Instruction Manual Fire Management So3220-9A

Instruction manual
FIRE MANAGEMENT SO3220-9A
Connect FIRE – Engine Management

Instruction manual
2
Instruction manual
Contents
1. Preface........................................................................................................................................................................ 4
1.1 Name and Address of manufacturer...................................................................................................................... 4
1.2 Legal information................................................................................................................................................... 5
1.2.1 Liability limitations........................................................................................................................................... 5
1.2.2 Copyright/authorization................................................................................................................................... 5
1.3 Target groups........................................................................................................................................................ 6
2. Basic safety instructions.............................................................................................................................................. 7
2.1 Safety information.................................................................................................................................................. 7
2.2 Work safety measures......................................................................................................................................... 10
2.3 Specific safety instructions.................................................................................................................................. 11
3. Training concept........................................................................................................................................................ 13
3.3 Training objectives............................................................................................................................................... 13
4. Introduction................................................................................................................................................................ 14
5. Sensors and Actuators.............................................................................................................................................. 15
6. The Connect FIRE engine......................................................................................................................................... 16
7. Connecting the Connect FIRE engine....................................................................................................................... 18
8. Starting the software................................................................................................................................................. 19
9. Starting the engine.................................................................................................................................................... 21
9.1Settings options.................................................................................................................................................... 23
10. Wiring Diagram........................................................................................................................................................ 26
11. Maintenance and cleaning...................................................................................................................................... 27
11.1 Maintenance and customer service............................................................................................................27
11.2 Spare parts........................................................................................................................................................ 27
12. Explanation of terminology used herein.........................................................................................................28
13. Copyright................................................................................................................................................................. 29
3
Instruction manual
1. Preface
This instruction manual is written to be read, understood and complied with in every respect by persons intending to
use the training system.
It contains basic tips and instructions to be observed during assembly, operation, maintenance, disassembly and
disposal involving the training system.
For that reason, this manual must be read through carefully before assembly by any teaching staff, students or other
users. Only the information in this manual can prevent errors and ensure faultless operation.
1.1 Name and Address of manufacturer
Manufacturer and servicing

address
LUCAS-NUELLE Lehr- und Messgeräte GmbH

Siemensstrasse 2
D-50170 Kerpen
Germany
Tel.: +49 (0) 22 73 5 67-0

Fax: +49 (0) 22 73 5 67-30
E-Mail: info@lucas-nuelle.com
www.lucas-nuelle.com
4
Instruction manual
1.2 Legal information
1.2.1 Liability limitations
LUCAS-NÜLLE GmbH accepts no liability for any damage occurring due to the following:
 Inappropriate or incompetent use

 Irresponsible or incorrect assembly and/or commissioning by operators or third parties
 Subsequent modifications by operators or third parties
 Natural wear and tear
 Negligent or incorrect handling, servicing or maintenance
 Actions not in keeping with the instruction manual
 Use of inappropriate materials.
1.2.2 Copyright/authorization
This instruction manual is authorized for the use of teaching staff and students.
The instruction manual contains specifications and drawings of a technical nature. These may not be reproduced
distributed, utilized without permission for competitive advantage or passed on to others either in part or in full.
The making of copies, including extracts, is expressly permitted to users of the training system, but only for internal
use in connection with the operation of the equipment.
5
Instruction manual
1.3 Target groups
Those groups at whom this instruction manual is targeted are described as listed in the following:
Target groups - Tasks - Qualification

Target group 1 Tasks Qualification
Training staff  Supervision of students  Automotive technician
 Teachers  Set-up of training system  Automotive engineer
 Trainer  Providing students with an initial  Automotive trainer
introduction to the training
 Educational assistance systems
 Laboratory assistance  Providing safety instructions for
students
 Enabling power supplies
 Rectification of minor faults
 Recognition of faults and safety
problems and guaranteeing
correct functioning of processes
related to the training system
 Observation of procedures
Target group 2 Tasks Qualification

