VtrSp1 Posted December 8, 2020 Report Share Posted December 8, 2020 I'm on planning to do a G4X wiring to a Caterham 485R. This car is powered by a Ford Duratec 2.0 Na with ITB Caterham Drive By Wire, because i want a full control in this car equipped with sequential gearbox. The car is controlled by a Lotus Ecu , a T6 Model (same ecu as the Evora, Exige V6 , Elise S3) Last week i have the time to disassembly the ITB Intake Manifold for check how caterham do the Drive By wire on ITB. They use a Throttle Valve Actuator VDO A2C53279226 for move the ITB by a rod. I try to search on the web some information about this Throttle Valve Actuator VDO and i find that is used in many Audi/VW Diesel car for move the flap in the intake manifold. Before starting with the G4X Extreme wiring, i need to say if i can use this VDO actuator or if it draw a lot of current and the ecu can't handle it.. Anyone can help me or have used before this VDO Actuator for ITB Drive By Wire in other engine/setup? Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 8, 2020 Report Share Posted December 8, 2020 Im pretty sure it will be ok. I have set one up with a Cosworth ECU before with only my benchtop 5A power supply and it worked ok. It wasnt a caterham though so be aware your linkage will influenece current requirement also. Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 8, 2020 Author Report Share Posted December 8, 2020 @Adamw , My caterham have the Barrell ITB , see the picture attached As for safety, is better measure the Ampere supply in the Oem wiring before start with the project? Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 8, 2020 Report Share Posted December 8, 2020 It wouldnt hurt to test if you have the opportunity, but I doubt it will be an issue with a relatively freely moving mechanisim like this. The G4X E-throttle controller is rated for 4.4A continuous with shorts bursts to about 10A. Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 9, 2020 Author Report Share Posted December 9, 2020 @Adamw ok, i do the test in this week. Another Question is regarding the Coil On Plug. This Engine have the coil on plug with crank and cam sensor, so i can do a direct spark. The car is equipped with a Bosch channel ignitor 0 227 100 211 It work fine with the G4X? Quote Link to comment Share on other sites More sharing options...
Brad Burnett Posted December 9, 2020 Report Share Posted December 9, 2020 Bosch ignitor will work fine. Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 10, 2020 Author Report Share Posted December 10, 2020 Thanks Brad :-) I have another question , i take a look at the Fuel system and the Caterham 485R is equipped with a Fuel Returnless system, but near the fuel tank i have a Fuel Pump Control Module (FPDM) with this code: au5a-9d370-fc It's a fuel pump control module from Ford Ecoboost Fiesta/Focus 1.0 engine M1DA. I take a look at the electrical wiring, i have a normal Fuel Pump Relay activated by the Oem Ecu and i think a PWM signal to the fuel pump control module. The Fuel Pump module, is a returnless system with a fuel pressure regolator I have search on the web for a few Wiring for this Fuel Pump Control Module but i don't find a clear information, Anyone have work before with this Fuel Pump control module? Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 11, 2020 Author Report Share Posted December 11, 2020 @Adamw , i have do a Current measure with my Bosch Clamp 30A to the ITB Throttle Motor Wire - , i do a few 0 to 100% pedal travel and a few partial travel movement . I record the Ampere graph , it's look 2.5-2.6 A peak current at 12 Volts Battery , it's fine for the G4X ? I need to measure them with 14 v on the battery? Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 11, 2020 Author Report Share Posted December 11, 2020 I have do a few measure at 13,7 Volt Battery I try Some time to do fast 0-100% pedal travel and i don't see more than 3.5A Peak Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 11, 2020 Author Report Share Posted December 11, 2020 I have do some check on the Caterham Fuel Pump Wiring and now it's clear.. If i do a direct current 12 V to fuel Pump, i have a 7 bar fuel pressure limited by the internal fuel pressure regulator in the tank. The ecu command by a Pwm Signal the FPDM for have a different fuel pressure in the rail. i don't find on the car a fuel pressure sensor . I do a analisys with my oscilloscope and i found this value in the screenshoot attacked... The Ecu command in fixed duty ever the fuel pump module, i change tps with the pedal, change rpm etc but the value is fixed Can i command this module with a Aux Link? Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 22, 2020 Author Report Share Posted December 22, 2020 @Adamw , the G4X Extreme Wiring to the Caterham is done and i try a few crank for see if the trigger is ok.. The ecu is locked for now, i unlock them tomorrow morning and i don't have connect a few sensor for the sequential box so i have a few analog error I attach the trigger scope log and the calibration..it's fine the trigger scope and setting for the first start? The other log show the Tp error accumulator for the E-throttle setting..any advice? Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 22, 2020 Report Share Posted December 22, 2020 Yes, triggerscope looks ok and your trigger settings look ok. The E-throttle error is due to the PID not well tuned so you have some oscillation after large movements. Probably need to lower proportional and increase derivative. Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 22, 2020 Author Report Share Posted December 22, 2020 @Adamw thanks for look and check at the log.. The Actuator at 600 Hz have a noise as whistle... This whistle is the same as when the ecu Oem was fitted... I had measure with the oscilloscope the frequency with Oem ecu and it was 600 Hz... It's better to turn up the frequency until i have no whistle? Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 22, 2020 Report Share Posted December 22, 2020 It is not a frequency problem - just PID. But yes, generally higher frequency will give less noise (but generates more heat in motor and controller). Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 22, 2020 Author Report Share Posted December 22, 2020 @Adamw great information..i do some PID test in the next day and report back after the first engine start Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 23, 2020 Author Report Share Posted December 23, 2020 @Adamw , i start the car and run perfect! I have only an issue,only when i shut down the ignition , the ecu have an error code 84 , Over-Current/Over-Temperature warning from the electronic Throttle Control hardware contained inside the ECU. I have connected the E-Throttle Relay 30 to the Main Rele 30 and the E-Throttle relay 86 to a Ignition Switch signal. Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 23, 2020 Report Share Posted December 23, 2020 3 hours ago, VtrSp1 said: I have only an issue,only when i shut down the ignition , the ecu have an error code 84 , Over-Current/Over-Temperature warning from the electronic Throttle Control hardware contained inside the ECU. I think this maybe a known problem at the moment, I have had logs from someone else with a similar problem and I passed it on to engineering this week for a look. It is marked to be fixed in the next firmware release. If you can clear the fault codes and do us a ECU log of it occuring may be helpful. Log Fault codes, battery voltage, aux 9/10 supply, aux 9/10 status and a selection of other common variables all at 50Hz would be good. Quote Link to comment Share on other sites More sharing options...
VtrSp1 Posted December 24, 2020 Author Report Share Posted December 24, 2020 @Adamw this is the log requested The error appear without shut off the engine, in this log the engine is off and i only switch off ignition I modify the wiring to E-Throttle Relay with 30 direct to Battery but this not solve the issue, the error appear on PcLink exactly after switched the ignition off. I think is firmware/software related Quote Link to comment Share on other sites More sharing options...
Brad Burnett Posted December 30, 2020 Report Share Posted December 30, 2020 On 12/23/2020 at 10:29 AM, VtrSp1 said: @Adamw , i start the car and run perfect! I have only an issue,only when i shut down the ignition , the ecu have an error code 84 , Over-Current/Over-Temperature warning from the electronic Throttle Control hardware contained inside the ECU. I have connected the E-Throttle Relay 30 to the Main Rele 30 and the E-Throttle relay 86 to a Ignition Switch signal. 02-Caterham485R ITB DBW SequentialBox.pclx 425.02 kB · 7 downloads @VtrSp1 I experience similar issues with the code 84. I typically notice this upon initial key on before the engine is even started. If you configure the DBW system to have "when stalled" setting set to "quiet" it will not happen as frequently, but still occurs. It typically doesnt really cause any ill effects on operation, just an annoyance. Quote Link to comment Share on other sites More sharing options...
Simon Posted December 30, 2020 Report Share Posted December 30, 2020 The latest firmware 6.19 has change to stop the code on power down. Its only of concern if it is generate during normal running of the throttle. Quote Link to comment Share on other sites More sharing options...
Adamw Posted December 31, 2020 Report Share Posted December 31, 2020 @Simon Both these guys are already on 6.19, I have passed Brads logs on to Engineering a couple of weeks ago and they think they have found the cause. It is marked to be fixed in release 6.20. Quote Link to comment Share on other sites More sharing options...
Mauri Posted June 7 Report Share Posted June 7 Hello, I'm new here, but the post fits my request Does anyone know the connector type for the VDO A2C53279226? On my CSR 2000 I like to switch from a single butterfly to Caterham reel drums and MBE 9A9 with e-gas Thank you in advance for your support Mauri Quote Link to comment Share on other sites More sharing options...
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