Perfect Power XMS4A, Manual

Page 1: ...XMS4A LetRipp II Engine Management System DIY MANUAL Version 2 1 ...

Page 2: ... CONNECTION 6 6 13 USB DRIVERS SETUP 7 7 COMPUTER REQUIREMENTS 7 8 PIN OUTS OF XMS4A UNIT 8 8 1 XMS4A PIN OUT TABLE 8 8 1 1 XMS4A IGNITION PIN OUT CONNECTOR 6 PIN 8 8 1 2 XMS 4A INJECTION PIN OUT CONNECTOR 8 PIN 8 8 1 3 XMS 4A AUXILIARY CONNECTOR 4 PIN 9 8 1 4 XMS 4A MAIN CONNECTOR 22 PIN 9 9 ASSESSING YOUR CAR S FUEL SYSTEM 10 9 1 IS YOUR CAR READY FOR FUEL INJECTION 10 9 2 HOW TO MAKE YOUR CAR R...

Page 3: ... MORE DETAIL 27 17 1 TWO WIRE IDLE SOFTWARE SETUP 27 17 1 1 F3 TWO WIRE IDLE FOR XMS4A 28 17 1 2 SHIFT F2 SYSTEM DEF 28 17 1 3 IDLE RPM TARGET 29 17 1 4 SHIFT F11 2WIRE IDLE 29 17 1 5 SETTING UP THE IDLE 30 18 DWELL TIME 30 18 1 WHAT IS DWELL 30 18 2 CAN IT DAMAGE YOUR COIL 30 18 3 DWELL SETUP VIA SOFTWARE 31 19 SETTING UP PARAMETERS 32 20 SYSTEM DEFINITION 33 21 SET POINTS 34 21 1 USES 34 21 2 WI...

Page 4: ...L 51 32 2 PRESSURE 51 32 3 IGNITION 51 32 4 SPARK PLUGS 52 32 5 COIL 52 32 6 TWO WIRE COIL 52 32 7 THREE WIRE COIL 52 32 8 FOUR WIRE COIL 53 32 9 TRIGGER WHEEL 53 32 10 TRIGGER SENSOR 53 32 11 ENGINE FAILURE NO COMPRESSION 54 33 BASIC XMS4A 2A WIRING DIAGRAM 55 34 BASIC XMS4A 4A WIRING DIAGRAM 56 Table of Figures Page no FIGURE 1 FUEL SYSTEM LAYOUT 10 FIGURE 2 ENLARGED VIEW OF SURGE TANK 11 FIGURE...

Page 5: ...plied in the XMS4A kit include 1 x XMS4A unit 1 x XMS4A harness 1 x Software CD that includes manuals and USB drivers 1 x USB tuning cable If you don t have all of the above items please contact us immediately either via www perfectpower com or info perfectpower com The use of a suitable dual channel ignition amplifier is required for all installations of the XMS4A product We do supply a product w...

Page 6: ...stalled AMP sensor A XMS4A 4A 4 Injection and Ignition Outputs 4 Cylinder Sequential Injection 4 Set points with installed AMP sensor B XMS4B 4A 4 Injection and Ignition Outputs Wideband lambda controller 4 Set points with installed AMP sensor B XMS4B 8A 8 Injection and Ignition Outputs Wideband lambda controller 4 Set points with installed AMP sensor C XMS4C 4A 4 Injection and Ignition Outputs ET...

Page 7: ...lows Main map entry Air temperature entry Engine temperature entry Acceleration enrichment AFR Short term loop adjustment AFR Long term trim Manifold pressure entry Fuel range Other fuel components Priming Idle control Set point control Soft Hard fuel cut 5 2 IGNITION Cylinders 2 3 4 6 8 Ignition Sequential 2 3 4 Cylinders Ignition outputs 2 4 8 Direct drive NO Output polarity Positive Main map si...

Page 8: ...vel YES CAM on off option YES 5 6 BOOST CONTROL For Turbo waste gate control YES PWM bleed Air temp map sites 24 PWM sites for cruising 24 PWM sites for full power 24 Target boost map sites 24 PID loop gain YES 5 7 PRIME FUEL 24 Map sites accessed by the engine temperature allow extra fuel during starting 5 8 IDLE CONTROL Target RPM map sites via temperature 16 For 2 wire idle motors YES PID contr...

