National Instruments NI EDIDS-2400 Series User manual

NI EDIDS-2400 Series User Manual | © National Instruments | 1
National Instruments Expandable
Direct Injector Driver System
NI EDIDS-2400 Series User Manual
NI EDIDS-2403
NI EDIDS-2406
NI EDIDS-2409
NI EDIDS-2412
NI Expandable Direct Injector Driver System User guide
February 2016

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NI EDIDS-2400 Series User Manual | © National Instruments | 3
Table of Contents
1. About the NI Expandable Direct Injector Driver System ............................................................................6
2. Warnings .....................................................................................................................................................7
2.1 REVERSE BATTERY POLARITY WARNING ....................................................................................8
2.2 HIGH VOLTAGE WARNING ..............................................................................................................9
3. Getting Started .........................................................................................................................................10
3.1 What Is Included ..............................................................................................................................11
3.2 Software ............................................................................................................................................13
3.2.1 SCM Software Installation .......................................................................................................14
3.2.2 NI-XNET Driver Installation .....................................................................................................18
3.2.3 Connecting To The DI Driver System .....................................................................................19
3.2.3.1 Out Of The Box Connection ..........................................................................................20
3.2.3.2 Changing The Network Settings Of The DI Driver System ............................................26
3.2.3.3 Manually Resetting The Controller Network Interface To DHCP ...................................28
3.2.3.4 SCM and Windows Firewall ...........................................................................................31
3.2.4 Updating DI Driver System Controller Software .....................................................................36
3.2.5 Backing Up the DI Driver System Software Image .................................................................38
3.2.6 Restoring A Backup Image To The DI Driver System Controller ............................................40
3.3 Hardware ..........................................................................................................................................43
3.3.1 C-Series Module Slot Assignments ........................................................................................44
3.3.2 Powering the System ..............................................................................................................46
3.3.3 Connecting Injectors, Sensors and Actuators .........................................................................48
3.3.3.1 Direct Injectors to DI Driver Channels ...........................................................................49
3.3.3.2 Port Fuel Injectors to PFI Channels ...............................................................................51
3.3.3.3 Proportional Solenoid Valves to PFI Lowside Channels ................................................53
3.3.3.4 Digital Signals to NI 9411 Digital Input Module ..............................................................54
3.3.3.5 Analog Signals to NI 9220 Analog Input Module ...........................................................57
3.3.4 DI Driver System Component User Manual Reference ..........................................................58
3.3.5 Optional Enclosure System .....................................................................................................59
3.4 Using DI Driver System to Control Fuel Pressure ...........................................................................62
3.5 Optimizing the DI Driver System .....................................................................................................64
4. NI Direct Injector Driver System Interface ...............................................................................................65
4.1 DI Driver Setup Window ..................................................................................................................67
4.1.1 DI Driver Scope Window .........................................................................................................78
4.2 PFI and LS Driver Setup Window ....................................................................................................79
4.2.1 PFI Module Control Tab ..........................................................................................................80
4.2.2 PFI 1-4 Tab .............................................................................................................................84
4.2.3 LS 1-4 Tab ...............................................................................................................................87
4.3 ESTTL Spark Setup .........................................................................................................................91
4.3.1 ESTTL 1 TDC Channel Mapping Tab .....................................................................................92
4.3.2 ChX Tabs .................................................................................................................................96
4.4 General Purpose ESTTL Setup Window .........................................................................................99
4.4.1 ESTTL 2 TDC Channel Mapping Tab ...................................................................................100
4.4.2 ESTTL 2 Pulse Generation Setup Tab .................................................................................103
4.5 Throttle Driver Setup Window ........................................................................................................106
4.5.1 Channel X Control Tab ..........................................................................................................109
4.5.2 Channel X Position Calibration Tab ......................................................................................112

