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  1. 1. 1 WHEEL UNIT SETUP AND ADJUSTMENT 1.1 UNPACKING THE WHEEL UNIT Before unpacking and setting up your driving system, prepare a clean area with adequate room for laying out the components. Review the list of wheel unit parts [Figures 1a & 1b] and verify that everything is present to complete assembly. ECCI recommends keeping the original box and packing materials in case the unit needs to be shipped in the future. If shipping is needed, the unit MUST be shipped partially disassembled as originally received, or damage will result. 1.2 WHEEL MOUNTING BRACKET Before starting, examine Figure 2 for how the wheel unit should appear when assembled. Lay out the components in a sufficient well-lit workspace. 1 Set the main steering chassis on a table upside down on a terry cloth towel or other soft non-abrasive cushioning material to avoid scratching the cover. If your unit has a Lexan cover, keep the protective covering on until all assembly is finished. 2 Using a 3/16 inch hex wrench, loosen the two center-most chassis tube bolts [Figure 3]. Do not remove them; back them out until the nuts between the bolt tubes and the gray central structural plate can be removed and discarded. Then re-install the two bolts about one turn and leave them loose. 3 Invert the table bracket assembly towards the central chassis structural plate and align the two central slots with the previously loosened chassis-tube bolts [Figure 3]. The table bracket should be seated between the spacer tubes and the main chassis structural plate. 4 Using a 1/8 inch hex wrench, attach the mounting bracket with the 3 supplied bracket mount screws and nuts [Figure 3]. After tightening these screws, turn the two center-most chassis bolts until tight, fully securing the mounting bracket to the main chassis plate. 5 Turn the unit upright and secure to a tabletop edge using the clamp of the mounting bracket [Figure 4]. Note that it is possible to adjust the angle of the unit by adjusting the height of the rear wheel mounting bracket. Rotate the bracket tensioning bolt [Figure 2] until it is perpendicular to the underside of your mounting surface. Turn until it contacts the underside of the surface. Do not over tighten. Turn till finger-tight and then using a wrench, turn one-half turn more. Then lock the bracket by tightening the pivot set screw. 1.3 STEERING WHEEL ASSEMBLY 1 With the wheel unit upright and secured to the tabletop the steering wheel and shift paddles can be mounted. Prior to assembly inspect the shift paddle set [Figure 5b]. Note the importance of the two wire management slots at the back side of the paddles. These slots accommodate the button wiring when the paddle/wheel assembly is tightened down to the steering unit hub. It is critical that the wires pass through these slots and avoid getting pinched during assembly. (For Momo Corse wheel skip to step 5): Remove the wheel attachment screws from the paddle set. Discard the small nuts that held them at the back of the assembly. From front to back, the screws will pass through the steering wheel, optional wheel spacer (if supplied), the shift paddle assembly, and into the threaded holes in the hub. Begin
  2. 2. assembly by putting two screws through the steering wheel at the ten and two o’clock position. Hold the heads in place on the wheel with a piece of masking tape. Note that the flanged button retaining ring must be placed between the steering wheel and the shift paddle set. The raised flange of this ring must point towards and fit into the large central hole in the paddle set. Place the paddle set over the screws making sure the button wires are in their slots. Once the paddles are close to the wheel, pull the paddle set wires towards you through the center hole of the wheel. 3 Next position this assembly over the steering unit hub making sure the wheel is upright. Guide the two screws into their respective holes. Pull the hub wires and connectors towards you through the center of the wheel/paddle assembly. Next remove the masking tape and turn the screws in gently making sure before tightening that the paddle button wires are not in danger of being pinched. The wheel should be centered and not cocked to one side. If it is tilted, remove the screws and use the next set of hub holes to counter the tilt. Turn the screws in until snug. Then install the remaining three screws and finally tighten all five screws progressively using the supplied hex wrench until tight. 4 Connect the button wires to the hub connectors as shown in Figure 5a. Wire colors do not matter, the paddles will function any way they are plugged in. Carefully arrange the wires within the hub cavity such that none are pinched when the center logo button is installed. The center logo button is installed by engaging the four prongs of the button through the button retaining ring that sits behind the wheel. Push the button firmly until flush. 5 Momo wheel only: Remove and discard the nuts from the five black wheel attachment screws. Place the paddle set only over the holes in the steering hub. Once the paddles are close to the wheel, pull the hub and paddle set wires towards you through the center hole of the wheel. Tighten the five black mounting screws. 6 Connect the button wires to the hub connectors as shown in Figure 5a. Wire colors do not matter, the paddles will function any way they are plugged in. Carefully arrange the wires within the hub cavity such that none are pinched when the MOMO wheel is installed. 7 Locate the four screws that mount the wheel. Pass them first through the E-logo plate and then through the holes in the wheel. Attach to the paddle set and tighten. 8 If you have a Lexan cover, you can now remove the protective covering. First loosen the cover mounting screws ½ turn. Do not pull the covering straight out, carefully pull the covering by pulling slowly parallel and close to the cover until it is removed. Then re- tighten the cover screws. 1.4 WHEEL ANGLE ADJUSTMENT The final step of wheel unit setup is to adjust the angle of the steering wheel to your preference. This is done by loosening the rear leg screws [Figure 4] until the rear leg can be moved up or down. Making this adjustment will also require loosening the bracket tensioning bolt under the mounting surface [See Figures 2 & 4]. The tensioning bolt and the rear leg puts pressure from bottom and top to hold the unit securely to the mounting service. To tilt the wheel more towards vertical, the rear leg must be extended downward and the bracket bolt must be backed down. To tilt the wheel more forward the rear leg must be raised and the bracket bolt extended.
