zeeltronic PDCI-24VT Owner's manual

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www.zeeltronic.com
[email protected]
updated 21.06.2022
firmware: 425.00.220616
PROGRAMMING MANUAL
PDCI-24VT PROGRAMMABLE DC-CDI IGNITION AND PV
CONTROLLER
PDCI-24VT is programmable DC-CDI with exhast valve controller which runs with single
pickup and two ignition coils. It is suitable for wasted spark twins, or “big bang twins”. PDCI-
24VT supports TPS, ignition and exhaust valve map switch, duty solenoid, general purpose
outputs (GPO), shift light, quick shift...
TECHNICAL DATA
Limit values:
- minimum revs 200 RPM
- maximum revs 20000 RPM
- minimum supply voltage 7 Volts
- recommended power supply voltage 12÷15 Volts
- maximum supply voltage 17 Volts
- maximum continuous current for and Duty Solenoid and GPO output 1 Amp
- stand-by current draw < 0.04 Amp
- current draw at 1300 RPM < 0.5 Amp
- current draw at 12000 RPM < 3 Amp
- output energy 75 mJ
Features:
- fast power-up (also starts only with condenser)
- full power starting spark energy already at 7Volts power supply
- one isolated input for magnetic pickup
- two independent ignition coil outputs
- two programmable ignitiom maps with 15 points
- external switch for changing ignition map while riding
- TPS input (Throttle Position Sensor)
- 3D interpolated ignition map, if TPS selected
- signal delay compensation
- duty cycle solenoid output
- general purpose outputs (GPO)
- soft rev limit (three stage rev limit)
- quick shift
- tachometer output
- reduced spark at high revs with closed throttle (TCT mode)
- easy and fast programming on the field, via hand held programmer

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- programming with PC
- programming while machine running
- 3D interpolated ignition map, if TPS used
- programmable power valve actuation
- two programmable PV curves
- external switch for changing PV curve while riding
- 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)
- fast processing for high accuracy - delays from 1us
- timing calculation for every 1 RPM change (1000, 1002, .. , 9805, 9806, ...)
- signal delay compensation ensure accurate ignition advance
- instant monitoring of rev's and angle, via LCD(hand held programmer)
- fast processing for high accuracy - delays from 1us
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. High voltage
is generated and touching free wires can cause electric shock, or PDCI damage.
Very important!
PDCI is protected against static discharge, but too high static charge can damage PDCI.
Be careful when using programmer on the dyno, because static charge can build up on the bike
and static discharge
can damage PDCI unit, or programmer. Make ground connection between dyno and bike frame
to prevent static
discharge.
1. HOW TO ENTER MENU
Connect handheld programmer to PDCI and wait few seconds for activation of handheld
programmer and press ENTER . Move through the menu with pressing + , or - and choose
with pressing ENTER .
Exit menu with choosing Exit.
2. MENU ORGANISATION
Set Ign. - set ignition parameters submenu
Set PV - set PV parameters submenu
Exit

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2.1. SET IGNITION PARAMETERS SUBMENU
Select Ign. Map - select active ignition map (#1, or #2)
Ign. Map Switch - activating/deactivating external switch for selecting ignition map
Set Ignition Map #1 - ignition map #1 settings
Set Ignition Map #2 - ignition map #2 settings
Advance - advance/retard whole ignition map
Advance 1 - advance/retard ignition coil output 1
Advance 2 - advance/retard ignition coil output 2
Gear Shift Light - shift light
Quick Shift - quick shift settings
Rev Limit 1 - rev limit ignition map #1
Rev Limit 2 - rev limit ignition map #2
Static Angle - static angle (stator position)
Compensation - signal delay compensation
Trigger Mode - trigger mode
GPO - general purpose output settings
Duty Solenoid - duty solenoid settings
Set TPS - TPS (Throttle Position Sensor) settings
Pulses Per Rev - number pulses per revolution from pickup
Kickback Protection - kickback protection settings
Stop SW Mode - select low, or high level stop
Ignition Test - sparks are generated for few seconds
Exit
2.2. SET PV PARAMETERS SUBMENU
Select PV Map - select active PV map (#1, or #2)
PV Map Switch - activating/deactivating external switch for selecting PV map
Set PV Map #1 - PV map #1 settings
Set PV Map #2 - PV map #2 settings
Deviation +- - deviation of PV position
Close Position - max close PV position
Open Position - max open PV position
PV Test - PV position test
Power-up Test - enable, or disable test cycle at power-up
Exit
3. SELECT IGN. MAP
Active map can be selected only, if map switch is disabled. When map switch is enabled, then
active map is selected by map switch.
Move to Select Ign. Map with pressing + , or - and press ENTER .
Select number of ignition map, with pressing + , or - and press ENTER .