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4.5.3 Channel X Control Calibration Tab .......................................................................................119
4.6 UEGO Setup Window ....................................................................................................................129
4.7 Digital Input Setup Window ............................................................................................................136
4.8 Expansion Digital and VR/Hall Input Setup Window .....................................................................140
4.8.1 VR/Hall Input Setup Window .................................................................................................144
4.9 Analog Input Setup Window .........................................................................................................146
4.10 Pulse Generation Setup Window .................................................................................................149
4.10.1 DI-TMP Tab .........................................................................................................................150
4.10.2 DI-EPT Tab ..........................................................................................................................154
4.10.2.1 DI Advanced Settings Window ...................................................................................159
4.10.3 PFI X Tabs ..........................................................................................................................163
4.11 Engine Position Tracking Setup Window .....................................................................................167
4.11.1 EPT Tab ...............................................................................................................................178
4.11.2 TDC Channel Mapping Tab .................................................................................................188
4.11.3 Cam Phase Capture Tab .....................................................................................................192
4.11.4 EPT Diagnostics Tab ...........................................................................................................198
4.13 Calibration Mode Setup Window ..................................................................................................201
4.14 Expansion Calibration Mode Setup Window ................................................................................205
4.15 Direct Mapping .............................................................................................................................209
4.16 Table Setup Window ....................................................................................................................212
4.16.1 Table1D ................................................................................................................................213
4.16.2 Table2D ................................................................................................................................216
4.17 Auxiliary PID Controller Setup Window .......................................................................................219
4.18 Rail Pressure Control Setup Window ..........................................................................................225
4.19 Auxiliary PWM Setup Window .....................................................................................................239
4.20 Expansion Auxiliary PWM Setup Window ...................................................................................242
4.21 Operating Point Setup Window ....................................................................................................245
4.22 User Variables ..............................................................................................................................253
4.23 XNET CAN Setup Window ..........................................................................................................255
4.23.1 NI-XNET Database Editor ...................................................................................................263
4.23.1.1 CAN Signal Dialog .....................................................................................................265
4.23.1.2 Manage NI-XNET Databases Dialog .........................................................................269
4.24 TDK HV Supply Control Setup Window .......................................................................................272
4.25 Active Flex Control Parameters Window .....................................................................................276
4.26 CalScopes Window ......................................................................................................................277
4.27 CalTrend Window .........................................................................................................................278
4.28 Log Data Setup Window ..............................................................................................................279
4.29 Faults Window ..............................................................................................................................284
4.30 Execution Information Window .....................................................................................................288
4.30.1 Static Info ............................................................................................................................289
4.30.2 Network ................................................................................................................................290
4.30.3 Run-Time Info ......................................................................................................................291
4.30.4 Expansion/Misc. Execution Info ..........................................................................................292
5. Troubleshooting ......................................................................................................................................293
6. Diagrams ................................................................................................................................................295
7. Additional Support/Feedback .................................................................................................................307
8. Important Information .............................................................................................................................308

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8.1 Warranty .........................................................................................................................................309
8.2 Copyright ........................................................................................................................................310
8.3 Trademarks .....................................................................................................................................311
8.4 Patents ............................................................................................................................................312
8.5 Warning Regarding Use of NI Products ........................................................................................313
8.6 Environmental Management ..........................................................................................................314

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1. About the NI Expandable Direct Injector Driver System
The NI Expandable Direct Injector Driver System features an NI cRIO-9082 controller, NI 9751 Direct Injector (DI)
driver module(s), and NI 9411 digital input module(s). The system can synchronize injector channels with production
crank/cam position sensors or optical encoders. The system will also accept external digital fuel command signals
from a production engine controller. The included DI driver module(s) provide the power electronics necessary to
drive high-power solenoid or piezoelectric direct injectors.
The NI Expandable Direct Injector Driver System comes in four different base models corresponding to different
direct injector channel configurations: the NI EDIDS-2403 drives 3 solenoid injectors (or 2 piezoelectric injectors),
the NI EDIDS-2406 drives 6 solenoid injectors (or 4 piezoelectric injectors), the NI EDIDS-2409 drives 9 solenoid
injectors (or 6 piezoelectric injectors), and the NI EDIDS-2412 drives 12 solenoid injectors (or 8 piezoelectric
injectors). The systems provide a digital input per injector channel for directly commanding each injector. The
system controller is delivered with a pre-installed feature-rich application. The deployment version of the NI Software
Calibration Manager Toolkit (SCM) is included for interfacing with and calibrating the system.
The NI Expandable Direct Injector Driver System supports optional C-series modules in slots 7 & 8 of the
cRIO-9082. The optional NI 9220 analog input module (slot 7) can be used for a variety of analog sensors. The
optional NI 9862 XNET CAN module (slot 8) can be used to send and receive parameter values within the system
to/from other CAN communication devices. The cRIO-9082 controller may be expanded with a NI-9155 MXIe
Expansion Chassis for additional optional modules with designated slots. Examples of optional modules designated
to expansion slots are NI-9758 Port Fuel Injector Driver Module, NI-9754 Engine Synchronous TTL Output Module,
NI-9757 Bosch LSU 4.2 and 4.9 O2 Sensor Module, NI-9759 Throttle Driver Module and the NI 9760 VR/Hall Sensor
Module.
Throughout this manual, the module model numbers NI 9XXX (ex. NI 9751) and module model names (ex. DI Driver
module) are used interchangeably. Also, the NI Expandable Direct Injector Driver System will be referred to as the
NI Direct Injector Driver System.

