RC Engine-EFI RC Engine Electronic Fuel Injection -- Conversion Kit For 120cc to 300cc engines Installation Manual ECOTRONS V1.2.3 http://www.ecotrons.com/
COPY RIGHTS ECOTRONS LLC ALL RIGHTS RESERVED Note: the EFI parts in this manual are installed on a DA150 engine as an example. This manual can also be used as guidelines or illustration for other small RC airplane engines. Some common sense shall be used to convert a different engine. If you are not sure about any specific details, please contact us info@ectorons.com. http://www.ecotrons.com/products/uav-engine-efi/
Chapter 1 EFI installation 1 Install the throttle body 1.1 Remove the stock carburetor
1.2 Replace the spacer / shim with Ecotrons adapter Note: the stock DA150 carburetor is about 25.4mm diameter outlet. The Ecotrons throttle body is 28mm diameter. The adapter is taper shape to connect the throttle body and the reed cage. The stock blue gasket is smaller than the outlet ID of the adapter; you need to cut the gasket to suit the adapter.
Note: Ecotrons 28mm throttle body is designed to replace the stock carburetor and has the same bolt spacing as the carb, so that you can bolt on the TB.
Ecotrons 28mm TB is designed to mount the Futaba servo motor easily. So the complete throttle body / servo is compact and light. 1.3 Install the Ecotrons throttle body with the servo motor Ecotrons 28mm TB is designed to mount Ecotrons small engine injectors. It comes with the injector fittings and thread-on fuel lines. The injector flow rates: 30g/min, 38, 60, 80, 128, 190, 248g/min etc.
2 Install the fuel supply system Note: this EFI has a fuel pressure regulator which requires a fuel return line back to the fuel tank.
Note: this fuel pump is a rotor type, has 25L/h flow rate. It has only limited sucking power. If there are too many air bubbles in the fuel lines, the pump will not work. Note: if you only have the fuel pump and the white case fuel pressure regulator, please install the fuel pump and regulator as following picture. Connect the wire connector to the fuel pump
3 Install the cylinder head temperature sensor (CHT sensor) Note: The CHT sensor must be installed at the cylinder head, closed to spark plug. If you can place it under the spark plug, it is also OK.
4 Secure the intake air temperature sensor (IAT) in the intake air channel or install it in the air box 5 Connect the ECU harness to the stock CDI and pickup sensor Note: for DA150 engines, EFI only controls the fuel injection, not ignition; because the factory pickup sensor (VRS type) is triggered right at the TDC. With this pickup sensor setting, the spark advance is always at 0 degree. EFI cannot advance the spark with this setting. If you want to use EFI to control the ignition, you need to re-align the pickup sensor or the magnet, so that the trigger pulse is happening at 30 degree ahead of the TDC.
Note: Don NOT plug the connectors in the wrong direction. The orange wire from the stock pickup sensor should be connected to the white wire of the adaptable cable, provided by Ecotrons.
6 Optional: Connect the EFI 5V power to the stock CDI Stock CDI uses a 4.8~6.6V battery. EFI requires a 12~16V battery. To avoid using 2 battery packs, you can use EFI s 5V output to supply the power to the stock CDI. There are two wires from ECU harness, green wire and yellow wire. The green wire is Ground, and the yellow wire is power 5V+. Note, this 5V+ can only supply limited power, suitable for DA150 CDI, but may not be suitable for other device. Mis-connect the 5V+ wire (yellow) and/or the Ground wire (green), can damage the EFI. Connect the green wire to the black wire of CDI; connect the yellow wire to the red wire of CDI. 7 Connect the servo motor wires to ECU harness There is no throttle position sensor in the EFI by default. EFI can read the PWM signal of the servo motor control. The servo PWM control signal usually has a duty cycle proportional to the throttle opening. You could add a TPS sensor to Ecotrons 28mm TB, but that is a customer order. Contact us for details. There are two wires from the EFI harness, labeled as servo-input. One wire is white, and the other is green. You need to connect the white wire to the white wire of the servo connector, and connect the green wire to the black wire of servo connector. ECU only read the signal of servo moto control, don t control the servo motor, you need use your own remoter to control the servo motor.
Ecotrons ECU can control the servo with a PWM duty cycle output. But the auto-pilot needs to send the command to ECU via serial communication or CAN bus. Note: the Servo-input wires may come with one connector, you can cut and splice them as in the picture. You can also add another adapter connector between the servo motor and ECU hanress. 8 Install the fuel injector
9 Connect the harness to 12v battery Note: the red is to the positive of battery; the black is to the negative of battery. There is one manual switch on the power wire; you can use this switch to power on EFI, or power off. Note: connect the negative of battery to the engine block. All ground wires should be common. Note: The black wire goes to negative of battery.
10 Mount the ECU Find a safe place to mount the ECU, avoid the severe vibration and severe hot conditions. Do not expose it to water / fluids. This ECU is NOT water proof. 25-pins ECU 11 Optional prime switch function There is a prime switch on the EFI harness. The function is to manually trigger the EFI to inject a little fuel before you start the engine by hand. This is like the carburetor choking. When you press it to the 1 position, it will inject a little starting fuel. It only injects one time even you leave it at 1 position. If you want to inject more fuel, you can cycle this switch, meaning back 0 position, and then press it again to 1 position.
Chapter 2 ECU and Harness 2.1 ECU
Pin # Name Color Note 1 NULL ---- ---------------------- 2 GNDP Black Power Ground 3 Mil-Lamp White Malfunction indication Lamp 4 NULL ---- ---- 5 NULL ---- --- 6 KEYSW Red Reverse Battery Protected Supply 7 ECT White Engine (coolant) Temperature sensor 8 GND Black Power Ground 9 IAT White Intake Air Temperature Sensor 10 NULL ---- ----------------------- 11 HALL White Crank Position Sensor (connect to the ignition pickup sensor signal) 12 NULL ---- ------------------ 13 AGND Green Analog Ground 14 Inj1 White Injector #1 LS Driver Output 15 ROUT White Relay control 16 VCCM Yellow Stock CDI power 17 NULL ---- ---- 18 NULL ---- ---- 19 NULL ---- --- 20 TXD Yellow Receive data from RS232 21 RXD White Sent Data to RS232 22 NULL ---- ---------------- 23 PERSW White Prime Switch 24 NULL ---- ---------------- 25 PWMIN White Servo signal input
2.2 Harness