2 1 Page 10 Ontronic user s manual English TOP BOTTOM Figure 2 10 High current connector Important Cylinder numbering ignition order Figure 2 11 Wiring diagram of the high current connector Page 11 Ontronic user s manual English TOP BOTTOM Figure 2 12 Medium current connector Important Cylinder numbering ignition order CA 4 WN mM e Injector 1 An Injector 2 Injector 4 Injector 5 Injector 7 n 3 Injector 8 Figure 2 13 Wiring diagram of the medium current connector Page 12 Flywheel Ontronic user s manual English TOP BOTTOM Figure 2 14 Weak current connector signals sensors Heating COM R 2322. Lambda Camshaft phasing Figure 2 15 Wiring diagram of the weak current connector Page 13 Ontronic user s manual English Estimated Wire cross section pin escripton type L sa Lei 1 Coil 1 Output 10 2 50 4 Ground output shielding Output 0 150 6 Injectors power supply 12V_ input 20 400 7 injectort Oupt 3 4150 8 injectort Ouput 3 150 9 Jiniectr3 ou 3 TI 150 10 ljectr3 Output 3 f 4150 1 lmjectors Output 3 TI 150 12 Injector5 Output a J 54150 13 Jinjector7 ou 3 f 2150 14 Injector7 Output 3 f 4150 i5 Exemdsysemi oa 1 19 16 Exemalsystem2 Oupt 1 18 7 Seiacomeciong meu Oupt 0 15 i8 Serarconnecton 3 4 hpu Oupt 0 f 15 19 Serial connection 5 Input Output o 150 20 Aspirated air temperature sensors npt 0 15 2 Aspiatedairtemperature sensor Input 0 mn 22 Throttle position sensor 5V Oupu 0 TI 150 23 Throttle position sensor signa Output 0 f 1450 24 Throttle position sensor ground OV Input 9 159 25 Crankshaft inductive sensor m 0 150 26 Crankshaft inductive sensors Im o 15 27 Camshaft inductive sensor phase
3. Zz Load 255 Injection tine es 4331 Air tmp C F Injection core el Fee Water imo C Startup corr 1 68 Turbe presse bar Accoleration coer X E Air pressure mbar 279 Mecontolce x pn 2o Battery Injectors wage PS 7 Awet na Spark advance core 25 6 Max rpm ege 2563 cCehlo za Missies 9 z TPU code fo 4125 de wo used W bmeg Sepercherges Sen v Syndwn Seet M fen Mate Gupa 2 M Leg Indian correo Startap Outprat t M oupa CON 1 oe for dialog Figure 3 6 Emulation mode 3 4 6 Flash programmation Once satisfied with the engine settings the emulated eprom code has to be programmed in the flash memory of Ontronic Data retention is then ensured To program the flash memory use the option Tools Program Flash Ok After each flash programmation it is worse verifying the flash content To do this e Quit emulation mode Tools Emulation Mode e Compare the virtual eprom code of the computer with the internal flash content Tools Compare to internal code Page 24 Ontronic user s manual English 3 5 Tuning 3 5 1 Engine configuration Prior to any engine startup the general engine parameters need to be defined The general engine parameters window comprises all basis engine parameters number of cylinders number of coils flywheel configuration cutoff etc To do this click on parameters from the main eprom code window
4. The general engine parameters window opens Figure 3 7 Golf 2000 16V c sec 02 bin Parameters Engne Setpoints Chee c SS Code 8 B m Overspeed rm NW Goll 1965 cm3 16V Teste Pe Ee Reference teeth 1 additional C1 missing JW Deceleration cutoff Si Figen kd Jeer 2000 kei advance fo Theoitthe kg 255 1 Theottle hysteresis 255 4 Deceleratian cutolf Gen oftset 635 Ide controt Engine type Almospheric C Supercharged Ide pes ben Phaung Ide tpane tp E Phasing enabled Theottie lent 255 Phang beat i500 Theottle beienee 255 2 legectors paramters Min ni time fus 1500 Lateneylus 1200 fv Ide consol d gm p fp o o o ss 5 Figure 3 7 General engine parameters window The following parameters need to be defined see below After having changed any numerical data the data need to be validated by pressing the return or enter key on the keyboard in order to prevent any intermediate garbage data to be sent while typing the new value for example while changing the cutoff Page 25 Ontronic user s manual English General engine parameters Cylinders Number of cylinders 1 12 Default value 4 Coils Number of coils When using double coils this value is the cylinder number divided by 2 For single coil engine distributed ignition this value is the number of cylinders In this configuration the coil w