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2. Warnings
Please read the following warnings for your safety and that of the product.

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2.1 REVERSE BATTERY POLARITY WARNING
NI Powertrain Controls power modules are not internally protected against reverse battery polarity.
Do not reverse the battery polarity or damage will occur. This event is not covered under warranty.
All NI Powertrain Controls modules with a 10-pin screw terminal block have identical external
power and ground connections. Please take necessary precautions to ensure that BATT (0)
and GND (9) are not connected in reverse polarity. The BATT (0) terminal will accept positive
7-32VDC with respect to the GND (9) terminal. Please refer to the user manual for details.
To provide system-level protection against reverse battery polarity, implement the following simple external
main-power-relay circuit:
Figure 2.1.a, Reverse Battery Protection Diagram
Notes:
1.) The relay shown is a type of automotive relay which includes an internal series diode with terminal 85. This diode
will prevent reverse battery from energizing the relay.
2.) Terminals 30 and 87 are screw terminals and should be connected with soldered ring terminals.
3.) Terminals 85 and 86 are 0.250 X 0.031 inch (6.3 X 0.8 mm) push-on terminals.
4.) A fuse is recommended between the battery and relay.
5.) An optional switch may be placed in series with relay terminal 86.
6.) Simply placing a high-current-capacity diode in series with the system power is not an acceptable method
of reverse battery protection because it will not allow the NI Powertrain Controls modules to perform current
recirculation while switching inductive loads.
7.) The relay is currently available from www.ni.com.

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2.2 HIGH VOLTAGE WARNING
HIGH VOLTAGE: This device is capable of operating at voltages up to 190V. Extreme care should
be taken to protect against shock. Even when the device is completely powered down, allow
approximately five minutes for the internal high voltage to dissipate. Do not touch any of the driver
module screw terminals or injector terminals while the device is powered.

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3. Getting Started
This guide will provide instructions to set up the NI Direct Injector Driver System hardware and software.

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3.1 What Is Included
Software
1. DI Driver System software image pre-installed on the system controller
2. NI Software Calibration Management Toolkit (SCM) for LabVIEW, downloaded from www.ni.com.
Hardware
1. Expandable Direct Injector Driver System
DI Driver System
cRIO-9082
Integrated
Controller & Chassis
781787-02
NI 9411
Digital Input
Module
779005-01
NI 9751
DI Driver
Module
782076-01
EDIDS-2403 1 1 1
EDIDS-2406 1 1 2
EDIDS-2409 1 2 3
EDIDS-2412 1 2 4
Table 3.1.a, I/O Hardware Included In The Expandable DI Driver System
Optional I/O modules supported by all DI Driver Systems
• NI-9220 16-Channel, 100 kS/s/ch, 16-bit, ±10 V Analog Input Module, 37-Pin D-SUB (P/N: 782615-01)
• NI-9862 1-Port High-Speed/FD NI-XNET CAN C Series Module (P/N: 781639-01)
Optional I/O modules supported by Optional NI-9155 MXIe Expansion Chassis
• NI-9411 6-Channel, 500 ns, ±5 to 24 V, Differential Digital Input Module (P/N: 779005-01)
• NI-9754 8 Channel TTL Output Module for Engine Synchronous Digital Output(P/N: 782077-01)
• NI-9757 2-Channel Bosch LSU 4.2 or 4.9 wideband sensor controller module (P/N: 782079-01)
• NI-9758 PFI Driver Module (P/N: 782080-01)
• NI-9759 Electronic Throttle Driver Module (P/N: 782081-01)

