Product Manual - protuneelectronics

0

Document Revision: (2) 0

0

Product Manual PR-4

t

1


1

Product Manual PR-4

Disclaimer

Printed copies of this manual are not controlled.

This document is intellectual property of Pro Tune Electronic Systems. This manual cannot be reproduced,

distributed or transmitted by any means, electronic or printed, without the proper authorization of Pro Tune

Electronic Systems.

The company, its employees and resellers are not responsible for the incorrect use of the information,

inaccuracies or omissions in this document.

Pro Tune reserves the right to make changes to this document without prior notice.

2


2

Product Manual PR-4

Congratulations!

You just bought a product from Pro Tune. We thank you for your trust in our products, which are produced

following stringent international standards together with highly rigorous quality control, so that you receive a

superior product in performance, finish and functionality.

Our products are 100% manufactured in Brazil, from the assembly of the electronic components, through

programming and finishing with the case machined in aluminum, which gives a durable and professional look to the

products.

We hope you have a great experience with Pro Tune products, and we are available to answer any questions

and supply any technical support you might have in installing or operating our products.

3


3

Product Manual PR-4

Glossary of terms and abbreviations

CAN – Controller Area Network .

CKP – Crankshaft Position Sensor.

CMP – Camshaft Position Sensor.

DATALOG – Sample set of readings from a group of sensors, saved on a device with memory.

ECU – Engine Control Unit.

ET – Engine Temperature.

GPS – Global Position System.

IAT – Intake Air Temperature.

MAF – Mass Air Flow.

MAP – Manifold Absolute Pressure.

NTC – Negative Temperature Coefficient.

OBD II – On-Board Diagnostic II.

PEAK & HOLD – Activation strategy for low impedance fuel injectors.

PINOUT – Diagram, or pin configuration of a device.

TDC – Top Dead Center – Highest position of the piston inside the cylinder.

PP – Pedal Position Sensor.

PWM – Pulse Width Modulation. RGB – Red Green Blue

SHIFT LIGHTS – Progressive lights with activation linked to engine speed.

TDL – Touch Dash Logger.

TP – Throttle Position.

TPS – Throttle Position Sensor.

USB - UNIVERSAL SERIAL BUS.

4


4

Product Manual PR-4

Summary

1. Overview 6

Harness Reference Table 7

2. Read Before Installing 9

3. Instalation Diagram 10

3.1 – Basic Wiring: 10

4.1 –Inputs 11

Crank and Camshaft Possiton Sensors 11

Manifold Absolute Pressure (MAP) 12

Throttle Position (TP) 12

Engine and Intake Air Temperatures Sensors 13

Lambda Sensor NTK UEGO 14

Mass Air Flow– MAF 14

Pedal Position Sensor 15

Vehicle Speed Sensor 15

Generic Potentiometer (Gear Position, Steering Angle, etc) 16

Load on Shift Lever 17

Oil / Fuel Pressure 18

Injectors – Sequential 18

Injectors – 8 Cilinders Semi-Sequential 19

Injectors – Secondary Injector Rail 19

Injectors – Secondary Injector Rail Semi-Sequential 20

Ignition Coils without Integrated Driver 20

Dual Ignition Coils without Integrated Driver Semi-Sequential 21

Triple Ignition Coils without Integrated Driver Semi-Sequential 21

Ignition Coils with Integrated Driver 22

Electric Fan 22

Electronic Throttle Control 23

Switch 24

Solenoid Valve 24

Tachometer Output 25

4. Sync 26

5


5

Product Manual PR-4

Trigger Wheel for Crank Position and Engine Speed: 26

Distributor for Rotation and Phase Reading: 28

Distributor only for phase reading: 28

Camshaft Position Sensor for Phase Reading: 28

6


6

Product Manual PR-4

1. Overview

The PR-4 ECU features a 48-pin waterproof connector. Its image can be seen in the figure below.

This connector uses a letter and number system to identify each pin, with the columns being identified by letters A to M and lines identified by numbers 1 to 4. In addition to this alphanumeric label, all Pro Tunes pre-wired harness has cables with identification printed on its cover.

