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SDS EM-5-D - User Manual

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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
use of SDS products. By using SDS products, the user understands and accepts this.
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
Question and Answer IconNeed help?

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

Summary

Disclaimer

Product Non-Conformance and User Responsibility

Products do not conform to standards; user assumes all responsibility for use and consequences.

System Description

EM-5 EFI System Overview

Microprocessor-based, digital, programmable EFI system for port type injectors.

Theory of Operation

EM-5 Functional Principles

ECU uses sensor inputs to determine injector timing and duration based on engine parameters.

Fuel System Components

Injectors

Importance of using properly sized and matched injectors for optimal performance and engine health.

Fuel Pressure Regulator

Recommendations for adjustable and non-adjustable regulators and their proper setup.

Fuel Pumps

Recommendations for using genuine Walbro pumps and proper installation procedures.

Fuel Lines

Guidelines for selecting and routing flexible fuel lines between airframe and engine.

Fuel Selector and Filters

Recommended Duplex selectors and importance of fuel filters, including annual checks.

Gascolators and Injector Mounting

Use of gascolators and procedures for welding injector bosses onto induction tubes.

Fuel Injector Mounting Details

Lycoming Parallel Valve Engine Mounting

Mounting EFI injectors directly into existing 1/8 NPT holes on Lycoming engine heads.

Lycoming Angle Valve Engine Mounting

Adapter installation for AV engines, similar to parallel valve procedure.

ECU Mounting and Wiring Considerations

ECU Location and Electrical Noise Prevention

Mounting ECU in passenger compartment, away from water and electrical noise sources.

EM-5 ECU Connector Identification

Identifying connectors for injector drive, main harness, and programmer on the EM-5 ECU.

Programmer and Main Harness Connections

Connecting programmer unit and 25-pin main harness to the ECU for system setup.

EM-5 Hookup Procedures

Hall Sensor and ECU Wiring

Wiring the Hall sensor for RPM signal and overview of ECU connections.

Main and Hall Sensor Connector Pinouts

Detailed pinout for 25-pin main harness and 9-pin Hall sensor connectors.

Injector Drive Harness Installation

Connecting the ECU injector outputs to the injector harness for proper fueling.

Dual ECU System Configuration

Relay Box Setup for ECU Switching

Using relay boxes to switch injector circuits between Primary and Backup ECUs.

Electrical System Recommendations

Component Current Draw and Fuse;Breaker Specs

Recommended breaker sizes for ECU, fuel pump, injectors, and other components.

Backup Power Strategy

Importance of backup power and recommendations for alternators or batteries.

Programmer and Mixture Knob Setup

Programmer Installation and Connectivity

Connecting programmer unit and mounting options for system access and diagnostics.

Mixture Knob Mounting and Use

Proper mounting of the mixture knob for easy access and preventing accidental adjustments.

Throttle Body and Sensor Installation

Throttle Body Mounting Options

Installing various throttle body sizes for different Lycoming and Continental engines.

Throttle Position and MAP Sensor Setup

Installing TPS for throttle response and MAP sensor with correct orientation.

Engine Sensor Installation and Routing

Temperature Sensor Types and Wiring

Installing CHT/Air temp sensors and routing cables away from spark plug wires.

Crank Sensor System

Hall Effect Sensor Types and Applications

D, F, and Lycoming F type sensors for fuel-only or fuel/spark control.

Hall Sensor Mounting Procedures

Specific mounts for Lycoming, Rotax, and Jabiru engines for correct sensor alignment.

Magnet Disc Installation and Indexing

Setting magnet air gap and indexing for spark control systems.

General System Information and Controls

EM-5 Reset and Power Management

Understanding EM-5 resets, power interruption effects, and programmer disconnection.

Injector Drivers and Mixture Knob Function

How injector drivers are triggered and the function of the mixture knob for tuning.

LCD Programmer Operation

Programmer Interface and Navigation

Navigating parameters, viewing system status, and accessing settings via the LCD programmer.

Gauge Modes and Error Code Interpretation

Using gauge modes for real-time sensor data and understanding error codes (ERR).

Gauge 2 Mode and Ignition Parameters

Monitoring mixture knob, acceleration pump, duty cycle, and ignition timing (F models).

Basic SDS Fuel Tuning

Fuel Tuning Strategy and Startup

Recommended tuning sequence, startup procedure, and using AFR meter for fine-tuning.

RPM Fuel and Manifold Pressure Tuning

Adjusting RPM Fuel and MAP values to determine base fuel injection and load-based fueling.

Lean Warning Configuration

Setting up lean warning for protection against lean conditions, requires TPS and wideband O2.

Idle, Acceleration Pump, and Engine Temp Tuning

Adjusting idle mixture, ACC pump for response, and engine temp for warmup enrichment.

Start Enrichment Configuration

Setting START and START CYCLES values for proper engine starting, especially in cold climates.

Closed Loop and Fuel Cutoff Limits

Recommendation to keep closed loop off and setting fuel cutoff limits for engine protection.

Values Lock, Fuel Trim, and Setup Mode

Locking values, using cylinder fuel trim, and configuring system setup mode.

Optional Fuel Flow Output Calibration

Calibrating fuel pulse output for engine monitors and totalizers.

Dual ECU Programmer Functions

SDS EFI AERO Programmer Features

New programmer unit, LOP key, Fault LED, and A B Prog key functionality.

Dual ECU System Management

Backup ECU Value Duplication and Switching

Copying values to backup ECU, switching between ECUs, and protection values.

Fuel Delivery and Engine Performance Concerns

Troubleshooting rich/lean mixtures and fuel delivery issues at high power.

EM-5 Aviation System ECU Pinouts

DB25 and DB9 Connector Pin Assignments

Detailed pinout for DB25 and DB9 connectors, including wire colors.

Troubleshooting and Diagnostics

Check Engine Light and Sensor Diagnostics

Understanding check engine light causes and using gauge modes for sensor troubleshooting.

Engine Start and Running Issues

Diagnosing problems like no start, rough idle, misses, or unstable RPM readings.

High Power, Misfire, and Lack of Power Issues

Diagnosing cut-outs, cylinder misfires, lack of power, and programmer display errors.

Fueling, RPM Limit, and Interference Issues

Addressing engine fuel issues, RPM limits, and spark plug wire interference.

Spark Plug Wire and Interference Issues

Wire and Plug Recommendations

Using suppression type wires and resistor plugs to prevent electrical noise and interference.

Technical Support, Warranty, and Repairs

Tech Help, Warranty, and Repair Procedures

Contacting support, warranty terms, and procedures for component repair or return.

System Specifications and Warnings

Tach Output and VP-X Breaker Warnings

Tach signal specs and critical warnings regarding VP-X circuit breaker sensitivity.

SDS EM-5-D Specifications

General IconGeneral
Channels50
Operating Temperature-40°C to +85°C
Receiver TypeGPS
Update Rate1Hz
Position Accuracy2.5m CEP
Acquisition Time (Typical)29 seconds
ProtocolNMEA 0183