5. mi 0 f 15 28 Camshaftinductive sensor phase Input 0 f 150 29 Turbo pressure sensor ground Output 0 1599 30 Turbopressuresensor signa mu 0 f 150 k 31 Turbo pressure sensor 5V Output o J 150 32 Coolant temperature sensor Input Io J 150 33 _ Coolanttemperature sensor mu o 15 34 lambdasensorsignal m 0o 150 35 Lambdasensorsiga m o 15 36 Rpmsinal sgnd cyle Oupt 1 19 37 Gearlamp ou 1 f 150 X 38 Exemalsysem3 Oou f tso 39 Injector 8 Output 41 injector6 Output SO L metoro L n 3 19 a3 meios oom 3 189 A mecos oo 3 19 45 Imjctr2 oom 3 i19 CO CO w CO Cl GD GW CO k wiwlwulw wj w CO Page 14 Ontronic user s manual English 46 Injector 2 Output 3 1 50 EE Ee Ss e 319 si feia rtp 319 m ci ow w Table 2 1 Connector wiring and electrical characteristics 3 Operating software 3 1 Installation and Configuration Ontronic is delivered with an installation CD containing the exclusive operating software The software is compatible with the following Microsoft amp operating systems Windows XP Windows NT SP1 Windows 98 Windows 95 The latest update of the software can be freely downloaded from t
6. 6460275 amp Throttle Throttle Injection duration Spark advance Water temperature Air temperature Turbo pressure Battery voltage Figure 3 4 Data acquisition 3 4 4 Opening Downloading an eprom code An eprom object file can be opened even if Ontronic is not connected to the computer An eprom file includes all the engine parameters cutoffs three dimensional and two dimensional maps correction and calibration graphs Figure 3 5 The Ontronic software being highly flexible it is possible to open an infinite number of eprom codes at the same time It is recommended to begin any tuning with an already existing eprom file having more or less the same characteristics power rom cylinders etc A large number of eprom file are available on the installation CD eprom directory In additional several eprom code are distributed freely by the user s community on The default eprom code which is pre programmed in the Ontronic flash memory reflects a 4 cylinders 2000 cm with a power of about 250 CV The internal eprom code can be downloaded by clicking on the download button as shown in Figure 3 2 The download time is about 4 seconds Page 21 English Iw Auto 16 46 34 Ontronic user s manual English E OnTronic File Tools Window Help Corrections Sensors calibration Ignition advance Coils load Lambda settings Acceleration a Acceleration b
7. A TH See rt fe Rane ee PERKARA PETRA Figure 3 10 Three dimensional map injection duration 3 5 5 Dynamic compensation acceleration pump Dynamic compensation acceleration pump is reguired when the operation parameters e g load change rapidly Dynamic compensation is automatically calculated by Ontronic It dynamically increases the fuel quantity injection duration during fast transients using state of the art differential equations As a result the injected fuel quantity is increased during a specific time window additional injection spike Two programmable factors are used to characterize the amplitude and time constant of the dynamic compensation Figure 3 11 e Factor A Defines the amplitude of the additional injection spike The higher this factor the higher the additional spike Page 33 Ontronic user s manual English e Factor B Defines the time constant of the additional injection spike The higher this factor the longer the injection spike The A and B factors can be individually adjusted for all engine operating states using 2 dedicated three dimensional maps Table 3 3 Normally the default settings suit almost all engines The settings are performed using The keyboard arrows right left to move along the curve The mouse to select a target point The keyboard function keys F1 F4 to increase the value s and F5 F8 to decrease the value s With the Ed menu