The PR-4 ECU has an integrated USB port on the top where an A-B USB cable can be plugged into the ECU for configuration. In addition, the ECU has CAN communication used to communicate with various CAN devices.

Pro Tune ECU has several functions, for example, Lambda Control, Boost Control, and others. Therefore, the factory-enabled functions on the ECU depends on whether a package (Advanced or Plus) is chosen at the purchase moment. If there is an interest in using new functions, the user can contact Pro Tune to purchase only the activation code needed, not requiring the exchange of the product or the installation of extra modules.

Before proceeding to the electrical installation, it is essential to choose the inputs to which the sensors will be connected to the ECU. On the inputs equipped with pull-up resistors, it is possible to operate in Temperature Mode to connect temperature sensors and buttons with ground-based operation.

The fast inputs are suitable for reading signals of sensors that have a high rate of variation, such as throttle position, pedal position, intake pressure sensor and mass flow sensor. Inputs up to 15 V are suitable for sensors with signal amplitude greater than 5V. These inputs can be used to, for example, read the trigger status of a 12V switch. The digital inputs are those that support frequency signals. At these inputs, for example, wheel speed sensors can be connected.

7


7

Product Manual PR-4

Harness Reference Table

The Functions of each wire and its respective pin in the connector can be seen in the following table.

PR-4 - Power

Pin Function Label

L2 Sensor Ground No Label

K3 Sensor 5V SENSOR 5V

L3 Power Ground No Label

L4 Power Ground No Label

M4 12V Power +12V_SWITCH

PR-4 – Crank Position Sensor

Pin Function Label

F4 Positive Input - Crank Position Sensor (CKP+) No Label

G4 Negative Input – Crank Position Sensor (CKP-) No Label

*The cables described above are part of a triple shielded black cable with the label CKP.

PR-4 – Camshaft Position Sensor

Pin Function Label

H4 Positive Input – Camshaft Position Sensor (CMP+) No Label

J4 Negative Input – Camshaft Position Sensor (CMP-) No Label

* The cables described above are part of a triple shielded black cable with the label CMP.

PR-4 – Injectors

Pin Function Label

A1 Injector 1 Output INJ_1

B1 Injector 2 Output INJ_2

C1 Injector 3 Output INJ_3

D1 Injector 4 Output INJ_4

PR-4 – Ignition

Pin Function Label

H1 Ignition 1 Output IGN_1

J1 Ignition 2 Output IGN_2

K1 Ignition 3 Output IGN_3

H2 Ignition 4 Output IGN_4

8


8

Product Manual PR-4

PR-4 – Auxiliaries Inputs

Pin Function Label

C2 Auxiliary Input 1 IN_1

D2 Auxiliary Input 2 IN_2

E2 Auxiliary Input 3 IN_3

F2 Auxiliary Input 4 IN_4

G2 Auxiliary Input 5 IN_5

G3 Auxiliary Input 6 IN_6

F3 Auxiliary Input 7 IN_7

H3 Auxiliary Input 8 IN_8

J3 Auxiliary Input 9 IN_9

E4 Digital Input 2 DIG_IN2

PR-4 - Auxiliaries Outputs

Pin Function Label

G1 Auxiliary Output 1 OUT_1

F1 Auxiliary Output 2 OUT_2

E1 Auxiliary Output 3 OUT_3

L1 Electronic Throttle Control Output (positive) ETC+

M1 Electronic Throttle Control Output (negative) ETC-

M3 Auxiliary Output 6 OUT_6

K4 Main Relay Output OUT_MAIN_RELAY

PR-4 – Lambda Sensor

Pin Function Label

A3 Lambda – Heater Ground LAMBDA1_HT-

B3 Lambda – Reference LAMBDA1_SENSOR REF

C3 Lambda – Calibration LAMBDA1_RCAL

D3 Lambda – Ipump LAMBDA1_IP

E3 Lambda – Nernst Cell No Label

PR-4 – Communication

Pin Function Label

A2 Pro Tune CAN Low CAN_LOW

B2 Pro Tune CAN High CAN_HIGH

9


9

Product Manual PR-4

2. Read Before Installing

Pro Tune products are developed with attention to robustness and reliability. However, some care is required when installing the product

1 – Internal combustion engines are very sensible devices and in case of accidents present lethal risks. It is very important that all care is taken, such as individual operator protection, fire prevention and fire fighting, prior checking of fuels and lubricants, as well as the installation, maintenance and operation done only by qualified people.

