zeeltronic PDCI-NS1V User manual

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www.zeeltronic.com
[email protected]
updated 07.08.2019
program version: 40.180119
USER MANUAL
PDCI-NS1V PROGRAMMABLE CDI IGNITION AND PV CONTROLLER
PDCI-NS1V is 2 channel DC-CDI and exhaust valve controller, specially designed for
Honda RS250 and NSR250. It is programmable with handheld programmer, or PC.
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
- stand-by current draw < 0.09 Amp
- current draw at 1300 RPM < 0.3 Amp
- current draw at 12000 RPM < 1.7 Amp
- 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 >50mJ
Important!
Circuit is fully protected against reverse polarity from firmware 31.170203.
Features:
- fast power-up (also starts only with condenser)
- full power starting spark energy already at 7Volts power supply
- two isolated input (pickup)
- two independent ignition coil outputs
- individual advance/retard of each output
- store and load function for two ignition maps
- external switch for changing ignition map while riding
- TPS input (Throttle Position Sensor)
- shift light output
- 2 power jet outputs(duty cycle solenoid output)
- quick shift (shift kill)
- soft rev limit (three stage rev limit)
- reduced spark at high revs with closed throttle (TCT mode)
- tachometer output
- easy and fast programming on the field, via hand held programmer
- programming while machine running - you can immediately see effects

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- each curve can be set in 4 to 15 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 8 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, ...)
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 to ignition coil. High
voltage is generated and touching free wires can cause electric shock, or damage the
unit.
1. HOW TO ENTER MENU


Connect programmer to PDCI and wait few seconds for activation of programmer and
press 'ENTER'.


Move through menu with pressing '+', or '-'and select with pressing 'ENTER'.


Exit menu with selecting Exit.
2. MENU ORGANIZATION
Set Ign. - ignition parameters submenu
Set PV - PV parameters submenu
Exit
2.1. SET IGNITION PARAMETERS SUBMENU
Load Ign. Map - load (select) ignition map
Save Ign. Map - save new ignition map
Set Ignition Map - ignition map parameters submenu
Advance - advance/retard whole ignition map on both ignition coil outputs
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

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Rev Limit - rev limit
Static Angle - static angle (pickup position)
Compensation - signal delay compensation (from pickup to spark plug)
Power Jet s - set power jets
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
Trigger Mode - select trigger mode for specific engine
Stop SW Mode - stop switch mode
Tach Ratio - tachometer output pulse ratio
Ignition Test - ignition spark test
Exit
2.2. SET PV PARAMETERS SUBMENU
Load PV Curve - load (select) PV curve
Save PV Curve - save new PV curve
Set PV Curve - PV curve parameters submenu
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
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 press
'ENTER'.


Select number of previously saved ignition curve, with pressing '+', or '-'and press
'ENTER' to confirm.
4. SAVE IGN. MAP


Enter Set Ign. menu and move to Save Ign. Map with pressing '+', or '-'and press
'ENTER'.


Select number to which you want to save your ignition curve, with pressing '+', or '-' and
press 'ENTER'to confirm.

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5. SET IGNITION MAP (if TPS disabled)


Enter Set Ign. menu and move to Set Ign. Map with pressing '+', or '-'and press
'ENTER'to confirm.
You entered submenu for setting ignition map.
Submenu organisation:
Nr. of Points - number of ignition curve points (from 4 to 15)
1) - first ignition curve point
2) - second ignition curve point
... ...
... ...
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. Later you can save it to any other position #1, or #2.
Curve Example:
5.1. SET IGNITION MAP (if TPS enabled)
Three ignition curves can be programmed for different TPS positions. PDCI does not
only switch between ignition curves, but also interpolate 3D map for all TPS positions
above 33%.


Enter Set Ign. menu and move to Set Ign. Map with pressing '+', or '-'and press
'ENTER'to confirm.
You entered submenu for setting ignition map.

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Submenu organisation:
3D Ignition Map - enable/disable 3D ignition map
Nr. of Points - number of ignition curve points (from 4 to 15)
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 number
#0. Later you can save it to any other number #1, or #2.
Ignition Map Example:
5.2. Change NUMBER OF IGNITION CURVE POINTS


Move to Nr. of Points with pressing '+', or '-'and press 'ENTER'to confirm.