Page 9: ...complete maps for all tuning data Maps can be switched while driving The two maps can hold different tuning for weather fuel grade or performance requirements The maps can be switched from a manual input or automatically via the SETPOINT procedure in the LetRipp Software 6 4 CALIBRATION All inputs can be calibrated to suit your existing sensors of your engine Calibration is performed for two reaso...

Page 10: ...ical AND OR fashion and polarity selection is possible 6 10 MAXIMUM RECORDINGS The units recorded are Max RPM Max Engine temperature Max Air temperature Max Manifold pressure AMP The maximum recordings can be retrieved and cleared by using a computer only 6 11 ONBOARD LOGGING COMING SOON All units have a very large memory for logging 64000 data points This converts to 5 Data channels 12800 recordi...

Page 11: ...llow the correct procedure Once the software and USB drivers have been correctly installed the unit will operate when connected to the USB port via the USB cable Thus the Computer will supply power to the unit Although all functions will work the unit will not power external sensors NOTE DO NOT ATTEMPT TO OPERATE THE XMS4A UNLESS THE USB INSTALLATION PROCEDURE HAS BEEN FOLLOWED FAILURE TO DO SO WI...

Page 12: ...gnition pulse output positive NOTE The XMS4A 2A has ignition outputs 1 and 2 8 1 2 XMS 4A INJECTION PIN OUT CONNECTOR 8 PIN Pin Signal Description 1 N C N C 2 INJ 1 Injector 1 output switched to ground 3 INJ 3 Injector 3 output switched to ground 4 GND Power Ground Chassis 5 N C N C 6 INJ 2 Injector 2 output switched to ground 7 INJ 4 Injector 4 output switched to ground 8 GND Power Ground Chassis...

Page 13: ... CB 1 3 GND Signal Ground 4 CB 2 5 Rev Counter Rev counter driver 6 AMPIN 0 5V input signal 7 TPSIN 0 5V input signal 8 N C Not used 9 5volts EXT 5 0 1A Output for TPS and AMP 10 5volt pull up 11 GND 12 N C Not used 13 Cb 1 14 GND 15 Cb 2 16 N C Not used 17 AIRT IN 0 5V input internal pullup 2k2 to 5 18 ENGT IN 0 5V input internal pullup 2k2 to 5 19 N C Not used 20 Launch Switch SWITCH input norma...

Page 14: ...uired e g 2 5 bar plus 0 6 bar boost should equal 3 1 bar fuel pressure under boosted conditions 9 2 HOW TO MAKE YOUR CAR READY FOR FUEL INJECTION Two fuel pumps are needed for the whole system to work One from the fuel tank supplying a surge tank this is a low pressure pump This pump must be able to supply enough fuel to keep the surge tank full at all times A high pressure fuel pump to supply th...

Page 15: ...S4A e heck for leaks if any fix them before moving on to anything else 3 CONCLUSION ou have diagnosed your fuel system as to whether it is suitable for fuel injection At this point 0 ASSESSING YOUR ENGINE he engine will need to be assessed to determine if it has a compatible trigger wheel cam 0 1 COMPATIBLE TRIGGER WHEEL he XMS4A has a set of trigger patterns that it can work with these are 0 2 r ...

Page 16: ...you want sequential ignition and injection then get an engine that has a cam sensor Do not try to fit your own cam sensor 10 3 HOW TO INSTALL A COMPATIBLE WHEEL AND PICKUP SENSOR NOTE If you are unable to weld or fabricate metal rather get a machine shop to do this part of the work for you First you need to get the engine onto TDC Most engines have timing marks on the crank pulley and on the surro...

Page 17: ...ommend that once the trigger wheel is secured to the pulley get a machine shop to skim the trigger wheel s teeth in a lathe This will ensure that the 60 2 tooth wheel runs true and that the XMS4A will get a nice even signal Fit the crank pulley back onto the crank Make a bracket for the pickup sensor and mount the sensor and bracket in place The gap between the sensor and the pickup wheel should b...

Page 18: ...UITABLE PLACES The best place to mount the unit isn t always the easiest Usually best locations are as follows Under the dashboard There is normally enough space It is free of moisture and excessive heat Figure 5 Typical under the dashboard installation Center consol It is also free of heat and moisture but may have space limitations Driver sidekick panel Free from heat and moisture Some vehicles ...