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4. IGN. MAP SWITCH
Enabling, or disabling ignition map switch. With ignition map switch is possible to change
ignition map while riding.
Move to Ign. Map Switch with pressing + , or - and press ENTER .
Enable, or disable external switch with pressing + , or - and press ENTER .
5. SET IGNITION MAP #1
Ignition advance between programmed points is interpolated.
Move to Set Ignition Map #1 with pressing + , or - and press ENTER .
Submenu organisation:
Nr. of Points - number of ignition curve points (from 4 to 15)
Curve TPS 0% - first ignition curve
Curve TPS 5% - second ignition curve
... ...
Curve TPS 100% -
Exit - exit submenu
Number of Curves and TPS values depends on TPS settings ... look at section Set TPS.
Important!
To avoid wrong processing, don't make unreasonable curve course.
Ignition Map Example:
Nr. of Points:
Move to Nr. of Points with pressing + , or - and press ENTER .
Select number of ignition points, with pressing + , or - and press ENTER .

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Set Curve TPS xxx%:
Procedure is same for each ignition curve.
xxx% value depend on TPS settings ... look at section Set TPS.
Move to Curve TPS xxx% with pressing + , or - and press ENTER .
Move to point you want to change, with pressing + , or - and press ENTER .
Change rev point with pressing + , or - (in 10 rpm steps) and press ENTER .
Change advance angle with pressing + , or - (in 0.1deg steps) and press ENTER .
Continue with same procedure for each point you want to change.
6. SET IGNITION MAP #2
Procedure is same as for ignition map #1... look at section SET IGNITION MAP #1.
7. ADVANCE
With this setting is possible to advance, or retard whole ignition map for both ignition outputs.
When setting is positive, then ignition map is advanced and when setting is negative, than
ignition map is retarded. Ignition map advance is unchanged, with setting 0.0deg.
Move to Advance, with pressing + , or - and then press ENTER .
Set advance with pressing + , or - (in 0.1deg steps) and press ENTER .
8. ADVANCE 1
With this setting is possible to advance, or retard whole ignition map for ignition output 1. When
setting is positive, then ignition map is advanced and when setting is negative, than ignition map
is retarded. Ignition map advance is unchanged, with setting 0.0deg.
Move to Advance 1, with pressing + , or - and then press ENTER .
Set advance with pressing + , or - (in 0.1deg steps) and press ENTER .
9. ADVANCE 2
With this setting is possible to advance, or retard whole ignition map for ignition output 2. When
setting is positive, then ignition map is advanced and when setting is negative, than ignition map
is retarded. Ignition map advance is unchanged, with setting 0.0deg.
Move to Advance 2, with pressing + , or - and then press ENTER .
Set advance with pressing + , or - (in 0.1deg steps) and press ENTER .
10. GEAR SHIFT LIGHT
Move to Gear Shift Light, with pressing + , or - and then press ENTER .
Set rev point for activating shift light with pressing + , or - and press ENTER .

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11. QUICK SHIFT
Move to Quick Shift, with pressing + , or - and then press ENTER to enter submenu.
Submenu organisation:
Shift Kill Time - basic kill time
Smart Shift - activating/deactivating automatic kill time for different revs
Exit
Move to Quick Shift, with pressing + , or - and then press ENTER .
Set kill time with pressing + , or - and press ENTER .
Move to Smart Shift with pressing + , or - and press ENTER .
Enable, or disable smart shift with pressing + , or - and press ENTER .
12. REV LIMIT 1
Rev limit for ignition map #1.
Move to Rev Limit 1 with pressing + , or - and press ENTER .
Change rev limit with pressing + , or - and press ENTER .
13. REV LIMIT 2
Rev limit for ignition map #2.
Move to Rev Limit 2 with pressing + , or - and press ENTER .
Change rev limit with pressing + , or - and press ENTER .
14. STATIC ANGLE
Move to Static Angle with pressing + , or - and press ENTER .
Set static angle with pressing + , or - and press ENTER .
Find more information's about static angle in section MEASURING STATIC ANGLE and
Explanation of trigger signal from pickup.
15. COMPENSATION
Delay compensation is compensation of signal delay from pickup to spark plugs.
Compensation ensures that ignition advance is same as programmed (accurate).
How to check, if compensation is correct:
- program flat ignition curve
- measure ignition advance with strobe light at low and at high revs
- if advance at low and high revs is not same, then compensation delay must be adjusted

