Download
Share
Print this page
  1. Manuals
  2. Brands
  3. SDS Manuals
  4. GPS
  5. EM-5-D
  6. Installation and tuning manual

SDS EM-5-D Installation And Tuning Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
EM-5 Aviation Installation and Tuning Manual for Version 31 Software.
Fuel Injection Portion.
May 12/20.
Disclaimer
These products do not conform to any recognized set of standards or certifications for
aviation applications.
This ECU is not waterproof and will not function as designed if moisture invades the enclosure
or power/ ground connections are interrupted.
Failure of this unit may result in a complete loss of engine power.
Use of these products on amateur built/ experimental aircraft is at the discretion of the buyer
who accepts full responsibility for any consequences resulting from its use. Since Racetech
Inc. cannot control the installation, programming, application environment or use of its
products, we accept no responsibility for damage, loss or personal injury resulting from the
SDS products, the user understands and accepts this.
use of SDS products. By using
If any user does not agree to this disclaimer, they may return the system/ parts in new
condition for a full refund
.
*********************************************************************************************************
Please read the entire manual before attempting any hookup or running of the system.
Due to the technical nature of this system, we have broken down the information into various separate
manuals to make the information easier to find and update. This manual covers the fuel injection
portion of the installation.
For tech help email Racetech/SDS at
racetech1@telus.net
or call 403-671-4015. When calling for
help please let us know which system you have. See below for descriptions of different systems.
System Description
SDS EM-5 is available in 2 different models for aviation applications:
EM-5-D controls fuel injectors only.
EM-5-F controls fuel and ignition timing using multiple ignition coils.
EM-5 is a microprocessor based, digital, programmable EFI system intended to control port type injectors. The
EM-5 allows you to access all points in the engine operating map with the engine running and alter them
according to your own specific needs utilizing a hand-held or panel mounted LCD programming box. As such,
the system can be used on virtually any engine type or displacement
1

Advertisement

loading
Need help?

Need help?

Do you have a question about the EM-5-D and is the answer not in the manual?

