1st Gen Haltech ECU Discussion

DBW throttle motor comes today so I'll bench test its force capability. Datasheet says <10A @ 12V which is a pretty powerful DC motor on its own, plus it has the gear reduction in the housing for more torque. I'd be surprised if it couldn't pull that cable effortlessly

Going the other route doesn't save me any effort - I still need to adapt another pulley to it

 

Funny ghost in the machine kinda thing going on with my e-fan that has an obvious solution, just didn't think it would be necessary. Apparently with the engine off the PWM signal being floating since the Haltech has zero power in a key off scenario makes it occasionally start up to like 5% and then turn off at random. So guess I'm putting the fan controller on a keyed ignition source haha.

 

Can you implement something akin to a deadband for the PWM?

Like, no fan motion until the input signal passes 5% DC or some other threshold so any spurious signal below that threshold gets effectively ignored?

Seems like it would be nice to still be able to run it off of constant power to help keep some airflow moving past the radiator after stopping in hot conditions, but maybe that’s not a big deal.

At one point, my dumb nerd brain thought it would be neat to have a PID controller running a PWM fan and electric water pump so that both could potentially run together post-shutdown if needed. Seemed cooler than just relying only on the fan and convection in the coolant system. I figured it was a solution looking for a problem, but a neat idea nonetheless

 

The fan controller is designed by Bosch and used in a ton of applications (OE BMW, Merc, Ford, Chevy...). It has some diagnostic duty modes that I think could cause this issue, it might be possible to put a diode in the PWM signal line to stop this behavior I guess. This is the table of various modes


I like the idea of the fan going when the engine isn't running for cooling but it doesn't really work in practice because there is no circulation, even at idle the engines cooling ability on the 5VZ is not radiator or fan limited it is water pump speed limited. I can run this fan at 100% (94.9% ) duty at a perfect 750rpm idle and it won't go below ~192F, but if I even raise the idle slightly to 1200rpm I can get it down to 187 in seconds. Without an e-pump and e-fan I can't see much purpose to running the fan without the engine running, so I have that box checked in the software, turns it off if engine RPM = 0. That's how I dialed in the low idle fan DC I have now, because 28% might as well be 100% for how much hot coolant is making it to the rad.

 

A 1-10k pull down resistor on the PWM wire near the fan side wouldn't work?

 

I have a 1K one I can try. Certainly worth a shot. I just wondered if it would negate the DPO signal.

 

that would have tripped me out. Picturing myself walking out to the garage next to my truck to hear the fan just randomly turn on by itself unprompted.

 

It was making me think I was going insane cuz the first couple of times I heard it I literally just heard the spin down like maybe the last 10 RPM before it pittered out. But then I finally heard it actually go off and I felt redeemed that I know that I wasn't just hearing things

 

Kinda bummed I cannot make the thermofan 1 channel into a 3d map, going to see if I can make a math channel and feed that channel to it.

 

Is that a paywall feature that they have on the higher end ecus?

 

I don't know, it isn't mentioned if it is. I don't even really have to use the dedicated Thermofan 1 channel anyway. I could use a generic and set it to duty cycle to control it myself. I think it is more of a failsafe thing from the Thermofan channel perspective. But in my case I am trying to make a more comprehensive failsafe anyway since I want a temp dependent override. The Haltech 3.11.x firmwares allow many more Generics (like a ton)... I'm not saying to update just for that though as you need to be ready to troubleshoot and retune when upgrading firmware.

 

The most recent firmware change notes for anyone curious...

Spoiler: Version Notes

Upgrade Notes

* Requires NSP V1.38.10.0 or newer.

V3.11.3 Release Notes

Changes

* Transmission Control Improvements:
* Added Transmission Control - Enable Shift When Engine Off to allow the transmission to shift even when the engine is off. This is intended to be used for testing. Shifts are still blocked when first starting the ecu if the driveshaft rpm is greater than 10.
* Stop transmission control from trying to shift into gear if engine is started with selector in gear (i.e. Neutral Lockout).

* A DTC is thrown if a TCA 8 and any CAN Keypad appears on the same physical bus. These two devices conflict and must be on seperate buses.