8. Ontronic user s manual English http www ontronic ch Vu ani User s manual Page 1 Ontronic user s manual Te INTHODUG TION EE 3 2 INSPAEEATION senam km mana 4 2 1 Reference Flywheels oooooooooooooooooooooooooooooooooooooooooooo 2 1 1 Reference flywheel crankshaft ste 2 1 2 Phase sensor camshaft ee sess eterne a es 2 2 didit 9 3 OPERATING SOFTWARE oom oma 15 3 1 Installation and Configuration oooooooooooooooocoooooooooo 15 3 2 Functions sisssiscsssescseicessossssesssessossessssesseinonssesdsaseseinansaseciossseseneicesssesssed nsssisonsenaesesnscssessesseietaonsesen 15 3 3 Serial connection to OntrOnic ooooooooooooooooooooooooooooooooooooo 16 3 4 Overview of the operating software management program oooooooooooocoooooo 16 3 4 1 Program Startup 3 4 2 Sensors Window setenta ee eR e AAA AR 3 4 3 Data acquisition 3 4 4 Opening Downloading an eprom code 3 4 5 Emulation mode 3 4 6 Flash programmation 3 5 Tuning eee 3 5 1 Engine configuration 3 3 2 Sensor Calibration sec TURRIS ia 3 5 3 Correction EEN 31 3 5 4 Injection and ignition tuning oom 3 5 5 Dynamic compensation acceleration pump Page 2 English Ontronic user s manual English 1 Introduction Ontronic is an electronic injection and ignition system Thanks to its high level electronic and modern control capabilities O
9. Water temp gt Inj Water temp gt lan P Airtemp gt Inj Air pressure gt Inj Battery gt Inj Battery gt Ign Aux Turbo pressure Throttle Battery Air temp Water temp Parameters Air pressure Lambda Startup gt Inj VW Golf 1986 cm3 16V type GZ000771 83x91 8 Sc Figure 3 5 Eprom object Injection duration Ignition advance Coils load Lambda settings Acceleration a Acceleration b Paramders Water temp gt inj Water temp gt ign Air temp gt inj Air pressure inj Battery Inj Battery Ign Startup Inj Aux 1 Turbo pressure Throttle Battery Air temp Water temp Air pressure Lambda Parameter Injection duration Ignition advance Coild load angle Lambda Acceleration a 3 5 5 Dynamic compensation acceleration pump Acceleration b 3 5 5 Dynamic compensation acceleration pump Engine parameters Injection correction as function of the coolant temperature Ignition correction as function of the coolant temperature Injection correction as function of the aspirated air temperature Injection correction as function of the barometric pressure Injection correction as function of the battery tension Ignition correction as function of the battery tension load angle Injection startup correction Auxiliary sensor calibration Turbo pressure sensor calibration Throttle sensor calibration Battery tension calibration Aspirated air temperature
10. at which Ontronic cuts injection to prevent exceeding this limit Default value 8500 rom Deceleration cutoff Deceleration cutoff This function allows the activation of the total closure of the injectors when the throttle is closed as long as engine rpm exceed a defined limit This economy measure is useful when the car is going down hill and where no motional power is needed Activating this function prevents undesired high fuel ratio combustion If rom decreases below rpm limit the injection is re activated see rpm limit rpm Page 27 Ontronic user s manual English Default value activated Rpm limit Threshold rpm where deceleration cutoff is deactivated If rom decreases below this limit the injection is re activated see deceleration cutoff Default value 3000 rom Throttle limit 255 Throttle position where deceleration cutoff is activated Default value 1 Throttle hysteresis 255 Deceleration cutoff throttle position hysteresis Injection is re activated if the throttle position exceeds throttle limit throttle hysteresis This prevents any sporadic cutoff activation deactivation effects Default value 4 dle control Idle control Idle rpm is controlled by reducing the injection time and reducing ignition advance if the engine rpm exceeds idle rpm and if the throttle position remains below defined limits This helps maintaining the idle rpm within acceptable limits Default va
11. ce teeth In order to scan the engine rotation in real time teethes detection and rev measurement an inductive sensor has to be installed The inductive sensors are standard inductive devices with 2 wires orderable from http www ontronic ch or in any automotive workshop The gap between the sensor and the flywheel teethes Page 4 Ontronic user s manual English should be 40 54 mm Figure 2 3 It is worse reading the technical specification for other types of inductive sensors The sensors and flywheel should be robustly fixed to the engine block and to the crankshaft respectively Any inaccurate or noisy teeth detection may result in misfiring and power decrease Figure 2 3 Inductive sensor gap Figure 2 4 shows the final installation of the reference