Questions and answers

Related Manuals for SDS EM-5-D

Summary of Contents for SDS EM-5-D

  • Page 1 See below for descriptions of different systems. System Description SDS EM-5 is available in 2 different models for aviation applications: EM-5-D controls fuel injectors only. EM-5-F controls fuel and ignition timing using multiple ignition coils.
  • Page 2 New for Version 31 Software V31 and higher software now allows RPM Fuel values to be adjusted up to a maximum of 350, prior to V31 max was 255. Also V31 can now produce an injector pulse width up to 65mS where older versions only went to 32mS.
  • Page 3 Fuel Pressure Regulator We supply either an adjustable Borla regulator with AN-6 fuel fittings or a non-adjustable OEM type with O-ring sealed inlet and either barb outlet or 1/8 or ¼ female NPT outlet fitting. We recommend the adjustable type have its fuel pressure set to 45-50 psi using the adjusting screw on the top of the regulator with the engine not running.
  • Page 4 Top engine mount fuel block You must use fuel return lines with SDS EFI. Fuel return lines have little or no pressure present. Return fuel should enter the tank(s) at least 4 inches from where the fuel feed exits. Installation of return lines into many tanks can be made in the access/ sender cover plate.
  • Page 5 Return line (lower) using Earls Stat-o-seals Fuel Selector On any system using more than one fuel tank, we recommend using a Duplex selector which has a feed and return port for each tank. This ensures that returned fuel always goes to the selected tank which prevents pumping fuel overboard.
  • Page 6 you’ll be able to get the TIG torch all the way around the boss to do a good weld. Also be sure to check that you’ll have cowling clearance for the boss and fuel fittings feeding it. Weld-in injector boss Make oval hole in induction tube Mark the outside of the tube where the boss will be placed.
  • Page 7 To mount these, remove the 1/8 NPT plugs from the injector ports (heat may be required). Slide the gold flange over the lower silver adapter from below. Apply Loctite 246 to the threads on the silver part and thread by hand into the injector port. Thread in until finger tight then tighten 1 to 1 ½ more turns (approx 40-60 inch lbs.).
  • Page 8 Apply Locktite 246 to the stainless cap screws and slide them through the tubular spacers. Alternately start to tighten the cap screws with an Allen wrench but stop just before the spacers start to touch the gold parts. Rotate the lower ring and top cap to the orientation shown below so you can get the Allen wrench on the cap screw.
  • Page 9 ECU Mounting and Wiring Considerations The ECU should be mounted in the passenger compartment in an area where they cannot get wet. If mounted horizontally, be sure the wiring harnesses have a drip loop to prevent water from running down them, into the ECU. The ECU is not waterproof! If possible, mounting the ECU with the connectors facing down gives the best protection against water ingress.
  • Page 10 3-1/8” Programmer unit cable connections: Dual board ECU with dual board programmer box and toggle switch. See end programming section for details. New for 2020, SDS EFI AERO programmer the Primary ecu cable goes to the right side connector as viewed from the rear.
  • Page 12 Gray 20 gauge and O2 sensor or Wideband meter hookup, pin 24 On the SDS main harness there is a single gray 20 gauge wire which you can connect to a wideband O2 sensor controller. Connection is required when you want to display the AFR (air/fuel ratio) in the SDS programmer or use Closed loop and Lean Warning functions in the SDS computer.
  • Page 13 Single board ECU Injector Drive Harness and wiring from 16 Pin White Molex to Injectors This connects the ECU injector outputs to the injector harness and also contains the injector ground wires and the option control wires. The two short black wires from pin 8 &16 should go to separate airframe grounds and have no other wires grounded to the same point.
  • Page 15 Dual ECU systems use relay boxes between the 16 pin Molex connectors and the connections to the injector harness. Relay box photo, 4 cylinder shown. For 6 cylinder dual systems please see the 6 cylinder dual supplement manual for details. 4cyl dual systems without individual cylinder trim: One injector relay box is used to switch fuel injector circuits between Primary and Backup ECU.
  • Page 16 This will not be supplied with systems in 2020 which have the newer programmer units with a built in fault LED. Using the SDS supplied lamp Mount the lamp for best visibility for the pilot. Drill a 1/4” hole for the lamp.
  • Page 17 Wiring connections are critical to proper ECU function. Make every connection with the thought that your life depends on each one. It does! Don’t let wires dangle loose which can lead to eventual breakage. Support them every few inches for least mechanical loading on them.
  • Page 18 Programmer Mounting, 3-1/8” Style Programmer unit Most aviation installations use the SDS aviation, panel mount programmer which mounts in a standard 3 1/8 instrument cutout. Where there is insufficient panel space, the hand held model may be used and stored elsewhere.
  • Page 19 Throttle Body Mounting 80, 60, 45 and 40mm throttle bodies Lycoming Vertical Induction Engines We supply a 60mm throttle body for these engines to fit in place of the carb or RSA-5 Bendix servo on O-320- O-540 engines. The TPS and throttle arm are already mounted. Use an ACS 2.5 inch aluminum flange and supplied 2.5 inch silicone hose coupler.