Students
 Set-up of training system  Must have had instruction
 Modifications to training system
 Trainees  Person with specific previous
set-up
instruction and reading and writing
 Students  Switching training system on and
skills in the language of their
off
 Apprentices country
 Rectification of minor faults
 Observation of procedures  Introduced to the training system
 Recognition of faults and safety by teaching staff
problems and guaranteeing
correct functioning of processes
related to the training system
Symbols used
Hazard symbols
Degree of risk Application
This symbol means there is a direct risk to life and health of people.
Ignoring this warning can result in a serious effect on the health of persons
and may result in life-threatening injuries.
This symbol means there is a direct risk to life and health of people.
Ignoring this warning can result in a serious effect on the health of persons
and may result in life-threatening injuries.
This symbol provides important advice on the proper and economic use of
the training system. Ignoring this warning can result in slight injuries or
adverse effects on health or may result in damage to the training system or
its environment.
6
Instruction manual
2. Basic safety instructions

2.1 Safety information
The training system is designed and constructed with the latest technology and according to recognized safety
guidelines. Nevertheless, incompetent or unauthorized use of the equipment may result in risks to life and limb of
users or third parties or to damage to the training system itself or to other equipment.
The training system may only be used if it is in technically perfect operating condition and following specified
procedures with attention paid to aspects of safety and risk. Any faults, which may adversely affect safety, must be
rectified immediately.
This instruction manual must be stored close to the training system itself and be accessible by anyone at any time.
Validity
Apart from definitive laws of the user's respective land, and the safety guidelines applicable for operation,
maintenance and assembly of equipment as set forth by the educational establishment or company involved, the
following instructions must be observed.
Any person given responsibility for the operation, set-up, maintenance or repair of the training system must have read
and understood the relevant instruction manual and any experiment instructions.
The valid regulations for prevention of accidents should be stored within view in the vicinity of the training system and
should be accessible to anyone there. Regular instruction of users must be undertaken by those responsible for the
equipment.
Modifications
Reconfiguration and/or modification of the training system by users may only be undertaken with the consent of the
supplier. The supplier assumes no liability for any measures taken without that consent or for any damage resulting
there from. This includes any use of the training system that contravenes the instruction manual (during
assembly/setup modifications and conduct of experiments using the training system).
Prevention of accidents during operation
The training system is safe to use if the instructions are adhered to correctly and the equipment uses the latest
technology. Danger may only occur under the following circumstances:
 Use of the training system by persons with no instruction

