zeeltronic PDCI-11V User manual

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www.zeeltronic.com
[email protected]
updated 21.07.2009
program version: 00.210709
USER MANUAL
PDCI-11V PROGRAMMABLE CDI IGNITION AND PV CONTROLLER
TECHNICAL DATA
Limit values:
- minimum revs 200 RPM
- maximum revs 20000 RPM
- minimum supply voltage 9 Volts
- maximum supply voltage 18 Volts
- max idle current draw 60 mAmp
- maximum continuous current for shift light and power jet output 1 Amp
- peak current for shift light and power jet output 5 Amp
- constant spark energy from idle to 13000 RPM >35mJ
Circuit is protected against reverse supply voltage (wrong connection).
Features:
- one channel isolated input (pickup)
- store and load function for two ignition curves
- TPS input (Throttle Position Sensor)
- shift light output
- 2 power jet outputs
- quick shift (shift kill)
- soft rev limit (three stage rev limit)
- external switch for changing ignition map while riding
- tachometer output
- easy and fast programming on the field, via hand held programmer
- programming while machine running - you can immediately see effects
- each curve can be set in 4 to 12 curve points
- 3D interpolated ignition map, if TPS selected
- signal delay compensation
- instant monitoring of rev's and angle, via LCD(hand held programmer)
- programmable power valve actuation
- store and load function for 5 PV curves
- programmable PV deviation
- programmable max close and max open positions
- self PV test on power-up
- PV error detecting (position sensor failure, servo motor failure)

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- fast processing for high accuracy - delays from 1us
- timing calculation for every 1 RPM change (1000, 1002, .. , 9805, 9806, ...)
Very important!
Resistor spark plugs must be used, because they produce less electromagnetic disturbances.
Danger of electric shock!
Avoid connecting PDCI to 12V power supply, before connecting it to ignition coil, because
high voltage is generated and touching free wires can cause electric shock, or damage of the
unit.
1. HOW TO ENTER MENU
PDCI must be connected to power supply. Connect programmer to PDCI and wait few
seconds for activation of programmer and then press enter. With pressing + or - you can
move through menu and with pressing enter you can choose.
You can exit menu with choosing Exit.
2. MENU ORGANISATION
Set Ign. - set ignition parameters submenu
Set PV - set PV parameters submenu
Exit
2.1. SET IGNITION PARAMETERS SUBMENU
Load Ign. Curve - load previously saved ignition curve set (from #1 to #2)
Save Ign. Curve - save new ignition curve set (from #1 to #2)
Ignition Curve - ignition curve parameters submenu
Advance - advance/retard whole ignition curve
Gear Shift Light - shift light
Shift Kill Time - shift kill time
Rev Limit - rev limit
Static Angle - static angle (stator position)
Compensation - signal delay compensation (from pickup to spark plug)
Power Jet 1 - power jet 1
Power Jet 2 - power jet 2
TPS - enable, or disable TPS
TPS close [0%] - calibrating TPS close position
TPS open [100%] - calibrating TPS open position
Remote SW - activating/deactivating external switch
Pulses Per Rev - number pulses per revolution from pickup
Exit

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2.2. SET PV PARAMETERS SUBMENU
Load PV Curve - load previously saved curve (from #1 to #5)
Save PV Curve - save new curve (from #1 to #5)
Set PV Curve - valve curve parameters submenu
Deviation +- - deviation of valve position
Close Position - max close valve position
Open Position - max open valve position
PV Test - valve position test
Power-up Test - enable, or disable test cycle at power-up
Initial Position - valve position after power-up (engine not running)
Exit
3. LOAD IGN. CURVE
Enter Set Ign. menu and move to Load Ign. Curve with pressing + or - and then press
enter .
Now you can select position number of previously saved ignition curve set, with pressing +
or - and then press enter .
4. SAVE IGN. CURVE
Enter Set Ign. menu and move to Save Ign. Curve with pressing + or - and then press
enter .
Now you can select position number to which you want to save your ignition curve set, with
pressing + or - and then press enter .
5. Change IGNITION CURVE (if TPS disabled)
Enter Set Ign. menu and move to Set Ignition Curve with pressing + or - and then press
enter .
Now you are in submenu for setting ignition curve.
Submenu organisation:
Nr. of Points - number of ignition curve points (from 4 to 12)
1) - first ignition curve point
2) - second ignition curve point
... ...
... ...
Exit Curve - exit submenu
Important!
To avoid wrong processing, don't make unreasonable curve course.
Every time you make any changes to ignition curve, it is automatically saved to position #0.
Then you can save it to any other position number #1 or #2.