2 – Place the wiring harness as far as possible from the ignition circuit.

3 – Avoid installing the ECU in the engine compartment.

4 – Place the product in an accessible location for the USB cable, preferably with the main connector facing down. 5 – When the wiring is done, keep unused (White) cables intact and connect them ti the negative battery terminal.

6 – Make sure the intake pressure measurement hose attachment is securely fastened. Poorly fixed or leaking hoses result in incorrect reading of intake pressure, which can cause serious engine damage. 7 – The intake hose must always be connected between the throttle body and the engine.

8 – If the triple cable named CMP is not used, do not cut it and isolate its wires individually. 9- Always check the wiring diagram of each sensor or actuator before finishing the harness and turning on the ECU. 10- Pay attention to the safe grounding of the engine block and the vehicle chassis. 11-Pay attention to the sensors ground (Pin L2), with black cable, which should not be connected to the battery or to the chassis of the vehicle. It is a ground wire for sensors, which must be used exclusively to connect the negative terminal of the sensors.

12- Use suitable fuses in the power circuit.

13- Use suppressive spark plug cables and resistive type spark plugs. 14- Use shielded USB communication cables.

10


10

Product Manual PR-4

3. Installation Diagram

3.1 – Basic Wiring:

Special Case:

When the user wishes that an auxiliary output to remain triggered after switching off the engine (electric water pump, electric fan, etc), the ECU (pin 87 of the relay) and the main relay power must be apart from each other in separated switches.

11


11

Product Manual PR-4

4.1 –Inputs

Crank and Camshaft Position Sensors

1 – Inductive type:

*PS: The mesh must be grounded either on the Power GND pin of the ECU or through the sensor. If the mesh is not grounded or grounded in the both sides, sync problems may occur.

2 – Hall effect type:

12


12

Product Manual PR-4

Manifold Absolute Pressure (MAP)

Pro Tune ECUs have an internal MAP sensor, all you have to do is install a hose connecting the intake manifold to the ECU. External MAP sensors can be used as well by following the diagram below.

Throttle Position (TP)

13


13

Product Manual PR-4

Engine and Intake Air Temperatures Sensors

Lambda Sensor LSU 4.2 / 4.9

CAUTION: LSU 4.2 and LSU 4.9 have different pinout. This scheme doesn’t illustrates sensor pinout.

14


14

Product Manual PR-4

Lambda Sensor NTK UEGO

Mass Air Flow– MAF

15


15

Product Manual PR-4

Pedal Position Sensor

Vehicle Speed Sensor

16


16

Product Manual PR-4

Generic Potentiometer (Gear Position, Steering Angle, etc)

17


17

Product Manual PR-4

Load on Shift Lever In order to use the Quick-Shift function, a load cell sensor must be applied to the vehicle shift lever. This

sensor is installed in Pro Tune’s factory, by sending the lever. For further information, contact technical support. Alternatively, an activation signal switch can be used, the connection description is located on page 24.

Pinout

Pin Function (4-way connector ) Function (5-way connector)

1 GND(-) + 12V

2 Sensor -

3 Sensor + GND(-)

4 + 5V

5 Signal (Vout)

18


18

Product Manual PR-4

Oil / Fuel Pressure

Injectors – Sequential

Ps: Up to two low impedance (Peak and Hold) injectors can be used per output with 2A/0,5A drive.