  3. 3. If a substantial change of wheel mounting angle is desired, it will be necessary to loosen the pivot set screw and the tensioning pivot nut [Figures 2 & 4]. For proper performance of the mounting system, the bracket tensioning bolt must be vertical and perpendicular to the underside of the mounting surface. 1.5 COCKPIT MOUNTING In addition to removable desktop mounting, the TRACKSTAR 6000 wheel unit is easily adapted to a custom driving cockpit. When attaching the unit permanently to a fixed framework, the table mounting bracket need not be used. The unit can be mounted directly to the cockpit sub-frame in its upright orientation or inverted under a monitor shelf. Another option is ECCI’s cockpit bracket available as an accessory. See ECCI’s website for ordering. 2 PEDAL UNIT ASSEMBLY AND ADJUSTMENT 2.1 ASSEMBLY SEQUENCE 1 Prepare a clean well lit area with adequate room for laying out the pedal components [Figure 8]. In addition to the supplied hex keys you will need a pair of ½ inch open end wrenches to complete assembly. The pedal unit is shipped in two components; the base and the pedal frame assembly. Study the side view illustration of the assembled pedal unit [Figure 9] before proceeding. If you have purchased a clutch pedal, refer to the clutch installation instructions first, for they supersede the following steps. 2 In the pedal base assembly, locate the two silver diagonal struts. Remove the two bolts holding these struts nearest the heel rest. Leave the rear bolt in place. Rotate these struts vertically until they are tilted towards the rear of the base [Figure 10]. 3 Retrieve the 6 inch long 5/16 diameter threaded rod and related nuts from the hardware kit supplied with the pedal unit. This rod will be used to attach the pedal frame assembly to the base at Pivot A as shown in Figure 10. Note that there are four vertical slots for this attachment. These are used to offer a variety of positions fore-to-aft of the pedal relative to the heel rest. If initial use will be at a typical desktop workstation, select the second slot from the front of the unit. If initial use will be in a low-slung cockpit situation, then select a slot further to the rear. In any case, after initial setup is completed, this position can be changed without disassembly of the entire pedal unit. 4 Position the pedal frame vertically with its mounting holes aligned with the chosen slot in the base unit [Figure 10, step 1]. 5 Guide one end of the threaded rod through one side of the base and frame holes. Before passing through the holes in the opposite side, twist two nuts onto the threaded rod. Guide the rod through the opposite side holes and twist the nuts apart so they contact the two sides of the pedal frame [Figure 11 step 2]. Makes sure the rod is centered in the frame. Turn the nuts no more than finger-tight. 6 Place the two washers and remaining two nuts onto the threaded rod [Figure 11 step 3]. Turn the nuts down finger-tight to the frame. 7 Note that each Pivot A base mounting slot has three notched positions. These are to adjust the vertical position of the pedals relative to the heel rest. Select the middle notch to start with and set the threaded rod into the same position on both sides. This
  4. 4. 8 Next pivot the diagonal struts forward [Figure 10 step 2] and align their holes with those in the pedal frame. The pedal frame and the struts will form a triangle. Insert the bolts at Pivot D [Figure 12] on each side. Make sure to insert the spacer washers between the strut and the pedal frame as shown. Turn finger tight, then back off one half turn. 9 Make sure the nuts holding the bottom end of the diagonal struts are backed off a bit from contact so the rod assembly can mover freely in the slot. Grasp the rod in the center of the base with one hand, grasp the top of the pedal Frame with the other, and rotate the pedal frame upright sliding the rod in the adjustment slot forward until the unit is at your preferred angle. Test the pedals to see if their geometry is correct for your seating position. Adjust until comfortable, and finally tighten all pivot bolt nuts. For more tips on adjusting geometry, see Section 2.4. 2.2 BASIC PEDAL PRESSURE ADJUSTMENT Pedal pressure for all non-PMB equipped pedals is done in two steps. Perform adjustment in the following sequence: 1 Overall pedal pressure, has three settings: light, medium and heavy. These are adjusted by changing the location of the pedal resistance spring and its upper and lower mounts to one of three possible positions [Figure 17]. Moving the spring towards the pedal arm pivot point will reduce the pressure needed to depress the pedal. Moving the spring away from the pivot will increase the required pressure. Generally it is recommended that the brake pedal be set in the medium or heavy; and the gas pedal in the light or medium position. 