zeeltronic PDCI-11V User manual

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www.zeeltronic.com
[email protected]
updated 06.08.2014
program version: 25.120326
USER MANUAL
PDCI-11V PROGRAMMABLE CDI IGNITION AND PV CONTROLLER
TECHNICAL DATA
Limit values:
- minimum revs 280 RPM
- maximum revs 20000 RPM
- minimum supply voltage 9 Volts
- maximum supply voltage 18 Volts
- max idle current draw 50 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 20000 RPM >65mJ
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
- external switch for changing PV map while riding
- programmable PV deviation
- programmable max close and max open positions
- self PV test on power-up

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- PV error detecting (position sensor failure, servo motor failure)
- 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. Map - load previously saved ignition curve set (from #1 to #2)
Save Ign. Map - save new ignition curve set (from #1 to #2)
Ignition Map - ignition curve parameters submenu
Advance - advance/retard whole ignition curve
Gear Shift Light - shift light
Quick Shift - quick shift parameters
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
Solenoid Output - solenoid parameters
TPS - enable, or disable TPS
TPS close [0%] - calibrating TPS close position
TPS open [100%] - calibrating TPS open position
TCT mode - reduced spark at high revs with closed throttle
Ign. Map SW - activating/deactivating external switch for selecting ignition map
Pulses Per Rev - number pulses per revolution from pickup
Stop SW Mode - stop switch mode
IgnitionTest - test ignition spark

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Exit
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
PV Curve SW - activating/deactivating external switch for selecting PV curve
Exit
3. LOAD IGN. MAP
Enter Set Ign. menu and move to Load Ign. Map with pressing + , or - and then press
enter .Select position number of previously saved ignition map, with pressing + or - and
then press enter .
4. SAVE IGN. MAP
Enter Set Ign. menu and move to Save Ign. Map with pressing + , or - and then press
enter .Select position number to which you want to save your ignition map, with pressing +
, or - and then press enter .
5. Change IGNITION MAP (if TPS disabled)
Enter Set Ign. menu and move to Set Ignition Map with pressing + , or - and then press
enter . You are in submenu for setting ignition map.
Submenu organisation:
Nr. of Points - number of ignition map points (from 4 to 12)
1) - first ignition map point
2) - second ignition map point
... ...
... ...
Exit - exit submenu
Important!
To avoid wrong processing, don't make unreasonable map course.
Every time you make any changes to ignition map, it is automatically saved to position #0.
Then you can save it to any other position number #1 or #2.

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Ignition map example with six curve points:
5.1. Set IGNITION MAP (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% (3D map interpolation). From 0% to 33% TPS is used only one
ignition curve.
Enter Set Ign. menu and move to Ignition Map with pressing + , or - and then press
enter. 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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Ignition map example:
5.2. Change NUMBER OF IGNITION CURVE POINTS
Move to Nr. of Points with pressing + , or - and then press enter .
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 .
Change rev point with pressing + , or - (in 100 rpm steps) and then press enter .
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 .
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 .
Change rev point with pressing + ,or - (in 100 rpm steps) and then press enter .

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8. QUICK SHIFT
Enter Set Ign. menu and move to Quick Shift with pressing + , or - and then press enter .
...you entered submenu for quick shift settings.
Submenu organisation:
Shift Kill Time - basic kill time
Smart Shift - activating/deactivating automatic kill time for different revs
Exit - exit submenu
8.1. SHIFT KILL TIME
Enter Quich Shift menu and move to Shift Kill Time with pressing + , or - and then press
enter.
Change kill time with pressing + , or - (in 10 ms steps) and then press enter .
8.2. SMART SHIFT
Smart shift function automatically adjusts kill time for different revs. Shift kill time must be
always set, as basic kill time.
Enter Quich Shift menu and move to Smart Shift with pressing + , or - and then press
enter.
Enable, or disable function with pressing + , or - and then press enter .
9. Set REV LIMIT
Enter Set Ign. menu and move to Rev Limit with pressing + , or - and then press enter .
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 .
Set static angle with pressing + , or - (in 0.1deg steps) and then press enter .
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.
Compensation helps that advance angles in ignition map are accurate.