Page 19: ...bonnet closed as the car would normally be driven If any moisture enters your chosen location disregard it and refer to section 10 1 for another possible location Away from heat generating devices for example on top of the exhaust tunnel or directly in front of the heater vents Anywhere the XMS4A can get wet Pretty simple to understand but if you know that your car leaks water by the passenger sid...

Page 20: ...this going to be free from moisture at all times 3 Is the ignition amplifier going to remain well below 60 degrees Celsius 4 Is the ignition amplifier more than 1 meter from the XMS4A If all 4 answers are YES then fit the ignition amplifier there 12 2 UNSUITABLE PLACES Anywhere in the engine bay Why you say The engine bay is a major heat generating and heat retaining cell Ignition amplifiers gener...

Page 21: ...ms The screened cable has a shield which acts as a faraday cage this reduces electrical noise from affecting our rpm signal Tip Only ground the screen wire at one end 13 3 WHAT SHOULD YOU USE A SCREENED CABLE ON Anything you would like to protect from interference In your case the crank and cam inputs Crank inputs are pins 2 and 13 of the 22 pin connector Cam inputs are pins 4 and 15 of the 22 pin...

Page 22: ...e sinusoidal wave in the winding The amplitude and frequency of this signal is proportional to the rotational speed of the engine Magnetic sensor signal 14 4 DIGITAL HALL EFFECT This type of signal is often referred to as a switch as it goes on and off 0 Missing teeth 15 TYPICAL SENSORS USED AND HOW TO WIRE THEM Descriptions of the most commonly used sensors and which of the wires on your XMS4A to...

Page 23: ...et manifold You need to give this Amp sensor vacuum so you will need to find this on the inlet manifold after the throttle body See picture below Perfect Power 2 5 Bar Amp Sensor XMS4 Black Yellow Black Red Pin 22 of 22 12 supply Pin 6 of 22 Amp input 12 volts switch power Fuse Vacume line 10 Amps Figure 7 Wiring of Perfect Power Amp Sensor If you are using another make of map sensor check with th...

Page 24: ...3 AIR TEMP Air temperature is important on boosted engines as the air temperature is raised considerably The air temp sensor relays to the XMS4A the temperature of the intake air in volts and the XMS4A uses this information to compensate for different engine conditions See section 26 The air temp sensor is normally fitted to the inlet pipe before the throttle body XMS4 Pin 17 of 22 Air temp input ...

Page 25: ...he sweeper signal If you have electronic throttle control the accelerator pedal position signal must be used Pin 7 of 22 TPS input Pin 11 of 22 Ground XMS4 Pin 9 of 22 5volt supply Throttle Position Sensor Figure 10 Wiring of Throttle Position Sensor WARNING Never assume that the two outer pins are power and ground and that the center pin is the signal If the TPS reading is in reverse as the throt...

Page 26: ... in system definition Shift F2 to OFF if you have no RPM 15 6 CAMSHAFT SENSOR This sensor reads off the camshaft and it identifies cylinder no l If you have a camshaft sensor this is how you wire it Magnetic Pin 15 of 22 CB2 input XMS4 Pin 4 of 22 CB2 input Cam Sensor Magnetic Hall effect Pin 10 of 22 5v pull up Pin 15 of 22 Cb2 input XMS4 Pin 9 of 22 5volt supply 2k2 2k2 Pin 4 of 22 CB2 input Cam...

Page 27: ...output can be used provided there is one spare To manifold To wastgate To atmosphere XMS4 Auxillary connector 5 Amp 12 Volts switch power 16 2 FUEL PUMP RELAY For safety reasons the XMS4A must control the fuel pump relay The XMS4A will switch the fuel pump off if the RPM input stops The fuel pump relay is connected to the XMS4A s auxiliary connector 30 87 85 86 Side View Bottom View Pin 85 and 86 ...

Page 28: ...a relay The fan is programmed to turn on at the desired engine temperature using the set points 30 87 85 86 Side View Bottom View Pin 85 and 86 Coil Pin 30 and 87 Relay Switch 30 87 85 86 12 Volts Switch Power Positive Battery Device Power eg Fan Fuse Fuse Example of a 4 Pin Relay XMS4 auxillary output 16 4 2 WIRE IDLE CONTROL MOTOR The XMS4A can control a two wire idle motor Pin 3 of 4 ...