2 Pedal spring preload is set by how far the screw supporting the lower spring seat is turned in towards the spring. Preload is defined as the amount of initial pressure needed to begin to move the pedal. To change preload, loosen the locknut on the lower spring bracket and turn the set screw. It may be advantageous to set preload at a moderate to high level if you like to rest your foot on the pedal. If preload is too light one might be applying brake with the slightest touch of the pedal. This is particularly a concern if one uses a two foot pedal method. Try different settings but make sure to tighten the lock nut to preserve your settings when finished with adjustment. 2.3 PMB BRAKE PEDAL PRESSURE ADJUSTMENT The ECCI PMB II (Pressure Modulated Brake) mechanism has two basic adjustments: 1 Main PMB pressure adjustment screw [Figure 15]. This screw sets the ultimate amount of pressure required to bring the brake pedal down to full travel. This effect is highly progressive and this screw should only be used for setting maximum braking pressure. Do not use this screw to adjust initial pedal pressure. 2 The Pedal spring preload adjustment screw sets the amount of initial pedal pressure required to begin to depress the pedal. It is set as described in Section 2.2. Make sure to tighten the lock nut after adjustment. If the user desires more brake pedal pressure resistance than the standard adjustments offer, a Race Brake kit is available from ECCI as an accessory. The Race Brake Kit dramatically increases the hardness of the pedal and the effort to reach full travel from 50lbs of the standard PMB to 145lbs. This should only be considered for hard mounted cockpit units for the amount of leg pressure needed requires solid mounting of both pedal unit and the seat.
  5. 5. 2.4 ADJUSTING PEDAL UNIT GEOMETRY The 6000 Trackstar pedals offer a wide range of adjustments [Figure 16]: 1 Fore and aft adjustment. Pivots A & B must be loosened and the bolt at ‘A’ installed in the desired stepped slot. The heel rest also rides in a horizontal slot allowing fine tuning of its spacing to the pedals. 2 Vertical adjustment. The pedal frame can be raised and lowered in each stepped Pivot A mounting slot to adjust the distance of the pedals from the heel rest. This accommodates a wide range of user shoe sizes. 3 The angle of the pedal frame from vertical is the most important ergonomic adjustment. A desktop setting will require a more canted geometry than a lay-down cockpit. Pedal frame angle is changed by loosening Pivots A , B, & D, and sliding the rod assembly of Pivot B along the adjustment slot until the desired angle is reached. All Pivots must be tightened after such an adjustment. Next the heel rest should be adjusted in angle to create a natural well for the driver’s heel. 4 Lateral pedal spacing is adjusted by loosening the two screws that hold the pedal pad to the pedal arm. The pedal pads can slide laterally to the user’s preference. Make sure to tighten the nuts firmly before using the pedals. 5 For those installing their controller in a tightly dimensioned cockpit… the Trackstar 6000 pedals can be reduced to only the pedal arm frame. When attached securely top and bottom, the pedal arm frame can be used without the base to provide a minimally intrusive installation. A special bracket for the top mount may need to be fabricated. 2.5 STABILIZING THE PEDAL UNIT The PMBII ECCI also offers an accessory part which locks the pedals in a fixed relationship to a driver’s seat. Called the “Instant Cockpit”, this is a telescoping t-bracket that locks the pedal chassis to the base of any chair. It is particularly useful if you use a caster-type office chair. It keeps the chair from rolling backward and the pedal unit from tipping forward when high PMB settings are used. Visit the ECCI website accessories pages to order this accessory. 3 STEERING RESISTANCE TUNING 3.1 THE MONOPOINT II SYSTEM The Trackstar 6000 was designed to provide the serious competitor the ability to tune all important steering feel characteristics to suit individual preference. The ECCI exclusive MONOPOINT II cam resistance system [Figure 21] offers fine adjustment of four important steering parameters: 1. Maximum steering resistance pressure - adjustable by changing the number of springs used [Figure 22 and 24]. 2. Steering centering pressure at the neutral position - adjustable by changing spring preload [Figure 24]. 3. Steering wheel lock - adjustable by changing positions of travel limiters [Figure 23]. 4. Rotational damping - FLDS equipped units only. See Section 3.6 for more information.
