Fueltec FT 500 Operating instructions

Programmable Electronic Fuel
Injection and Ignition System
Installation and
Operation Guide

3
1Presentation
The FuelTech FT500 is a real-time fully programmable fuel injection system which allows the adjustment of fuel
and ignition maps according to the engine needs. Programming can be done directly on the module through its 4.3"
touchscreen or via FT Manager Software with USB high-speed communication. Maps and compensations can be set as 2D
or 3D tables, and its resolution can be changed via FT Manager Software. This ECU can be used with any type of Otto
cycle using indirect injection, 2 or 4 strokes, up to 12 cylinders or 4 rotors, gasoline, ethanol, methanol, CNG,
nitromethane and other compatible fuels.
The electronic throttle control is fully integrated to the ECU, adjusted directly on its display without the need for
additional modules or computers. Alerts can be programmed for situations that may be dangerous for the engine like
RPM excess, low oil pressure, engine temperature, among others. These alerts can also be programmed to limit the
engine RPM or shut it off, bringing more security to the end user. The unit also has five fully independent calibrations
stored onboard, allowing different configurations of engines and/or cars.
Ignition can be controlled through distributor or crank trigger. Thus, it is possible to work with a single coil,
double coils or with individual coils per cylinder, in wasted spark or sequential modes. Fuel injectors can be controlled in
sequential mode with individual compensation per cylinder and injection phase angle control. Semi sequential and
multipoint modes are also supported.
The unit also has the favorites menu, which facilitate access to the main menus of the engine tuning, allowing you
to perform quick changes in the maps. The dashboard is fully configurable, allowing the user to change the size and the
type of readings for each parameter as well as the reading limits displayed on the screen.

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2Summary
1Presentation ..........................................................................................................................................................................3
2Summary ...............................................................................................................................................................................4
3Warranty terms......................................................................................................................................................................7
4Characteristics......................................................................................................................................................................8
4.1 Harness connections –24 way connector.............................................................................................................................10
4.2 Harness connections –16 way connector.............................................................................................................................11
4.3 Auxiliary outputs...............................................................................................................................................................................12
4.4 Internal MAP sensor ........................................................................................................................................................................12
4.5 USB port ..............................................................................................................................................................................................12
4.6 FuelTech CAN network ..................................................................................................................................................................12
5First steps with FT500 –read before installation .............................................................................................................13
6Getting to know the ECU...................................................................................................................................................14
6.1 Main Menu........................................................................................................................................................................................14
6.2 Dashboard screen .........................................................................................................................................................................15
6.3 Diagnostic panel ............................................................................................................................................................................16
7Engine settings ...................................................................................................................................................................17
7.1 Engine setup ....................................................................................................................................................................................17
7.2 RPM signal .........................................................................................................................................................................................18
7.3 Ignition................................................................................................................................................................................................20
7.4 Fuel injection ....................................................................................................................................................................................21
7.5 Pedal/throttle ....................................................................................................................................................................................22
7.6 Idle actuators...................................................................................................................................................................................24
7.7 Fuel injectors deadtime................................................................................................................................................................25
7.8 Ignition Dwell ....................................................................................................................................................................................25
7.9 Wiring harness connection table ...............................................................................................................................................25
8FuelTech base map ..........................................................................................................................................................26
9Electrical installation ..........................................................................................................................................................27
10 FT500 connection on previous FT installation ................................................................................................................29
10.1 Connection on an FT200, FT250, FT300, FT350 installation:..............................................................................................29
10.2 Connection on an FT400 installation: ......................................................................................................................................29
10.3 Ignition calibration..........................................................................................................................................................................30
10.4 Injection time differences between FT500 and previous FT ECUs...................................................................................30
11 Fuel injectors.......................................................................................................................................................................31
12 Ignition .................................................................................................................................................................................32
12.1 Ignition with distributor ...................................................................................................................................................................32
12.2 Ignition with crank trigger .............................................................................................................................................................33
13 Sensors and actuators.......................................................................................................................................................36
13.1 Intake air temperature sensor.....................................................................................................................................................36
13.2 Engine temperature sensor .........................................................................................................................................................36
13.3 Fuel and oil pressure sensor –PS-10B.......................................................................................................................................36
13.4 Throttle position sensor (TPS) .........................................................................................................................................................36
13.5 Crank trigger/RPM sensor..............................................................................................................................................................37
13.5.1 Distributor ..................................................................................................................................................................................37
13.5.2 Crank trigger............................................................................................................................................................................37
13.5.3 Crankshaft trigger sensor .....................................................................................................................................................40
13.6 Camshaft position sensor.............................................................................................................................................................41
13.7 O2 sensor ..........................................................................................................................................................................................41
13.8 Step motor –idle speed...............................................................................................................................................................42
14 Auxiliary outputs..................................................................................................................................................................43
14.1 Cooling fan 1 and 2 ......................................................................................................................................................................43
14.2 Air conditioning................................................................................................................................................................................43
14.3 Shift alert ............................................................................................................................................................................................43