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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.
Default value is 30us and is correct for most applications.
Change Compensation:
Enter menu and move to Compensation with pressing + , or - and then press enter .
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 .
...you entered submenu for Power Jet 1.
12.1. Power Jet 1 Mode
Power jet 1 can operate in simple, or advanced mode. Simple mode, have only one 'on' and
'off' point. Advanced mode has multiple on/off points.
12.2. Power Jet 1 Simple Mode
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
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.
12.2. Power Jet 1 Advanced Mode
Power Jet Advanced mode can be used only when TPS enabled!
Power Jet Range 1:
Press enter to program range 1 parameters.
- TPS range ... press - , or + to select upper TPS value ... press enter to confirm
- move to switch point from 1, to 6 with pressing - , or +
- press enter to program switch point
- press - , or + to select revs ... press enter to confirm

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- press - to switch 'off' power jet, or press + to switch 'on' power jet
- to exit Power Jet Range, move to Exit with pressing - , or + and press enter to confirm
Power Jet Range 2:
Press enter to program range 2 parameters.
- TPS range ... press - , or + to select upper TPS value ... press enter to confirm
- move to switch point from 1, to 6 with pressing - , or +
- press enter to program switch point
- press - , or + to select revs ... press enter to confirm
- press - to switch 'off' power jet, or press + to switch 'on' power jet
- to exit Power Jet Range, move to Exit with pressing - , or + and press enter to confirm
Power Jet Range 3
Press enter to program range 3 parameters.
- move to switch point from 1, to 6 with pressing - , or +
- press enter to program switch point
- press - , or + to select revs ... press enter to confirm
- press - to switch 'off' power jet, or press + to switch 'on' power jet
- to exit Power Jet Range, move to Exit with pressing - , or + and press enter to confirm
Example:
Power jet Range 1 ... 0-40%TPS (takes control when TPS position is between 0%, 40%)
1) 0RPM ... on (PJ 'on' when engine not running)
2) 3000RPM ... off (PJ switch 'off' when revs rise and pass 3000rpm)
(PJ switch 'on' when revs drop and pass 3000rpm)
3) 5000RPM ... off (PJ remain 'off' position)
4) 8000RPM ... off (PJ remain 'off' position)
5) 10000RPM ... off (PJ remain 'off' position)
6) 12000RPM ... on (PJ switch 'on' when revs rise and pass 12000rpm)
(PJ switch 'off' when revs drop and pass 12000rpm)
Power jet Range 2 ... 41-80%TPS (takes control when TPS position is between 41%, 80%)
1) 0RPM ... on (PJ 'on' when engine not running)
2) 3000RPM ... off (PJ switch 'off' when revs rise and pass 3000rpm)
(PJ switch 'on' when revs drop and pass 3000rpm)
3) 5000RPM ... off (PJ remain 'off' position)
4) 8000RPM ... on (PJ switch 'on' when revs rise and pass 8000rpm)
(PJ switch 'off' when revs drop and pass 8000rpm)
5) 10000RPM ... off (PJ switch 'off' when revs rise and pass 10000rpm)
(PJ switch 'on' when revs drop and pass 10000rpm)
6) 12000RPM ... off (PJ remain 'off' position)
Power jet Range 3 ... 81-100%TPS (takes control when TPS position is between 81%, 100%)
1) 0RPM ... on (PJ 'on' when engine not running)
2) 3000RPM ... on (PJ remain 'on' position)
3) 5000RPM ... off (PJ switch 'off' when revs rise and pass 5000rpm)
(PJ switch 'on' when revs drop and pass 5000rpm)
4) 8000RPM ... on (PJ switch 'on' when revs rise and pass 8000rpm)
(PJ switch 'off' when revs drop and pass 8000rpm)

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5) 10000RPM ... off (PJ switch 'off' when revs rise and pass 10000rpm)
(PJ switch 'on' when revs drop and pass 10000rpm)
6) 12000RPM ... off (PJ remain 'off' position)
13. SOLENOID OUTPUT
Enter Set Ign. menu and move to Solenoid Output with pressing + , or - and then press
enter .
...you entered submenu for setting Solenoid Output parameters.
Submenu organisation:
Output type - select output type (Power Jet 2, or Duty Solenoid)
Power Jet 2 (if selected) - set Power Jet 2 parameters
Duty Solenoid (if selected) - set Duty Solenoid parameters
Exit - exit submenu
13.1. OUTPUT TYPE
Solenoid output function can be configured as Power Jet 2, or Duty Solenoid. Duty solenoid
is used for adjusting A/F ratio on some carburettors.
Enter Solenoid Output. menu and move to Output type with pressing + , or - and then
press enter .
Change solenoid Output type with pressing + , or - and then press enter .
13.2. POWER JET 2 (if selected in Output Type menu)
Same settings as Power Jet 1 Simple Mode...look at section 12.2.
13.3. DUTY SOLENOID (if selected in Output Type menu)
Three duty cycle curves for different throttle positions can be programmed. Each curve can be
programmed in 8 rev points.
Enter Solenoid Output menu and move to Duty Solenoid with pressing + , or - and then
press enter .
...you enterd submenu for setting Duty Solenoid parameters.
Submenu organisation:
Curve 0-33% - duty cycle curve from 0 to 33% TPS
Curve 34-66% - duty cycle curve from 34 to 66% TPS
Curve 67-100% - duty cycle curve from 67 to 100% TPS
Exit - exit submenu