Fixes

* Cam Control now correctly sets outputs to minimum when targetting 0 angle

* Air Con - Pulse Off Time maximum value has been increased from 10s to 30s

* Fixes 2017 WRX CAN AC request to follow AC Controllers request state

* Fixes the U1213 "Input State Out Of Sync" DTC when using analogue inputs with a Separate Enable Input

* Fixed the Subaru - EJ20 Liberty GT Gen 4 trigger type causing Home Tooth Count Error on the Trigger System Errors channel.
* Any ECU configured with Subaru - EJ20 Liberty GT Gen 4 will automatically get moved to Subaru - EJ25 WRX MY06 which is functionally equivalent to the previous implementation.

V3.11.2 Release Notes

Changes

* Updated the minimum NSP version to V1.38.10. It is required to prevent read/write problems to some tables in the following functions
* Torque Management
* Intake Air Bleed
* Sequential Twin Turbo
* Transmission Control
* Line Pressure Control
* Accumulator Back Pressure Control
* Torque Model

Fixes

* O2 Control State channel now correctly shows the Transient Throttle and Delayed states
* Short Term Fuel Trims will now also be disabled when O2 Control State is Transient Throttle or Delayed

V3.11.1 Release Notes

Fixes

* Fixes issue with some keypads not working in V3.11.0
* Fixed all the missing vehicle CAN I/O pins.
* Fixes issues with widebands not correctly showing states (e.g. Sensor Cold)
* Fixes issues where a false redify is shown when pullup is on and input type set to Analogue - Resistance on spi pins.
* Fixes issues where some Elite ecu's show uncessesary settings on the Throttle Position Input when a fixed input is used.

* CAN Wideband inputs now have additional channels available (requires v3.11.1 wideband firmware)
* Pump Current
* Free Air Current
* Heater Duty
* Heater Resistance
* Calibration Resistor
* Stored Calibration Resistor

V3.11.0 Release Notes

Important Notes

* MAP Prediction / Fuel Film Model corrections now get applied before bank corrections.
* This fixes an issue where the corrections weren't applied when Engine Configuration - Fuel System - Cylinder and Bank Correction Stages is set to No Corrections
* DTC Code P1800 should no longer flag as current due to this configuration.
* This will result in a minor change to the long term correction of banked O2 control.
* This will also mean that the fuel film model won't get applied to banked Nitrous stages.

* Vehicle CAN - Bosch Motorsport ABS - now uses ABS Mode instead of Rotary Trim Module 1
* You will need to reconfigure if you were using Rotary Trim Module 1 with Bosch Motorsport ABS.

Features

* Idle Control Stepper motor now supports parking
* Stepper Home On Shutdown must be enabled and ECR function must be enabled
* Stepper will calibrate itself after ignition off and then park itself

* Connections - Third Party CAN added.
* Includes optional CAN bus with selectable speed.
* Devices can be connecteded to the Third Party bus, Haltech Bus or Vehicle Bus
* Bus speed must match between all devices
* CAN IDs must not conflict between devices on a bus.
* If you are unsure, it is safest to use the Third Party bus.
* Allows communications with Anti-lock Braking Systems (ABS), Inertial Measurement Units (IMUs) and Transmission Controllers (TCMs) over CAN.
* Supported Devices:
* Bosch Motorsport M4 ABS & IMU
* Continental RSX ABS & IMU
* Continental TEVES ABS
* Mainline Dyno (was already supported)
* Dyno Dynamics Dyno
* Supported Sensors, Channels, etc. (depending on selected device. Most require some configuration):
* Anti-lock Braking Systems (ABS):
* Vehicle Speed: Front Left, Front Right, Rear Left, Rear Right
* Brake Pressure Front
* Brake Pressure Rear
* Brake Switch
* ABS channels (no configuration): ABS Armed, ABS Active, ABS Error
* Dynamometers (Dynos) - moved from Haltech CAN System
The following channels (no configuration required):
* Dyno Speed
* Dyno Power
* Dyno Wheel Torque
* Dyno Tractive Effort
* Dyno Ambient Air Temp
* Dyno Ambient Air Pressure
* Dyno Relative Humidity
* Dyno Lambda 1
* Dyno Lambda 2
* Dyno Derived Engine Torque
* Brake Specific Fuel Consumption (BSFC)
* Inertial Measurement Units (IMUs):
* Yaw Rate
* Pitch Rate
* Roll Rate
* Lateral G
* Longitudinal G
* Vertical G

* Connections - CAN - Haltech CAN System Added devices:
* Dash updated to support Dash Types. Dash types are:
* Generic - Broadcast of Haltech Dash protocol
* iC-7 - Supports IC-7 Inputs and Outputs to be configured and used by an ECU
* uC-10 - Supports UC-10 Inputs and Outputs to be configured and used by an ECU

* Added support for NTK LZA09 (6 mA) wideband sensors (version 3 CAN wideband only)
* Requires firmware upgrade of CAN wideband.
* Existing NTK calibrations are now named NTK LZA08 (4 mA)
* If an NTK wideband sensor fails to calibrate, a reason is now given.