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14.4 Fuel pump ........................................................................................................................................................................................43
14.5 Variable camshaft control/Powerglide gearbox ..................................................................................................................44
14.6 Progressive nitrous control ............................................................................................................................................................44
14.7 Boost control.....................................................................................................................................................................................45
15 Electronic throttle control..................................................................................................................................................46
15.1 Connection table –throttle bodies and pedals...................................................................................................................46
16 Sensors and Calibration....................................................................................................................................................47
16.1 TPS calibration..................................................................................................................................................................................47
16.2 Electronic throttle/pedal calibration .........................................................................................................................................47
16.3 Fuel/oil pressure sensors inputs ...................................................................................................................................................48
16.4 Intake air and engine temperature sensors...........................................................................................................................48
16.5 O2 sensor inputs #1 and #2 ......................................................................................................................................................49
16.6 Traction type.....................................................................................................................................................................................50
16.7 Wheel speed (front/rear)...............................................................................................................................................................50
16.8 Driveshaft RPM .................................................................................................................................................................................51
16.9 Gearbox RPM ...................................................................................................................................................................................51
16.10 Gear detection ...............................................................................................................................................................................52
17 Starting the engine for the first time ................................................................................................................................54
17.1 First engine start...............................................................................................................................................................................54
17.2 Ignition calibration..........................................................................................................................................................................54
18 Fuel tables adjust...............................................................................................................................................................56
18.1 Main fuel table ................................................................................................................................................................................56
18.2 Overall fuel trim ...............................................................................................................................................................................56
18.3 RPM compensation .......................................................................................................................................................................57
18.4 O2 Closed Loop..............................................................................................................................................................................57
18.5 TPS idle fuel table............................................................................................................................................................................58
18.6 Acceleration fuel enrichment and decay .............................................................................................................................59
18.7 Engine temperature compensation.........................................................................................................................................60
18.8 Intake air temperature compensation ....................................................................................................................................60
18.9 Battery voltage compensation ..................................................................................................................................................60
18.10 MAP / TPS compensation..............................................................................................................................................................60
18.11 Prime cranking pulse .....................................................................................................................................................................60
18.12 Engine start .......................................................................................................................................................................................61
18.13 Post-start enrichment.....................................................................................................................................................................61
18.14 Individual cylinder trim ..................................................................................................................................................................61
18.15 Rotor compensation......................................................................................................................................................................61
18.16 Enrichment per gear .....................................................................................................................................................................61
18.17 Gear shift fuel enrichment ...........................................................................................................................................................62
18.18 Fuel injection phase angle table ..............................................................................................................................................62
19 Ignition tables adjust .........................................................................................................................................................63
19.1 Main ignition table..........................................................................................................................................................................63
19.2 Overall ignition trim.........................................................................................................................................................................63
19.3 MAP/TPS compensation ................................................................................................................................................................64
19.4 Engine temperature compensation.........................................................................................................................................64
19.5 Intake air temperature compensation ....................................................................................................................................64
19.6 Rotary timing split............................................................................................................................................................................64
19.7 Individual cylinder trim ..................................................................................................................................................................64
19.8 Rotor compensation......................................................................................................................................................................64
19.9 Timing limits.......................................................................................................................................................................................64
19.10 Gear compensation......................................................................................................................................................................65
19.11 Gear shift compensation .............................................................................................................................................................65
20 Other functions...................................................................................................................................................................66
20.1 Internal datalogger ........................................................................................................................................................................66
20.2 Idle speed control ..........................................................................................................................................................................67
20.3 Deceleration cut-off ......................................................................................................................................................................68
20.4 Revolution limiter .............................................................................................................................................................................68
20.5 Shift alert ............................................................................................................................................................................................68

