Emerald K3 User manual

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Emerald K3
Engine management system
Operating manual
Draft v0.51

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•TheECUcanstoreup tothree completelyseparatemaps.
•IfsettodosotheECUwill allowyoutofreelyswitchbetweenmapson-the-
fly.
•Themapping softwarealsoholdsthree mapsinmemoryandwill switchmaps
insyncwiththeECU.
•Themapping softwareusesanewfileformatthatallowsthree mapsbeto
storedwithintheonefile.
•A0-5voltsignalviaananalogueinputcanbeusedtoinstructtheECUwhich
maptouse.Asimpletwopositionon-offswitchcanbeusedtoprovidea
high-lowsignalthatwillenableyoutoswitchbetweentwomaps. Toswitch
betweenthree mapsarotarymulti-positionorpotentiometercanbeused.
Mapswitching

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Mapswitching–software
TheK3ECUhastheabilitytoretainthree totallyseparatemapswithintheECU. The
laptoporPCalsohasthree mapscreensavailable. ForaslongasthePCis
communicatingwiththeECUitwillautomaticallyswitchthemapsdisplayedtostay
insync. Ifyouwanttoworkonamapthatisnotcurrentlyselectedwithoutusingthe
ECUtoswitchmapsyoucanpowerdowntheECU(orunplug thecommunications
lead)andselect‘Switchtomap’fromthe‘File’menu.
Thereisashortcuttothismapselectionscreenbyclicking thePCmapboxatthe
bottomofthemainscreen.
Note: Topreventconfusion thePCwill notallowyou toswitchmapswhenlinkedto
theECU.
Forexample:ifmapping onarolling roadyoucanalterthefuelandignitionsettings
onmap1(greenmap)viathelivemappingpage(F8)andthen, viaaswitchonthe
dash, switchtomap2(redmap). ThePCwill bring theredmaptothefrontofthe
screenandyoucanalterfuelandignitiontiming againviathelivemapping screen
exactlyasbefore. SwitchtheECUtomap3(yellowmap)andrepeatthemapping
process.

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Mapswitching-configuration
Therearevariouswaysofsettingup theECUtoreadtheswitching signal. Beloware
twoexamples.
Example1
TheECUistoswitchbetweentwomapsaccording toauseractivatedswitch. Inthis
particularcaseAuxIn35 isunusedsoitisavailableasaninputsource forthemap
switchingfunction. Byenabling theinternalpull-up resistorontheAuxIn35 inputwe
canchangemapsusing asimpleswitchtoearth.
AuxIn35
ECU
Mapswitch
+5v
Withtheswitchintheopenpositiontheinternalpull-up resistorresultsintheECU
reading5vattheAuxIn35 input. WiththeswitchintheclosedpositiontheECUwill
read0vattheAuxIn35 input. Theinternalpull-upto+5vforAuxIn35 mustbe
enabledinthe‘Inputchannels’sectionofthe‘ECUconfiguration’asshownbelow.

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Toconfigurethemapswitching functionselect‘Mapswitching’fromthe‘ECU
configuration’menu.
Inthisexamplewehavetwovoltagelevels, 0vand5v, atAuxIn35 depending onthe
positionofaswitch.
TheinputsourcehasbeensettoAuxIn35. Twovoltagelevelsareusedtodetermine
whichmaptheECUshouldbeusing. Map1isselectedifthevoltageis below a
certainthresholdandMap3isselectedifthevoltageis above acertainthreshold.
Map2isselectediftheinputvoltageliesbetweenthe above andthe below thresholds.
Forthisexamplethemid-pointvoltageof2.51 voltsisusedastheaboveandbelow
thresholds. Map1isselectedifthevoltageatAuxIn35 isbelow2.51 volts(switchis
intheclosedposition)andMap3isselectedifthevoltageatAuxIn35 isabove2.51
volts(switchisintheopenposition). Map2isnotusedandcannotbeactivated.
WhentheECUisconnectedthelivereadingspanelshowsthereal-timeinputvoltage
usedforthemapswitchingfunction. Thebargraph hasaverticalscalethatpresents0
to5voltsandisalsocolourcodedtoshowthevoltagetomapselectionrelationship.
Theverticalcolourcodingofthebargraphiscolourcodedaccordingtothemap
switchingsettings.

