Nira I7r Bedienungsanleitung

NIRA i7r

Handbook

NIRA i7r Handbook version A6, December 2015

This handbook is protected by copyright laws. It may not be redistributed in any form

without written consent of Nira Control AB.

Release 2015-12-01

The purpose of this handbook is to serve as a guide during installation and calibration

of NIRA i7r. Descriptions, content and specifications in this handbook may be

changed at any time. This handbook could contain errors –therefore it should not be

regarded as a definitive installation guide. Nira Control AB is not responsible for any

personal or property damages due to errors in this handbook, the professional

installing NIRA i7r is responsible for the installation.

Misuse of NIRA i7r and/or NIRA rk can cause severe personal injury and engine

damage. Nira Control AB is not responsible for any injuries, accidents or damages due

to misuse or ignorance.

Repairs of NIRA i7r, e.g. replacement of parts, will affect the safety of the product and

are not allowed under any circumstances. Nira Control AB is not responsible for any

problems, accidents etc, caused by non-approved parts or repairs not carried out by

Nira Control AB.

NIRA i7r must be installed by professional automotive technicians in accordance with

the instructions in this handbook, following good practice.

NIRA i7r is only intended for racing use and not for use on public roads. It is not

certified for use on vehicles subject to emission standards unless the appropriate

waivers have been issued. Please check with the relevant authorities for more

information.

NIRA rk is protected by applicable software copyright laws. You may not distribute

this software without the written consent of Nira Control AB. You may not copy this

software. Your purchase of NIRA i7r includes a single license to use NIRA rk together

with NIRA i7r.

1 Overview.................................................................................................................5

1.1 Content of your NIRA i7r Package...................................................................5

1.2 Glossary ...........................................................................................................6

1.3 NIRA i7r Functionality......................................................................................8

2 Combustion, Lambda and Measurement Principles ...............................................10

2.1 Relationship Between A/F, Lambda and Smoke...........................................10

2.2 Measurement Principles ................................................................................11

3 Installing NIRA i7r..................................................................................................14

3.1 Injectors .........................................................................................................15

3.2 Fuel Pressure Control Actuators ....................................................................16

3.3 Crank Position Sensor (CKP) and Trigger Wheel ...........................................17

3.4 Cam Position Sensor (CMP) ...........................................................................20

3.5 Acceleration Pedal Position (APP)..................................................................21

3.6 Manifold Absolute Pressure (MAP) and Intake Air Temp (MAT) ....................21

3.7 Engine Coolant Temperature Sensor (ECT)...................................................22

3.8 Manifold Air Temperature Sensor (MAT) .......................................................22

3.9 Lambda Sensor..............................................................................................23

3.10 Exhaust Gas Temperature. ............................................................................24

3.11 Boost Pressure Actuator ................................................................................25

3.12 Main Relay .....................................................................................................27

3.13 Pre Fuel Pump Relay......................................................................................28

3.14 Mounting NIRA i7r in the Vehicle ..................................................................29

4 NIRA rk Software ...................................................................................................29

4.1 Installation of NIRA rk ....................................................................................30

4.2 Getting Started..............................................................................................30

4.3 Using NIRA rk ................................................................................................33

4.4 Parameters.....................................................................................................36

4.5 PID Controllers ..............................................................................................47

4.6 Gauges ..........................................................................................................48

4.7 Logging .........................................................................................................51

4.8 Locking the i3d Data Set ...............................................................................54

4.9 FlexiPorts™ - Set up ......................................................................................54

5 Fuel Handling........................................................................................................56

5.1 Fuel Mass.......................................................................................................56

5.2 Injection Control ............................................................................................60

5.3 Fuel Pressure Control ....................................................................................65

6 Boost Controller ....................................................................................................69

6.1 Boost Controller Initial set up ........................................................................69

6.2 Boost Actuator Control Mode .......................................................................70

6.3 Boost Controller ............................................................................................71

7 Starting the Engine................................................................................................74

7.1 Setting Up Parameters Offline.......................................................................74

7.2 Going Online .................................................................................................85

7.3 Quick Troubleshooting Guide .......................................................................88

7.4 Other Adjustments ........................................................................................89

8 Electrical Specifications .........................................................................................90

8.1 Input ..............................................................................................................90

8.2 Output ...........................................................................................................92

8.3 Communication .............................................................................................93

9 Appendix A ...........................................................................................................94

10 Appendix B .........................................................................................................95

Overview

NIRA i7r is a sophisticated electronic engine management system developed

specifically for racing. NIRA i7r controls ignition, fuel injection, idle speed, boost

pressure and several other engine functions. It can be used with many different types

of engines.