  6. 6. 3.2 TUNING SUGGESTIONS This setup might suit a driver with a light touch that races primarily tight road courses. This offers a short throw lightly sprung steering action which will get you through chicanes quickly all while maintaining optimal hand position for the accessory buttons at full lock. A light spring setting reduces driver fatigue for those competing in full-length races. With reduced pressure you can maintain precision cornering technique on the 190th lap without the sloppiness that can come from muscle fatigue. With light spring settings, the FLDS will provide primary resistance for wheel movement. A driver running ovals might prefer more resistance and travel. A wide range of travel can offer more fine steering adjustment in long sweeping corners, or could be set up for more pit lane maneuverability. Up to 240 degrees or travel is available with the Trackstar 6000. With heavier spring settings the role of FLDS is reduced. Most drivers will prefer moderate to light spring settings when using an FLDS equipped system. 3.3 STEERING LOCK ADJUSTMENT Four positions of steering lock are available: 180, 200, 220, and 240 degrees. The default factory setting is 240. This adjustment should be performed first before other changes to steering resistance are contemplated. 1 Loosen the eight screws that attach the steering unit cover to the chassis. Then remove the cover exposing the mechanism. 2 Loosen the locknut on the preload adjusting screw underneath the steering unit, directly below the springs [Figure 21]. Turn the adjusting screw counterclockwise until the spring pack is loosened. 3 Grasp the top of the spring pack and pull it out from underneath the pressure arm. Remove the springs and spring retainers from the unit. 4 Locate the wheel travel limiter [Figure 26], a disk-shaped element close to the main chassis structural plate. Rotate the steering wheel 90 degrees to the left. The two retaining screws for the left-hand travel adjuster stop will now be accessible. Using the supplied 3/32quot; hex key, loosen and remove the 2 screws and position the stop as desired, rotating the wheel as required to provide access. The positions are explained in Figure 23. 5 Next tighten the screws. Repeat the adjustment as described above for the right-hand travel adjuster stop, making certain that the adjuster is moved exactly the same amount as the left-hand stop. 6 Reinstall the spring set following steps 4-6 in the following section.
  7. 7. 3.4 STEERING SPRING RESISTANCE ADJUSTMENT The MONOPOINT II system relies on a single spring pack of up to three springs. The springs are designed to rest one inside another. Figure 24 shows the various possible combinations of springs along with recommended preload settings. To adjust overall steering resistance pressure, perform the following steps: 1 Loosen the locknut on the preload adjusting screw underneath the steering unit, directly below the springs [Figure 21]. Turn the adjusting screw counterclockwise until the spring pack is loosened. 2 Grasp the top of the spring pack and pull out from underneath the roller on pressure arm. Remove the springs and spring retainers from the unit. 3 The tool and parts kit provided with the unit includes additional steering springs. Select the desired combination of springs [Figure 21], and install them on the lower spring retainer, making certain that they are seated in their respective pockets. The default factory setting is 116lb. 4 Place the spring pack with the lower retainer over the preload adjustment screw. Tilt the top of the spring set outward slightly to accept the upper spring retainer, insert the retainer, and tilt the assembly back underneath the roller on the pressure arm. Work the wheel from lock to lock to seat the springs. When the spring(s) are no longer loose on the lower seat, the preload measurement setting centering pressure at neutral can begin. 3.5 STEERING CENTERING PRESSURE AT NEUTRAL To adjust centering pressure at neutral position, refer to the preload settings in Figure 24. This adjustment will not affect maximum resistance at full lock; it should be used only to adjust feel characteristics through the very center of travel. See Figure 25 for a graphic explanation of the effect of this adjustment. 1 Locate the preload adjusting screw [Figure 21]. Insert the supplied 3/16quot; hex key wrench. With the steering wheel at center position, turn the preload adjusting screw clockwise by hand (as viewed from the bottom) only until there is no up/down looseness (gap) in the spring pack between the upper and lower spring seats. Move the wheel back and forth to help determine the point between loose and engaged. 2 Refer to Figure 24 to determine what level of preload you desire. The preload setting has a major effect on centering force around neutral. The lowest setting will result in a very loose feeling through center with almost no centering force. The maximum setting will result in a pronounced centering effect, especially with heavier spring combinations. Figure 25 illustrates the effect this adjustment has on overall resistance characteristics. Carefully to count the number of rotations of the screw, turn only until the desired preload setting is reached. 3 WARNING! Do not exceed the maximum number of turns listed in the table for the combination of springs being used – excessive preload pressure WILL damage the steering camshaft and is considered MISUSE. This is NOT covered under warranty! 4 Tighten the preload adjuster locknut, while holding the preload adjuster screw in position.
