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Merlins Ecuflash EVO 7-8-9 TUNING GUIDE-V1.7A

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MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE MITSUBISHI EVO 7-8-9 TUNING REV: 1.7a [email protected] Page 1 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE TABLE OF CONTENTS SECTION 1 œ INTRODUCTION TO ECUFLASH TUNING 12 1.1-INTRODUCTION AND ACKNOWLEDGMENTS 12 1.2-TUNING ABBREVIATIONS AND ACRONYMS 13 1.3-REQUIRED EQUIPMENT 14 1.4-ECUFLASH INTRODUCTION 17 1.5-PROGRAM INSTALLATION AND SETUP 17 1.6-XML DEFINITION FILES 17 1.7-RUN ECUFLASH 20 1.8-SETTING THE USER LEVEL & DIRECTORY 21 1.9-SETTING THE DEFAULT COLOUR MAP 22 1.10-CONNECTING TO THE ECU 23 1.11-ECU OPERATIONS 24 1.12-READING THE IMMOBILIZER CODE 25 1.13-EDITING FUNCTIONS AND 3D GRAPH VIEWING 26 1.14-GETTING STARTED œ PRELIMINARY TUNING ACTIVITIES 27 SECTION 2 œ FUEL TUNING 28 2.01-INTRODUCTION TO EVO FUEL METERING 28 2.02-FUEL TUNING œ STOCK LO-OCTANE FUEL MAP EVO7-8-9 31 2.03-FUEL TUNING œ TUNED LO-OCTANE FUEL MAP EVO7-8 32 2.04-FUEL TUNING œ TUNED LO-OCTANE FUEL MAP EVO9 32 2.05-FUEL TUNING œ STOCK HI OCTANE FUEL MAP 33 2.06-FUEL TUNING œ TUNED HI OCTANE FUEL MAP 34 2.07-FUEL TUNING œ OPEN LOOP TEMP THRESHOLD 35 2.08-FUEL TUNING - OPEN LOOP LOAD THRESHOLD V RPM 36 2.09-FUEL TUNING - OPEN LOOP TPS THRESHOLD V RPM 37 2.10-FUEL TUNING - DECEL FUELCUT DELAY V LOAD 38 2.11-FUEL TUNING - ACCEL ENRICH BASE V ENGINE TEMP 39 2.12-FUEL TUNING - ASYNCH_ACCEL TPS V RPM LIMIT 39 2.13-FUEL TUNING - LIMP HOME LOAD MAP, TPS V RPM 40 2.14-FUEL TUNING œ AFR AND KNOCKSUM 41 SECTION 3 œ IGNITION TUNING 42 3.01-IGNITION TUNING INTRODUCTION 42 3.02-IGNITION TUNING œ STOCK LO-OCTANE SPARK MAP 47 REV: 1.7a [email protected] Page 2 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE 3.03-IGNITION TUNING œ STOCK HI-OCTANE SPARK MAP 49 3.04-IGNITION TUNING œ CAT WARMUP RETARD SPARK MAP 55 3.05-IGNITION TUNING - ELIMINATING SHIFT KNOCK 56 SECTION 4 œ MIVEC TUNING 57 4.01-EVO IX MIVEC TUNING INTRODUCTION 57 4.02-EVO IX CAM TIMING 57 4.03-MIVEC TUNINGœ LIMIT ADJUSTMENTS 58 4.04-MIVEC TUNING - MAP DISCUSSION WITH EXAMPLES 59 SECTION 5 œ INJECTOR TUNING 65 5.01-INJECTOR SETUP INTRODUCTION 65 5.02-INJECTOR TUNING œ INJECTOR SIZE SCALING 66 5.03-INJECTOR TUNING - LATENCY 67 5.04-INJECTOR TUNING - SCALING & LATENCY EXAMPLES 68 5.05-INJECTOR TUNING œ NEW INJECTOR SETUP METHOD #1 69 5.06-INJECTOR TUNING œ NEW INJECTOR SETUP METHOD #2 71 5.07-INJECTOR TUNING œ EXAMPLE CASES 76 5.08-INJECTOR TUNING œ START PRIMER IPW V TEMP 77 5.09-INJECTOR TUNING œ START CRANKING IPW V TEMP 78 5.10-INJECTOR TUNING œ POST START ENRICH DECAY V TEMP 79 SECTION 6 œ BOOST