Select number of ignition points, with pressing '+', or '-'and press 'ENTER'to confirm.
5.3. Change PARAMETERS OF IGNITION CURVE POINT


Move to point you want to change, with pressing '+', or '-'and press 'ENTER'to confirm.


Change rev point with pressing '+', or '-'(in 100 rpm steps) and press 'ENTER'to
confirm.


Change advance angle of output 1 with pressing '+', or '-'(in 0.1deg steps) and press
'ENTER'to confirm.


Change advance angle of output 2 with pressing '+', or '-'(in 0.1deg steps) and press
'ENTER'to confirm.

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6. ADVANCE
With Advance setting is possible to advance, or retard whole ignition map on both
ignition outputs. When setting is positive then ignition map is advanced and when
setting is negative then ignition map is retarded. With Advance 0.0deg, ignition map is
unchanged.


Enter menu and move to Advance with pressing '+', or '-'and press 'ENTER'to
confirm.


Set advance with pressing '+', or '-'(in 0.1deg steps) and press 'ENTER'to confirm.
7. ADVANCE 1
With Advance 1 is possible to advance, or retard whole map only on output 1. When
setting is positive then ignition map is advanced and when setting is negative then
ignition map is retarded. With Advance 1 0.0deg, ignition map is unchanged.


Enter Set Ign. menu and move to Advance 1 with pressing '+', or '-'and press 'ENTER'
to confirm.


Set advance with pressing '+', or '-'(in 0.1deg steps) and press 'ENTER'to confirm.
8. ADVANCE 2
With Advance 2 setting is possible to advance, or retard whole map only on output 2.
When setting is positive then ignition cmap is advanced and when setting is negative
then ignition cmap is retarded. With Advance 2 0.0deg, ignition curve is unchanged.


Enter Set Ign. menu and move to Advance 2 with pressing '+', or '-'and press 'ENTER'
to confirm.


Set advance with pressing '+', or '-'(in 0.1deg steps) and press 'ENTER'to confirm.
9. GEAR SHIFT LIGHT


Enter Set Ign. menu and move to Gear Shift Light with pressing '+', or '-'and press
'ENTER'to confirm


Change rev point with pressing '+', or '-'(in 100 rpm steps) and press 'ENTER'to
confirm

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10. QUICK SHIFT


Enter Set Ign. menu and move to Quick Shift with pressing '+', or '-'and press
'ENTER'to confirm.
...you entered submenu Quick Shift.
Submenu organisation:
Shift Kill Time - basic kill time (at 12000rpm)
Smart Shift - activating/deactivating automatic kill time for different revs
Exit - exit submenu
10.1. SHIFT KILL TIME


Enter Quich Shift menu and move to Shift Kill Time with pressing '+', or '-'and press
'ENTER'to confirm.


Set kill time with pressing '+', or '-'(in 1ms steps) and press 'ENTER'to confirm.
10.2. 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 press
'ENTER'to confirm.


Enable, or disable Smart Shift function with pressing '+', or '-'and press 'ENTER'to
confirm.
11. REV LIMIT


Enter Set Ign. menu and move to Rev Limit with pressing '+', or '-'and press 'ENTER'
to confirm.


Set Rev Limit with pressing '+', or '-'and press 'ENTER'to confirm.
12. STATIC ANGLE
Static angle is reference point for CDI unit. Correct static angle is very important for
correct ignition advance. If programmed static angle is not same as mechanical position
of pickup(trigger point), then ignition advance will not be correct. Too much difference
will result in bad running engine, or even non operational engine. Ignition is always after
static angle(trigger point)...that means that static angle must be always greater than
maximum ignition advance.


Enter Set Ign. menu and move to Static Angle with pressing '+', or '-'and press
'ENTER'to confirm.


Set static angle with pressing '+', or '-'(in 0.1deg steps) and press 'ENTER'to confirm.