  8. 8. 3 WARNING! Do not exceed the maximum number of turns listed in the table for the combination of springs being used – excessive preload pressure WILL damage the steering camshaft and is considered MISUSE. This is NOT covered under warranty! 4 Tighten the preload adjuster locknut, while holding the preload adjuster screw in position. 3.6 FLDS - FLUID DAMPED STEERING The FLDS system uses a belt driven rotary fluid damper [Figure 26]. For each wheel rotation the damper will rotate multiple times. ECCI provides each unit with the pulley ratio best suited for the steering wheel diameter ordered. Some users may wish to reduce or increase the amount of damping. Pulleys are color-coded for legibility. ECCI offers alternative pulleys in several different ratios [Figure 27]. Generally, someone who uses many rapid wheel movement corrections while driving may prefer a lighter pulley, while someone using very steady measured wheel movements may prefer even heavier damping. Steering wheel diameter also has an effect on damping force. Diameters smaller than the standard 13-1/2 inch wheel will create less leverage on the steering shaft. This will increase the level of damping perceived by the driver. A heavy pulley with a small diameter wheel like a Momo will provide a very high level of damping resistance. ECCI units have a very different feel than other driving systems and there is a period of user acclimation needed before getting best results from such adjustments. 3.7 SHIFT PADDLE ADJUSTMENT The Trackstar 6000 unit is provided with Formula-1 style behind-the-wheel paddles to perform gear shift functions. The paddles have a short throw to make rapid and reliable shifting possible. This throw is adjustable, but the original factory setting is designed to provide the proper amount for consistent switch actuation. If you encounter shifting anomalies, like failed trigger inputs or double-shifting, the cause could be either a failing button or drifting outside of proper throw adjustment. Paddle throw is set by throw limiter stops, which constrain the movement of the paddle levers within their limits. All ECCI paddle sets have their initial at-rest position established by set- screws accessed from the back of the paddle set. If adjustment is needed, boot up your computer and go to the Game Controllers module in the Control Panel. The test window has indicators that light up when a paddle button is depressed. Loosen the 3/8” lock nut and turn the set screw in until it activates the button indicator light, then back off. Proper at-rest button position is set by positioning the set screw one-third turn back from the point of button actuation. Then tighten the lock nut. Set maximum paddle lever throw to provide a visual gap of about 0.5mm from the paddle button surface to the face of the paddle lever. This gap is needed to assure reliability of multiple inputs like rapid downshifts. On Momo paddles, look for similar adjusters accessible from the front of the paddle set. Non-Momo paddle sets have set screws set into the paddle levers themselves and accessed from the back of the paddles. Momo wheel equipped units are provided with additional adjustability. Special two-piece paddle levers are provided that allow for adjustment for distance in depth from the wheel rim. Refer to Figure 28 for an illustration of how to adjust this distance.
  9. 9. 4 CONNECTING TO YOUR COMPUTER 4.1 USB HD ULTRA EQUIPPED WHEEL & PEDAL SYSTEM (STANDARD) 1 Before doing anything else, connect the pedal unit chassis to your computer case or other ground with the ground cable. 2 The pedal unit connects to the wheel unit via the integral DB-9 cable. This cable connects to a DB-9 port on the right side of the steering unit just underneath the cover. If you are having trouble connecting the screw terminals due to tight space, remove the cover first. 3 The Trackstar 6000 USB system is connected to your computer via USB cable to a USB 1.1 compatible port on your computer. If you have several devices connected that rely on USB ports for power, make sure to connect the TRACKSTAR 6000 directly to a USB port on the host computer. NEVER connect the controller to a powered expansion hub. Voltage drops and interference from other devices will seriously affect performance. If one must simultaneously use other USB-powered devices, connect those to the remote hub instead. Control performance will be completely assured if you connect the TRACKSTAR as the sole peripheral on a USB root hub. Be especially wary of cheap motherboard integrated USB systems. Many of these use a single root hub controller that is shared by multiple ports on the computer case. If you have such a system, you may wish to install a quality USB PCI bus card that includes one USB root controller at each of several USB ports. A good choice would be an add-in card that utilizes the OPTI FireLink 82C861 USB controller. For a list of lab-certified add-on PCI cards, visit the following website: www.usbman.com The Trackstar 6000 uses the universal HID driver that is native to Windows operating systems. No driver disk or outside software is necessary. When the unit is plugged in it will be automatically recognized as “ECCI HI-DEF USB” in your operating system and software titles. If you have multiple game controllers, make sure that the ECCI HI-DEF is at the top of the controllers list. The Trackstar 6000 HI-DEF USB offers nearly 1000 discrete points of resolution on the steering and pedal axes. If you are experiencing control anomalies, try unplugging all other USB powered items like scanners and DVR external drives and running the driving system alone into a port on your machine. This will determine whether the problem lies with interference from other USB peripherals or the basic interface. 4.2 STAND-ALONE USB HD ULTRA PEDAL UNIT ONLY (NO WHEEL) Before doing anything else, connect the pedal unit chassis to your computer case or other ground with the ground cable. The pedal unit connects to your computer via the USB cable attached to the pedals. Before plugging into your computer, it is necessary to connect the DB-9 connector of the pedal unit into the DB-9 port on the back of the pedal unit electronics cartridge. This is left unplugged from the factory for impacts during shipping could damage the controller. Note that this uncoupled connection indicates that you will eventually be able to upgrade your standalone pedal unit to a full system with a wheel in the future if you wish. From the cable connector