19


19

Product Manual PR-4

Injectors – 8 Cylinders Semi-Sequential

Injectors – Secondary Injector Rail

20


20

Product Manual PR-4

Injectors – Secondary Injector Rail Semi-Sequential

Ignition Coils without Integrated Driver Except MSD coils and drivers

21


21

Product Manual PR-4

Dual Ignition Coils without Integrated Driver Semi-Sequential

Triple Ignition Coils without Integrated Driver Semi-Sequential

22


22

Product Manual PR-4

Ignition Coils with Integrated Driver

Electric Fan

23


23

Product Manual PR-4

Electronic Throttle Control

NOTE: The installation of an electronic throttle body requires some basic care to avoid damage to the user and

the device. Pro Tune recommends the following steps as a guide for installation. 1- Wire the sensor ground, 5 V sensor and TPS cables but KEEP OFF the motor wires (ETC + and ETC -). 2- Install the accelerator pedal. 3- Use Pro Tune Workbench to calibrate the pedal position and throttle position sensors. Then select the

ETC template that will be used. 4- Once the calibration is completed, connect the ETC motor cable (ETC+ and ETC-). Test to see if the

device is working properly. If you wish to use a device model other than those listed in Pro Tune Workbench software, you must send

the device to Pro Tune.

24


24

Product Manual PR-4

Switch

Solenoid Valve

25


25

Product Manual PR-4

Tachometer Output

26


26

Product Manual PR-4

4. Sync

Trigger Wheel for Crank Position and Engine Speed:

Use a trigger wheel with a good finish quality, preferably the original engine trigger wheel. Important comments: Use a trigger wheel with teeth width at least one and a half times the width of the sensor pole, so as the distance between the teeth, which should be symmetrical. The missing teeth width of the trigger wheel should be at least one and a half times the size of the tooth, that is, 2.25 times the size of the pole of the sensor. Also note that the distance between the sensor and the trigger wheel should be between 0.6 mm and 1 mm. In general, most of sensors require a distance of 0.8 mm for the trigger wheel. Example:

27


27

Product Manual PR-4

28


28

Product Manual PR-4

Distributor for Rotation and Phase Reading:

The distributor timing requires a distributor equipped with a Hall sensor. If the simultaneous or semi-sequential injection strategy is used, all of the distributor teeth can be the same size. For the sequential injection strategy, it is necessary for the distributor to have one of the teeth smaller than the others in order to identify the cylinder 1. If the distributor is symmetrical and the user wishes to use these strategies, it is possible to remove the first half of the tooth referring to cylinder 1 , for identification of phase in this tooth.

Distributor only for phase reading: In this case, use a hall distributor with only one tooth. The teeth (or windows) of the distributor should be

removed, leaving only one (as shown below).

Camshaft Position Sensor for Phase Reading: When using a phase sensor in the camshaft, make sure that the size of the tooth in the camshaft is

approximately one and a half times the width of the sensor pole.

29


29

Product Manual PR-4

Warranty / Support

Pro Tune products have a one year warranty (3 months legal warranty plus 9 months of special warranty

provided by Pro Tune) from the date of sale to the costumer. The warranty covers only manufacturing defects, and

any maintenance or repair will only occur at the Pro Tune factory. For the exchange or repair of any product under

warranty, it is necessary to present the invoice of the product purchase to one of Pro Tune's authorized resellers

with readable date.

Damage caused to products or other parts due to improper installation are not covered by the warranty.

Products with violation marks or mechanical shocks automatically lose their warranty. The warranty does not extend

to content or adjustments in the product memory.

If you have any questions regarding installation or operation, please contact our Technical Support team.

Pro Tune Technical Support

Comercial Phone: +55 (51) 3477 1653 Cell Phone: +55 (51) 9 8115 8314

E-mail: [email protected]

Pro Tune Electronic Systems Brigadeiro Ivo Borges, 148

CEP: 92420-050 Canoas, RS, Brazil Brazilian Industry

www.protuneelectronics.com.br

http://www.protuneelectronics.com.br/

30


30

Product Manual PR-4

Pro Tune Electronic Systems

Brigadeiro Ivo Borges, 232 - 92420-050

Canoas, RS, Brazil

Brazilian Industry

www.protuneelectronics.com.br

Product Manual - protuneelectronics

Documents

Transcript of Product Manual - protuneelectronics