* Increased the number of generics
* Sensors up to 20
* Conditions up to 20
* Outputs up to 20
* Timers up to 10

* Generic Outputs can now have 0 outputs.
* This can be useful when using the table for other purposes.

* Reduces the time taken for the Vehicle Speed channels to drop to 0 when coming to a stop.
* Vehicle Speed sensors now have a 1.2 mph (2 km/h) minimum reading. When below this, 0 mph (0 km/h) is used instead, and the sensor filter is bypassed.
* PD16 SPI & I/O Box DPI period & frequency measurements now have a gradual timeout.
* This means that things like vehicle speed can continuously approach 0, rather than waiting for the timeout before dropping to 0.
* PD16 SPIs require upgrading PD16 firmware to version 1.7.0 or greater to benefit from this change.
Simply plug your USB cable into the PD16 USB port with NSP open, and you should be prompted to update.
* I/O Box DPIs require upgrading I/O Box firmware to version 1.12.0 or greater to benefit from this change.
This will automatically be done if firmware upgrading the ECU/VCU while the I/O box is powered and connected to the Haltech CAN bus.
It can also be done manually by going to I/O Expander Box A/B in the tree on the left of NSP, and clicking the Upgrade Device Firmware button.

* Added support for Turbosmart eSG40, eSG50 and eSG76 electronic wastegates.

* Added Vehicle CAN:
* Honda S2000 2006+
Signals supported: (Requires configuration)
* 4x Vehicle Speed sensors
* Steering Angle
* Brake Pressure Front
* Nissan Infiniti G35
Signals supported: (Requires configuration)
* 4x Vehicle Speed sensors
* Vehicle Speed - Drivetrain
* Air Con Request
* Air Con Output
* Brake Pressure Front
* Traction Control Enable
* Steering Angle
* Lateral G
* Yaw Rate
* Cruise Control Enabled Light
* Thermo Fan 1 State
* Check Engine Light

* Cam Control can now use ECU DPI pins.
* This allows single connector ECUs to be used on Honda K series engines.
* DPI channels will no longer update if the DPI isn't assigned to a function.

* Improves responsiveness of I/O box DPI when used for state inputs (e.g. button & switch inputs)
* Requires I/O box firmware to be updated to v1.11.0 or greater.
* Also requires either:
* Elite firmware version 3.11.0 or greater.
* Nexus firmware version 1.25.0 or greater.

* Vehicle Speed Calibrate buttons now work if the calibration setting had a value of 0 in it.
* Also fixes the calibration values for vehicle speed sensors coming in via Vehicle CAN

* Throttle Blip now supports throttle blippers. [Elite 2500 & 1500]
* When the Throttle Blip Actuation Method is set to Blip Actuator, an output will be available for assignment.
* This output will be pulsed on to blip the throttle. The Blip Duration table determines how long to pulse the output.

* Cam Control will now flag DTCs if there are cam sensor errors if the engine has been running for 5 seconds or more.

* When Input Type is set to Resistance and the Pull Up is disabled, the Input Type setting and the input Pull Up setting will now redify.

* Idle Control
* Renamed Decel Fuel Cut Restore to Closed Loop Activation Offset to better represent it's behaviour.
* Added an enable setting for the Vehicle Speed check.
* Decel Offset will no longer hold

* Windscreen Wipers
* Can now have separate high and low speed outputs.
* Park Inputs are now optional
* Added Home Delay settings for Front and Rear wipers.
* The output will remain on for this long after reaching the park signal when parking.
* This allows the wipers to be stopped somewhere other than the park signal location.
* Parking will now always use low speed mode to park (if configured for low and high speed).

* Traction Control - Added Ignition Correction table.