flywheel and its sensor Figure 2 4 Reference flywheel and inductive sensor The angle between the reference teeth additional or missing and the top dead centre of cylinder 1 is called general offset angle as shown in Figure 2 6 This angle can be arbitrary chosen and programmed It is however good to choose it as far as possible to all cylinder top dead centres As a matter of a fact for high compression ratio engines the engine rotational speed rpm may significantly decrease in this region leading to wrong reference teeth detection especially at Page 5 Ontronic user s manual English very low rpm e g during startup It is therefore wise to shi
12. ds the programmed value a signal is activated on output 3 Figure 2 14 A relay can be activated to activate external systems for example a fan Default value Activated 3 5 2 Sensor calibration The different sensors are to be calibrated Each sensor has its own specific calibration curve within an eprom object Figure 3 8 The default calibrations correspond to the sensors delivered with Ontronic http Awww ontronic ch If a different type of sensor is utilized it is required to calibrate them using the corresponding calibration curve It may also be that some sensors deviate from they generic characteristics In such a case some corrections may be required It is recommended to enter emulation mode in order to calibrate a sensor 3 4 5 In this mode the values read by Ontronic are displayed in real time by a white cross on all graphs and maps It is thus easy to adjust the curve for different input values e g temperature pressure position etc Page 29 Ontronic user s manual Golf2000_16 _c_sec_02 bin 3D maps Injection duration F Ignition advance Coils load Lambda settings Acceleration a Acceleration H Parameters Corrections Water temp gt Inj Water temp gt Ign Airtemp gt Inj Air pressure gt Inj Battery gt Inj Battery gt lan Startup gt Inj Sensors calibration Aux Turbo pressure Throttle Battery Air temp Iv Wat
13. er temp Air pressure English Lambda vw Golf 1986 cm3 15V type GZ000771 8391 8 Sc E Water temp Figure 3 8 Sensor specific calibration curve Each sensor temperature pressure tension position returns a the actual operating position on the ADC axis Analog to Digital Converter This specific point can then be adjusted accordingly Y axis The settings are performed using The keyboard arrows right left to move along the curve The mouse to select a target point The keyboard function keys F1 F4 to increase the value s and F5 F8 to decrease the value s With the Ed menu where several useful amplification relative or absolute reset smoothing CTRL A and interpolation functions are available As for throttle calibration a special tool is available in the ect menu Figure 3 9 Simply follow the instructions to calibrate the throttle Page 30 Ontronic user s manual English ESSE OnTronic File Mc Tools Window Help Minimum Medium Maximum Set to Gain Sensors calibration Aux Smooth CtrA E Turbo pressure jw Throttle Batter LJ Throttle w Stepper Follow Fix Point Ctrl F Unfix All gt Ini 538 23 out Fix all f Fix lt gt Unfix Calibrate throttle Figure 3 9 Throttle calibration The list of all calibration curves are shown in Table 3 3 3 5 3 Correction graphs Climatic factors significantly impact the nominal engine set
14. ft the reference teeth far to any tdc For 4 cylinders engines a general offset angle of 90 is thus recommended Figure 2 6 This value is then programmed in Ontronic refer to chapter 3 5 7 2 1 2 Phase sensor camshaft A phase sensor has to be installed for all phased engine on the camshaft sequential injection Important e Engines with 8 cylinders or more require double coils for example 4 double coils for an 8 cylinders engine Therefore they cannot be phased e Two strokes engines are obviously not phased The installation of the camshaft sensor is similar to the flywheel Figure 2 5 shows the overall installation of the reference flywheel and the phase sensor Figure 2 5 Installation of the phase sensor tdc explosion cylinder 1 Counter clockwise rotation Page 6 Ontronic user s manual English Flywheel with additional reference teeth gt Top Dead Center on cylinder 1 explosion Crankshaft Camshaft Figure 2 6 Flywheel with additional reference teeth Page 7 Ontronic user s manual English Flywheel with missing reference teeth gt Top Dead Center on cylinder 1 explosion Crankshaft Sensor Lok Camshaft Figure 2 7 Flywheel with missing reference teeth Page 8 Ontronic user s manual English 2 2 Wiring Ontronic is delivered with or without wiring cable The wiring and electrical connections jobs should be achieved by an experienced person