Page 29: ...4A will engage the relay is programmed in the set points 30 87 85 86 12 Volts Switch Power Positive Battery Device Power eg Shift light Fuse Fuse 16 6 REV COUNTER The XMS4A has a dedicated rev counter output on pin 5 of 22 This output is a square wave and can operate most modern rev counters Should your rev counter not operate correctly See Troubleshooting 16 7 INJECTORS 12 Key Switch Max 3A XMS 4...

Page 30: ...e coil s There are many makes and models of ignition amplifiers available You will need to use the Perfect Power Blue Fire ignition amplifier or any positive triggering ignition amplifier XMS4A 2 Cb1 Cb1 Blue Fire 12 Volts Coil Pack Spark Plugs Ig1 out Ig2 out Crank Sensor Typical wiring of wasted spark Typical wiring of a single coil for a distibutor 12 volt Blue Fire 12 volt Ig1 out Ig2 out CB1 ...

Page 31: ...le motor to compensate when extra load is applied to the engine during idle conditions The idle can also be adjusted as the engine temperature changes 17 1 TWO WIRE IDLE SOFTWARE SETUP The XMS4A unit can control a two wire idle motor The wiring is done through an auxiliary connector See Section 16 4 for wiring details Set the idle in the LetRipp Software using the following maps ...

Page 32: ...P II XMS4A DIY MANUAL V2 1 www perfectpower com 28 PERFECT POWER XMS4A Engine Management System DIY MANUAL V2 1 17 1 1 F3 TWO WIRE IDLE FOR XMS4A 17 1 2 SHIFT F2 SYSTEM DEF Tick the Idle Control En check box ...

Page 33: ...m idle PWM Idle Maximum This is the maximum idle PWM Idle Kick Open This is the amount that the idle motor will kick open Idle Kick Window This is the amount of RPM that if exceeded the kick is invoked Idle High Position This is the idle PWM when the engine is returning to idle after being revved 2 Wire Window This is the amount of RPM above or below the target idle RPM that if exceeded the idle c...

Page 34: ...ick Open 5 Idle Kick Window 50 Each idle motor reacts differently so you will need to experiment with the settings yourself To test how your settings will react to load conditions you can turn on the air conditioner or the headlights In the graph above we can see that the RPM in Red drops below our target RPM and falls below the Idle Kick Window The XMS4A detects the RPM drop and invokes the Kick ...

Page 35: ...m 31 PERFECT POWER XMS4A Engine Management System DIY MANUAL V2 1 Dwell too short Dwell just right Dwell too long 18 3 DWELL SETUP VIA SOFTWARE Open the F3 Dwell Prime Idle map Enter a dwell curve Refer to LetRipp II Software User Guide for more details ...

Page 36: ...degrees the pickup sensor is from the gap at TDC Ignition advance limit Enter the amount of ignition advance in degrees that must not be exceeded Ignition retard limit Enter the amount of ignition retard in degrees that must not be exceeded Start time Enter the time in seconds that the fuel pump will run when the XMS4A is powered up The fuel pump will switch back on when the XMS4A sees RPM Acceler...

Page 37: ...ells in the main fuel map Cam every 2 turn Enables sequential operation provided that there is a cam signal Inj Trim Enable Enables the individual injector trim circuit Neg CAM Edge Switches the trigger edge from positive to negative High CB2 Level Switches the trigger level from low to high Launch Control Enables the launch control circuit AMP Extrap En Enables extrapolation between cells in the ...

Page 38: ...ll engines have devices that need to be activated at certain critical times you will learn how to activate these devices They are activated via the XMS4A s set points 21 1 USES Fuel pump activation Cooling fan activation Shift lights 21 2 WIRING XMS4 Auxillary connector Relay Fuel Pump XMS4 Auxillary connector Relay Radiator and Fan ...

Page 39: ...UP VIA SOFTWARE Each auxiliary output can be set for a specific task The Set point map F6 is used for this purpose 22 CALIBRATION OF SENSORS All sensors are not the same and each one needs to be setup so that the XMS4A displays the correct values We are going to take the different sensors air temp engine temp throttle position and amp voltages and program the XMS4A to understand what voltage repre...

