ECOTRONS DLE120 User manual

UAV engine EFI installation manual-DLE120-V1.4
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UAV engine EFI
installation manual
-DLE120 engine
Installation Manual
V1.4
COPY RIGHTS ECOTRONS LLC
ALL RIGHTS RESERVED
Http://www.ecotrons.com

UAV engine EFI installation manual-DLE120-V1.4
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Note: If you are not sure about any specific details,
please contact us at [email protected].
Index
Page
Revision
Date
Note
1
First Edition
5.3.2015
V1.1
2
Second Edition
6.12.2015
V1.2
3
Third Edition
9.5.2016
V1.3
4
Fourth Edition
23.6.2016
V1.4

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Content
Introduction.....................................................................................................................5
Chapter 1 EFI installation................................................................................................8
1.1 Remove the stock carburetor and install the throttle body ..................................8
1.2 Install the fuel supply system............................................................................10
1.3 Install the cylinder head temperature sensor (CHT)..........................................12
1.4 Install the intake air temperature sensor (IAT)..................................................13
1.5 Install the ignition system .................................................................................13
1.5.1 Connect the ECU harness to the CDI.....................................................13
1.5.2 Connect the Hall-Sensor connector to the stock Hall sensor..................16
1.6 Servo motor installation....................................................................................16
1.6.1 Parameters of servo motor.....................................................................16
1.6.2 Installation of servo motor ......................................................................18
1.7 The connection of TPS signal...........................................................................25
1.7.1 Connect the TPS sensor connector........................................................25
1.7.2 Connect the servo motor wires to ECU harness.....................................26
1.8 Control Servo motor.........................................................................................33
1.9 Install the fuel injector and connect the connector............................................34
1.10 Connect the harness to 12v battery................................................................34
1.11 Mount the ECU...............................................................................................35
1.12 Mount the Harness.........................................................................................38

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1.13 Optional prime switch function........................................................................38
Chapter 2 ALM-ECU integration for tuning....................................................................40
2.1 Install the wideband O2 sensor........................................................................40
2.2 Connect the ALM to ECU.................................................................................40
2.2.1 Connect the ALM to ECU via ANOUT ....................................................40
2.2.2 Connect ALM-CAN to ECU via CAN channel.........................................42
2.3 Use ALM to log lambda (AFR) and do Auto-Tuning..........................................42
Chapter 3 Broadcast protocol........................................................................................44
3.1 ECU broadcast data list on RS232...................................................................44
3.2 ECU broadcast data list on CAN bus................................................................45
3.2.1 The CAN Baud rate setting of ECU........................................................45
3.2.2 Can bus broadcast.................................................................................46
Chapter 4 Communication Settings...............................................................................48
4.1 COM communication mode..............................................................................52
4.2 USB communication mode...............................................................................53
4.3 CAN communication mode...............................................................................53
4.4 Ethernet communication mode.........................................................................54
Chapter 5 Initial test after the installation.......................................................................56
Chapter 6 How do we know the fuel injector flow rate ...................................................60
Chapter 7 UAV EFI Maintenance ..................................................................................61

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Introduction
UAV EFI for DLE engine is an Electronic Fuel Injection conversion kit for the UAV engine.
It is a bolt-on EFI kit to a lot of small engines. For example, DLE-40, DLE-60, DLE-120,
DLE-170 etc. We can supply the suitable EFI kit for most of UAV engines. The
displacement of the engines can be in the range of 20cc to 300cc, and even larger
engines.
This UAV EFI kit has below features:
Electronic fuel injection (EFI)
Quick engine start even at cold temperatures
More power and torque than the carbureted version
High fuel efficiency and low carbon emissions
OBD - on board diagnosis
Performance tuning for advanced users.
Altitude compensations
Transient fuel compensations
Servo motor control (optional)
Ignition control (optional)
Parts:
1. ECU
2. Harness (including the connectors)
3. Throttle Body
Throttle body
Servo motor(included)
TPS sensor(optional)
Fuel injector (mounted on the throttle body)
4. Fuel pump assembly
Rotary fuel pump with pressure regulator (outside of the tank, 25L/h))
5. Baro sensor (integrated in ECU)
6. Engine temperature sensor
7. Intake air temperature sensor
8. Ecotrons CDI - ECU controlled (optional, you can use your own CDI).

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9. Serial communication cable (to a computer)
10. USB adaptor - included
11. CD for tuning software (downloadable from our website)
Note:The kit requires a 12V battery by default.
37-pin ECU and Harness
Fuel pump group

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Throttle body with TPS and Servo motor Throttle body with Servo motor
Engine temperature and intake air temperature Ecotrons CDI Unit

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Chapter 1 EFI installation
1.1 Remove the stock carburetor and install the
throttle body
Note: the stock DLE 120 carburetor is about 22mm diameter outlet. The Ecotrons throttle
body is also 22mm diameter. So it is a bolt-on replacement.
Note: Ecotrons Small throttle body is designed to replace the stock carburetor and has
the same or similar spacing as the carburetor, so that you can bolt on the throttle body.
Ecotrons throttle body is designed to mount the Futaba servo motor easily. So the
complete throttle body / servo is compact and light.
Ecotrons Small throttle body is designed to mount Ecotrons’ small engine injectors. It
comes with the injector fittings and thread-on fuel lines. The injector flow rates: 30g/min,
38, 60, 80, 128, 190, 248g/min etc.