15. hasing enabled Page 26 Ontronic user s manual English Engine phasing Ontronic features a special procedure to accommodate for quick and efficient engine startup During startup engine phasing can be disabled Engine synchronization is therefore achieved after only one crankshaft rotation instead of 4 if Ontronic should wait for the camshaft signal phase sensor This allows for efficient startup at very low rpm For engines with 8 cylinders or more this option shall not be activated since double coils are used For distributed ignition with only 1 coil this option should be activated and phasing rpm set to 0 see phasing rpm below Default value activated Phasing rpm Rpm where Ontronic enters phasing The injectors will then open and close only 1 time per cycle 720 crankshaft This value corresponds to the rpm where it is absolutely sure that engine has started Default value 700 rom Minimum injection time us Minimal allowable injection time in microseconds us Refer to the injectors technical documentation Generally this value is between 1200 and 1500 us Default value 1500 us Latency us Injector latency in microseconds us Refer to the injectors technical documentation Generally this value is between 800 and 1200 us Default value 800 us Overspeed rpm Treshold rom where the gear lamp flashes flash light Default value 8100 rom Cutoff rpm Cutoff rpm Rpm
16. he internet site http www ontronic ch Software updates are released regularly The following hardware configuration is recommended Table 3 1 Operating system Pentium Ill 1000 MHz or above 128 Mb or above ix Serial COM or USB 15 Table 3 1 Recommended hardware configuration The Ontronic operating software is to be installed by double clicking on Setup exe from the installation CD Then simply follow the standard installation instructions 3 2 Functions The Ontronic operating software is used for the following functions e Engine configuration cylinders cutoffs etc e Sensors calibration Page 15 Ontronic user s manual English e Correction factors e Injection and ignition tuning All those process parameters are grouped in an entity object called eprom as an analogy to the first generation of electronic injection systems where all parameters were stored in an eprom Physically Ontronic does not feature an internal eprom but a flash memory electrically erasable memory as well as a fast memory SRAM for emulation purposes see chapter3 4 5 Emulation mode In emulation mode all engine parameters can be updated and modified online as the engine is operating dynamo meter road Once satisfied with the settings the flash memory can be written The tuning functions are described in chapter 3 5 3 3 Serial connection to Ontronic The connection dialog between Ontronic and t
17. he computer is ensured by a standard serial data cable to be connected in a computer serial port COM RS232 on which the operating software has been previously installed Use preferably the COM port number 1 COM 1 Different ports can be activated using the Ontronic operating software In case the computer does not feature any serial port Ontronic can also be connected to an USB port using a dedicated COM USB interface Such interfaces can be ordered online from http www ontronic ch The connection cable should respect the wiring diagram 3 4 Overview of the operating software management program 3 4 1 Program Startup Once Ontronic is connected as described in chapter 2 the computer can be connected to Ontronic using a standard serial cable Then start the Ontronic operating software from the Windows menu start Figure 3 1 Page 16 Ontronic user s manual English My Documents 2 My Recent Documents o LJ My Pictures D My Music EJ My Network Places Je contrat panei D Connect To B ouse 6 S amp S Printers and Faxes e Kazaa Lite K Hep and Support J search 177 Run Figure 3 1 Windows start menu Once the software has started the main Ontronic window opens The main basic functions and tools are shown in Figure 3 2 Page 17 Ontronic user s manual English OnTronic Acquisition de donn es T l chargement nseurs eprom interne Mode mulation Stat
