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Let's try to organize the details in subsections, and simple format (not lengthy sentences) '''Ignition''' * stock Distributor, ignch0 (?) ** This also feeds the tach signal into the stock Tach without any problems when firing correctly. '''Input-Trigger''' * stock Distributor (Hall Trigger) and the stock Bosch008 module (it is quite tough) for ignition. '''Injection''' * 4 individually wired with flyback (big custom Jorgen setup for 550cc injectors @ 100psi (5bar)). IIRC we have high impedance injectors now. Also right now it is setup to have 2 banks with 4 injectors. '''Sensors''' * bosch CLT sensor * GM IAT * TPS from ITBs * WB02 [http://www.vems.hu/files/GRMracer/GRM2010/v3.3_n000536-2010.09.17-11.35.03smoother2.vemscfg vemscfg] [http://www.vems.hu/files/GRMracer/GRM2010/v3.3_n000536-2010.09.17-14.53.55.vemslog vemslog] [http://www.vems.hu/files/GRMracer/GRM2010/v3.3_n000536-2010.09.18-01.12.28_grmracer.vemscfg More normal shape of Alpha-N VE table] Thank-you Jorgen! I suggest connecting the MAP hose before the throttle blades instead of after, it makes the air pressure correction simple. Not only for barometric correction but also for any RAM air effect or any filter restriction. I'll try to find a spot all the vac pickups are on the after throttle position. I might be able to fab something. ---- http://www.vems.hu/files/GRMracer/GRMcar2010.jpg [http://www.vems.hu/files/GRMracer/cutout_1.JPG cutout on 1.0.53] This is a snapshot showing an odd log event where Injectors get zero'd. I thought this was a fuel pump relay problem, but the logs show that the injectors PW goes to zero. Is this with the very old 1.0.53 ? -- Yes Maybe tps or kpa threshold reached (if ECU config does not match the config posted on the page) ? Hard to tell, but you'll likely need to upgrade to 1.1.81 anyway. -- I have upgraded and I am very happy. I'll find the old config and post it with it. I would have done it earlier,but I could only get tables&config as the VemsTune would crash trying to talk to it. '''1.0.53 Currently running car''' This is the configation we had when we left the track at the end of 2009. We just got the car to do a pass at 14.7 with a bad clutch. So the weekend was spent replacing the clutch. Also got the Knock sensor wiring in place. I need to get the correct pinouts. Nitrous wiring now also in place. [http://www.vems.hu/files/GRMracer/config2010GRM.txt 2010_Config.txt] [http://www.vems.hu/files/GRMracer/tables2010GRM.txt 2010_tables.txt] ''Air leak fixed'' System is supposed to be full Alpha-N, but at 2500 RPM constant throttle, PW for injector is zeroized. I'll post megatune log in am when I can start the car. ----- '''1.1.70 Newest version That ran the car''' [http://www.vems.hu/files/GRMracer/running_1_1_70_tp.vemscfg 1.1.70 vemscfg] for Alpha-N with TPS calibration * this Configuration had the stock tach bouncing +/- 500RPM. and basically '''sounded terrible, but did in fact run''' ** '''the reference tooth table is wrong ! '''. It's traversed from bottom to top. If you just upload the applicable c004 (4+1) configlet, which has: ** h[1]=00 03 02 01 FF FF FF FF ** but '''it would be wise to start from the beginning by writing details thematically organized on this page, including trigger and wiring section'''. '''Absolutely essential to get it run properly within reasonable time.''' * "Neither method made a large difference in the running." ** Suggested improvements ** One thing that would be fantastic for upgrading and starting cars would be a setting in the gui that allowed for a start & time mode. Something like the standard warmup/crank mode with a fixed timing. (I did find that the old command Manmda00 for 0d and Manmda28 for 10d and Manmda50 for 20d advance) ** '''implemented, try Tools / "ign lock" in VemsTune. Similar to "iac lock"''' ** another thing that would be fantastic is a software switch that allows on the very basic controls to be used for very