1.1 Content of your NIRA i7r Package

When you purchased NIRA i7r, you should have received the following:

NIRA i7r

NIRA rk calibration software

Additional order of following parts could be made.

Wiring harness

Communication interface (Kvaser CAN-dongle)

1.1.1 NIRA i7r

NIRA i7r is a highly sophisticated,dual core microprocessor based engine

management system designed for sophisticated needs of control. NIRA i7r offers an

unusual level of flexibility in how input signals are interpreted and processed. It also

gives you significant control over the mapping of the output signals. This allows NIRA

i7r to work with many different sensors, actuators and engine types. Setup,

configuration and programming of NIRA i7r is done via the NIRA rk software.

1.1.2 Wiring Harness

Contact Nira for more information

1.1.3 NIRA rk

NIRA rk is the calibration software that allows you to setup and configure a large

number of parameters in NIRA i7r. It is designed to run on a PC using the Windows

operating system and communicates with NIRA i7r via a Kvaser CAN-dongle.

The many functions of NIRA rk are described in detail starting in chapter 4.

NIRA rk is protected by applicable software copyright laws. You may not distribute

this software without the express written consent of Nira Control AB. You may not

copy this software other than for personal use. Your purchase of NIRA i7r includes a

single license to use NIRA rk together with NIRA i7r.

1.1.4 Communication interface

The Kvaser CAN-dongle connects NIRA i7r to the PC running NIRA rk software. The

CAN-dongle connects to your PC via a USB port. Drivers for the Kvaser USB-CAN

dongle are delivered together with the NIRA rk application software. Run the Kvaser

USB-CAN installer file before attempting to connect to NIRA i7r.

1.2 Glossary

60-2 lost

Common pattern on the crankshaft trig wheel. The

trig wheel has 58 tooth-window pairs, spaced 6

degrees apart. Two tooth-window pairs are missing

(“2-lost”) and the resulting wider window serves as

the reference point.

Absolute pressure

Absolute pressure is measured starting at 0 kPa.

This is the pressure in vacuum. At sea-level the

absolute pressure is approximately 100 kPa, +/- 10

kPa depending on the weather (high or low

pressure.)

Ambient pressure

The pressure around us; approx 90 –110 kPa

absolute pressure depending on the weather (low

or high pressure.) The pressure decreases with

altitude.

APP

Acceleration Pedal Position

BAC

Boost Actuator Control

Boost Control

Csd

Crankshaft degrees. A four-stroke engine turns 720

crankshaft degrees during one complete

combustion cycle. (The camshaft turns half as fast

as the crankshaft and thus completes 360 degrees

during the four strokes.)

Default values

These are base values or recommended values.

EGTC

Exhaust Gas Temperature Control. Nira-developed

exhaust gas temperature measurement unit. Can

be connected to NIRA i7r.

FML

Fuel Mass Limitation.

FMSP

Fuel Mass Setpoint. The requested fuel mass after

all limitations.

FPC

Fuel Pressure Control

GND

Ground (kl31)

Grounding can be done to the body, engine block

or directly to the battery. Ground is sometimes

referred to as minus or 0 Volt. Poor ground

connections can cause problems that are hard to

find. Make sure the ground connections are proper.

MAP

Manifold Absolute Pressure. Pressure in the intake

manifold after the throttle plate. On a naturally

aspirated engine this varies between 25kPa and

100kPa.

MAT

Intake Air Temperature or Manifold Air

Temperature. Refers to the temperature of the air in

the intake manifold. The temperature can be as

much as 150 degrees hotter than the ambient air

temperature on a turbo charged engine.

The density of the air decreases with increasing

temperature. Therefore it’s important to be able to

measure the temperature accurately in order to

determine the engine load.

Pull-down resistor

A pull-down resistor connects an input or an output

to ground (0V). It pulls down the voltage on the

input or output to ground level (0V).