  10. 10. back to the pots, your pedal unit is the same as that provided with a complete system. Upgrading to a full system will require relocating the logic board to the wheel unit. Instructions for this will be provided with the upgrade. (Next go to section 4.5) 4.3 CALIBRATION - SEPARATED AXIS MODE (DEFAULT SETTING) 1 Close all other programs first. Then click the Start button. Go to Control Panel and select Game Controllers from the menu. 2 The Game Controllers dialog box should appear. Windows should automatically recognize that the ECCI HI-DEF USB controller is connected. If this does not appear check your connections, and if still no control shows up, reboot and start again. 3 Highlight the controller, and then click on the Properties button. Select the Settings tab and click on Calibrate. You must follow the prompts carefully to calibrate your system. Leave the controls untouched to set center point then click a button on the wheel. 4 A square joystick calibration box will appear. It will prompt you to move the controller to the limits of travel. The steering wheel will be recognized here as the X-axis, moving the crosshair horizontally in the box. The Y-axis will not be active. After moving the wheel left and right, release it to center and press a button to move on. 5 Next you will be prompted to verify the center point once again Make sure the wheel is centered then press a button. 6 A horizontal box with a blue calibration bar will appear. This box will calibrate the gas pedal. Move the pedal down all the way, release it, repeat several times and press a button. If the bar does not move fully to the ends of the box, ignore it. This is normal at this stage of calibration. 7 Another horizontal box will appear. This will recognize the clutch pedal. Move the pedal down all the way, release it, repeat several times and press a button. If you do not have a clutch, simply press a button to bypass this step. 8 A third horizontal box will appear. This will calibrate the brake pedal. Move the pedal down all the way, release it, repeat several times then press a button. If you have a PMB-equipped unit and wish to reduce the amount of brake pedal pressure to reach maximum braking, you can ‘short calibrate’ the brake pedal. Press down only as hard as you wish for maximum braking, release and press a button. 9 After finishing select Test. Carefully observe the movement of your controls in the square box and the vertical slider bars. Make sure that the wheel and each pedal are recognized and operating smoothly to their limits of travel. If not, recalibrate. Ignore the inactive slider bar if you do not have a clutch installed. You are now finished. Click OK to accept calibration. 4.4 CALIBRATION - ALTERNATE LINKED AXIS MODE The unit will automatically start up in Separated axis mode which allows independent and simultaneous operation of pedals. Separated mode is preferable for most sophisticated racing simulations. However, some gaming titles fail to support separated pedal mode. In this case you must use linked axis mode.
  11. 11. Linked axis mode emulates a simple two-axis joystick. Steering acts on the joystick X-axis and gas and brake pedals work in opposite directions on the ‘Y-axis’. Linked mode is simple to activate. 1 Disconnect the USB plug from the computer and wait ten seconds. 2 Next hold down one of the buttons or paddles on the wheel while you plug the unit back into the USB port. Be sure to hold the button down while plugging in and for at least five seconds after the plug insertion. This will initialize Linked mode. 3 It is important to remember when switching from separated to linked mode or back you must recalibrate the controller in the Windows Control Panel - Game Controller routine. Failure to do this will cause improper operation. Do not reboot the computer when switching modes. The computer needs to be running to initialize linked mode. If your computer is rebooted for any reason and you wish to use linked mode, you will need to re-initialize it after restart using the above steps. If no buttons are held down during initialization, it will always start up in separated mode. 4 Next follow steps 1 through 3 in Section 4.3. After completing these go to step 5 below. 5 A square joystick calibration box will appear. It will prompt you to move the control to the limits of travel. Turn the steering wheel left and right to its limits. This will move the crosshair horizontally in the box. Gas and brake pedals will be recognized on the Y-axis, moving the crosshair vertically in the box. Move both pedals to the limit several times, release them, and press a button. 6 You will be prompted to verify the center point now. Make sure the wheel is centered and none of the pedals are depressed. Then press a button to go to the next step. 7 A horizontal box will appear. This will be inactive in Linked mode. Linked mode does not support clutch operation. If you need a clutch, use Separated mode. Press a button on the wheel to continue. Two more horizontal boxes will appear. These will be inactive as long as you are in Linked mode. Just press a wheel button when prompted until you finish. 8 After finishing select Test. Carefully observe the movement of your controls in the square box. Make sure that the wheel and each pedal are recognized and operating smoothly to their limits of travel. If not, recalibrate. In linked mode none of the slider bars will be active. This is normal. You are now finished. 4.5 CALIBRATION – STAND-ALONE PEDAL UNIT (NO WHEEL) Calibration of a stand-alone pedal unit is similar to that of a full system except that the control axis and buttons of the wheel will not be active. They will appear on the calibration screens but should be ignored. Both separated and linked axis modes are available. Follow the steps in Sections 4.3 and 4.4 for the mode desired, but keep in mind to click past the wheel calibration window. If one wants to add button functions to the pedal unit the accessory expansion port is active. Instructions for adding buttons are provided in section 5.0. 4.6 PROPERLY CALIBRATING THE PMB-II BRAKE PEDAL The optional PMBII brake mechanism allows you to tailor both the feel and the response of the brake to your personal preferences. The action of the PMBII allows the brake to be set up based on pressure applied rather than distance traveled.