 Incorrect operation of the training system
 Use of the training system that contravenes the instructions.
7
Instruction manual
Operators
All the safety features and operating instructions provided by the manufacturer are to be regarded as prerequisites
for the safe operation of the training system and for avoiding accidents.
The operator and teaching staff are responsible for the prevention of accidents when using the equipment. Staff
should be fully conversant with their tasks relating to use of the training system.
The operator must guarantee the following:
 Training staff are sufficiently trained for their specific task in relation to safety regulations
 Safety regulations for the workplace are made known to training staff and students and this action is
documented
 Safety regulations are available for inspection at any time
 Safety regulations are obeyed.
Electrical installations must meet the valid local standards. In particular, suitable earthing connections must be
provided for the training system.
Legal regulations for the prevention of accidents
 Apart from the regulations specified here and all the contents of this instruction manual, as signified by
hazard symbols, the following general guidelines are also binding for the use of the training system:
 Safety regulations for EU member states
 Relevant safety regulations in countries outside the EU
Training system users
The training system is manufactured using the latest technology. It is safe to use and should be operated
appropriately by persons who have received instruction under supervision of qualified teaching staff.
Non-compliance may result in risk to life and limb for the operator or for third parties, damage to the training system
or other equipment and may endanger the efficient use of the training system.
Function checks, maintenance work
Regular function checks and maintenance work advance safety!
Training staff should check the training system before use for any visible damage or deficits. Any changes, which
may affect safety, should be rectified at once.
The training staff is responsible for maintaining the training system in perfect condition at all times.
Maintenance and cleaning work are not permitted when the training system is in operation.
8
Instruction manual
Protective systems
Existing protection may only be removed during the course of setting up an experiment with the power supply turned
off and must be properly replaced after the work is completed.
Ensuring safety of the workplace
During upkeep, cleaning and reconfiguration of the training system, the workplace should be protected appropriate to
the circumstances.
Power should be turned off and protection provided to stop it being turned back on.
The housing and rear of the devices may not be covered since this may lead to impermissible heating of the
equipment and to the possible failure of the training system.
Fuses should only be removed and replaced by authorized personnel!
Safety equipment
Safety equipment may not be modified, removed or rendered inoperable. Unprotected elements may cause life
endangering injuries.
All safety equipment, such as safety switches, covers and barriers must always be functional. The operation of the
training system is not permitted if the safety equipment is faulty or missing. Correct functioning of the necessary
safety equipment must be checked before starting the training system.
9
Instruction manual
2.2 Work safety measures
Personal safety
For your own safety, the necessary protective clothing and equipment must be worn. It is not permissible to wear
loose clothing or jewellery that may become trapped within the training system. Long hair should be bound with a
hair net.
Prohibition of gloves: when working next to moving or rotating pieces of equipment, gloves may not be worn.
Persons under the influence of drugs, alcohol or medication capable of affecting reactions are prohibited from
operating, maintaining or repairing the training system.
Foot protection
Danger of crushing!
Panels and other items of equipment are heavy and may have sharp edges that could fall on people's feet if not
correctly handled.
Always wear appropriate, safe footwear.
10
Instruction manual
2.3 Specific safety instructions
Danger due to exhaust fumes!
If rooms are not properly aired and ventilated, exhaust fumes may cause a toxic hazard. For this reason, the engine
should only be run for the duration of the individual experiments and turned off immediately afterwards!
Danger due to electric current!
It should be observed that the plugs for the training system (cables and sockets) are always connected to the
correct, identical colours and patterns!
Danger due to electric current!
The training system may only be used with the supplied cabling. Always use safety cabling and safety plugs and
make sure that the measuring cables are in perfect condition. All experiment cables must have continuous double
insulation throughout their length.
Danger due to rotating components!
The training equipment may only be used when the cover is properly shut. None of the safety features may be
turned off or by-passed!
Danger due to high ignition voltages!
Never touch the safety cover of the spark plug!
Danger due to electric current
Use the equipment in the training system only at the specified operating voltages.
11
Instruction manual
Danger due to heat!
Take care to avoid overheating of the engine!
The engine is fan-cooled. The fan needs to be blowing air into the engine throughout the time that the engine is
running. The engine may not get any hotter than 95°C.
Danger of crushing!
Always keep the cover closed when the engine is running. The engine produces a large torque that could cause
injury if the equipment is used incorrectly
Danger due to heat!
The cover may not be opened when the engine is running due to the risk of burns.
12
Instruction manual
3. Training concept
The Connect – FIRE engine is a four-stroke single cylinder engine that can assist in cementing theoretical teaching.
The engine can form a link between education in a laboratory, which can be somewhat abstract for some, and a
practical training program on a real vehicle with an emphasis on diagnostics
The engine’s simplicity of operation and unrestricted access to its key parameters offers plenty of potential for
motivating and testing trainees.
Before working with the Connect – FIRE engine, it is advisable to work through the theoretical background of
sensors, and engine management.
Proper use of the equipment cannot be guaranteed in the absence of the requisite theoretical knowledge. It is the
responsibility of the system’s users to obtain such knowledge before using the equipment.
This knowledge can be gained via Lucas Nuelle’s “Connect”, “Connect Light” or “Unitrain-I” training systems.
3 . 1 Requirements
 32 bit Windows computer with FIRE-Software

 12V power supply
 Connect Control Unit
 FIRE engine
 Exhaust extraction for FIRE engine
 Serial interface cable
 Multimeter
 Max. Humidity: 60% non-condensing
 Max. Ambient temperature: 35 ° C
3.2 Technical information
 Engine type: air-cooled single cylinder 4 stroke engine

 Bore/stroke 39 x 26 mm
 Cylinder capacity 31 cc
 Compression ratio: 8 : 1
 Max power 1.1 kW (1.5 hp) / 7000 rpm
 Max torque 1.64 Nm / 4500 rpm
 Tank capacity: 0.7 L
 Motor oil capacity 0.1 L
 Injector resistance 12. – 18
3.3 Training objectives

After this hands-on exercise, you will be able to:
 Recognize and name the sensors and actuators.