Page 40: ...he atmospheric pressure Now calibrate the lower and upper scale so that the XMS4A shows the amp value at 0 9 with just the ignition on See the LetRipp software guide for the actual steps on setting this up in the software 22 2 ENGINE TEMP This sensor must be calibrated so the XMS4A can compensate for cold and hot conditions You can place the engine temp sensor in boiling water to get a hot point r...

Page 41: ... experience and what voltage this will be into the lower calibration point 22 4 THROTTLE POSITION The throttle calibration is done so that the full 24 deflection sites are used From no throttle to full throttle is setup in the LetRipp software See the LetRipp software manual for throttle position calibration steps The throttle position sensor also generates a voltage for no throttle and for full t...

Page 42: ... engine to The lower calibration scale is normally set at 600 rpm The ops mode must be the same as the trigger wheel on the engine If your trigger wheel is 60 2 then tick the radio button next to universal 60 2 or select the trigger type you have See section 12 1 for more details 23 2 LIMIT It is always a good idea to have a rev limit Why Well the rev limit will prevent the engine from exceeding i...

Page 43: ...tle is only slightly open and not WOT Disable the cold start by adding zero s to the entire fuelling temp table Check that the cooling fan works if the XMS4A is controlling a relay to turn the cooling fan on at high temperatures Change the high temperature to a temperature lower than room temperature Confirm that the fan comes on Change the temperature setting back to where it was and confirm that...

Page 44: ...is running there are some things that will need to be done so let s get to it Having the following items displayed in the LetRipp software will help a lot RPM AMP Injector m s 25 1 FIRST THINGS TO DO WHEN CRANKING THE ENGINE Under first time cranking you must check that you have rpm Normally it is between 180 and 220 rpm The amp reading should be between 0 85 and 1 0 bar with the ignition on Under...

Page 45: ...p 25 4 FUEL SETUP WITH AMP A good fuel map to start up on should have the same values in the main fuel map The amp multiplier should have the same values as the amp gradient Now the only thing you may need to setup is the fuel range The first start map which you have loaded already in the section before this one has a fuel range of 2 5 this number can be adjusted up or down depending the amount of...

Page 46: ...ent System DIY MANUAL V2 1 If the engine doesn t rev up when the throttle is pushed you have two options Option 1 The upper AMP multiplier must be increased Then the AMP multiplier must be blended from the upper multiplier to the idle multiplier See the LetRipp Software guide for more details ...

Page 47: ...to ask you never know Is the battery fully charged A weak battery will cause endless havoc make sure your battery is 100 Is there still fuel pressure at the injectors Check that the fuel pump is switching on Is the XMS4A getting power Take the USB tuning cable off the XMS4A and see if the green LED comes on when the ignition key is turned on Do you have spark Warning Take extreme care whilst doing...

Page 48: ... just much faster than you opening a door Now if the injector has not fully opened and you switch it off you don t get a proper spray pattern and it causes problems at idle If you are having fuel problems at idle consider this fact and increase the injector ms opening time 27 TUNING YOUR XMS4A FOR THE FIRST TIME 27 1 OPTIONS Take your car to the local tuning expert and have them map the engine for...

Page 49: ...vert carbon C in the fuel into carbon dioxide CO2 CO only forms when combustion has taken place A typical cause for a high CO reading is too rich a fuel mixture 27 3 1 3 CARBON DIOXIDE CO2 CO2 is measured in percentage by volume of the exhaust gas As a general rule the engine is operating at its best when CO2 is at its highest level of approx 12 15 The CO2 measurement will always peak at any value...

Page 50: ...ph shows the general relationships Some engines with extensive ignition mapping can run on 0 5 CO other older engines may need 3 5 CO to perform The principle remains the same the most efficient engine is nearly the most powerful one Don t underestimate the influence of the driver on the fuel consumption The other factor is the operating point Unless you are racing engines operate on the road at 3...