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Curve Example with six curve points:
5.1. Set IGNITION CURVE (if TPS enabled)
Three ignition curves must be programmed for different TPS positions. PDCI does not only
switch between ignition curves, but also calculate timing between programmed curves for all
TPS positions above 33%. From 0% to 33% TPS is used only one ignition curve.
Enter Set Ign. menu and move to Ignition Curve with pressing + or - and then press
enter.
Now you are in submenu for selecting ignition curve.
Submenu organisation:
Nr. of Points - number of ignition curve points (from 4 to 10)
Curve 0-33% - ignition curve from 0 to 33% TPS
Curve 66% - ignition curve for 66% TPS
Curve 100% - ignition curve for 100% TPS
Exit - exit submenu
Important!
To avoid wrong processing, don't make unreasonable curve course.
Every time you make any changes to ignition curve, it is automatically saved to position #0.
Then you can save it to any other position number #1 or #2.

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Curve Example:
5.2. Change NUMBER OF IGNITION CURVE POINTS
Move to Nr. of Points with pressing + or - and then press enter .
Now you can select number of ignition points, with pressing + or - and then press enter .
5.3. Change PARAMETERS OF IGNITION CURVE POINT
Move to point you want to change, with pressing + or - and then press enter .
Now you can change rev point with pressing + or - (in 100 rpm steps) and then press
enter .
Now you can change advance angle with pressing + or - (in 0.1deg steps) and then press
enter .
6. Set ADVANCE
With this setting is possible to advance or retard whole ignition curve. When setting is
positive then ignition curve is advanced and when setting is negative than ignition curve is
retarded. With Advance 0.0deg, ignition curve is unchanged.
Enter menu and move to Advance with pressing + or - and then press enter .
Now you can set advance with pressing + or - (in 0.1deg steps) and then press enter .
7. Set GEAR SHIFT LIGHT
Enter Set Ign. menu and move to Gear Shift Light with pressing + or - and then press
enter .
Now you can change rev point with pressing + or - (in 100 rpm steps) and then press
enter .

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8. Set SHIFT KILL TIME
Enter Set Ign. menu and move to Shift Kill Time with pressing + or - and then press enter.
Now you can change kill time with pressing + or - (in 10 ms steps) and then press enter .
9. Set REV LIMIT
Enter Set Ign. menu and move to Rev Limit with pressing + or - and then press enter .
Now you can change rev limit with pressing + or - (in 100 rpm steps) and then press
enter .
10. Set STATIC ANGLE
Enter Set Ign. menu and move to Static Angle with pressing + or - and then press enter .
Now you can set static angle with pressing + or - (in 0.1deg steps) and then press enter .
More information's about static angle you can find in section 29.
11. Set COMPENSATION
It is compensation of signal delay from pickup to spark plugs. You can check this delay with
stroboscope lamp. Without this compensation, ignition advance angle decreasing with rising
revs.
This compensation helps that advance angles in ignition curve are real (more accurate).
How to check, if compensation is correct:
First you must set flat ignition curve. Then measure with stroboscope lamp, if mark at
flywheel moving when changing revs. If mark moving then you must change compensation
delay.
Change Compensation:
Enter menu and move to Compensation with pressing + or - and then press enter .
Now you can change compensation delay with pressing + or - and then press enter .
12. Set POWER JET 1 parameters
Enter Set Ign. menu and move to Power Jet 1 with pressing + or - and then press enter .
Now you are in submenu for selecting Power Jet 1 parameters.
Submenu organisation:
Power Jet 1 ON RPM - revs for activating power jet 1
Power Jet 1 OFF RPM - revs for deactivating power jet 1
Power Jet 1 ON TPS (if TPS enabled) - throttle position for activating power jet 1
Power Jet 1 OFF TPS (if TPS enabled) - throttle position for deactivating power jet 1
Exit - exit submenu