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Example2
TheECUistoswitchbetweenthethree mapsaccordingtoa3-wayrotaryposition
switchmountedonthedashboard.
Aswiththepreviousexample, usingananalogueinputthathasaninternalpull-up
resistorsimplifiesthemapswitchwiring. Usingsuchaninputgivesustwovoltage
levelswithaswitchtoearth(open=5volts, closed=0volts).Byswitching this
inputtoearthviaaresistorwecreateapotentialdividercircuitwhichwillresultina
thirdvoltagelevelofbetween0voltsand5volts(depending onthevalueofthe
resistorused).AstheECUuses1K internalpull-up resistorswecanswitchthe
inputtoearthviaanother1K resistortogiveamid-pointvoltagelevelof2.5volts.
ECU
1
2
3
1K Ω
Aux7b
+5v 1K
Ω
InthisexampleAux7bisfree sowillbeassignedtothemapswitching function.
Aux7b, Aux8bandAux9bhavefixedinternal1K pull-up resistors.
Withtherotarypositionswitchatposition1Aux7bisconnectedtoearthwhich
resultsinaninputvoltageof0volts.
Atposition2Aux7bisconnectedtoearthviaa1K resistorresultingin2.5voltsat
Aux7b.
Atposition3Aux7bisunconnectedsowillbeat5voltsduetotheinternalpull-up
resistor.

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TheECUconfigurationforthisexampleisshownbelow.
Herethemapswitchthresholdshavebeensetsothattheboundariesarespacedevenly
givemorethanenoughroomforerror.
Themapswitching functionmonitors theinputvoltageapproximately5timesper
second. Beforechanging mapstheECUwill re-evaluatethenewmapaccordingto
thecurrentrunning conditionstoensurethechangeisseamless. Thisprocess takes
approximately1-2mS.
TheECUwill switchmapson-the-flyregardless ofenginerpmorload.

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Thisfunctionisusedtointerrupt/reduce enginepowersothatafastgearchangecan
bemadewithoutlifting thethrottle. Enginepowerisreducedbyretardingtheignition
toasetposition. Thisignitiontiming canbenegative(AfterTDC).Ifturbo-charged,
thisretardedignitiontiming duringagearchangecanprovideaformofanti-lag.
Theflatshiftfunctionwillbeactivatedifcertainuseradjustableconditionsaremet
andauserassignedinputisactivated.
Thisflatshiftfunctioncanbeconfiguredaccording tothegearboxtypeused.
•Sequentialgearbox.
Theuserassignedinputcanbewiredagearlevermovementswitchorclutch
switch. Theflatshiftfunctioncanbeconfiguredtointerruptpowerfora
specificamountoftimeaccordingtothegearselected.
•H-patterngearbox.
Theuserassignedinputcanbewiredtoaclutchpositionorpressureswitch.
Theflatshiftfunctioncanbeconfiguredtointerruptpowerforaslongasthe
inputisactivated, i.e. untiltheclutchpedalisreleased.
Select‘fullthrottlegearshift’fromthe‘Additionalmaps’menutoaccess thesettings
pageforthisfunction. Thesettingsaregroupedinto3areas onthescreen; Activation
conditions, Enginecontrolsettings and Powercuttable.
Full throttlegearshift(Flat shift)

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Activationconditions
Theactivationconditionsdeterminehowandwhenthegearshiftfunctioncanbe
activated.
•Flatshiftenabled:Setswhetherthisfunctionisenabledornot.
•Clutchinput:Showsthecurrentclutchswitchstatus .
•Throttepositionatorabove:Throttlepositionmustbeabovethisbeforethe
flatshiftfunctionwillactivate.
•Enginespeedatorabove:Theflatshiftfunctionwillonlyactivateabove
thisrpm.
•Re-activatedelay:HowlongtheECUwillwaitbeforeallowing
thisfunctiontoactivateagain.
Enginecontrolsettings
Thisenginecontrolsettingsdeterminehowtheenginepoweriscutandhowlowthe
enginerpmisallowedtodrop.
•Retardignitionto:Sets thefixedignitiontiming duringthegear
change. Youcanretardasfaras-30 °BTDC(30
°ATDC).
•Powercuttype:Continuousforapowercutforaslongasthe
inputswitchisactivateorTimedforatimedcut
accordingtothegeartable.
•Minimumenginespeed:Whenactivatethisfunctionwillnotallowthe
enginerpmtofallbelowthissetting.