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And we also have 14mm, 18mm, 22mm, 28mm throttle body for UAV engines, so we can
provide the UAV EFI kit for different engines with different displacement.
Some engines, you can use the throttle body to replace the carburetor completely, and
for some engines, you need make the adapter to bolt on the throttle body.
Note: Some custom system comes with the throttle position sensor, so if you want to use
the throttle position sensor, you also need to install the TPS sensor on the throttle body.
Note：Because the stock blot is too long, so you cannot use them to bolt on the throttle
body directly. You may need to add a suitable washer/ nut, as shown in this picture.
Or cut the stock blot short.

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1.2 Install the fuel supply system
Customers have to find a good location to install the fuel pump. By default, the
fuel pump should be lower than the fuel tank.
The fuel feed inlet in the tank should be submerged in the fuel all the time.
There should be an inline fuel filter.
Note: The EFI has a fuel pressure regulator which requires a fuel return line
back to the fuel tank.

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Note: The fuel pump is a rotor type, has 25L/h flow rate. It has only limited
sucking power. If there are too many air bubbles in the fuel lines, the pump will
not work.
Connect the connector to the fuel pump

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1.3 Install the cylinder head temperature sensor
(CHT)
Note: The CHT sensor must be installed at the cylinder head, closed to spark plug. If you
can place it under the spark plug, it is also OK.

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1.4 Install the intake air temperature sensor (IAT)
Install the intake air temperature sensor in the intake air channel or install it in the air box.
1.5 Install the ignition system
For DLE series engine, Ecotrons CDI is compatible and can be installed directly. So the
EFI will control both fuel and spark in standard EFI kit.
If you want the ECU to control the CDI ignition timing, and if you have Ecotrons CDI
included in the kit, you need to do this.
1.5.1 Connect the ECU harness to the CDI
Please connect the CDI connector from ECU harness to the Ecotrons CDI unit.

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Ecotrons CDI Unit
Connect the “CDI Power”from ECU harness to the red connector of Ecotrons CDI.
Connect the “CDI Ctrl”from ECU harness to the black connector of Ecotrons CDI.
The connector which is labeled “Tachometer” can be connected to your own
Tachometer.

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Note:
1) CDI Power: it gives Ecotrons CDI power.
2) CDI Ctrl: ECU outputs to control Ecotrons CDI.
3) Do NOT plug the connectors in the wrong direction.

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1.5.2 Connect the Hall-Sensor connector to the stock
Hall sensor.
1.6 Servo motor installation
1.6.1 Parameters of servo motor
The servo motor is installed on the throttle body for an UAV EFI system by default. It is to
open and close the throttle valve, as the throttle actuator.
We use the Futaba S3016 servo motor in our EFI system.

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Futaba servo S3016:
Type
Analog Servo
Torque
4.8V: 47.0 oz-in(3.38kg-cm)
6.0V: 58.0oz-in(4.18kg-cm)
Speed
4.8V: 0.25 sec/60
6.0V: 0.20 sec/60
Weight
1.20 oz(34.0 g)
Size
length: 1.22 in(31.0 mm)
width: 0.63 in(16.0 mm)
height:1.21 in(30.7mm)
There are three wires in servo. The black is ground, the white is the control signal line,
and the red is the power line, which is 5V.

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1.6.2 Installation of servo motor
Note: Usually we install the Servo motor on the throttle body, you don’t need
re-install it.
If you need install the servo motor, please see the following information as
reference.
The Servo is controlled by the “auto-pilot” of the UAV, via a PWM signal. The PWM duty
cycle is inversely proportional to the throttle.
What’s the best range of rotation angle when the servo motor is installed?

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Note:You would assume the total rotation angle of a servo motor is 0-180 degrees; but
actually, the servo rotation angle is about 90 degrees when used to control the throttle.

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As shown in the above picture, the servo angular positions of -45 degree to 45 degree are
corresponding to throttle position of 0 to 180 degrees.
Example of installation:
We use the Futaba S3016 servo motor in our EFI system.
The simplest method for servo motor installation:
By default, the servo rotation travelling is about 180 degrees. But we are going to only
use half of that travelling range. Try to manually rotate the servo arm to find the upper and
lower mechanical stop positions. It is about 180 degree travelling range.
Note: Don’t rotate more than 180 degrees with too much force; otherwise it could
damage the servo motor. (The purple circle in the picture is the reference point).
0 position of the servo arm.