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20.6 Cooling fans 1 and 2 ....................................................................................................................................................................69
20.7 Air conditioning................................................................................................................................................................................69
20.8 Fuel pump ........................................................................................................................................................................................69
20.9 Camshaft control............................................................................................................................................................................70
20.10 Progressive nitrous control ............................................................................................................................................................70
20.11 Boost control.....................................................................................................................................................................................71
20.12 Boost activated output .................................................................................................................................................................71
20.13 Tachometer output ........................................................................................................................................................................71
21 Drag race features ............................................................................................................................................................72
21.1 Burnout mode..................................................................................................................................................................................72
21.2 3-step (boost spool) .......................................................................................................................................................................72
21.3 2-step rev limiter..............................................................................................................................................................................73
21.4 Spool assist table ............................................................................................................................................................................73
21.5 Gear shift output .............................................................................................................................................................................73
21.6 Time based fuel enrichment.......................................................................................................................................................74
21.7 Time based advance/retard timing .........................................................................................................................................74
21.8 Time based revolution limiter ......................................................................................................................................................74
21.9 Time based RPM (retard) ..............................................................................................................................................................74
21.10 Time based speed (cut) ...............................................................................................................................................................75
21.11 Time based speed (retard)..........................................................................................................................................................75
21.12 Pro-Nitrous..........................................................................................................................................................................................76
21.13 Time based output.........................................................................................................................................................................77
22 Alert settings ........................................................................................................................................................................78
22.1 Safe mode RPM limiter .................................................................................................................................................................78
22.2 Alerts....................................................................................................................................................................................................78
23 Favorites ..............................................................................................................................................................................79
24 Interface settings................................................................................................................................................................80
24.1 LCD backlight settings...................................................................................................................................................................80
24.2 Alert sound settings ........................................................................................................................................................................80
24.3 Dashboard setup............................................................................................................................................................................80
24.4 Startup screen selection ...............................................................................................................................................................81
24.5 Clear peaks ......................................................................................................................................................................................81
24.6 Protection setup ..............................................................................................................................................................................81
24.7 Measurement units.........................................................................................................................................................................82
24.8 Demonstration mode....................................................................................................................................................................82
24.9 Touchscreen calibration...............................................................................................................................................................82
24.10 Serial number and software version .........................................................................................................................................82
25 File manager ......................................................................................................................................................................83
25.1 FuelTech base map generator..................................................................................................................................................83
25.2 Edit map file name ........................................................................................................................................................................83
25.3 Copy map to another file............................................................................................................................................................83
25.4 Erase file.............................................................................................................................................................................................83
26 Rotary engines setup.........................................................................................................................................................84
26.1 Crank angle sensor installation and alignment ....................................................................................................................84
26.2 Crank angle sensor wiring ............................................................................................................................................................85
26.3 ECU setup..........................................................................................................................................................................................85
26.4 Ignition coils wiring..........................................................................................................................................................................86
27 FT500 –electrical diagram ..............................................................................................................................................87
27.1 FT500 –4 cylinders –sequential fuel –SparkPRO-2 –wasted spark coil.......................................................................87
27.2 FT500 –4 cylinders –sequential fuel –SparkPRO-4 –coil-on-plug.................................................................................88
27.3 FT500 –2 rotors –sequential fuel –SparkPRO-4 ...................................................................................................................89