* Added ABS Mode sensor
* Input type options: Analog Voltage, button(s), or CAN (Vehicle bus or 3rd party ABS).
* This value will be transmitted on the Vehicle CAN bus if Bosch Motorsport is selected.
* This value will be transmitted on the selected bus for Third Party ABS if Bosch Motorsport or Continental RSX is selected. But only if the input isn't from the 3rd party ABS unit itself.

* Added Virtual Outputs. These can be assigned to output pins when you don't want to use a pin.
This is sometimes desired when using Generic Outputs etc.

* Added the following channels:
* Last Engine Limiting Function
* Time Since Engine Limiter
* Drive By Wire Disable Reason - will get set if ever the Drive-by-Wire throttle redundancy checker disables the Drive-by-Wire throttle.
* Latest Flagged DTC - this will contain the latest flagged DTC. If that DTC is later cleared, this resets to 0.
* Latest Cleared DTC - this will contain the latest cleared DTC. If that DTC is later flagged, this resets to 0.

* Ride Height sensors
* Sensors now have a Zero Offset setting, similar to the Shock Travel sensors. It is on the same tab as the calibration table.
* Ride Height Front and Ride Height Rear channels have been renamed to Ride Height Front Uncalibrated and Ride Height Rear Uncalibrated.

* Emergency Stop Hazard Flash setting added to Electrical - Indicators
* If Brake Pedal State remains at On (Hard Braking) while the vehicle speed drops below 14 km/hr, Hazard Lights will turn on (if enabled).
NOTE: After an emergency stop is initiated, the Hazard lights can be turned off by pressing the Hazard input. If Hazard input is a Push On/Push Off configuration, it will need to be pressed twice to disable the Hazard lights output.
* This is no longer an automatic sub-feature of the Brake Light Pulsing.

* Trans Brake - On In Reverse now obeys the Trans-Brake Enable Condition.

* Adds Transmission Slip Percentage channel.
* Requires the following to be enabled:
* Transmission Input RPM Sensor
* Vehicle Speed
* Gear Ratio
* Gear Detection

* Main Limiter Hard Cut Hysteresis maximum increased to 3000 rpm.

* O2 Control State channel changes:
* will now split into two channels if doing banked O2 Control Bank 1 State and O2 Control Bank 2 State.
* The state channel(s) will now display Sensor Cold, Input Below Minimum or Input Above Maximum when appropriate.
* Firmware behaviour hasn't changed. Previous firmware didn't update the state channel when O2 Control was stopped for one of those reasons.

* Adds trigger patterns:
* Dodge Viper (58x + 5x)
* Lamborghini Gallardo

* The following tables now have a third axis available
* Torque Converter Lock Duty Cycle
* RPM Shift Point
* Throttle Blip Duration
* Flat Shift Cut Percentage
* Flat Shift Recovery Time table
* Traction Control Desired Slip
* Traction Control Cut Percentage

* Line Pressure Solenoid will now be off when the engine is stopped.

* Added transmission support for:
* Jatco (Nissan) 4AX Series
* Jatco (Nissan) 4R Series

* Wheel Slip channels are now visible for 4WD. They're calculated based off the fastest and slowest sensor reading.

* Changes Reverse Lights conditions so that any of the following will turn on the reverse lights:
* Current Gear = Reverse
* Current Gear Selector Position = Reverse
* Reverse Switch Enabled and On.
* Trans brake On and Reverse Light On With Trans Brake enabled.
* This fixes an issue where Reverse Lights didn't come on when Reverse Switch is enabled but Gear Detection and Selector Position are both disabled.
* This also fixes an issue where reverse lights stay on when no longer in reverse if the clutch is depressed and Gear Detection is Gear Ratio.
* Previous firmware conditions were:
* Gear = Reverse
* Selector Position = Reverse
* Trans brake On and Reverse Light On With Trans Brake enabled.

* Fuel Level sensor now has the choice between the calibration being Volume or Percentage.

* Brake Lights now allows 2 outputs

* Added error checks for when ignition cylinder and/or bank corrections are enabled when the Ignition Mode and Trigger Pattern don't support them.
* This effects:
* Ignition Tuning - Corrections - Cylinder Correction
* Ignition Tuning - Knock - Mode
* Engine Functions - Nitrous Controllers - Ignition Correction (when Apply Overall Corrections To Bank is set to either 1 Only or 2 only
* Engine Functions - Water Injection Advanced - Ignition Correction (when Apply Overall Corrections To Bank is set to either 1 Only or 2 only

* Increases maximum Engine Capacity to 65L / 3661 cubic inches.