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Change Compensation:
Move to Compensation with pressing + , or - and press ENTER .
Change compensation delay with pressing + , or - and press ENTER .
16. Set TRIGGER MODE
Move to Trigger Mode with pressing + , or - and then press ENTER .
Change Trigger Mode with pressing + , or - and then press ENTER .
Trigger signal from pickup consist of positive and negative pulse. Positive pulse must be first
and is generated by leading edge of trigger bar...negative pulse must be second and is generated
by trailing edge of trigger bar.
If trigger signal is opposite (first negative and second positive), then wires from the pickup have
to be swapped...that changes polarity of signal from pickup.
Positive pulse defines static angle position and negative pulse defines idle running timing
position.
When Trigger Mode 1 is selected, then only positive signal is detected and ignition timing is
calculated for all revs as programmed with ignition map.
When Trigger Mode 2 is selected, then both signals are detected. Revs of first ignition point
define switching point between, programmed ignition map and idle running timing position.
Trigger Mode 2 ensures stable ignition advance at starting and is recomended for larger
displasment cylinders (prevents kickback).
- Ignition timing is defined with trailing edge of trigger bar, at revs lower then first ignition point
(idle advance...se drawing above).
- Ignition timing is defined with programmed map, at revs higher then first ignition point.
Example: if first ignition point is programmed at 1500rpm, then below 1500rpm ignition timing
is defined with trailing edge of trigger bar (idle advance...se drawing above) and above 1500rpm
ignition timing is defined by programmed ignition map.

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Set Trigger Mode 1 when using custom, or modified trigger rotor, or upgrade from static ignition
timing CDI.
Set Trigger Mode 2 when using original trigger rotors, or flywheels. First ignition point should
be programmed somewhere between 1000-2000rpm.
17. GPO (General Purpose Output)
GPO is general purpose output.
GPO changes state when revs and TPS are higher/lower then programmed value.
GPO is de-energized (OFF) when engine not running!
Display explanation:
GPO 1 10% .
OFF 5000 ON .
- 10% means TPS value
- 5000 means RPM value
- OFF means de-energized GPO
- ON means energized GPO
Explanation of operation of above settings:
GPO is ON when revs are above 5000 rpm and TPS is above 10%, otherwise GPO is OFF.
Move to GPO with pressing + , or - and then press ENTER .
Change ON/OFF state with pressing + , or - and press ENTER .
Change TPS value with pressing + , or - and press ENTER .
Change RPM value with pressing + , or - and press ENTER .
When TPS disabled, then GPO TPS value can’t be adjusted and TPS position does not affect on
GPO operation.
18. DUTY SOLENOID
Three duty cycle curves for different throttle positions can be programmed. Each curve can be
programmed in 8 rev points.
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
Invert Operatio - enable, or disable inverted operation of duty solenoid
Exit - exit submenu

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18.1. Set PARAMETERS FOR DUTY SOLENOID CURVE
Move to Curve xxx% with pressing + , or - and press ENTER .
Move to point you want to change, with pressing + , or - and press ENTER .
Change rev point with pressing + , or - and press ENTER .
Change duty cycle with pressing + , or - and press ENTER .
Continue with same procedure for each point you want to change.
When TPS disable, then only one curve can be programmed...TPS position does not affect on
duty solenoid operation.
19. Set TPS
Settings for Throttle Position Sensor.
Move to Set TPS with pressing + , or - and press ENTER .
Submenu organization:
TPS enable/disable - enable, or disable TPS
TPS close [0%] - calibrate TPS close position
TPS open [100%] - calibrate TPS open position
Nr. of TPS Ign. Points - number of TPS ignition points
Set TPS Points - set TPS points for ignition map
Exit - exit submenu
TPS enable/disable:
Move to TPS with pressing + , or - and press ENTER .
Enable, or disable TPS with pressing + , or - and press ENTER .
When TPS disabled, then other TPS parameters can’t be adjusted.
TPS close [0%]:
For correct operation, TPS close position must be calibrated!
Move to TPS close [0%] with pressing + , or - and press ENTER .
Hold throttle at close position and confirm calibration with pressing ENTER , or exit calibration
with pressing - . Displayed number should be between 0 and 500.
TPS open [100%]:
For correct operation, TPS open position must be calibrated!
Move to TPS open [100%] with pressing + , or - and press ENTER .
Hold throttle at open position and confirm calibration with pressing ENTER , or exit calibration
with pressing - . Displayed number must be greater then for TPS close position.
Nr. of TPS Ign. Points
Move to Nr. of TPS Ign. Points with pressing + , or - and press ENTER to continue.
Select number of ignition points, with pressing + , or - and press ENTER to continue.