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How to measure static angle?
The most accurate procedure is with dial gauge.
Apply to single and multiple cylinder engines.
Necessary tools:
- stroboscope light
- dial gauge
Follow the procedure:


measure approximate static angle, just to have starting point...look at drawing below.
Anticlockwise rotation:
TRIGGER POINT
TDC
static angle
Clockwise rotation:
TDC
TRIGGER POINT
static angle


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

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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)
Equation for calculating from degrees to millimetres:


remove sparkplug from cylinder head and place dial gauge


find TDC (Top Dead Centre)


rotate engine backwards (opposite from engine running rotation) to calculated advance
in millimetres (in example is 1,3mm) and make marks on rotor and stator


remove dial gauge and place sparkplug back to cylinder head


start engine and run with constant revs of about 3000rpm, or 4000rpm


use stroboscope light to check, if marks on rotor and stator align


adjust static angle with programmer to align marks on the rotor and stator
Result of above procedure is very accurate static angle.
13. 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 ignition advance is correct (accurate).
How to check, if compensation is correct:


Set flat ignition curve...16deg advance is suitable for most engines


Measure with stroboscope lamp, if mark at flywheel moving when changing revs. If mark
moves, then change compensation delay.
Change Compensation:


Enter Set Ign. menu and move to Compensation with pressing '+', or '-'and press
'ENTER'to confirm.


Set Compensation with pressing '+', or '-'and press 'ENTER'to confirm.
( ) ( )
2
2sincos1
mminlengthconrod
mmin2bydividedstrokeengine
mminadvanceignition
degreesinadvanceignition
αα
α
⋅−−−⋅+=
=
=
=
=
RLRLT
L
R
T

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14. POWER JETS


Enter Set Ign. menu and move to Power Jets with pressing '+', or '-'and press 'ENTER'
to confirm.
...you entered submenu Power Jets.
Submenu organisation:
Invert Polarity - invert power jet operation (invert open/close)
set Power Jet 1 - activating/deactivating soft rev limit
set Power Jet 2 - activating/deactivating soft rev limit
Exit - exit submenu
14.1. INVERT POLARITY of power jets


Enter Power Jets menu and move to Invert Polarity with pressing '+', or '-'and press
'ENTER'to confirm.


Enable/disable Invert Polarity with pressing '+', or '-'and press 'ENTER'to confirm.
14.2. set Power Jet 1 (if TPS enabled)
Three duty cycle curves for different throttle positions can be programmed. Each curve
can be programmed in 8 rev points.


Enter Power Jets menu and move to set Power Jet 1 with pressing '+', or '-'and press
'ENTER'to confirm.
...you entered submenu set Power Jet 1.
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
14.3. Change PARAMETERS OF POWER JET CURVE POINT


Move to point you want to change, with pressing '+', or '-'and press 'ENTER'to confirm.


Change rev point with pressing '+', or '-'(in 100 rpm steps) and press 'ENTER'to
confirm.


Change duty cycle with pressing '+', or '-'(in 1% steps) and press 'ENTER'to confirm.
14.4. set Power Jet 2
Same as with set Power Jet 1.

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15. TPS


Enter Set Ign. menu and move to TPS with pressing '+', or '-'and press 'ENTER'to
confirm.


Enable/disable TPS with pressing '+', or '-'and press 'ENTER'to confirm.
16. Set TPS close [0%] (if TPS enabled)
TPS close position must be calibrated to ensure correct TPS operation!


Enter Set Ign. menu and move to TPS close [0%] with pressing '+', or '-'and press
'ENTER'to confirm.


Leave throttle at close position and confirm calibrating with pressing 'ENTER', or exit
calibration with pressing '-'. Displayed number should be between 0 and 500.
17. Set TPS open [100%] (if TPS enabled)
TPS open position must be calibrated to ensure correct TPS operation!


Enter Set Ign. menu and move to TPS open [100%] with pressing '+', or '-'and press
'ENTER'to confirm.


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.
18. 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 press 'ENTER'
to confirm.


Enable, or disable TCT mode with pressing '+', or '-'and press 'ENTER'to confirm.
This setting is primarily for race use, for normal road use the recommended setting is
'DISABLED'.
If you getting errors on the rev counter then 'DISABLE' this setting.
19. IGN. MAP SW
Enabling, or disabling ignition map switch, for changing ignition maps while riding.


Enter Set Ign. menu and move to Ign. Map SW with pressing '+', or '-'and press
'ENTER'to confirm.


Enable or disable external switch with pressing '+', or '-'and press 'ENTER'to confirm.