 Determine the difference between an actuator and a sensor.
 Connect the controller unit to the FIRE engine.
 Explain how speed-limiting works.
 Determine the pick-up or operating time of the fuel relay (injection duration).
 Measure the pump pressure of the fuel pump.
 Explain the changes in fuel pressure.
 Interpret the injection duration and injection correction characteristics.
 Read the values out of the family of characteristics for injection duration and injection correction.
 Determine the injection period for idle speed.
13
Instruction manual
4. Introduction
The Connect FIRE engine you see before you is a self-contained miniature engine management system. The engine
contains a number of sensors and actuators that are found in contemporary vehicles.
During the hands-on exercise, you are able to change the injection duration. You should only do this when the
exercise instructions state that this should occur!
The engine has also been equipped with a so-called loading brake.
NEVER SWITCH ON THE BRAKE WHEN STARTING THE ENGINE!
THE TIME IT TAKES TO ACTIVATE THE BRAKE SHOULD NOT EXCEED THE PERIOD DURING WHICH
MEASUREMENTS ARE BEING MADE (due to the large amount of heat generated).
Before the exercise, students should work through the theory and enter any required settings or adjustments into the
software of the FIRE engine themselves.
Good luck!
14
Instruction manual
5. Sensors and Actuators
Nowadays, it is impossible to imagine automotive engineering without electronics. To obtain an overview of the
electronics found in motor vehicles, this can be divided into 3 subgroups;
1. Sensors
2. Electronic Control Unit
3. Actuators
The sensors or probes register the various operating conditions within the engine.
Examples are: the engine temperature sensor and the crankshaft position sensor.
The controller unit or central computer processes the signals of the sensors (input) and compares them to the data
stored in the memory or the family of characteristics. The controller unit subsequently converts the input signals into
output signals.
The actuators are operated by output signals from the controller unit and thus alter the response of the engine.
Examples are: the injector and the idle control valve.
ECU
15
Instruction manual
6. The Connect FIRE engine

Open the cover of the FIRE engine and try to name all the sensors and actuators. You will see that all the
components have been labelled with a letter. Write down these letters in the table below and state the name of the
component. In the last column, you should indicate whether the component is a sensor or an actuator.
Component Letter Name Sensor or Actuator
16
Instruction manual
Component Letter Name Sensor or Actuator
17
Instruction manual
7. Connecting the Connect FIRE engine
Before you connect the FIRE engine, you first need to establish whether the FIRE engine meets certain
requirements;
 Oil level; if the oil level is too low, fill up with oil until the oil level is correct.
 Fuel; check to make sure there is sufficient fuel in the tank.
Please also ensure that the following bridge connectors

are inserted.
Oil level
Fuel
Please note!
If the fuel pump starts clicking while performing the exercise, it has run out of fuel. Fill the fuel tank to continue.
1) Connect the cable harness: First connect the cable harness of the FIRE engine to the controller unit; the
labelling of the wires must correspond with the labelling on the controller unit.
2) Connect the power supply unit: Now connect the power box to the controller unit. This is done with a red wire
and a black wire. Connect the black wire to pin 39 of the controller unit and the earth (black, blue) of the power supply
unit. Connect the red wire to pin 30 (+12V) of the controller unit and the positive (red wire) of the power box.
3) Connect the PC to the controller unit: Now connect the computer to the controller unit. This is done with the
serial cable. The RS232 connector is below the ignition lock on the controller unit. Insert the RS232 cable into this
slot. The other end of the cable is connected to the back of the computer by means of the COM port
(1-4).
4) Extracting engine exhaust fumes: Make sure that the extractor unit is properly connected to the exhaust pipe to
ensure that exhaust fumes cannot escape into the room.
18
Instruction manual
8. Starting the software
Now that all the components are connected, the software can be started:
1) Turn on the computer
2) Click on the “Fire” icon to start the software
3) Select the language and click “Next”
The controller unit will now read the data in the family of characteristics of the computer. This will take about 2
minutes.
Once the reference field data has been retrieved, the FIRE menu with an empty reference field will appear on your
computer screen. If you now click on the arrow at the middle of the top of the submenu, you can call up various
characteristics.
19
Instruction manual
Select the injection duration reference field as shown in the picture on the previous page. You will see that the yellow
area changes into an “Injection” reference field.
If you now operate the throttle lever on the right hand side of the FIRE engine, you will see a red bar moving through
the reference field from the top to the bottom (Z-axis).
A change in the angle of the throttle will be shown on the Z-axis in degrees of 0° – 90°.
Because the FIRE engine is not running at the present, the red area can only move in the first row of 0 rpm.
20
Instruction manual
9. Starting the engine

