FuelTech FT500 LITE Operating instructions

Programmable Electronic Fuel
Injection and Ignition System
Installation and
Operation Guide
Programmable Electronic Fuel
Injection and Ignition System
Installation and
Operation Guide

FT500 SFI / FT500LITE SFI
3
1. Index
2. Presentation......................................................................................5
3. Warranty terms ................................................................................6
4. Characteristics..................................................................................7
4.1 Harness connections - 24 way connector ..........................8
4.2 Harness connections - 16 way connector ..........................9
4.3 Output table of FT500......................................................... 10
4.4 Auxiliary outputs ................................................................... 11
4.5 Internal MAP sensor ............................................................. 11
4.6 USB port................................................................................. 11
4.7 FuelTech CAN network......................................................... 11
5. First steps with FT500 / FT500LITE read before installation 12
6. Getting to know the ECU............................................................. 12
6.1 Main menu.............................................................................. 12
6.2 FTManager shortcuts............................................................ 14
6.3 Warning sounds in FT500LITE........................................... 14
6.4 Dashboard screen................................................................. 15
6.5 Diagnostic panel.................................................................... 15
6.6 Test time based features...................................................... 16
7. Engine settings.............................................................................. 17
7.1 Engine setup.......................................................................... 17
7.2 RPM signal.............................................................................. 19
7.3 Ignition .................................................................................... 21
7.4 Fuel injection.......................................................................... 22
7.5 Pedal/Throttle ........................................................................ 23
7.6 Idle actuators ......................................................................... 24
7.7 FuelTech base map............................................................... 25
7.8 Fuel injectors deadtime........................................................ 26
7.9 Ignition Dwell......................................................................... 26
7.10 Map options......................................................................... 26
7.11 Advanced map options...................................................... 27
8. Electrical installation..................................................................... 28
9. FT500 connection on previous FT installation........................ 30
9.1 Connection on an FT200, FT250, FT300, FT350 installation:.30
9.2 Connection on an FT400 installation: ............................... 30
9.3 Ignition calibration................................................................. 31
9.4 Injection time differences between FT500 /FT500LITE and previous
FT ECUs ......................................................................................................................31
10. Fuel injectors................................................................................. 32
11. Ignition............................................................................................ 32
12. Sensors and actuators................................................................. 36
12.1 Intake air temperature sensor .......................................... 36
12.2 Engine temperature sensor............................................... 36
12.3 Fuel and oil pressure sensor – PS-10B.......................... 37
12.4 Throttle position sensor (TPS)......................................... 37
12.5 Crank trigger/RPM sensor................................................. 37
12.6 Camshaft position sensor.................................................. 41
12.7 O2 sensor............................................................................ 41
12.8 Step motor – idle speed.................................................... 42
13. Auxiliary outputs........................................................................... 43
13.1 Cooling fan 1 e 2 ............................................................... 43
13.2 Idle valve.............................................................................. 43
13.3 Air conditioning................................................................... 43
13.4 Shift Alert............................................................................. 43
13.5 Fuel pump............................................................................ 43
13.6 Variable camshaft control/Powerglide gearbox............. 44
13.7 Progressive nitrous control ............................................... 44
13.8 Boost Control – N75.......................................................... 44
13.9 BoostController ................................................................... 45
14. Electronic throttle control ............................................................ 45
14.1 Connection table – throttle bodies and pedals ............. 46
15. Sensors and Calibration .............................................................. 46
15.1 TPS calibration.................................................................... 46
15.2 Electronic throttle/pedal calibration ............................... 47
15.3 Fuel/oil pressure sensors inputs...................................... 47
15.4 Intake air and engine temperature sensors ................... 47
15.5 O2 sensor inputs................................................................ 48
15.6 Speed inputs ....................................................................... 49
15.7 Driveshaft RPM and Input shaft RPM .............................. 50
15.8 Driveshaft RPM.................................................................... 50
15.9 Gearbox RPM ...................................................................... 50
15.10 Gear detection.................................................................. 51
15.11 Nitrous bottle pressure ................................................... 52
15.12 Clutch position.................................................................. 52
15.13 Clutch pressure ................................................................ 52
15.14 Ride Height....................................................................... 52
15.15 Pitch Rate.......................................................................... 52
15.16 CAN communication........................................................ 52
15.17 EGT..................................................................................... 53
16. Starting the engine for the first time......................................... 53
16.1 First engine start ................................................................ 53
16.2 Ignition calibration.............................................................. 53
17. Fuel tables adjust ......................................................................... 54
17.1 Main fuel table .................................................................... 54
17.2 Overall fuel trim .................................................................. 54
17.3 RPM compensation ............................................................ 55
17.4 O2 Closed Loop ................................................................. 55
17.5 Idle speed by TPS table .................................................... 56
17.6 Acceleration fuel enrichment and decay........................ 56
17.7 Engine temperature compensation ................................. 57