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Set TPS points:
Move to Set TPS Points with pressing + , or - and press ENTER .
Adjust TPS value with pressing + , or - and press ENTER .
Continue with same procedure for all TPS points.
First TPS point must be lowest value, each next point must have higher value then previous.
20. 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 ensures better engine cooling
and lubrication when TPS closed.
TPS must be enabled.
Move to TCT mode with pressing + , or - and press ENTER .
Enable, or disable TCT mode with pressing + , or - and press ENTER .
21. PULSES PER REV
It is number of pulses per rev from pickup coil and is important for correct rev reading.
Set 1 for twins “big bang”operation and set 2 for twins wasted spark.
Move to Pulses Per Rev with pressing + , or - and press ENTER .
Change nr. of pulses per rev with pressing + , or - and press ENTER .
22. KICKBACK PROTECTION
Move to Kickback Protection with pressing + , or - and press ENTER .
Submenu organization:
Lobe Length - trigger rotor lobe length in degrees (only with Trigger Mode 2)
Min Starting Rpm - minimal rpm for starting engine
Nr Revs Without Ignition - number revolutions without ignition
Exit - exit submenu
Lobe Length:
Lobe length is used to calculate RPM at starting. Wrong value result in wrong calculation.

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Min Starting Rpm:
Minimal rpm for starting engine.
Move to Min Starting Rpm with pressing + , or - and press ENTER .
Set rpm with pressing + , or - and press ENTER .
Nr Revs Without Ignition
Number revolutions without ignition at starting.
Move to Nr Revs Without Ignition with pressing + , or - and press ENTER .
Set number with pressing + , or - and press ENTER .
23. Set STOP SWITCH MODE
It defines stop switch position for engine stop.
"low stop" ... engine stops when low level signal (when stop switch connected to the
ground).
"high stop" ... engine stops when high level signal (when stop switch is opened).
Move to Stop SW Mode with pressing + , or - and press ENTER .
Change Stop SW Mode with pressing + , or - and press ENTER .
24. IGNITION TEST
Spark execution test without running engine. Spark can be optically checked, with removed
spark plug connected to plug cup and to the ground.
Move to Ignition Test with pressing + , or - and press ENTER .
After pressing enter multiple sparks will occur for about 1s.
25. MONITORING
Connect programmer to PDCI and wait few seconds for activation of programmer. Fist
information displayed on the programmer is firmware version.
Programmer shows revs, calculated ignition advance angle, 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.
Important!
Do not use too much force when connecting, or disconnecting programmer unit!

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26. MEASURING STATIC ANGLE
Measuring correct static angle is very important. Wrong static angle will cause inaccurate ignition
advance. If static angle is programmed larger than mechanical static angle, then ignition advance
will be smaller then programmed, or vice versa.
The most accurate procedure of measuring static angle is with dial gauge and strobe light.
Procedure applies to single and multiple cylinder engines. If you have a multi cylinder engine
with multple pickups it is recommended (but not required) that you perform this procedure on
each cylinder/pickup pair for most accurate timing.
Necessary tools:
- strobe light
- dial gauge
Follow the procedure:
Measure approximate static angle with a degree wheel, just to have starting point...look at the
drawing below.
Counterclockwise rotation:
Clockwise rotation:
。program CDI with measured approximate static angle
。program CDI with flat ignition curve...16deg advance is suitable for most engines.
。find information about engine stroke and conrod length
。convert programmed flat ignition advance angle to millimetres
Example:
α=16deg (ignition advance)
L=110mm (conrod length)
R=54/2=27mm (engine stroke divided by 2)
T=1,3mm (calculated ignition advance in mm)

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Equation for calculating from degrees to millimetres:
 ignition advance in degrees
Tignition advance in mm
Rengine stroke divided by 2 in mm
L conrod length in mm
Downloadable spreadsheet is available on request.
。remove sparkplug from cylinder head and mount dial gauge in cylinder.
。find TDC (Top Dead Centre)
。rotate engine backwards (opposite from running engine rotation) to calculated advance
in millimetres (in example above it is 1,3mm) and make marks on rotor and stator
。remove dial gauge and install sparkplug back in cylinder head
。start engine and run at constant speed of 3000rpm to 4000rpm
。use a strobe light to check alignment of marks on rotor and stator
。adjust static angle with programmer to align marks on the rotor and stator
Result of above procedure is very accurate static angle.
Important!
。Static angle is reference point for CDI to calculate delay for programmed ignition
advance.
。Static angle has to be greater then maximum ignition advance!
。Example - If maximum advance in ignition map is 30deg, then static angle has to
be at least 31deg.
。Very large static angles are not a good solution, because it decreases
electronic ignition advance stability (do not use static angle greater then 45deg if not necessary).
If you find when testing with your strobe light that your timing marks are off by 10 or more
degrees it may be neccessary to reverse the wiring from the reluctor pickup to the ignition and
test again. Reluctor pickups have polarity but it is rarely marked on the pickups so must be
determined by the trial and error method. Incorrect wiring polarity will cause the reluctor pickup
to send the trigger signal on the trailing edge of the rotor instead of the required leading edge of
the rotor.

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