* Engine Functions - Intercooler Spray - Minimum Load has been converted to Minimum Manifold Pressure.
* This will be automatically upgraded such that functionality won't change.
e.g. if Fuel Load was Throttle Position, then the minimum MAP is -14.5 psi (-100 kPa).

* Combined Fuel Feed and Fuel Return into one tree item and added a Filter that is used for both of these.

* Fuel Film Bank 2 channels no longer exist.

* DPI and SPI Period and Active Time channels no longer flash red when the input has timed out.

* The Fuel - Load and Ignition - Load channels will show the load type in brackets after the channel name.
* For example, Fuel - Load (MAP) or Fuel - Load (TPS).



Fixes

* Fixes an issue where NTK wideband sensors could report as 'Uncalibrated' after previously being calibrated.

* Fixes an issue with Transmission Control start-up for Sequentials with Gear Detection set to Transmission Control

* Cam Control outputs now properly turn off when the engine is stopped.
* Previous firmware could pulse the outputs if the Duty Cycle Min setting was non-zero.

* Fixes an issue where Injector Open Circuit and Short Circuit DTCs would never trip.

* Vehicle CAN now correctly receives values when Receive Only Mode is enabled.

* Fixes an issue where the Check Engine Light only flashed for one sequence when Engine Protection was active. It now repeats the flash sequence with 1 second gap between flash sequences.

* Fixes an issue where Haltech CAN Keypad middle and right LEDs wouldn't light up when an output was on or in an error state.

* Fixes RPM not reading for Dodge - Viper (4th Gen) trigger pattern, and possibly others.

* Fixes an issue where Torque Converter Minimum TPS and Maximum TPS settings were greyed out when using DBW throttle.

* Generic Outputs no longer activate any outputs until conditions have been checked. This can prevent a brief flicker on start-up in some circumstances (e.g. Active State set to High).

* Removed extra Nitrous Bottle Opener enable settings from the Nitrous Controllers.

* Fixes the Suzuki - Swift ZC32A M16A trigger pattern.

* P1800 DTC is no longer falsely flagged when injectors are disabled.
"Fuel Cylinder Corrections couldn't all be applied."

* Fixes an issue where headlights and/or indicators could initially flash on when the ECU first turns on.

* [VMS & VMST] Fixes an issue where the errors pane on the right hand side of NSP showed errors related to fuel injection cylinder corrections

* [VMS & VMST] Fixes the default map to remove errors.

 

What thermostat are you running?

 

Stocker

 

Hmm.. I use the 170 with an under drive crankshaft pulley (would effect water pump speed) and I'm 189 at 675-725 idle. Just comparing things mechanically.

 

Under drive pulley shouldn't affect pump speed because it's cam belt driven. But the 10° cooler stat appears to do what it says at idle at least huh

 

Oh yeah, the timing belt does the driving. Dang it, looking for a "problem" that isn't there.

 

Haltech did send out an email with some decent discounts.
They had the Elite 2500-T showing at 40% off

 

Bosch pedal adaptation seems possible by reusing the top left stock firewall nut for the factory pedal wire, creating a small triangular plate that attaches the bottom two mounting holes to the two pedal mount nuts, and possibly just drilling another hole through the firewall for the final top right hole. Could probably run with 3 but the top is where all the force will be so kinda sketchy if you don't.

I am holding it in place in the Pic because I don't have an M6 bolt quite long enough to get a nut on to hold it in place

 

I was able to drill the main shaft down about 3/4" with no issues, but for some reason could only manage to tap around 3/16" into it before my tap just refused to go further (and I didn't want to break it). Tried to TIG weld the edge but all it did was melt a bolt and the shaft didn't so much as pool and started burning the seal. So I'll probably just use some high strength locktite on it.

Adapter plate stack is supposed to come this week. (assuming it works the first time, PM me for STEP files to manufacture your own)

Did disassemble the TB and the internal return spring is very strong so the motor will have plenty of overhead to pull the relatively light transmission cable. Probably just going to weld a stack of thick fender washers or something for that. Interesting note, it'll have to be driven upside down due to the Bosch plate opening the reverse direction as factory.

Maybe this should be on my build thread but just figured this is relevant enough since it's the Haltech driving it, and similar requirements would be needed to be met by anyone else doing this.