Pull-up resistor

A pull-up resistor connects an input or an output to

+12 V (or +5 V). It pulls up the voltage on the input

or output to +12 V (or +5 V).

Terminal 15 (kl 15)

Terminal 15 is a term used to describe battery

voltage (+12 V) after the ignition switch. Most

sensors and actuators used with NIRA i7r that

require battery voltage should be connected to

terminal 15.

Terminal 30 (kl 30)

Terminal 30 is a term used to describe battery

voltage (+12 V)

Terminal 31 (kl 31)

Se Ground

(Volumetric Efficiency)

A V.E. value of 1.0 means that 100% of the cylinder

volume gets filled during the intake stroke. For

example, if the cylinder volume is 500 cc, the

engine breathes in exactly 500 cc of air.

Do not confuse V.E. with engine efficiency. A V.E.

value above 1.0 means there’s some amount of

supercharging due to resonance, which is unusual.

If, during calibration, the V.E. table has values

above 1.1, or the lambda table is not in line with

actual (measured) lambda, you may have made a

mistake.

Many standard engines have an average V.E. of

0.85.

1.3 NIRA i7r Functionality

NIRA i7r reads sensor values, processes the data and sends output signals to various

actuators.

NIRA i7r is a fully sequential engine management system for engines with up to 8

cylinders.

By using the NIRA rk software, you have the ability to modify many of the parameters

that control the data processing and the output signals in NIRA i7r.

1.3.1 Sensors

MAP sensor (Manifold Absolute Pressure)

Boost sensor (Pre throttle pressure measurement)

MAT sensor (Manifold Air Temperature)

CKP sensor (Crankshaft Position) Inductive or Hall

APP (Acceleration Pedal Position)

CMP sensor (Cam Position. The crankshaft rotates two revolutions per four

strokes in a four-stroke engine. The camshaft rotates half as fast as the

crankshaft so it completes one revolution per four strokes. The CMP sensor is

used to determine in which of the two crank revolutions the engine is. This is

used during cranking.) Inductive or Hall

ECT (Engine Coolant Temp)

Fuel Temperature (for display purpose)

Fuel Pressure

Oil Pressure

Lambda sensor (NIRA i7r Street controls Bosch LSU 4.9 lambda sensor without

external electronics)

EGTC (Exhaust Gas Temperature. Measures the exhaust gas temperature in the

exhaust manifold where the headers collect. NIRA i7r handles either digital

egtc reading, resistive reading or 0-5V analog input)

1.3.2 Output Functions

NIRA i7r processes the input signals and controls the output signals in order to

manage the following actuators.

8 Fuel injectors (amount and sequence)

Fuel Pressure Control (controls pressure control and/or volume control valve)

Boost pressure control valve (controls boost pressure H bridge or PWM output)

Fuel pump relay

Main relay (for actuator power supply)

Fan relay (for controlling radiator fan)

In addition to standard engine management, NIRA i7r includes a set of additional

engine control strategies and functions. These are listed in section 1.3.3 and are

described in detail later in this manual.

1.3.3 Additional Control Strategies/Functions

FlexiPorts™ - a very advanced function that controls fuel injection and boost

pressure in relation to input axes configured during calibration

Start fuel Handling –allows precision control of fuel injection during cranking

based ECT, engine speed derivate and cranking time

Alarms –adjustable alarm thresholds reduce the risk of engine damage

Limp home –any input sensor value out of range is replaced with a reasonable

value to keep the engine running, albeit at reduced power. Sets error code

Diagnostics –read error codes

Logging –advanced data logging and graphical analysis tools in NIRA rk

software

Combustion, Lambda and

Measurement Principles

For combustion to take place, oxygen needs to be available. The oxygen content of

the air changes with air temperature and pressure.

Thus diesel engines runs on excess amount of air, the volumetric efficiency and A/F

calc is used to avoid smoke

2.1 Relationship Between A/F, Lambda and Smoke

A/F means Air-Fuel ratio. It’s always given as a ratio of masses. The stoichiometric A/F

is different for different types of fuel.

Example of stoichiometric A/F ratios:

Air/98 Octane Gasoline = 14.6

Air/Methanol = 6.8

Air/Ethanol = 9.0

Air/E85 = 11

Diesel = 14,7

Lambda is defined as:

λ= (actual air fuel ratio)/(stoichiometeric ratio)

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