TUNING 80 6.01-BOOST TUNING INTRODUCTION 80 6.02-BOOST CONTROL - AIRFLOW / BOOST LIMIT V RPM 82 6.03-BOOST CONTROL - BOOST V RPM 83 6.04-BOOST CONTROL - MIN LOAD FOR BOOST CONTROL 84 6.05-BOOST CONTROL - MIN TEMP FOR BOOST CONTROL 84 6.06-BOOST CONTROL - RPM/MPH CROSSOVER 85 6.07-BOOST CONTROL - BOOST CUT DELAY 86 6.08-BOOST CONTROL - WGDC V RPM 87 6.09-BOOST TUNING - 3-PORT BOOST CONTROL INTRODUCTION 88 6.10-BOOST TUNING - GM 3-PORT BCS 89 6.11-BOOST TUNING œ GRIMMSPEED EVO 3-PORT BCS 90 6.12-BOOST TUNING œ TACTRIX EVO 3-PORT BCS 90 6.13- BOOST TUNING œ 3-PORT BCS INSTALATION 91 6.14-BOOST TUNING - BOOST ERROR CORRECTION 95 6.15-BOOST TUNING - ERROR CORRECTION INTERVAL 97 6.16- BOOST TUNING œ 3-PORT EXAMPLE MAPS 98 REV: 1.7a [email protected] Page 3 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE SECTION 7 œ LEAN SPOOL TUNING 100 7.01-LEAN SPOOL TUNING INTRODUCTION 100 7.02-FUEL LEAN SPOOL œ LOAD THRESHOLD V RPM 100 7.03-FUEL LEAN SPOOL œ AFR TABLE 101 7.04-FUEL LEAN SPOOL œ START RPM 102 7.05-FUEL LEAN SPOOL œ STOP RPM 102 7.06-FUEL LEAN SPOOL œ MIN TEMP 102 7.07-FUEL LEAN SPOOL œ DECAY TIME RICH SIDE 103 7.08-FUEL LEAN SPOOL œ DECAY TIME LEAN SIDE 103 7.09-FUEL LEAN SPOOL œ LOAD HYSTERESIS 104 7.10-FUEL LEAN SPOOL œ AFR ENABLE 104 7.11-FUEL LEAN SPOOL œ AFR CLIP 104 SECTION 8 œ KNOCK TUNING 105 8.1-KNOCK TUNING - KNOCKSUM & OCTANE NUMBER 105 8.2-KNOCK TUNING œ OCTANE UPDATE THRESHOLD 107 8.3-KNOCK TUNING œ KNOCKBASE 107 8.4-KNOCK TUNING œ REAL OR FALSE KNOCK? 109 8.5-KNOCK TUNING œ DET-CANS 110 8.6-KNOCK TUNING œ ELIMINATING FALSE KNOCK 111 8.7-KNOCK TUNING œ ADJUSTING LOAD THRESHOLD V RPM 111 8.8-KNOCK TUNING œ ADJUSTING MULTIPLIER V RPM 112 8.9-KNOCK TUNING œ ADJUSTING KNOCK ADDERS 113 8.10-KNOCK TUNING œ KNOCK MULTIPLIERS EVO7 & EVO8 113 SECTION 9 œ ALS TUNING 114 9.1-ALS TUNING INTRODUCTION 114 9.2-ALS TUNING - TRIGGERS 114 9.3-ALS TUNING - TIMERS 115 9.4-ALS TUNING œ AIR INJECTION TIME V RPM 115 9.5-ALS TUNING œ MAXIMUM IGNITION RETARD SETTING 116 9.6-ALS TUNING œ RETARDING THE IGNITION MAP 117 9.7-ALS TUNING œ JUST THE POS AND BANGS PLEASE! 117 SECTION 10 œ MISCELANEOUS ECU FUNCTIONS 118 10.01-LIMITS - SPEED 118 10.02-LIMITS - REV LIMIT 118 10.03-THERMO FAN - DUTY CYCLE, SPEED BELOW 20KPH 119 10.04-THERMO FAN - DUTY CYCLE, SPEED ABOVE 20KPH 120 REV: 1.7a [email protected] Page 4 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE 10.05-THERMO FAN - SPEED SET-POINTS & HYSTERESIS 121 10.06-EGR CONTROL - IGNITION ADVANCE DURING EGR 122 10.07-EGR CONTROL - DUTY CYCLE V LOAD V RPM 123 10.08-EGR CONTROL - DUTY FACTOR V TEMP 123 10.09-INTERCOOLER SPRAY CONTROL 124 10.10-IGNITION_COIL CHARGE TIME V BATTERY VOLTAGE 125 10.11-IGNITION_COIL