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3Warranty terms
The use of this equipment implies the total accordance with the terms described in this manual and
exempts the manufacturer from any responsibility regarding to product misuse.
Read all the information in this manual before starting the product installation.
This product must be installed and tuned by specialized auto shops and/or personnel with experience on
engine tuning.
Before starting any electric installation, disconnect the battery.
The inobservance of any of the warnings or precautions described in this manual might cause engine damage and
lead to the invalidation of this product warranty. The improper use of the product might cause engine damage.
This product does not have a certification for the use on aircraft or any flying devices, as it has not been designed
for such use purpose.
In some countries where an annual inspection of vehicles is enforced, no modification in the OEM ECU is
permitted. Be informed about local laws and regulations prior to the product installation.
Important warnings for proper installation of this product:
Always cut the unused parts of cables off NEVER roll up the excess
The black wire of the harness MUST be connected directly to the , as well as
The use of the 16 way harness is mandatory, even when connecting the FT500 on an installation for
previous FT ECUs.
WARNING
It is a good practice to save your maps on the PC, as a security backup. In case of problems with your ECU,
this will be the guarantee that your calibrations are saved. In some cases, when the ECU is upgraded by the
factory, its memory may be erased also.
Limited Warranty
This product warranty is limited to one year from the date of purchase and covers only manufacturing defects
warranty. In case of product exchange, please contact FuelTech tech support.
Damages caused by misuse of the unit are not covered by the warranty. This analysis is done by FuelTech tech
support team.
The violation of the warranty seal results in the invalidation of the Product Warranty.
Manual version 1.2 June/2015
ECU version 1.40

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4Characteristics
Inputs and specifications
Max RPM: 32000RPM
103 psi internal MAP sensor (7 bar - absolute), 14.7psi of vacuum and 88psi of positive pressure (boost)
4. touchscreen with 16.8 million colors
375MIPS processor (Processing capabilities Millions of Instructions per Second)
Otto cycle engine control: 1, 2, 3, 4, 5, 6, 8, 10 and 12 cylinders and 2, 3 and 4 rotors
2 injector banks (staged injection banks A and B)
Injection time resolution 0.001ms
Ignition angle resolution 0.01°
11 input channels totally configurable (intake air temperature, coolant temperature, fuel and oil pressure, TPS,
external MAP sensor, electronic throttle and pedal position sensors, etc.)
2 fixed inputs (RPM signal and Cam sync sensor)
4 outputs to control stepper motor (idle air control valve, etc.)
20 configurable output channels (fuel, ignition and auxiliary outputs)
Distributor and crank trigger ignition control
USB port for PC communication through laptop software FT Manager
FuelTech CAN port (CAN communication with FuelTech ECUs and Racepak IQ3 dashes and VNET networks)
Working temperature: -10ºC a 60ºC
Sensors editable reading scales
Functions
Sequential, semi sequential and multipoint fuel control
Wasted spark and sequential ignition control
Idle speed control by electronic throttle, stepper motor, ignition timing and PWM valve
Main fuel map, idle speed and fuel enrichment by MAP or TPS
Real time programmable by the screen or PC through FT Manager Software
Individual fuel and ignition trim per cylinder/rotor
Fuel and ignition maps by 2D table or 3D table (32x32 points)
Configurable fuel and ignition map resolution (through FT Manager Software and USB cable)
Fuel injection phase angle control
Fuel enrichment and decay adjust
Deadtime compensation table by battery voltage
Ignition timing compensation by boost/vacuum and throttle position (TPS)
Fuel compensation by air and coolant temperature and by battery voltage
RPM limiter by fuel and ignition
Deceleration fuel cut-off
Two-step RPM limiter with timing retard and fuel enrichment
Burnout mode
Control of up to two cooling fans by coolant temperature
Prime pulse and post-start enrichment maps
Fuel pump prime control
VTEC control
Progressive nitrous control with timing retard and fuel enrichment
User and tuner protection passwords
Audible and visual alert, including external shift light control
Check control with on-screen warning, safety mode and engine shut-off by exceeded pressure, RPM, coolant
temperature, duty cycle, oil and fuel pressure
Display brightness and sound warning adjusts
5 memory positions to save different adjusts and maps
Dashboard screen
Injection time (in milliseconds), ignition timing (in °BTDC), RPM, TPS (in %), manifold air pressure, air and coolant
temperature in °F, oil and fuel pressure in PSI (including maximum and minimum register)
O2 sensor readings, boost and nitrous, internal datalogger and burnout mode buttons and battery voltage
Internal datalogger
Multiple logs recording, up to 64 channels, over 2h recording
Configurable sampling rate per channel (25Hz, 50Hz, 100Hz and 200Hz)
PC communication through USB cable and channel customization via FT Manager Software