Page 51: ...6 2 6 3 6 4 6 5 6 6 6 7 6 8 13 20 13 15 13 12 13 08 13 03 13 00 12 96 12 93 12 90 12 86 12 83 12 80 12 75 12 70 12 66 12 64 12 59 12 54 12 51 12 46 12 43 12 40 12 37 12 30 12 25 12 25 12 22 12 18 12 13 12 10 12 09 12 03 12 00 11 96 6 9 7 0 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 8 0 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 9 0 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 10 0 11 93 11 89 11 86 11 82 11 79 11 76 11 ...

Page 52: ...ngine when it is cold is important to get it started This map is what makes it possible in a few steps See the screen shot below Should the engine still not start under cold conditions increase the amount of fuel at that temperature until it starts Increase the gradient of fuel for colder temperatures and degrease the amount of prime for warmer engine temperatures ...

Page 53: ...e the increase the 20 to a 40 Note All three of these maps influence acceleration so you will need to adjust each map until the engine responds the way you want it to 30 SETTING THE BOOST CONTROL UP This section explains how to setup your XMS4A for open or closed loop boost control This section only applies to turbo charged engines 30 1 CLOSED LOOP This implies that the XMS4A will regulate the boo...

Page 54: ...ions 1 8 and 9 16 low high A Assign a wire in the SETPOINT screen to the BOOST CONTROL function B Choose some settings in the PWM Low table in PERCENTAGE 99 means 100 bleeding Do the same with the PWM High table C Adjust the map so that the boost is what you want it for each rpm site Note During operation the BLEEDING PWM is controlled by the two columns of throttle position 1 8 and 8 16 and is mo...

Page 55: ...rive train 31 3 CONCLUSION With the clutch switch installed and all the parameters enabled the engine has launch control and that means no turbo lag 32 TROUBLESHOOTING Here we will go through every possible reason that we can think of as to why the engine is not running and we will offer solutions 32 1 FUEL Fueling problems are the biggest cause for the engines failure to perform or even start 32 ...

Page 56: ...hen it so it can reach the negative terminal on the battery I will refer to this wire as the trigger wire Don t secure it to the battery Take the coil lead off the distributor and place the end close to a piece of metal on the engine There must be an air gap between the lead and the metal Take the trigger wire and tap it onto the negative battery terminal If you see a spark from the end of the coi...

Page 57: ...XMS4A ignition outputs and not through an ignition amplifier If your coil has built in amplifiers but requires a negative signal to trigger a Perfect Power Auto Inverter will be needed There are many other coils on the market and I can t list all of them If I have not mentioned your particular type of coil you must consult the manufacturer for the wiring details and run the above tests on your coi...

Page 58: ...t are as follows Broken cam belt or cam chain The easiest way to see if the belt or chain is broken is to watch the cam pulley under cranking If the cam pulley doesn t turn then the belt or chain is broken If you are unable to see the cam pulley take the oil filler cap off and you should be able to see the camshaft No Compression The best way of checking this is with a compression tester It is a r...

Page 59: ...f 4 Pin 3 of 4 Pin 4 of 4 Switched 12volts Pin 1 of 22 Pin 9 of 22 Map A B Pin 7 of 22 Pin18 of 22 Pin 5 of 22 Pin 10 of 22 Pin 22 of 22 Fuel Pump 1 2 3 4 5 6 7 8 0 Pin 3 of 22 Pin 11 of 22 Pin 14 of 22 Switched 12volts Ignition Key Battery RPM TPS IAC valve 1 2 3 4 Engine Temp Battery 12volts Pin 2 of 8 Pin 6 of 8 Pin 5 of 12 Pin 12 of 12 Pin 6 of 12 Pin 11of 12 Switched 12volts Switched 12volts ...

Page 60: ...volts Pin 1 of 22 Pin 2 of 22 Pin 13 of 22 Pin 9 of 22 Pin 7 of 22 Pin18 of 22 Pin 17 of 22 Pin 5 of 22 Pin 2 of 8 Pin 10 of 22 Pin 22 of 22 Fuel Pump 56 PERFECT POWER XMS4A Engine Management System DIY MANUAL V2 1 1 2 3 4 5 6 7 8 0 Pin 3 of 22 Pin 11 of 22 Pin 14 of 22 Pin 6 of 8 Pin 4 of 8 Pin 8 of 8 Switched 12volts Switched 12volts Switched 12volts Ignition Key Battery RPM TPS 60 2 Crank IAC v...