FT500 SFI / FT500LITE SFI
4
17.8 Intake air temperature compensation ............................. 57
17.9 Battery votlage compensation.......................................... 57
17.10 MAP / TPS compensation .............................................. 58
17.11 Prime cranking pulse....................................................... 58
17.12 Engine start....................................................................... 58
17.13 Post-start enrichment...................................................... 58
17.14 individual cylinder trim.................................................... 59
17.15 Rotor compensation ........................................................ 59
17.16 Enrichment per gear........................................................ 59
17.17 Gear shift fuel enrichment.............................................. 59
17.18 Fuel injection phase angle table.................................... 59
18. Ignition tables adjust.................................................................... 60
18.1 Main ignition table.............................................................. 60
18.2 Overall ignition trim............................................................ 60
18.3 MAP/TPS compensation.................................................... 60
18.4 Engine temperature compensation ................................. 61
18.5 Intake air temperature compensation ............................. 61
18.6 Rotary timing split .............................................................. 61
18.7 Individual cylinder trim ...................................................... 61
18.8 Rotor compensation........................................................... 61
18.9 Timing limits ........................................................................ 61
18.10 Gear compensation.......................................................... 62
18.11 Gear shift compensation................................................. 62
19. Other functions ............................................................................. 63
19.1 Internal datalogger ............................................................. 63
19.2 Idle speed control............................................................... 64
19.3 Deceleration cut-off ........................................................... 66
19.4 Revolution limiter................................................................ 66
19.5 Shift Light............................................................................. 66
19.6 Cooling fans 1 and 2......................................................... 66
19.7 Air conditioning................................................................... 67
19.8 Fuel pump............................................................................ 67
19.9 Camshaft control................................................................. 67
19.10 Progressive nitrous control............................................. 67
19.11 Boost control .................................................................... 69
19.12 Boost activated output.................................................... 70
19.13 Tachometer output........................................................... 70
19.14 MAP signal output ........................................................... 71
19.15 BoostController................................................................. 71
19.16 Start button....................................................................... 75
20. Drag race features........................................................................ 75
20.1 Burnout mode ..................................................................... 75
20.2 3-step (boost spool) ......................................................... 76
20.3 2-step rev limiter ................................................................ 76
20.4 Timing table for rev launch ............................................... 77
20.5 Gear shift output................................................................. 78
20.6 Time based fuel enrichment............................................. 78
20.7 Pro-Nitrous........................................................................... 81
20.8 Time based output ............................................................. 83
20.9 Wheelie Control................................................................... 83
20.10 Davis Technologies.......................................................... 84
20.11 Staging control ................................................................. 84
21. Alert settings................................................................................. 85
21.1 Safe mode RPM limiter...................................................... 85
21.2 Alerts .................................................................................... 85
22. Favorites......................................................................................... 86
23. Interface settings .......................................................................... 87
23.1 LCD blacklight settings...................................................... 87
23.2 Alert sound settings........................................................... 87
23.3 Dashboard setup ................................................................ 87
23.4 Startup screen selection.................................................... 87
23.5 Clear peaks.......................................................................... 87
23.6 Protection setup.................................................................. 88
23.7 Measurement units............................................................. 88
23.8 Demonstration mode ......................................................... 88
23.9 Touchscreen calibration..................................................... 88
23.10 Serial number and software version............................. 88
24. File manager.................................................................................. 89
24.1 FuelTech base map generator ........................................ 89
24.2 Edit map file name ............................................................. 89
24.3 Copy map to another file .................................................. 89
24.4 Erase file .............................................................................. 89
25. Rotary engines setup................................................................... 90
25.1 Crank angle sensor installation and alignment.............. 90
25.2 Crank angle sensor wiring ................................................ 90
25.3 ECU setup............................................................................ 91
25.4 Ignition coils wiring ............................................................ 91
26. FT500 SFI / FT500LITE SFI – electrical diagram................... 92
27. FT500 SFI / FT500LITE SFI – ECU Dimensions..................... 95

FT500 SFI / FT500LITE SFI
5
2. Presentation
Congratulations! You are now part of the high performance world
of FuelTech! Know that this equipment is exactly the same used in
many winners cars around the world. From NHRA drag race cars and
circuit race cars to exotic brands with 12 cylinder, the FT500 SFI and
FT500LITE SFI represent the maximum technology, ease of use and
performance that an ECU can provide. We, from FuelTech, wish you
have many victories and have fun on your path, because winning is
in our DNA!
The FuelTech FT500 SFI/FT500LITE SFI is a fully programmable
ECU, which allows you to change all fuel and timing tables, as the
engine conditions, in real time. You can tune your engine directly
on the ECU, through its screen touchscreen 4.3’’ (only FT500 SFI)
or via FTManager software (FT500 SFI and FT500LITE SFI) with
high-speed USB communication. The tuning of main fuel and timing
tables may be performed in basic (2D) or advanced (3D) mode with
configurable break points. It can be applied to any type of engine 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 module and
configured directly in the display without any additional computer or
module. It is possible to set alerts to dangerous situations for the
engine, such as over rev, low oil pressure, high engine temperature,
among others. These alerts can also be programmed to limit rpm or
shut off the engine bringing more security the user. The ECU also
features five maps fully independent, allowing different settings to
engines and/or cars.
The timing control can be done through distributor or crank trigger.
Thus, it is possible to work with a single coil, double coils or COP coils,
on wasted spark or sequential ignition. The fuel injectors can work on
sequential, semi-sequential or multipoint mode, with individual cylinder
trim. Tune the injection phase angle is also possible.
The equipment also has the Favorites menu, which seeks to facilitate
access to the main engine setup menus, allowing executing rapid
changes in maps. The dashboard panel is fully configurable, where
the user can change the display size and the types of readings for
each parameter, as well as reading range presented on the screen.
The FT500LITE SFI is a FT500 SFI without touchscreen. If you want
to upgrade your FT500LITE SFI to FT500 SFI, please contact our
technical support.
Presentation