  12. 12. 1 When calibrating the PMBII you do not have to use the full mechanical travel of the pedal. Calibrate using the amount of pressure you want to establish as 100% braking pressure. Optimal anti-lockup performance is obtained when slightly more pressure is applied than you would normally desire. This helps prevent brake lock at the limit of braking. You should have to work the brake a bit to get full lock. Do not exceed your maximum pressure target during the calibration. If you exceed your target, go back and start calibration again. 2 Note the calibration numbers returned at your desired maximum pressure setting and write them down. Use this number for consistency in future calibration. 3 Now finish calibrating the remaining controls and go to into your simulation program. If the program uses the Windows Direct-X calibration information directly, no further calibration is required, just go out on the track and drive. 4 If the program requires its own calibration (i.e. NASCAR 2003), calibrate the PMB brake pedal in the controller options screen the same way as you did in Windows, being careful to only apply the amount of pressure you want to represent full braking. Write down the calibration number at your maximum pedal pressure level to use for future reference. 5 Now go out and take a few laps. If it seems like you need to apply too much pressure to get the desired braking effect, go back and recalibrate. This time move the brake to a slightly lower maximum pressure which will return calibration numbers a few numbers lower than before. Go back out to the track and see how this works. If the brake feels too light, go back and recalibrate to calibration values that are slightly higher than the previous calibration values. You will need to do some experimentation to get just the right braking effect. 6 If for some reason your desired pressures seem to be past the limit of brake travel, or are less than 50% of the brake travel you may need to adjust the PMBII pressure adjustment. If this does not get the desired result, you may need to get a heavier PMBII accessory spring from ECCI or the Race Brake Kit. All but a very few users find their optimal setting by just adjusting calibration with the stock spring. 5.0 ACCESSORY EXPANSION PORT The ECCI USB HD ULTRA system supports four analog control axes and up to 28 digital on/off buttons. ECCI wheels offer two or six accessory buttons as standard on the paddle set. The ECCI USB HD board has a jumper that selects the wheel button mode. Depending on which paddle set you have, two or six accessory buttons, you may want to move this jumper [Figure 7]. Accessing additional button functions is done through the DB-9 port on the side of the electronics pan in the wheel unit. This lies just under the right side of the unit cover. The additional buttons are acquired through creating a custom button console. Pre-made consoles and cables are not available from ECCI. Those constructing a console should refer to Figure 30 for pin assignments. The buttons are activated through a column and row matrix of pin combinations. Buttons are in sets of four (rows) served by multiple commons (columns). Rows 1 to 4 correspond with the four primary switches. Changing the common lead from one column to another accesses the next set of four, and so on. This scheme allows nine wires to control 20 buttons.