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2. Piezo Injector Inductors (P/N: 782082-01)
Piezo Injector Inductor Packs
Included In Each DI Driver System
DI Driver System Number of Inductors
EDIDS-2403 2 (1 pack)
EDIDS-2406 4 (2 packs)
EDIDS-2409 6 (3 packs)
EDIDS-2412 8 (4 packs)
Table 3.1.b, Number of Inductors Included With The DI Driver System
3. Reverse Battery Protection Relay (P/N: 782784-01)
4. NI 9411 Module Breakout Harness(es) per NI 9411 Module (P/N: 782785-01)
NI-9411 Breakout Harnesses
Included In Each DI Driver System
DI Driver System Number of Harnesses
EDIDS-2403 1
EDIDS-2406 1
EDIDS-2409 2
EDIDS-2412 2
Table 3.1.c, Number of Harnesses Included With The DI Driver System

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3.2 Software

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3.2.1 SCM Software Installation
Software Download
At the time of shipping, the DI Driver System controller is pre-programmed with the latest version of software.
However, in order to interact with the system, NI Software Calibration Management Toolkit (SCM) must be
downloaded and installed to a PC with Windows 7 or newer. To download SCM follow the link below.
Download SCM Software
The link will take you to this webpage; click on download to begin the download process.
Enter your NI User Account information as directed. If you do not have an NI User Account, create one for free and
then proceed.

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Download the most recent version of the software. When prompted, choose the option to save the file.
Software Installation

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After the download is complete, browse to the location on disk where the file was saved. Extract the contents of
the .zip file.
After extracting the file, open the created directory and run the Setup.exe application. If prompted, install
Microsoft .NET Framework 4.0.
When prompted at the User Information screen, enter the relevant information and select the option to install the
evaluation version of the license. The evaluation license is a free, perpetual license of SCM that allows users to
interface to SCM-supported targets, but does not allow them to modify any code.

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From there, follow the instructions and prompts to finish installing the software.

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3.2.2 NI-XNET Driver Installation
If the user plans to utilize CAN communication on the NI EDIDS they must install NI-XNET Drivers. The drivers are
free to download at http://sine.ni.com/psp/app/doc/p/id/psp-903/lang/en.
For installtion instructions refer to NI-XNET Hardware and Software Installtion Guide. For additional information on
NI-XNET refer to NI-XNET Support.

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3.2.3 Connecting To The DI Driver System
This section provides information about connecting to the DI Driver System user interface via SCM and how to
change the network interface settings of the system controller.

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3.2.3.1 Out Of The Box Connection
This section describes how to establish a connection with the DI Driver System user interface via SCM. NI ships the
DI Driver System with an IP address of 192.168.1.100 and a Subnet mask of 255.255.255.0. The Windows PC used
to interface with the system must have a similar IP address and Subnet mask, but the IP address must be different in
the last address number. The directions below illustrate how to make the initial network connection to the system and
open the system user interface.
1. The customer must provide a Windows 7 (or later) PC with an Ethernet LAN port.
2. Install SCM for LabVIEW to the PC.
3. Check the Windows Firewall settings or 3rd party firewall settings to allow SCM to communicate with the external
system.
4. Power up the DI Driver System controller. The DI Driver and PFI Driver modules do not need to be powered if
simply attempting to establish a connection to the user interface. Wait about 1 minute for both the USER1 and USER
FPGA1 LEDs to start blinking.
5. Using a CAT5E Ethernet cable, connect the Windows PC LAN port directly to the Ethernet port of the cRIO-9082
controller . If the green and amber LEDs directly under the controller Ethernet port are not active, then there is no
physical Ethernet connection to the PC. Please diagnose the Ethernet cable connection problem.
6. Go to the Windows Control Panel and select Network and Sharing Center. From the Network and Sharing
Center select Change adapter settings from the left menu.
7. A list of network connections available on the PC will open. Right click the Local Area Connection port to select
Properties.