18. ime uS 4031 Air temp C Injection corr 96 2 6 Water temp C Startup corr 1 AA Turbo pressure bar na Acceleration corr 26 p 0 Air pressure mbar Idle control corr LC Battery VJ Injectors usage Aux 1 Spark advance corr 25 6 Max rpm rpm Coils Load Missfires 2 TPU code a Idle Iv Phased jw Emulated Supercharged Short Iw Syucinu Devel Flash bight Output 2 Luny Idlecontrol Startup Output 1 Output 3 Rpm cutoff Figure 3 3 Sensor s window GE load throttle position or turbo pressure 255 Injection time Injection duration per cycle uS Injection corr Injection correction Page 19 Ontronic user s manual English Startup corr Startup injection correction Coils load Coils load TPU code De TEEN idis Engmesoped Emulated Emulation mode activated Flash light Gear lamp flash light Table 3 2 Description of the parameters in the sensors window 3 4 3 Data acquisition All data received from Ontronic are permanently stored in the operating software memory Figure 3 4 The memory capacity reaches about 6 hours All this data can subsequently be visualized and analysed by opening the data acquisition window as shown in Figure 3 2 Page 20 Ontronic user s manual S am Data ai LLELLE File Edit Acquisition 1500 00 RPM 164544 Refresh lt gt gt gt fas 1
19. ional rpm load and value as shown in Figure 3 10 e The X axis represents the engine rpm Increasing rpm go the right direction e The Y axis represents the engine load Increasing engine load throttle position or boost pressure go to the depth e The Z axis represents the parameter to be tuned injection duration ignition advance coil load etc In emulation mode the current positions read by Ontronic on the maps are displayed by a white cross This allows the engine developer to easily figure out which points need to be modified Figure 3 6 The settings are performed using The keyboard arrows right left to move along the curve The mouse to select a target point The keyboard function keys F1 F4 to increase the value s and F5 F8 to decrease the value s With the Ed menu where several useful amplification relative or absolute reset smoothing CTRL A and interpolation functions are available The current position read can be automatically followed by the cursor activating the option Edit Follow The cursor position is indicated in the 3 text boxes rpm load value The X Y and Z values can be updated manually in he corresponding text box The map can be turned in three dimensions and zoomed using the 4 slide bars Figure 3 10 The three dimensional tuning maps and their meaning are shown in Table 3 3 Page 32 Ontronic user s manual English Ter Wee H re He HH Lt PH AA
20. ires ign 1 6 have to be connected together on the single coil each connections loading the coil for a specific cylinder This limits therefore the number of cylinders to 6 for single coil Moreover the engine needs to be always phased see phasing rpm below Default value 4 Reference teeth Type of reference teeth for tdc detection refer to chapter 2 1 1 Default value additional Injection advance Injection advance injection calibration Angle at which the injector opens cylinder specific Default value 100 General offset General offset angle tdc relative to the teeth just after the reference teeth additional or missing refer to chapter 2 7 7 This angle can be arbitrary chosen and programmed It is however useful to choose it as far as possible from any cylinder top dead centers As a matter of a fact high compression ratio engines see their engine rotation speed significantly decreasing in this region leading to wrong reference teeth detection especially at very low revs e g during startup It is therefore recommended to shift the reference teeth far from any tdc For 4 cylinders engines a general offset angle of 90 is suggested Figure 2 6 Default value 90 Engine type Engine type atmospheric or supercharged The load criterion is defined as the throttle position for atmospheric engines or as the turbo pressure for supercharged engines Default value atmospheric P