Now that you have connected all the components and started the software, you can start the engine.
Before you start the FIRE engine, check in the brake menu to make sure that the tick box is ticked off. Also check in
the edit mode area so that the performance map has been ticked on and the lambda control is ticked off.
If these settings are correct, you can turn the ignition key to the ignition position. You should be able to hear the
cooling fan blowing.
Turn the throttle handle until this is at approximately 10° - 30° (more if the engine is cold). You can now start the
engine manually.
Once the engine has started, you can turn the throttle valve lever to about 15°. You can check this on the menu for
current values. Once the temperature has reached about 40 °C you can change the throttle position as desired. You
will also see that the red area moves right across the performance map.
Throttle position set to Injection duration

around approx 30° setting
Brake off
Lambda control off
21
Instruction manual
First start and extended periods of storage

For the first start or after an extended period of storage, it may be necessary to bleed any air from the fuel line before
fuel will be injected. As the engine needs to be pull started, this can greatly help with starting the engine.
By removing the line from Pin 4 and connecting to earth VERY QUICKLY (less than 1 second) a few times. This
opens the fuel injector briefly and allows the air to be purged. This must be done quickly to ensure the fuel injector is
not overheated and damaged.
Also care must be taken so that too much fuel is not injected into the cylinder and “floods” the spark plug.
Ensure there is fuel pressure

shown on the gauge. Should
be around 0.3 Bar
22
Instruction manual
9.1Settings options
The engine management system allows for manual control or adjustment to the performance map.
To edit the performance Cross indicates value of Save current configuration

map; Select area and sensor output or
increase with + and actuator input
decrease with – or
pressing the on the
keyboard
Open saved
configurations
23
Instruction manual
Brake on, and

strength of brake
setting.
To edit the performance

map; Select area and
increase with + and
decrease with – or pressing
the arrow buttons on the
keyboard.
24
Instruction manual
Addition of performance
values to be measured
25
Instruction manual
10. Wiring Diagram
ECU Pin “Fire“ Function
4 Fuel injector
9 Ignition coil
11 Fuel pump relay
12 Output PWM1 signal (Brake)
18 Idle control valve
30 Reference voltage TPS
38 Crankshaft position sensor
27 Oxygen sensor
35 Throttle Position Sensor (TPS)
36 Negative Temperature Coefficient (NTC) temperature sensor
26
Instruction manual
11. Maintenance and cleaning
The specifications in the “Basic safety instructions” section must be obeyed at all costs.
Non-compliance may result in:
Possible risks to life and limb of the operator or third parties, damage of the training system, of
individual products or other equipment or efficient operation of the training system.
Safety measures
Maintenance work on the training system may only be carried out by qualified staff in suitable rooms. Expendable
parts which have worn and any visibly defective parts must be replaced. After maintenance has been completed, the
training system should be checked for proper functionality. The training system and its surroundings must be cleaned
of dirt at appropriate, regular intervals.
The training system requires no servicing.
Check for mechanical damage each time the training system is used. In particular, check for any damage to power
cables.
11.1 Maintenance and customer service
The specifications in the “Basic safety instructions” section must be obeyed at all costs!
The customer service address can be obtained from your local dealer.
The manufacturer's address is provided in the section titled “Name and address of manufacturer
11.2 Spare parts
LUCAS-NÜLLE GmbH assumes no liability whatever for any damage caused by the use of spare
parts or accessories not supplied by us and any guarantee is thereby invalidated. See the section
“Basic Safety Instructions”
Ordering spares from

LUCAS-NÜLLE GmbH
When ordering spares, please provide the following data:
 Article number
 Order number/delivery date
 Name of the spare part
 Number of spare parts required
The address for our spare parts sales department can be found in the following section:
“Name and address of manufacturer”
27
Instruction manual
12. Explanation of terminology used herein
Modifications
Any changes to the original state or a revision or addition to the product that entails by extension, a
newer version of the product.
Instructions (for use)