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13.3.1 Set PARAMETERS FOR DUTY SOLENOID CURVE POINT
Move to point you want to change, with pressing + , or - and then press enter .
Change rev point with pressing + , or - (in 100 rpm steps) and then press enter .
Change duty cycle with pressing + , or - (in 1% 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 .
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. TCT mode
Throttle Close spark Termination mode, reduces number of sparks (spark is active every third
revolution) above 8000rpm, when throttle is closed. TCT mode ensure better engine cooling.
Enter Set Ign. menu and move to TCT mode with pressing + , or - and then press enter .
Enable, or disable TCT mode with pressing + , or - and then press enter .
TCT mode is primarily for race use, for normal road use the recommended setting is
'DISABLED'.
If you get errors on the rev counter then 'DISABLE' TCT mode.

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18. Set Ignition Map SW
Enabling, or disabling external switch for changing ignition curves while riding.
Enter Set Ign. menu and move to Ign. Map SW with pressing + , or - and then press
enter .
Enable, or disable external switch with pressing + ,or - and then press enter .
19. Set PULSES PER REV
It is number of pulses per rev from pickup coil and is important for correct rev reading. Set 1
for single cylinder engines. Set 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.
Change nr. of pulses per rev with pressing + , or - and then press enter .
20. Set STOP SWITCH MODE
Stop switch can be set as 'low stop', or as 'high stop'.
Low stop operation ... engine stops with low level signal (stop switch connected to the
ground)
High stop operation ... engine stops with high level signal (stop switch is opened)
Enter Set Ign. menu and move to Stop SW Mode with pressing + , or - and then press
enter.
Change stop switch mode with pressing + , or - and then press enter .
21. IGNITION TEST
Enter Set Ign. menu and move to Ignition Test with pressing + , or - and then press enter,
to activate spark test...spark will be generated for few seconds.
Before making spark test, connect PDCI to ignition coil!
22. LOAD PV CURVE
Enter Set PV menu and move to Load PV Curve with pressing + , or - and then press
enter.
Select position number of previously saved ignition curve set, with pressing + ,or - and
then press enter .

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23. SAVE PV CURVE
Enter Set PV menu and move to Save PV Curve with pressing + ,or - and then press enter.
Select position number to which you want to save your ignition curve set, with pressing + ,
or - and then press enter .
24. Set PV Curve
Enter Set PV menu and move to Set PV Curve with pressing + ,or - and then press enter .
...you enterd 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.
24.1. Change Number of Curve Points
Move to Nr. of Points with pressing + , or - and then press enter .
Select number of curve points, with pressing + , or - and then press enter .
24.2. Change Parameters of Valve Position Curve Points
Move to point you want to change, with pressing + , or - and then press enter .
Change rev point with pressing + , or - (in 100 rpm steps) and then press enter .
Change valve position from 0% to 100%, with pressing + , or - (in 1% steps) and then
press enter .
25. Set Deviation
Enter Set PV menu and move to Deviation with pressing + , or - and then press enter .
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 +-2% and should meet in most cases.

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26. Set MAX CLOSE POSITION
Enter Set PV menu and move to Close Position with pressing + , or - and then press
enter .
Set close position with pressing + , or - and then press enter .
Max close position is when curve is set to 0%. Close position can be moved to any position.
27. Set MAX OPEN POSITION
Enter Set PV menu and move to Open Position with pressing + , or - and then press
enter .
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
position.
28. PV Test
Enter Set PV menu and move to PV Test with pressing + , or - and then press enter .
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.
29. 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 .
Enable, or disable power-up test with pressing + ,or - and then press enter .
30. PV CURVE SW
Enabling, or disabling PV curve switch for changing PV curves while riding.
Enter Set PV menu and move to PV Curve SW with pressing + , or - and then press
enter .
Enable, or disable PV Curve switch with pressing + , or - and then press enter .
31. 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.

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Calculating mm to deg or vice versa:
32. MONITORING
Connect programmer to PDCI and wait few seconds for activation of programmer. Fist
information displayed on the programmer is firmware 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!
33. ERROR REPORTS
PVerr 1 – position sensor error or servo motor disconnected
PVerr 2 – servo motor error (short connection)