  • Page 20: Air Temperature Sensor

    Temperature Sensors 1/8 NPT, Bosch M 12 X 1.5mm and GM 3/8 NPT temp sensors Air cooled engines usually use the Racetech sensor provided. This has 1/8 NPT threads and is screwed into a primer or injector port as shown below. Other air cooled engines may also use oil temperature.
  • Page 21 Crank Sensor (Hall Effect) and Mounts Systems controlling fuel only (many Rotax and Jabiru engines) use an adjustable, single element Hall Effect sensor and 2 or 3 magnets mounted to the crankshaft to send rpm information to the ECU. Magnets should pass over the center of the small black squares at the end of the sensors. On Dual ECU systems, the crank sensor cables are color coded green for primary and red for backup.
  • Page 22 Jabiru and Rotax magnet discs Set magnet air gap from the sensor to .050 - .080 inches by shimming the sensor or moving the collar as the case may be. Indexing of the magnet discs is not important on fuel-only systems. The ECU just needs a frequency. 4 cylinder engines will use 2 magnets 180 degrees apart, 6 cylinder engines have 3 magnets 120 degrees apart.
  • Page 23 EM-5 will automatically perform a reset. This takes about 0.5 seconds and the engine will falter during that period. When this happens, the SDS EFI startup screen will appear in the LCD window. Reset can also be caused by the switching of high current devices such as electric pumps, motors or solenoids.
  • Page 24 percentage to the injector pulse width. From the straight up or 12 o’clock position, the mixture can be leaned roughly 50% by turning the knob fully counter clockwise or 50% richer by turning it fully clockwise. The knob is very useful in determining a rich or lean condition and is used in cruise flight for leaning the mixture in LOP operations and we recommend it be mounted in all aviation installations.
  • Page 25 The programmer allows you to access all points within each parameter and change values to program the system. When powered up, SDS EFI should appear in the LCD window along with the system type, software version and burn#. From here, parameters may be called up by pressing the right or left parameter select buttons (<...
  • Page 26 KNOCK RETARD (E, F only) MAGNET POSITION (E, F only) LCD BRIGHTNESS LCD CONTRAST START CYCLES START 32 points RPM IGN (E,F only) 38 points IGN RET-ADV/LOAD (E,F only) 64 points ENGINE TEMP 32 points MANIFOLD PRESS or TP 64 points RPM FUEL 38 points ACC PUMP SENSE...
  • Page 27 Gauge 1 or 4 mode can be accessed by pressing the gauge button once. Gauge 1 mode Gauge 1 mode showing error codes MP displays engine vacuum in inches mercury absolute. The MP reading will change to ERR if the map sensor loses its connection on the ground or power wires.
  • Page 28 Gauge 4 mode END OF GAUGE MODE SECTION ********************************************************************************************** Basic SDS Fuel Tuning Important programming and tuning tips: CLOSED LOOP MUST be turned OFF, and it is normally off when shipped from the factory. We highly recommend using a mixture meter to aid in tuning.
  • Page 29 The rpm band is divided into 38 ranges, either 100 or 250 rpm apart. This parameter is where the main fuel programming is done in SDS systems. The variables which ultimately determine the RPM FUEL values are engine displacement, injector flow rate and volumetric efficiency of the engine.
  • Page 30 Startup Procedure Make sure that fuel at the correct pressure is present at the injectors. Turn on ignition and computer power. Crank the engine, rotate mixture knob richer while cranking. If engine does not fire, see troubleshooting section. You may also have to increase the START values to get the engine to fire. Once the engine is running, use the mixture knob to get a smooth idle.
  • Page 31 The more open the throttle is, the higher the manifold pressure, so the manifold pressure values must be higher. SDS delivers a longer injection pulse to get more fuel into the cylinder. By adjusting the manifold pressure values from their default, you can change the mixture of the engine at different pressures to achieve best power or economy.
  • Page 32 If the MP fluctuates over more than 3 ranges, you may have to install a .025 to .035 inch orifice in the MAP sensor line to help average and stabilize the vacuum seen by the SDS computer. Acceleration Pump (ACC Pump) You must have a TPS installed to have this function active.
  • Page 33 You should aim for a 0 value when the engine is at normal operating temperature. Most engines will not require extra fuel after 100-140 degrees F. The values should decrease in a fairly linear fashion from cold to operating temperature then have 0's entered above this threshold. Temperatures can be displayed in F or C.
  • Page 34 Fuel Cutoff, Rev and MAP Limiting RPM and MAP limiting in SDS are very harsh so it is not recommended that you constantly hit the rev and MAP limits with SDS. These limits are intended for protection only, primarily for propeller governor or blade loss conditions.
  • Page 35 Values Lock This feature allows you to lock out the programmer function to prevent accidental changes to your values. To lock your values, select VALUES LOCK window in the LCD programmer. The +1 and -1 buttons are used to select it to the ON or OFF position. When you are done programming for a while or plan to disconnect the programmer always engage VALUES LOCK ON.
  • Page 36 Optional Fuel Flow Output to Engine Monitors SDS EM-5 ECUs with V26.1 or higher software have the capability to output a fuel pulse signal similar to electro/mechanical flow meters. This capability is also activated through a discrete PIN number for each individual software burn# once the option is paid for.
  • Page 37 And if using PIN13, the blue LED will light when the PIN13 input sees 6 volts or higher. Fault LED This takes over in place of the SDS panel mounted check engine light. If this LED is flashing, then check Gauge1 screen RPM, MAP and Temperature readings to see if any display ERR.
  • Page 38 Dual board ecu’s, Duplicating values into the Backup Ecu. We generally recommend that you duplicate all values in both ECUs with a few exceptions: Magnet Position: This value will be different in the Backup ecu vs. the Primary ecu. On 4cyl engines: In the backup ecu set the Acc Pump Sense to 1, Acc Pump Lo RPM and Acc Pump Hi RPM to zero, due to the backup ecu not being connected to the Throttle Position sensor.
  • Page 39 EM-5 Aviation System ECU Pinouts DB25 Pin 1 Switched 12V power ECU, Red 20 ga. TPS 5V Knob 5V MAP 5V Future use, brown. MAP signal Air temp + Coil trigger 8 cyl. Channel A Coil trigger 4 cyl./6 cyl. Channel A, Channel C 8 cyl. Coil trigger 6 cyl.