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Powercuttable
Thistableisonlyusedwhenthepowercuttypeissetto‘timed’. Atimedpowercut
isusuallyonlyusedifyouhaveasequentialgearbox.
Setthecuttimeaccordingtotheselectedgear.Ifthecut-timeissettozero, the
functionwillnotactivate.

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Clutchswitchwiringexample
AuxIn10(pin10)
ECU
Clutchswitch
Anyspareanalogueinputcanbeusedtoactivatethefullthrottlegearshiftfunction.
ThisexampleusesECUpin10 (AuxIn10), withtheinternalpull-up enabled, wiredto
aswitchontheclutchpedal.
Whentheclutchpedalisup (notpressed)theclutchswitchcontactsareopen. The
internalpull-up resistorsets theinputlevel‘high’. Whentheclutchpedalisdownthe
switchcontactsareclosed,theAuxIn10 inputisconnectedtoearthwhichsetsthe
input‘low’.
Inthisexampletheclutchinputisactivelow,i.e.thesignalatAuxIn10 islowwhen
theclutchispressed. TheECUshouldbeconfiguredtoreadAuxIn10 astheclutch
signalandalsosettorecognisethattheclutchisdown/pressedwhenthesignallevel
islow.
Select‘Inputchannels’fromthe‘ECUconfiguration’menu. Asshownbelow, the
clutchswitchchannelhasbeensetto AuxIn10,theinputactivehasbeensetto Low
andthe internal1Kpull-up to5v hasbeenenabled.ECUinputsAuxIn10 and
AuxIn35 haveswitchableinternalpull-up resistors.Ifanotherinputconnectionwhere
tobeusedinstead, e.g.AuxIn34 orAuxIn36, anexternalpull-up resistorwouldneed
tobefitted.TheAuxIn7b, AuxIn8bandAuxIn9binputshaveinternalpull-ups.
exampleclutchswitchconfigurationsettings

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TheECUisabletocalculatetheselectedgearbyusingenginerpm, roadspeedanda
gearpositionlook-uptable.
Select‘Gearposition’fromthe‘ECUconfiguration’menutoaccess thegearposition
calculationsettings…
Gearcalculationfunction
•Enabled:Setswhetherthisfunctionisenabledornot.
•Matcherror:SetshowclosetheECU’scalculationsmustbetothe
figuressetinthegearpos table.
Gearpostable
Foreachoftheforwardgearssetthespeed(mph/kmh)per1,000rpminthetable.
TheeasiestmethodtodeterminethesevaluesistosetthePCdataloggertorecord
enginerpmandroadspeed.Driveforashortamountoftimeineachgearandthen
usethedataloggertrace todeterminethetablesettings.
Forexamplein3rd gear, ataroadspeedof38.0mph, withanenginespeedof
3,193rpm:-
Mphper1,000rpm=__38.0__ x1000 = 11.9
3193
Note:gearpositioncalculationsaresuspendedwhiletheclutchswitchinputisactive
(clutch=down).Ifaclutchswitchisnotfittedensurethatinputisdisabled.
Gearposition

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TheECUhas4wheelspeed(frequencymeasurement)inputchannelsviaAuxportB.
Theseinputchannelscanbewireddirectlytoinductivewheelspeedsensorsora
digitalspeedsignal.
Forspeedmeasurementonlyonewheelspeedsignalisneeded. Ifthismeasurement
isusedtocalculatetheselectedgearthesignalmustbefromadrivenwheel.
Select‘WheelSpeedSensors’fromthe‘ECUconfiguration’menutoaccess the
wheelspeedsensorsettings.
Thefourwheelspeedinputchannelsareidentifiedasfollows
Input Label AuxPortBpinnumber
Channel1 LF(Left Front) 2
Channel2 RF(Right Front) 3
Channel3 LR(Left Rear) 4
Channel4 RR (Right Rear) 5
Roadspeedmeasurement

