Dear Customer, Please DO NOT THROW THIS AWAY,
READ CAREFULLY
VEMS GenBoard v3.x is very flexible, there is much room for customization.
It is possible to get a working system relatively fast,
but there are some important things to consider even for an assembled, cased unit.
Important Warnings - failing these will result in damage:
connect all grounds 1 GND and 4 GND5-s from Econoseal-36 (GND5 is sometimes marked as powerGND or PGND) before applying power. GND and GND5 should meet 10 .. 15cm (6 inch) from the ECM. Use strong wires (0.75-1 mm2) and don't let any chance for disconnection during operation.
there must be a fuse (usually 10A, or 15A for multi-injector lowZ setups) between injector_common and +supply
connect the flyback connection directly (no fuse) to the injector_common signal.
There must be no fuse between injector_common and (EC36-pin 23) flyback pin.
Flyback pin (EC36-pin 23) must be connected with airwire or 30V transient diode to onboard flyback trace. This must be done on the non-assembled unit (already done on the assembled controller).
with DVM in diode mode, all injector outputs should measure max 1.4V between injector output (+) to injector_common (-) , (even with injectors unconnected). With the 30V flyback, reference (DVM-) to the internal flyback trace (verified for the assembled controller).
use a separate fuse for each ignition channel (5A) (one 7.5 or 10A fuse if a multiple-output module is used with a shared supply pin)
use a 3-5A fuse for the WBO2 heater channel
use a 1-3A fuse for the board supply
Rescue1 kit
0805 SMD resistors: appr 15 values, 4..6 pieces of each. Standard notation: 104 (means 10*10^4) = 1003 (100*10^3)=100kOhm
ES2J/ER2J 2A 600V fast SMB (surface mount, rather big) diodes (optional) Normally not needed
3x1n4007 1A throughole diode - general purpose. Used (across iac valve, relay solenoid, cathode to +12V).
1x 30V transient suppression diode (1k5E30 black, bigger than 1n4007). When applied into flyback path (either in loom or inside case)
it increases flyback voltage by 30V. Must NOT be used with assembled controller with 30V flyback (which already has internally,
30V+30V would kill the FETs!).
If used, PWM-ing MUST be disabled (injector-pwm-duty=100%,
injector full duty time=25.5msec => works for highZ injectors,
or lowZ with current-limiting "ballast" power-resistors)
and all non-injectors driven from injector output (iac valve, relay) must have a flyback diode (eg, 1n4007)
Barrel-like 1.5uH 5.4A inductor (marked 1R5). Thin wire can be used instead.
red, yellow, black, brown, brown striped throughole resistor is 2.4k Ohm, useful between LCD contrast and GND
Rescue2 - capacitors and 2 zener diodes Capacitors don't have text on them, so -if ever needed- ways to tell their value:
measure with DVM that can measure capacitance
measure by applying 50..60 Hz sinewave with 10k limiting resistor and measure AC voltage across the resistor, than calc.
keying by size, number, tape-material examine the cap size (0805 is the smallest we use, 1206 is medium and 1210 is huge), the number of caps and the tape-material (trans is transparent plastic, paper is paper) will tell you the value according to a table below:
Rescue2 v0.07:
3*1n 0805 50V paper
5*10n 0805 50V paper
4*100n 0805 50V paper
6*220n 0805 50V paper
2*1u 0805 25V paper (tall)
2*2.2u 0805 16V trans (tall)
1*10u 1206 25V trans
2*1u 1206 50V trans
Update your printed list if you use some capacitors, so you can keep track.
www.vems.hu/wiki/ for more info