21. lue activated Idle rpm Threshold rpm at which idle control is activated if the throttle position is below throttle limit Default value 1500 rom Idle span rpm Rpm span rpm window where idle is controlled Rpm is maintained between idle rpm and idle rom idle span From that limit the injection duration and ignition advance are progressively decreased Default value 800 rom Throttle limit Threshold throttle position where idle control is activated Default value 1 Throttle hysteresis Throttle hysteresis value for idle control Idle control is deactivated when the throttle position exceeds throttle limit throttle hysteresis This prevents any sporadic activation deactivation effects Default value 2 Page 28 Ontronic user s manual English Output 1 External controller When rpm and load throttle position boost pressure exceeds the programmed values a signal is activated on output 1 Figure 2 14 A relay can be activated to activate external systems for example a water injection pump Default value Deactivated Output 2 External controller When rpm and load throttle position boost pressure exceeds the programmed values a signal is activated on output 2 Figure 2 14 A relay can be activated to activate external systems for example a water injection pump Default value Deactivated Output 3 External controller When the coolant temperature excee
22. mensional maps Integrated data acquisition Lambda control Between 4 and 128 teethes Additional or missing reference teeth for the top dead center tdc detection Operating software Reference flywheel Table 1 1 Characteristics Page 3 Ontronic user s manual English 2 Installation 2 1 Reference Flywheels Ontronic permanently tracks the engine angular position the revs rotation per minute rpm as well as the phase of the engine for 4 strokes phased engines exclusively To achieve this two reference wheels have to be installed one on the crankshaft flywheel the second one on the camshaft for 4 strokes phased engines exclusively 2 1 1 Reference flywheel crankshaft Ontronic is compatible with an arbitrary number of teethes between 4 and 128 teeth on the crankshaft reference flywheel As a matter of fact a wide range of original flywheels can be conserved Different flywheel types and sizes can be orders from http www ontronic ch Between 16 and 36 teethes seems a good compromise between flywheel production difficulty and engine management accuracy In order to identify the top dead center tdc an additional or missing reference teeth is placed at a special location on the flywheel Figure 2 1 and next Ontronic is also compatible with 2 missing teethes flywheels Sodemo type This configuration is however not recommended Figure 2 1 Additional reference teeth Figure 2 2 Missing referen
23. ntronic is especially dedicated to demanding applications The injection and ignition device is fully programmable as function of optimization criteria The numerical data processing is performed by a 32 bit microprocessor which processes all service parameters to injection and ignition data using multi dimensional maps climatic correction sensors calibration static and dynamic engine processes Table 1 1 shows the main characteristics of Ontronic 1 2 3 4 5 6 8 10 or 12 cylinders Engine types 2 or 4 strokes Atmospheric or supercharged Sequential or non sequential non sequential for 8 cylinders or more Programmable injection advance High or low impedance injectors Between 0 and 32 ms injection duration One coil per cylinder Double ignition coils for 2 4 6 8 10 and 12 cylinders engines Ignition type Distributed for 1 to 6 cylinders only Between 0 and 65 ignition advance Between 0 and 720 angular loading time Barometric pressure intern Supercharge pressure for supercharged engines only Throttle position Aspirated air temperature Coolant temperature Rpm sensor crankshaft Phase sensor camshaft for phased engines only Lambda CO Auxiliary input Injection type Sensors Ontronic is compatible with all sensor types calibrable with the operating software Connection to Ontronic through the computer serial port COM RS232 Compatible Windows XP NT ME 98 95 6 three dimensional maps 15 bi di