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LF,RF, LR, RR sensorsettings
Eachchannelisenabledandconfiguredindependentlyfromtheotherchannels. This
flexibilityallowsdiffering wheelsizesand/orsensorsetups oneachofthefour
wheels.
Clickthelabelbutton(LF, RF, LR, RR)toaccess thesettingsforthatinputchannel.
Eachchannelhasthefollowingsettings:
•Enabled:Ticktheenableboxifthischannelisused.
•Wheelroll:Distance travelledforonerotationofthewheel.
•Triggerpoints:Numberofpulsesperwheelrotation
Thetriggerpointssettingcanbedeterminedbycountingthenumberofteeth/points
thatwillpassthewheelspeedsensorinonerevolutionofthewheel.
Aquick/simplemethodtodeterminethewheelroll settingistoputachalkmarkat
thebottomofthetyre(atthe6o’clockposition)and markthegroundatthesame
point.Rollthecarforwardssothewheelrotates once andmarkthegroundinline
withthetyremark. Thedistance betweenthetwogroundchalkmarks,inmm,isthe
‘wheelroll’. Arolling roadcanbeusedtocompareactualandmeasuredroadspeeds
-adjustthewheelrollvalueifnecessary.
Options
•Drivetrain:Thissettingisnotcurrentlyused.
•Roadspeedsource:Settothechannelyouwishtomeasureroadspeedfrom
•Sensortype:Globalsettingforwheelspeedsensors, inductiveor
digital. Opencollectordigitalsensorswillrequirea
pull-up resistor.

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3
2
1
TheEmeraldK3isabletoreadEGT viaanexternalsignalconditioning unit. To
ensurethebestaccuracytheexhaustgas temperaturereadingistransmitteddigitally
betweenthesignalconditioning unitandtheECU.
TheVAG G235 exhaustgastemperatureinterface combinesathermocoupleprobe,
suitableforpre-turbogas temperaturemeasurements, alongwithacombined
amplifierandserialdataoutput.TheserialdataoutputlinefromtheG235 shouldbe
wiredtoECUpin13.
pin13
ECU
EGTinterface
+12vsupply
pin28
pin29
1
2
3
VAG
G235
thermocouple
probe
VAGG235 toEmeraldK3connectiondiagram
WiresideofG235 loomconnector
Exhaust GasTemperature

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TosettheECUtoreadtheG235 exhaustgas temperatureserialdatathe‘EGT
interface’settinginthe‘Inputchannels’sectionoftheECUconfigurationshouldbe
to‘[2]VAGG235’asshownbelow..
Once configuredtoreadEGT fromtheG235
thisEGT measurementcanbedisplayedonthe
‘liveadjustments’screen. ThisEGT reading
canalsoberecorded,alongwithother
readings,intothedata-logger.
TheEGT canbeused,inconjunctionwiththefeedbacktable, toadjustthefuelling
and/orboostpressure.

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TheK3ECUcanbeconfiguredtosettransmitdatatoexternaldevices, suchas
dashboards, usingit’s Controller Area Networkinterface.
TheCANwasoriginallydevelopedbyBoschGmbhasarobustserial
communicationsprotocoltopass informationbetweencontrollersonanautomotive
network.Communicationspeedscanbeup to1Mbit/sbetweenmultipledevices
sharingthesame2-wireCANbus.
TheCANbuswiring shouldbeatwisted-paircableand,ifrequired, shielded. The
CAN busmustbeterminatedateachendbya120 resistor.TheK3ECU, withit’s
internal120 terminationresistor,providesoneend oftheCANbus. When
connectinganotherdevice/syoumustensurethattheCANbusiscorrectlyterminated
withanother120 resistor.Thisterminationresistormustbeattheotherendofthe
CAN bus. Somedevices(e.g.theAIMMXLdashlogger) alsohaveaninternal
terminationresistorsoanexternalresistorisnotrequired.
AIMdashloggerconnection
ECU
COMMS
AIM
CAN_L
CAN_H
1
2
Refertothe‘Communicationsport’sectionofthemanualforfurtherdetailsofthe
communicationsport.
CANdata-link