  13. 13. In constructing a button panel it is necessary to provide switching diodes in the circuit of every switch. Switching diodes reject ghost signals from other wires in the matrix that cause multiple button signals when one button is depressed. The switch diode recommended by ECCI for this purpose is type 1N4148, a common part, available at most electronics supply stores. They can also be purchased online from suppliers like Newark Electronics. You will need one diode per switch, so order as many as you need. Wiring diagrams to assist making add-on peripherals are provided in this manual. [Figures 30 - 32]. If you are using the expansion port to access extra buttons, you may need to make sure that diodes are also present at the wheel mounted buttons. These are not provided in systems with only two accessory buttons. If you have the six-button paddle set, this is already built-in and nothings needs to be done. With two button paddles you will either need to install the six- button paddle upgrade from ECCI or hand wire in diodes into the switch wiring. 6.0 POT REPLACEMENT AND POT SETUP Potentiometers (Pots) are the electro-mechanical components that sense the position of the wheel or pedal and translate this to electrical information read by the ECCI USB HD system. These are long-lived but will eventually wear out. The sign of pot wear is notchy, inconsistent response at the same spot in the axis travel. If the problem is variable, occurring in different areas of travel at different times, the problem may instead be a loose pot shaft nut or a loose wire connector. Rule these things out first before ordering new pots. If you need new pots, use only ECCI pots. ECCI pots are specifically made for ECCI controllers and have the required resistance range and performance characteristics. ECCI cannot warrant the performance of any system not using ECCI pots. When replacements are needed order the ECCI HP Racing pots. The USB HD uses a different pot for steering and pedals. Make sure to specify what you need. The steering pot is 100K the pedals use 50K. Unless you have a rare premature failure (under 1 year), ECCI recommends replacing the entire set rather than the single pot with the problem. If your clutch pedal is not used much this could be excluded. Pots typically last up to two years under daily use conditions. 6.1 POT REPLACEMENT PROCEDURES Pot replacement requires specific procedures to complete properly. Figure 14 shows the procedure to remove the pedal pot cartridge. Figure 29b shows in detail the mounting of pedal pots. Figure 29a shows the mounting of the steering pot. Pot service steps are explained in more detail with photographs on ECCI’s website at this web address: www.ecci.net/instructions/6000hdusbpotservice.htm 6.2 CHECKING POTS If you are unsure if your pots are setup properly or in need of service take the following steps. 1 Connect all cables, making sure the ground cable is properly attached and start the computer. Go to Control Panel and select Game Controllers from the menu. The Game Controllers dialog box should appear showing the ECCI HI-DEF USB controller is connected. If this does not appear recheck your connections. 2 Highlight the controller, and then click on the Properties button. Select the Settings tab and click on Calibrate. Leave the wheel untouched to set center point then click a button.
  14. 14. 3 A square calibration box will appear. The steering wheel will be recognized here as the X- axis, moving the crosshair horizontally in the box. Click the box next to Display raw data. Numbers will be displayed for the X-axis. Leaving the steering wheel centered, the raw data number displayed should read between 510 - 530. 4 Move the wheel slowly left and right, and observe the numbers. The numbers should ascend and descend in single values If the numbers halt, reverse, or skip this indicates a faulty pot. If the numbers run smoothly, let the wheel return to center and make sure the numerical value at center has remained consistent. Press a button to move on. 5 A horizontal box with a blue bar will appear. This is the first of three similar screens with boxes. The first box will show calibration values for the gas pedal. The second the clutch pedal and the third the brake. Ignore the percent % values shown in each bar and pay attention only to the Raw Data numbers. Check to make sure the Raw Data values fall within the following ranges. Verify each pedal in turn before moving to the next. GAS raw data – 1013 at rest to 10 fully depressed CLUTCH raw data – 1013 at rest to 10 fully depressed BRAKE - PMBII raw data – 1013 at rest to +/-250 (varies w/ desired max pressure) 6 If one or more of your pedals has values outside of these ranges, you may need to re-set the static pot position. If you noticed irregularities in the flow of numbers this might be indicative of a worn pot. To re-set your pot position to fall within range or for instructions on replacing a worn pot consult the ECCI pot service webpage mentioned in step 6.1. 6.3 CARING FOR YOUR ECCI SYSTEM The exterior surfaces of ECCI systems are powder coated steel with vinyl overlay graphics and for some units a Lexan steering unit cover.. Use a moderately wet cloth with plain hot water for cleaning. For heavy cleaning only use a diluted mild dishwashing liquid such as Dawn. DO NOT use dripping wet cloths or strong cleaning solvents, for damage to electronic components and finishes may occur. NEVER use 409 or similar household cleaners. 409 will quickly etch and ruin aluminum. Such damage is not covered under warranty. 7.0 SERVICE AND TECHNICAL SUPPORT If you are experiencing trouble, first make sure all of your connections are secure. This is the most common source of faults. Also check the white pin connectors on the circuit board for looseness. Sometimes installation and handling can cause a loose terminal. Before contacting ECCI about any problem, troubleshooting help is available more quickly online. Check the ECCI website troubleshooting pages and visit the Extreme Competition Controls Hardware Forum hosted on: www.racesimcentral.org Help and advice on problems, tweaks, and setups is available there from many experienced users and from ECCIs official representative. It is quite possible that the problem you are having already has a solution posted there just a mouse click away. ECCI support can also be reached by E-mailing: sales@ecci.net or calling (612) 824-6733. ECCI does not maintain a full-time phone presence, so please exhaust other alternatives before calling. Leave a callback number on our voicemail system if you have to call.