CHARGE TIME CORRECTION V VOLTS 125 10.12-ALTERNATOR œ CHARGE MAP 126 10.13-ALTERNATOR œ G TERMINAL DEAD ZONE 126 10.14-IDLE - RPM CONTROL V TEMP 127 10.15-IDLE - STABILISATION CONTROL 128 10.16-IDLE œ ISCV STEPPERMOTOR DEMAND V TEMP 129 10.17-IDLE - TIMING AT IDLE & IDLE STABILITY 130 10.18-SENSOR CALIBRATION œ MAF SIZE 131 10.19-SENSOR CALIBRATION œ MAF TEMP/BARO CORRECTION 131 10.20-SENSOR CALIBRATION œ MAF SCALING 132 10.21-PERIPHERY BIT PARAMETERS 133 SECTION 11 œ EXPANDING MAXIMUM LOAD CAPABILITY 135 11.1-EXPANDING THE LOAD SCALE FOR HIGH BOOST 135 11.2-EXPANDING MAXIMUM LOAD & FUEL LIMITS 137 SECTION 12 œ TUNING WITH CAMS PRIMER 138 12.1-CAM TUNING - INTRODUCTION 138 12.2-CAM TUNING - SPARK MAP FOR STARTING & IDLE 138 12.3-CAM TUNING - IDLE STABILITY TIMING CONTROL 139 12.4-CAM TUNING - IDLE CONTROL ISCV SETTINGS 140 12.5-CAM TUNING - HI-OCTANE SPARK MAP 141 APPENDIX 2: LOGGING BOOST OR AFR WITH EVOSCAN 142 A2.1-INTRODUCTION 142 A2.2-BOOST LOGGING INTRODUCTION 142 A2.3-ROMS CURRENTLY COVERED 142 A2.4-MAP SENSOR SWAP 143 A2.5: PRESSURE CONVERSIONS 143 A2.6-ROM MODS FOR USDM EVO9 ROMS 88590013, 88590014, 88590015 144 A2.7-LOGGING BOOST IN EVOSCAN/MITSULOGGER 147 A2.8-INCREASING LOGGING BAUD-RATE 148 A2.9-WIRING THE 3-BAR MAP SENSOR TO EDM & AUDM EVO9 148 REV: 1.7a [email protected] Page 5 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE A2.10-SENSOR PART NUMBER 148 A2.11-LOGGING AIR FUEL RATIO IN EVOSCAN 148 APPENDIX 3: ECU PIN DESCRIPTIONS AND WIRING 149 A3.1: EVO7 ECU PIN FUNCTION & WIRE COLOUR 150 A3.2: EVO6 ECU PIN FUNCTION & WIRE COLOUR 151 A3.3: EVO9 ECU PIN FUNCTION & WIRE COLOUR 152 A3.4: EVO1 TO EVO3 & RVR ECU PIN CONFIGURATION 153 A3.5: EVO4 TO EVO8 ECU PIN CONFIGURATIONS 153 A3.6: EVO 9 ECU PIN CONFIGURATION 154 APPENDIX 5: MISCELLANEOUS EVO ROM FILE IDENTIFIER 155 APPENDIX 6: 2-BYTE LOGGING & MUT TABLE SETUP 156 APPENDIX 7: INTAKE HARDPIPES & IDLE CONTROL ISSUES 158 APPENDIX 8: OBDII CONNECTOR & CLEARINGFAULT CODES 159 A8.1-OBD-II CODE INTRODUCTION 159 A8.2-MITSUBISHI ECU SELF-DIAGNOSTICS & FAULT CODES 159 A8.3-OBD-II DIAGNOSTIC CONNECTOR 160 A8.4-CLEARING A FAULT CODE WITH EVOSCAN 161 A8.5-CLEARING A FAULT CODE WITHOUT EVOSCAN 161 APPENDIX 9: OBD-II POWERTRAIN FAULT CODES 162 A9.1-P00XX FUEL, AIR METERING & AUX EMISSIONS CONTROLS 162 A9.2-P01XX FUEL AND AIR METERING 163 A9.3-P02XX FUEL AND AIR METERING 164 A9.4-P03XX IGNITION AND TRIGGER SYSTEMS AND KNOCK SENSOR 166 A9.5-P04XX AUXILIARY EMISSION CONTROLS 167 A9.6-P05XX SPEED, IDLE & AUXILIARY INPUTS 169 A9.7-P06XX ECU AND AUXILIARY INPUTS 170 A9.8-P08XX MANUAL TRANSMISSION 171 REV: 1.7a [email protected] Page 6 of 172 MERLINS EcuFLASH EVO 7-8-9 TUNING GUIDE List of Tables Table 1..................................................................... ABBREVIATIONS AND ACRONYMNS 13 Table 2........................ TYPICAL INJECTOR SCALING AND LATENCY PARAMETERS 68 Table 3...............................................................GM 3 BAR MAP SENSOR CALIBRATION 81 Table 4............................................ROUGH GUIDE TO LOAD v BOOST LEVEL - Evo9 83 Table 5.....................................................................................................RPM per MPH Guide 85 Table 6........................
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  • Development and Demonstration of Control Strategies for a Common Rail Direct Injection Armoured Fighting Vehicle Engine

    Development and Demonstration of Control Strategies for a Common Rail Direct Injection Armoured Fighting Vehicle Engine

    Defence Science Journal, Vol. 67, No. 4, July 2017, pp. 382-389, DOI : 10.14429/dsj.67.11450 2017, DESIDOC Development and Demonstration of Control Strategies for a Common Rail Direct Injection Armoured Fighting Vehicle Engine Jensen Samuel J.@,*, Paul Pramod M.@, A. Ramesh@, Anand Mammen Thomas!, V. Ramanujachari!, R. Murugesan#, and A. Kumarasamy# @Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai - 600 036, India !Research and Innovation Centre, Chennai - 600 013, India #Combat Vehicles Research and Development Establishment, Chennai - 600 054, India *E-mail: [email protected] ABSTRACT The development of a controller which can be used for engines used in armoured fighting vehicles is discussed. This involved choosing a state of the art reference common rail automotive Diesel engine and setting-up of a transient engine testing facility. The dynamometer through special real-time software was controlled to vary the engine speed and throttle position. The reference engine was first tested with its stock ECU and its bounds of operation were identified. Several software modules were developed in-house in stages and evaluated on special test benches before being integrated and tested on the reference engine. Complete engine control software was thus developed in Simulink and flashed on to an open engine controller which was then interfaced with the engine. The developed control software includes strategies for closed loop control of fuel rail pressure, boost pressure, idle speed, coolant temperature based engine de-rating, control of fuel injection timing, duration and number of injections per cycle based on engine speed and driver input. The developed control algorithms also facilitated online calibration of engine maps and manual over-ride and control of engine parameters whenever required.