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K3CANconfiguration
Select‘CANdata-link’fromthe‘ECUconfiguration’menu.
Fromthe‘Device’dropdownmenuselect‘AIMdashboard’. ToenablethisK3to
AIMdata-linkensurethe‘data-link’checkboxisticked.
BeforeconfigurationchangescantakeeffecttheECUmustbeupdated, select
‘UpdateECUconfiguration’fromthe‘ECU’menu.
AIMMXLconfiguration
UsingtheAIMRace Studio2softwareselect‘Systemmanager’.
RetrievethecurrentconfigurationfromtheAIMdashbyclicking the‘Receive’
button.Clickthe‘ECUmanufacturer’entryforthecurrentconfigurationandsetto
‘AIM’. Clickthe‘ECUmodel’entryforthecurrentconfigurationandsetto
‘PROT_CAN’.
Ifyouwishtochangehow/whatdatafromtheECUisdisplayedontheAIMdash
clickthe‘Systemconfiguration’tabandsetaccordingly. Once youarehappywith
yourchannel/displaysettingsupdatetheAIMdashbyclicking the‘Transmit’button.
RefertoyourAIMmanualfordetailedinformation.

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AlthoughtheK3cannotdirectlycontrolawideband lambdasensoritcanreada0-5v
analoguesignalthatrelatestoAFR/lambda. Many widebandlambdasensor
controllersproduce a0-5vsignalforusewithECU’sordata-loggers.
ThisAFRdatacanberecordedintheEmeralddata-logger, displayedinthelive
adjustmentsscreenandusedbytheECUforclosedloopand/oradaptivefuelling
functions.
The0-5vsignalisconvertedtoAFRbyauseradjustablelook-uptableintheECU
configuration. ThistablemustbesettomatchtheAFR/voltageofyourlambdasignal
conditioning unit.
EmeraldK3toInnovate LC-1 connectionexample
AnInnovateLC-1isusedinthisexamplebuttheprinciplescanbeappliedtomany
otherwidebandlambdacontrollers.
TheInnovateLC-1manualshouldbereadcarefullybeforeinstallation.
Itisabsolutelyessentialthatthecorrectsensorcalibrationroutineisfollowed-thisis
detailedintheInnovatemanual.
Wiring
LC-1 Function Wireto..
Red +12vsupply Ignitioncontrolled+12v
Blue Heaterground Goodchassisgroundorbattery(-) terminal
White Systemground Join withGreenwiretoECUpin30
Yellow Analogueout1
(narrowbandlambdasignal) ECUpin7viainlineresistor. See note 1
Brown Analogueout2
(AFRsignal) AnyspareanalogueECUinputviaan inlineresistor.(see note2).AuxIn35
(ECUpin35)isusedinthisexample.
Green Analogueground Join withWhitewiretoECUpin30
Black Calibrationwire Calibrationbutton
Connectiontoawidebandlambda

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30
35
Earth
Switched+12vsupply
Tocalibrationswitch
7
Emerald
K3
LC-1
100Ω
100Ω
Note1:
Narrowbandlambdasignal. Thisconnectionisoptional. IfusedensuretheLC-1is
settooutputa0-1vnarrowbandsimulatedsignalonanalogue1. TheLC-1is
normallysettodothisbydefault. A100 resistor*shouldbefittedinlinebetween
theyellowanalogueout1wireandtheECUpin7.
Note2:
WidebandAFRsignal. A100 resistor*shouldbefittedinlinebetweenthebrown
analogueout2wireandtheECUanalogueinputpin(AuxIn35, pin35 inthis
example)
*TheLC-1outputsarequitesensitiveandcanbecomeunstableifconnectedtoa
capacitiveload. TheinlineresistorbufferstheLC-1fromtheECUinputsignal
filters.