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Example:
Power jet 1 ON (RPM) = 8000rpm
Power jet 1 OFF (RPM) = 10000rpm
Power jet 1 ON (TPS) = 70%TPS
power jet 1 OFF (TPS) = 90%TPS
Power jet is switched on when revs are between 8000-10000rpm and throttle position is
between 70-90%, otherwise power jet is switched off.
12.1. Set POWER JET 1 ON RPM
Enter Set Ign. menu and move to Power Jet 1 ON RPM with pressing + or - and then press
enter .
Now you can change rev limit with pressing + or - (in 100 rpm steps) and then press
enter .
12.2. Set POWER JET 1 OFF RPM
Enter Set Ign. menu and move to Power Jet 1 OFF RPM with pressing + or - and then
press enter .
Now you can change rev limit with pressing + or - (in 100 rpm steps) and then press
enter .
12.3. Set POWER JET 1 ON TPS (if TPS enabled)
Enter Set Ign. menu and move to Power Jet 1 ON TPS with pressing + or - and then press
enter .
Now you can change TPS position with pressing + or - (in 1%TPS steps) and then press
enter .
12.4. Set POWER JET 1 OFF TPS (if TPS enabled)
Enter Set Ign. menu and move to Power Jet 1 OFF TPS with pressing + or - and then press
enter .
Now you can change TPS position with pressing + or - (in 1%TPS steps) and then press
enter .

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13. Set POWER JET 2 parameters
Enter Set Ign. menu and move to Power Jet 2 with pressing + or - and then press enter .
Now you are in submenu for selecting Power Jet 2 parameters.
Submenu organisation:
Power Jet 2 ON RPM - revs for activating power jet 2
Power Jet 2 OFF RPM - revs for deactivating power jet 2
Power Jet 2 ON TPS (if TPS enabled) - throttle position for activating power jet 2
Power Jet 2 OFF TPS (if TPS enabled) - throttle position for deactivating power jet 2
Exit - exit submenu
Example:
Power jet 2 ON (RPM) = 8000rpm
Power jet 2 OFF (RPM) = 10000rpm
Power jet 2 ON (TPS) = 70%TPS
power jet 2 OFF (TPS) = 90%TPS
Power jet is switched on when revs are between 8000-10000rpm and throttle position is
between 70-90%, otherwise power jet is switched off.
13.1. Set POWER JET 2 ON RPM
Enter Set Ign. menu and move to Power Jet 2 ON RPM with pressing + or - and then press
enter .
Now you can change rev limit with pressing + or - (in 100 rpm steps) and then press
enter .
13.2. Set POWER JET 2 OFF RPM
Enter Set Ign. menu and move to Power Jet 2 OFF RPM with pressing + or - and then
press enter .
Now you can change rev limit with pressing + or - (in 100 rpm steps) and then press
enter .
13.3. Set POWER JET 2 ON TPS (if TPS enabled)
Enter Set Ign. menu and move to Power Jet 2 ON TPS with pressing + or - and then press
enter .
Now you can change TPS position with pressing + or - (in 1%TPS steps) and then press
enter .

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13.4. Set POWER JET 2 OFF TPS (if TPS enabled)
Enter Set Ign. menu and move to Power Jet 2 OFF TPS with pressing + or - and then press
enter .
Now you can change TPS position with pressing + or - (in 1%TPS steps) and then press
enter .
14. Set TPS
Enabling or disabling Throttle Position Sensor.
Enter Set Ign. menu and move to TPS with pressing + or - and then press enter .
Now you can enable or disable TPS with pressing + or - and then press enter .
15. Set TPS close [0%] (if TPS enabled)
For correct operation, TPS close position must be calibrated!
Enter Set Ign. menu and move to TPS close [0%] with pressing + or - and then press
enter.
Leave throttle at close position and confirm calibrating with pressing enter , or exit
calibration with pressing - . Displayed number should be between 0 and 500.
16. Set TPS open [100%] (if TPS enabled)
For correct operation, TPS open position must be calibrated!
Enter Set Ign. menu and move to TPS open [100%] with pressing + or - and then press
enter .
Move throttle to maximum open position and confirm calibrating with pressing enter , or exit
calibration with pressing -. Displayed number should be between 500 and 1010.
17. Set REMOTE SW
Enabling or disabling external switch for changing ignition curves while riding.
Enter Set Ign. menu and move to Remote SW with pressing + or - and then press enter .
Now you can enable or disable external switch with pressing + or - and then press enter .
18. Set PULSES PER REV
It is number of pulses per rev from pickup coil and is important for correct rev reading.
Setting is 2 for all twins with wasted spark ignition system.
Enter Set Ign. menu and move to Pulses Per Rev with pressing + or - and then press enter.
Now you can change nr. of pulses per rev with pressing + or - and then press enter .

