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Last Post 23 Feb 2018 10:09 PM by  Reanimotion
The FrankenCIS 928 CIS-E Hybrid install
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Reanimotion
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08 Mar 2015 12:20 PM
    Changing from K-Jet (CIS basic) to KE-Jet (CIS-E)
    As far as we know this has never been done before, simply because CIS-E was just too difficult to adapt without programmable control.

    Take one eWUR development 928 with CIS basic


    Step 1 - remove fuel system ( note the FrankenCIS eWUR )
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    11 Mar 2015 08:22 AM
    The main components chosen are
    0 438 101 018 Mercedes Fuel Distributor
    0 438 121 037 Air Plate Housing from the same vehicle
    0 438 161 013 System pressure regulator
    VW DPR instead of the Mercedes one
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    20 Mar 2015 02:08 PM
    Step 2
    assemble

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    23 Mar 2015 12:22 PM
    Posted this morning on Pelican
    Our first on the road report for the CIS-E hybrid monster.
    Seems to run fine and like normal CIS in behaviour, nice and happy on the road with a flat map at 130 positive
    I’m using a grey DPR so the centre point on these is lean
    There is a pretty massive jump at Zero (our 100) between negative and positive so the DPR itself is jumpy when changing direction which would explain why Bosch ran them with a positive bias of 30ma or 6ma
    We also have an issue on warm starts without the cold start injector active, no fuel and not turning fast enough to come out of cranking mode – 300rpm is the default setting and we need 100, there will be an updated ini file to allow this
    we also might need some additional speed and resolution to control the EHA/DPR 100hz And 100 steps just isn’t fine enough control I think
    we have 256 to play with so I’m thinking 50 below zero and 200 above should give us the numbers


    Because of the above I'm doing a few small firmware changed to alter the way in which DPR control behaves.
    Currently we discuss everything in Duty Cycle terms which is fine for the injector based eWUR as we are really targeting pressure here anyway and Duty Cycle helps keep the concept clean and separate

    With the DPR / EHA based systems all documentation and official information discusses mA of current at the DPR so rather than confuse thinks I've decided to replicate that in an offset map
    -100 to 0mA to +155mA should come very close to the real world output if the VE to duty ratio is 1:1 considering the firmware pwm steps are 200 and the actual electrical range is +/-212mA

    I'm also trying a higher frequency than 100hz to see if the pressures flatten out a bit when control improves

    Finally the gauge CP and System pressure representation in Tuner Studio was not honouring the sensor calibration values so the ini file has also been updated and a pressure conversion in the firmware for eWUR pressure targeting will need to be verified and implemented
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    26 Mar 2015 11:01 PM
    3.7kHz control frequency on the DPR seems to have done the trick

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    31 Mar 2015 12:13 AM
    Spent the last week on and off trying various methods to control the Idle valve properly and at a reasonable load

    of all the solutions mentioned by MegaSquirt users - the cheapest and simplest is the 1n4001 flyback diode specified by the MegaSquirt documentation
    added and running at 153Hz on the bench between 30 and 70% duty cycle the Mosfet is cool to the touch and hum is minimal if rubber isolated

    also lost an o2 sensor apparently, possibly either temperature shock during firmware updates and/or very low rpm and rich mixtures while idle control testing. Innovate LC-2 controller with LSU4.2 sensor and Error 8, and odd AFR results including random drops to 7.5
    so I've ordered a new sensor and will also dual wire to allow switching in a 14point7 Spartan 2 with LSU4.9 sensor
    possible combination options will now be
    Innovate LC-2 and LSU4.2
    Innovate LC-2 and LSU4.9
    14point7 Spartan-2 and LSU4.9
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    04 Apr 2015 09:11 AM
    There is a firmware update available now on the downloads page of the website

    FrankenCIS 5.4.4k - which addresses the issues mentioned for CIS-E applications

    http://www.frankencis.com:8084/wiki...S-Firmware

    On the road testing and self tuning over the last 24 hours has provided good results
    I do need a real TPS sensor to take advantage of the fuel cuts and closed loop idle though. The air plate sensor is ok as a secondary MAF but useless as a TPS.
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    14 Apr 2015 11:05 AM
    The registered version of TunerStudio is a must for anyone wishing to get the best from the system.
    I was curious as to the benefits of the Live Tune features, as I had heard nothing but good things from various sources.

    Firstly there is an internal AFR table generator that, when given appropriate engine parameters seems to create a fairly relevant starting point for road tuning.
    I popped in the numbers to generate a table, then used Live Tune to refine the VE tables over a hour of driving. Frankly very good, and the changes were definitely noticeable and positive.
    Part throttle drivability is now way better then the original CIS could ever imagine being.

    I'm definitely not an engine tuner, and the auto system has probably now saved a couple of hours of Dyno time
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    14 Apr 2015 11:08 AM
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    14 Apr 2015 11:44 AM
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    14 Apr 2015 12:03 PM
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    15 Oct 2016 05:37 PM

    also lost an o2 sensor apparently, possibly either temperature shock during firmware updates and/or very low rpm and rich mixtures while idle control testing. Innovate LC-2 controller with LSU4.2 sensor and Error 8, and odd AFR results including random drops to 7.5
    so I've ordered a new sensor and will also dual wire to allow switching in a 14point7 Spartan 2 with LSU4.9 sensor
    possible combination options will now be
    Innovate LC-2 and LSU4.2
    Innovate LC-2 and LSU4.9
    14point7 Spartan-2 and LSU4.9

    informative update I forgot to post

    Innovate wideband controllers are basically junk! If you have the choice DO NOT PURCHASE..

    used a 14Point7 controller on the LSU4.2 sensor that innovate was doing it's unhappy error 8 on and the sensor is fine.
    there are several reasons for this but basically, from what I have been able to research, the Innovate drives the sensor poorly and out of spec!
    So whatever you do, spend some money on a known system that uses the calibration resistor on the sensor and not the lazy-ass free air calibration Innovate and other seemingly cheap and or dodgy systems provide. In OEM installations the sensors last for years and Bosch didn't go to the trouble of laser etching a calibration on each sensor for nothing.
    The older I get the more obvious it becomes that advertised enhancements are basically dodgy shortcuts masking lazy errors!!
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    23 Feb 2018 10:09 PM
    My last tuner studio project from the FrankenCIS system on the 928 before removal

    please use only as an example reference ONLY

    DO NOT UNDER ANY CIRCUMSTANCES TRY AND LOAD IT INTO AN ECU

    http://www.frankencis.com/portals/2....53.59.zip
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