24. sensor calibration Coolant temperature sensor calibration Barometric pressure sensor calibration internal sensor Lambda sensor calibration CO Table 3 3 Eprom file content Page 22 3D 3D 3D 3D 3D 3D Num eric Ontronic user s manual English 3 4 5 Emulation mode In emulation mode the eprom code is sent to the fast memory SRAM of Ontronic In this mode each modification performed on the maps and in the engine parameters are updated instantaneously in Ontronic The new settings are therefore immediately available on the engine even during operation This mode is used to tune an engine in real time on dynamometer or on the road as well as to calibrate the sensors Emulation mode is activated or deactivated by clicking on the Tools Emulation menu or by clicking on the button emulation Figure 3 2 If the power supply in interrupted during emulation Ontronic will restart in normal mode using the latest settings of the internal Flash memory It is then required to re enter emulation In emulation mode the current positions read by Ontronic on the maps are displayed by a white cross This allows the engine developer to easily figure out which points need to be modified Figure 3 6 Page 23 Ontronic user s manual English Pie Tode Window Hp Dwlela ci au A Lanka tre Accetection e Are H C Pures MAY Gali 1386 cn 18 1 Lambea CO HI Spork edvence 2379 1 00 11 8
25. tings For instance as aspirated air is cold the air density increases leading to an higher aspirated mass flow lower fuel air ratio In order to overcome these effects Ontronic continuously scans all climatic factors and automatically adjust all service parameters using two dimensional correction graphs The default correction graphs should normally suit a wide variety of engines and may not need to be modified It is however possible that some engines are more sensible to specific parameters for example cold startup The list of all correction graphs are shown in Table 3 3 The settings are performed using The keyboard arrows right left to move along the curve The mouse to select a target point The keyboard function keys F1 F4 to increase the value s and F5 F8 to decrease the value s Page 31 Ontronic user s manual English With the Ed menu where several useful amplification relative or absolute reset smoothing CTRL A and interpolation functions are available 3 5 4 Injection and ignition tuning The injection duration the ignition advance and the coil load timing have to be tuned for all engines It is the base task of the motor engineer Ideally tuning should be performed on a dynamometer as all the engine can be maintained in steady state static operation Onroad tuning can also be envisaged but may lead to difficulties stabilizing the engine rpm The corresponding maps are three dimens
26. us de connection mulation Status du port COM Not o ie for dialog Figure 3 2 Ontronic main window When Ontronic is not connected e g no data flow to the computer the message not connected appears in the task bar at the bottom of the main window connection status emulation When Ontronic is connected the message connected appears This means that the computer receives the data flow from Ontronic If the connected message does not appear after having powered on disconnected Ontronic immediately and check for the following issues 1 Was the wiring of Ontronic performed correctly 2 Is the power supply in accordance to the diagrams of chapter 2 2 with ground and 12V 3 Was the serial connection cable COM performed and connected correctly 4 Is the computer serial port COM available and opened All Ontronic devices are systematically tested before shipment Check meticulously the 4 points mentioned above before contacting our technical support 3 4 2 Sensors Window Page 18 Ontronic user s manual English The different real time process parameters the sensor values and other parameters can be displayed at any time by opening the sensors window as shown in Figure 3 3 The window opens with all engine parameters The descriptions of all parameters are presented in Table 3 2 T Sensors Rpm Lambda iCO Spark advance 2379 1 00 11 8 oss Load 4255 Injection t
27. where several useful amplification relative or absolute reset smoothing CTRL A and interpolation functions are available Figure 3 11 Dynamic operation compensation Page 34
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