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19. LOAD PV CURVE
Enter Set PV menu and move to Load PV Curve with pressing + or - and then press enter.
Now you can select position number of previously saved ignition curve set, with pressing +
or - and then press enter .
20. SAVE PV CURVE
Enter Set PV menu and move to Save PV Curve with pressing + or - and then press enter.
Now you can select position number to which you want to save your ignition curve set, with
pressing + or - and then press enter .
21. Set PV Curve
Enter Set PV menu and move to Set PV Curve with pressing + or - and then press enter .
Now you are in submenu for setting valve curve.
Submenu organisation:
Nr. of Points - number of valve curve points (from 2 to 8)
1) - first valve position point
2) - second valve position point
... ...
... ...
Exit - exit submenu
Important!
To avoid wrong processing, don't make unreasonable curve course.
Every time you make any changes to valve curve, it is automatically saved to #0 position.
Then you can save it to any other position number from #1 to #5.
21.1. Change Number of Curve Points
Move to Nr. of Points with pressing + or - and then press enter .
Now you can select number of curve points, with pressing + or - and then press enter .
21.2. Change Parameters of Valve Position Curve Points
Move to point you want to change, with pressing + or - and then press enter .
Now you can change rev point with pressing + or - (in 100 rpm steps) and then press
enter .
Now you can change valve position from 0% to 100%, with pressing + or - (in 1% steps)
and then press enter .

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22. Set Deviation
Enter Set PV menu and move to Deviation with pressing + or - and then press enter .
Now you can change deviation from 2% to 20% with pressing + or - (in 1% steps) and then
press enter .
Deviation means how accurate valve is moved to calculated position. If deviation is too low
then servo motor won't be stabile – it will always search for calculated position in small
movements. Default setting is +-5% and should meet in most cases.
23. Set MAX CLOSE POSITION
Enter Set PV menu and move to Close Position with pressing + or - and then press enter .
Now you can set close position with pressing + or - and then press enter .
Max close position is when curve is set to 0%. This close position can be moved to any
desired position. For RZ350 default close position is 240. Max close position can be moved to
deeply closed or less closed position.
24. Set MAX OPEN POSITION
Enter Set PV menu and move to Open Position with pressing + or - and then press enter .
Now you can set open position with pressing + or - and then press enter .
Max open position is when curve is set to 100%. This open position can be moved to any
desired position. For RZ350 default open position is 512. Max open position can be moved to
more open or less open position.
25. PV Test
Enter Set PV menu and move to PV Test with pressing + or - and then press enter .
Now you can set valve position with pressing + or - and then press enter .
PV test can be used for testing or measuring valve position. Valve can be moved to any
position from 0% to 100%, without engine running.
26. Set POWER-UP Test
Enabling or disabling test cycle of PV servo at power-up.
Enter Set PV menu and move to Power-up Test with pressing + or - and then press enter .
Now you can enable or disable power-up test with pressing + or - and then press enter .

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27. Set INITIAL POSITION
It is PV position (open or close) after power-up when engine does not running.
Enter Set PV menu and move to Initial Position with pressing + or - and then press enter.
Now you can set PV initial position to open or close, with pressing + or - and then press
enter .
28. MECHANICAL SETTINGS (Static Angle)
Static Angle is ignition advance angle, set with stator (generator).
Measure this angle with dial gauge. This measured Static Angle is your maximum advance
angle you can set with PDCI.
Calculating mm to deg or vice versa:
29. MONITORING
Connect programmer to PDCI and wait few seconds for activation of programmer. Fist
information displayed on the programmer is software version.
With programmer you can watch revs, calculated advance ignition angle, selected ignition
curve, TPS position...depends on setting in the menu.
Information!
You can connect or disconnect PDCI unit from programmer any time you want, without any
harm. It is not important, if motor running or not and if power supply is connected or not.
Important!
Do not use too much force when connecting or disconnecting programmer unit!
30. ERROR REPORTS
PVerr 1 – position sensor error or servo motor disconnected
PVerr 2 – servo motor error (short connection)