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20. Trigger Mode
Select trigger mode for specific engine.
Trigger Mode '1' is for RS250 NF5 and NSR250 MC21
Trigger Mode '2' is for RS250 NX5


Enter Set Ign. menu and move to Trigger Mode with pressing '+', or '-'and press
'ENTER'to confirm.


Change Trigger Mode with pressing '+', or '-'and press 'ENTER'to confirm.
21. Stop Switch Mode
It defines stop switch position for engine stop.
"Low Level Stop" ... engine stops at low level signal (when stop switch connected to
the ground).
"High Level Stop" ... engine stops at high level signal (when stop switch is opened).


Enter Set Ign. menu and move to Stop SW Mode with pressing '+', or '-'and press
'ENTER'to confirm.


Change Stop SW Mode with pressing '+', or '-'and press 'ENTER'to confirm.
22. Tach Ratio
Tachometer output pulse ratio can be set to 1, or 2 pulses per revolution.


Enter Set Ign. menu and move to Tach Ratio with pressing '+', or '-'and press 'ENTER'
to confirm.


Change Tach Ratio with pressing '+', or '-'and press 'ENTER'to confirm.
23. 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.
Enter Set Ign. menu and move to Ignition Test with pressing '+', or '-'. With pressing
'ENTER'multiple sparks will occur, for about 1s separately on each cylinder.
24. Load PV Curve


Enter Set PV menu and move to Load PV Curve with pressing '+', or '-'and press
'ENTER'.


Select number of previously saved ignition curve, with pressing '+', or '-'and press
'ENTER' to confirm.

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25. Save PV Curve


Enter Set Ign. menu and move to Save PV Curve with pressing '+', or '-'and press
'ENTER'.


Select number to which you want to save your ignition curve, with pressing '+', or '-' and
press 'ENTER'to confirm.
26. Set PV Curve


Enter Set PV menu and move to Set PV Curve with pressing '+', or '-'and press
'ENTER'.
...you entered submenu for setting PV curve.
Submenu organisation:
Nr. of Points - number of PV 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 PV curve, it is automatically saved to number #0.
Later you can save it to any other number from #1, or 2#.
26.1. Change Number of Curve Points


Move to Nr. of Points with pressing '+', or '-' and press 'ENTER'to confirm.


Select number of curve points, with pressing '+', or '-' and press 'ENTER'to confirm.
24.2. Change Parameters of PV Curve Points


Move to point you want to change, with pressing '+', or '-' and press 'ENTER'to confirm.


Change rev point with pressing '+', or '-' and press 'ENTER'to confirm.


Change PV position from 0% to 100%, with pressing '+', or '-' and press 'ENTER'to
confirm.

- 14 -
25. Deviation


Enter Set PV menu and move to Deviation with pressing '+', or '-' and press 'ENTER'to
confirm.


Change deviation from 2% to 20% with pressing '+', or '-'(in 1% steps) and then
'ENTER'to confirm.
Deviation means how accurate valve move 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.
26. Close Position
Max close position must be calibrated. Max close position is when curve is set to 0%.
Close position can be moved to any desired position.


Enter Set PV menu and move to Close Position with pressing '+', or '-' and press
'ENTER'to confirm.


Set close position with pressing '+', or '-' and press 'ENTER'to confirm.
27. Open Position
Max open position must be calibrated. Max open position is when curve is set to 100%.
Open position can be moved to any desired position.


Enter Set PV menu and move to Open Position with pressing '+', or '-' and press
'ENTER'to confirm.


Set open position with pressing '+', or '-' and press 'ENTER'to confirm.
28. PV Test
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.


Enter Set PV menu and move to PV Test with pressing '+', or '-' and press 'ENTER'to
confirm.


Set valve position with pressing '+', or '-' and press 'ENTER'to confirm.
29. Powe-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 press
'ENTER'to confirm.


Enable, or disable power-up test with pressing '+', or '-' and press 'ENTER'to confirm.

- 15 -
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 press
'ENTER'to confirm.


Enable, or disable PV Curve switch with pressing '+', or '-' and press 'ENTER'to
confirm.
31. 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, 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!
32. ERROR REPORTS
PVerr 1 – position sensor error, or servo motor disconnected
PVerr 2 – servo motor error (short connection)