FT500 SFI / FT500LITE SFI
6
3. Warranty 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.
NOTE:
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
battery’s negative terminal, as well as each one of the sensors’
ground wires.
• The use of the 16 way harness is mandatory, even when
connecting the FT500 / FT500LITE 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.
- In FT500 is NOT possible to change the
language.
Limited Warranty
This product warranty is limited to one year from the date of purchase
and covers only manufacturing defects upon presentation of purchase
invoice.
This ECU has a serial number that’s linked to the purchase invoice and
to the 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 3.3– April/2017
ECU version – 3.10
Warranty terms

FT500 SFI / FT500LITE SFI
7
Characteristics
4. Characteristics
Inputs and specifications
• 103 psi internal MAP sensor (7 bar - absolute), 14.7psi of
vacuum and 88psi of positive pressure (boost);
• 4.3” Touchscreen with 16,8 milion colors (FT500 only);
• 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;
• FuelTech CAN port (CAN communication with FuelTech ECUs
and Racepak IQ3 dashes and VNET Networks);
• Compatible with Racepak AiM;
• 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 FTManager
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 FTManager
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;
• Exclusive Drag Race features: burnout mode, 2-step, 3-step,
timing table for rev launch, 2-step by wheel speed, time based
rpm limiter by ignition cut or timing retard, time based fuel
enrichment, time based speed/driveshaft rpm control by ignition
cut or timing retard
• 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, ignition timing (in °BTDC), RPM, TPS (in %),
manifold air pressure, air and coolant temperature in °F, oil and
fuel pressure in PSI;
• O2 sensor readings, boost and nitrous, internal datalogger and
burnout mode buttons and battery voltage;
• Wheel speed input, driveshaft rpm input, gear change detection;
Internal datalogger
• Multiple logs recording, up to 128 channels, over 1h recording;
• Configurable sampling rate per channel (25Hz, 50Hz, 100Hz
and 200Hz);
• PC communication through USB cable and channel customization
via FTManager Software;
Box Content
• 1 FT500 or FT500LITE ECU;
• 1 wiring harness;
• 1 USB flash drive (contains FTManager Software, FT guides, etc.);
• 1 Mini USB cable;
• 1 FT500 / FT500LITE installation guide;
• 1 Smart clip support.
ECU Dimensions
• 5,5in x 3,2in x 1,3in.
Weight
• FT500LITE SFI: 150g;
• FT500 SFI: 235g.

FT500 SFI / FT500LITE SFI
8
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
8Magnetic 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 2
core shielded cable 17 RPM signal input
Connected to the crank trigger sensor (hall or magnetic) or to the
distributor. To VR sensors, use the shield wire the sensor shield. To Hall
sensor, use the shield as negative
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
Characteristics

FT500 SFI / FT500LITE SFI
9
Characteristics
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 Ignition output #6 can be configured as injector or auxiliary output
Gray #7 4 Gray output #7 Ignition output #7 can be configured as injector or auxiliary output
Blue #4 6 Blue output #4 Injector output #4 can be configured as auxiliary output
Blue #5 8 Blue output #5 Injector output #5 can be configured as auxiliary output
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

FT500 SFI / FT500LITE SFI
10
4.3 Output table of FT500
Wire
color Output type
Max current
for negative
activation (0V) for
each output
Max current for
positive activation
for each output
Application Notes
Blue Open collector
(Lo side) 5A* Can’t activate by positive
Fuel injectors, relays,
solenoid valves Drive loads always by negative
Gray
Open collector
with current
source in 5V
(Lo side)
1A* 30mA in 5V
Inductive ignition control,
fuel injectors, relays,
solenoid valves
Drive loads always by negative
Yellow PUSH-PULL ou
HALF BRIDGE 5A* 5A** in 12V
Electronic throttle, step
motor, MSD/M&W and
other ignitions activated
by 12V
When used to control relays,
valves or any other load by
negative, there is a risk of 12V
return to the ECU. This will keep
the ECU always powered on.
In this case, an external diode
or a relay with built-in diode is
required for protection.
* Total max current combined with all outputs driving loads by negative: 15A continuous
** Total max current combined with all outputs driving loads by positive: 5A continuous
NOTE:
Blue outputs cannot control ignition because they do not have a pullup resistor.
Characteristics