Information from the product manufacturer for the safe and efficient use of the training system
Maintenance
Combination of all technical and administrative measures necessary to maintain the training system in
serviceable, ready-to-use and safe condition or restore it to such a condition so that it can fulfil its
intended function. This includes monitoring, recovery, repair, adjustment and cleaning.
Safety equipment
Safety measures (other than isolating measures) to reduce risks (e.g. safety equipment with
mechanical proximity response, electronic safety equipment, pneumatic safety equipment).
Repairs
An aspect of maintenance involving manual work on a unit, including replacement of expended or
worn components and re-establishment of faulty components or functions.
Risks/hazards/dangers
Combination of the probability of damage occurring and the severity of such damage.
Electrician
An electrician is defined to be someone whose professional training, knowledge and experience and
whose familiarity with the relevant standards qualifies that person to perform the assigned work and to
identify possible safety hazards. Note: Professional training may also be deemed to include several
years of experience working in the relevant field.
Electrically instructed person

Electrically instructed persons are persons instructed (and, where necessary, trained) by an electrician
regarding the tasks to be performed and the risks of incorrect conduct, as well as about the necessary
safety equipment and safety measures.
Supplier
Persons or organisations (e.g. manufacturers, contractors, installers, integrators), supplying products
and/or services relating to the training system.
Users
Persons or organisations capable of setting up and/or using the training system in order to complete a
required function. This includes a range of actions from cleaning to disposal of the training system at
the end of its lifespan.
28
Instruction manual
13. Copyright
1st edition
Copyright © 2012 LUCAS-NÜLLE GmbH.
All rights reserved.
This instruction manual is protected by

copyright and may not be reproduced in any
form, as a photocopy, on microfilm or by any
other method or copied to a format readable by
machines, in particular computers, without the
specific written permission of Lucas-Nuelle
GmbH. Any changes performed without the
authorization of LUCAS-NÜLLE will invalidate all
product liability and warranty claims.
Made in Germany.
29
Instruction manual
30

Instruction Manual Fire Management So3220-9A

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instruction Manual Fire Management So3220-9A

Uploaded by

Copyright:

Available Formats

Instruction manual

FIRE MANAGEMENT SO3220-9A

Connect FIRE – Engine Management

1.1 Name and Address of manufacturer

Manufacturer and servicing

LUCAS-NUELLE Lehr- und Messgeräte GmbH

Tel.: +49 (0) 22 73 5 67-0

1.2 Legal information

1.2.1 Liability limitations

 Inappropriate or incompetent use

1.3 Target groups

Target groups - Tasks - Qualification

Target group 2 Tasks Qualification

2. Basic safety instructions

Prevention of accidents during operation

 Use of the training system by persons with no instruction

The operator must guarantee the following:

Legal regulations for the prevention of accidents

Training system users

Function checks, maintenance work

Regular function checks and maintenance work advance safety!

Ensuring safety of the workplace

Fuses should only be removed and replaced by authorized personnel!

2.2 Work safety measures

Always wear appropriate, safe footwear.

2.3 Specific safety instructions

Danger due to exhaust fumes!

Danger due to electric current!

Danger due to electric current!

Danger due to rotating components!

Danger due to high ignition voltages!

Never touch the safety cover of the spark plug!

Danger due to electric current

Danger due to heat!

Take care to avoid overheating of the engine!

Danger due to heat!

 32 bit Windows computer with FIRE-Software

3.2 Technical information

 Engine type: air-cooled single cylinder 4 stroke engine

3.3 Training objectives

 Recognize and name the sensors and actuators.

NEVER SWITCH ON THE BRAKE WHEN STARTING THE ENGINE!

5. Sensors and Actuators

6. The Connect FIRE engine

Component Letter Name Sensor or Actuator

Component Letter Name Sensor or Actuator

7. Connecting the Connect FIRE engine

Please also ensure that the following bridge connectors

8. Starting the software

1) Turn on the computer

2) Click on the “Fire” icon to start the software

3) Select the language and click “Next”

9. Starting the engine

Throttle position set to Injection duration

Lambda control off

First start and extended periods of storage

Ensure there is fuel pressure

To edit the performance Cross indicates value of Save current configuration

Brake on, and

To edit the performance

10. Wiring Diagram

ECU Pin “Fire“ Function

11 Fuel pump relay