  • Page 40: Check Engine Light

    12.5 volts. Some problems cannot be detected such as MAP sensor broken signal wire. Just because the LED is turned off doesn’t mean everything is good with the system. SDS cannot detect faulty O2 sensors. SDS cannot detect all sensor problems.
  • Page 41 8. Try a different brand of spark plug wires. 9. If Knock sensor is being used, Knock Sense value may be too high. If there is no knock sensor on the SDS, system set Knock Sense to 1, and Knock Retard to zero.
  • Page 42 4. If ECU is a dual board unit, only the primary provides power to the programmer, so the Primary ecu board must be powered up for the programmer unit to display data and operate. SDS EFI in Window: 1. TPS connections are wrong. Try unplugging the TPS cable.
  • Page 43 8. Try a different brand of spark plug wires. Must use Suppression type plug wires with SDS. 9. If Knock sensor is being used, Knock Sense value may be too high. If there is no knock sensor on the SDS system set Knock Sense to 1, and Knock Retard to zero.
  • Page 44 4. If +12V has been accidentally shorted to the EM-5 case, the circuit board may need repair, due to a broken ground circuit. SDS EFI in Window: 1. TPS connections are wrong. Try unplugging the TPS cable. 2. Power has been interrupted or EM-5 has reset.
  • Page 45 Don’t ground the SDS EM-5 to the engine. Engine ground may be noisy and cause the EM-5 to malfunction. Ground it to the chassis of the aircraft or to a grounding buss. Be sure to sand off any paint where the connection is.
  • Page 46 All SDS electronic components are guaranteed to be free from defects in workmanship and material for a period of 3 years from the date of sale to original purchaser if installed according to this manual. SDS shall make the sole determination with regards to all warranty claims.
  • Page 47 Calgary, Alberta, Canada T3A 5W9 Phone 403-671-4015 ----------------------------------------------------------------------------------------------------------------------- All SDS software, PCB design and this manual is the exclusive property of Simple Digital System. Unauthorized use or reproduction is a violation of copyright. Tach Output Frequency For setting up your engine monitor or steam type tachometer, 4 cylinder systems output 2 pulses per crank rev, 6 cylinder systems are 3 pulses per rev and 8 cylinder are 4 pulses per rev.
  • Page 48 Write down your values here MAN PRES RPM FUEL ENG TEMP START RPM IGN RET/LOAD VAL 1000 1000 1100 1100 1200 1200 1300 1300 1400 1400 1500 1500 1600 1600 1700 1700 1800 1800 1900 1900 2000 2000 2100 2100 2200 2200 2350...

This manual is also suitable for:

Em-5-f