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Weight: 280g (10oz)
Package contents: 1 FT500 ECU
1 wiring harness
1 USB flash drive (contains FT Manager Software, FT guides, etc.)
1 Mini USB cable
1 FT500 installation guide
1 Smart clip support
ECU dimensions: 141mm (5,5in) x 82mm (3,2in) x 33mm (1,3in)

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4.1 Harness connections 24 way connector
Wire color
Pin
Function
Information
Blue #1
24
Blue output #1
These outputs are usually used for injector control. When needed,
they can be configured as auxiliary outputs.
Blue #2
23
Blue output #2
Blue #3
13
Blue output #3
Blue #6
2
Blue output #6
Blue #7
4
Blue output #7
Blue #8
6
Blue output #8
White #4
9
White input #4
Standard: oil pressure
These inputs can be set up as
any kind of analog or digital
sensor.
White #5
7
White input #5
Standard: coolant temperature
White #6
5
White input #6
Standard: fuel pressure
White #7
3
White input #7
Standard: air temperature
White #11
11
White input #11
Standard: TPS signal
Gray #1
18
Gray output #1
These outputs are usually used for ignition control.
When needed, they can be set up as injector outputs or auxiliary
outputs.
By standard, Gray output #8 is used as a tachometer output.
Gray #2
16
Gray output #2
Gray #3
14
Gray output #3
Gray #4
12
Gray output #4
Gray #5
10
Gray output #5
Gray #8
1
Gray output #8
White wire from the
2 core shielded
cable
8
Magnetic RPM sensor
reference
Connected to the negative wire of the magnetic sensor. When OEM
ECU is reading the sensor in parallel, split this wire with OEM sensor
negative Do not connect when using hall effect sensor.
Red wire from the 1
core shielded cable
17
RPM signal input
Connected to the crank trigger sensor (hall or magnetic) or to the
distributor.
Connect the shield to the sensor shield (when applicable)
White wire from the
1 core shielded
cable
15
Cam sync signal input
Connected to the cam sync sensor (hall or magnetic)
Use the shield as negative to the sensor
Red
21
12V input from relay
Connected to the pin 87 of the Main Relay.
Black
19
Battery negative input
Connected directly to the battery negative with no seams. Do not
connect this wire to the chassis, engine block or head.
Black/White
22
Power ground input
Engine ground (head/block). Connect the three black/white wires
from the harnesses in different points of the engine.
Do not connect it directly to the battery negative.
Green/Red
20
5V output for sensors
5V voltage output for TPS, electronic throttle and pedal sensors

11
4.2 Harness connections 16 way connector
Wire color
Pin
Function
Information
White #1
1
White input #1
Standard: O2 sensor input
These inputs can be set up as any
kind of analog or digital sensor.
MAP signal output can only be set
up on white #5, #7, #10 or #11.
White #2
5
White input #2
Standard: two-step input
White #3
7
White input #3
Standard: air conditioning button
White #8
12
White input #8
Standard: pedal #2 signal input
White #9
10
White input #9
Standard: pedal #1 signal input
White #10
3
White input #10
MAP signal output or TPS #2
(electronic throttle)
Gray #6
2
Gray output #6
These outputs are usually used for ignition control.
When needed, they can be set up as injector outputs or auxiliary outputs.
Gray #7
4
Gray output #7
Blue #4
6
Blue output #4
These outputs are usually used for injector control. When needed, they can
be configured as auxiliary outputs.
Blue #5
8
Blue output #5
Black/White
9
Power ground inputs
Engine ground (head/block) Connect the three black/white wires from the
harnesses in different points of the engine.
Do not connect it directly to the battery negative.
Black/White
11
Yellow #1
13
Yellow output #1
Electronic throttle and step motor outputs. Also used as injection or auxiliary
outputs (cooling fan, fuel pump, etc.)
Yellow #2
14
Yellow output #2
Yellow #3
15
Yellow output #3
Yellow #4
16
Yellow output #4