rough tuning. But that is not well enough defined. ** '''implemented: req_fuel, ign lock and iac lock''' are such rough controls. But it's still needed to get the basic settings right (and wiring details are needed to verify those). [http://www.vems.hu/files/GRMracer/v3.3_n000536-2010.09.06-15.36.56_idleBlip.vemslog Idle] Blipping the throttle during warmup [http://www.vems.hu/files/GRMracer/v3.3_n000536-2010.09.06-15.44.24_longidle.vemslog Long idle] [http://www.vems.hu/files/GRMracer/v3.3_n000536-2010.09.06-16.15.27_closedThrottle.vemslog idle] Closed throttles [http://www.vems.hu/files/GRMracer/v3.3_n000536-2010.09.06-16.17.46_stuck_throttle.vemslog stuck throttle?] [http://www.vems.hu/files/GRMracer/running_1_1_70_tp.vemscfg running config] [http://www.vems.hu/files/GRMracer/running_1_1_70a_plus_imprts.vemscfg another version] ---- ''' Migration ''' Had the car running on 1.0.53 -- we had a few issues, so I figured I'd update to the current Release. The website indicates 1.1.81 is the current release. I don't seem to be triggering on 1.1.81. So I'm downgrading to 1.1.78 (after I check the changes page). * '''Publish .vemslog or .vemscfg''' ** saved after you upgraded firmware and uploaded the old config and tables from VemsTune (VemsTune is needed for upgrade, MegaTune will not be enough) ** note: saved from the new firmware (that you have problem with, eg. 1.1.81). Note: not the "intended", but the actually saved .vemscfg ** See IssueReports : triggerlog could also help, but it can likely be fixed in configuration if the HW worked with earlier firmwares Basic trigger setup is simple Hall trigger (4 window on distributor total 720d) Could this be the problem. I have time arranged for a dyno in the next two weeks. So it would be fabulous to have it running on the newer firmware. Still have a few mechanical bits to do like change the Clutch back to a real clutch. the stock 8v one that is in it now doesn't do its job. ''' Update''' Getting car ready a month in advance this time. Getting New ITB manifold installed issues before were with major air leaks in the old ones.. I'll have updates this weekend as install happens. BTW the new software looks fantastic!!! '''Update''' $2006 Challenge: Were off and going. Running a 3.3 with Release 1.0.53 our msq file is *[http://www.vems.hu/files/GRMracer/alpha_n_full.msq msq file] *[http://www.vems.hu/files/GRMracer/full_alpha_nconfig.txt config.txt] *[http://www.vems.hu/files/GRMracer/full_alpha_ntables.txt tables.txt] *[http://www.vems.hu/files/GRMracer/basciallyrunning.xls log] * more logs **[http://www.vems.hu/files/GRMracer/datalog200610241615bogging2percent.xls bogging if more than 2% throttle] very aggressive spark curve ** msq file to come **[http://www.vems.hu/files/GRMracer/datalog200610241615rev%20happy.xls reving nicely no load] ** msq file to come **[http://www.vems.hu/files/GRMracer/datalog200610241645_highidle.xls high idle problem after spark curve change] **[http://www.vems.hu/files/GRMracer/idlingissues.msq recent msq] reqfuel 12.5 ---------- [http://www.vems.hu/wiki/index.php?page=MembersPage%2FJanneMantyla Rushi's] old configs *[http://www.vems.hu/files/GRMracer/rushiCivic_aN_D15_VPower.msq msq file MT1.0.36] *[http://www.vems.hu/files/GRMracer/rushi_config.txt config.txt] *[http://www.vems.hu/files/GRMracer/rushi_tables.txt tables.txt] Question regarding PulseWidthCalculation for full AlphaN. The PulseWidth is calculated by the following equation <code> PW(ms) = req_fuel(ms) * load/100 * VE/100 * gammae/100 </code> * '''This makes req_fuel *2.55 * 2.55 the maximum injector pulsewidth''' (without enrichments) in speed-density mode (or hybrid load=TPS, TPS/MAP blended, MAP mode when config13 bit2=0) * in AlphaN mode the *load/100 part is usually eliminated (by setting config13 bit2=1) so maximum injector pulsewidth = req_fuel * 2.55 (without enrichments) A little matlab snippet to figure out how the VE table entries correlated with time. My value for the bin was 22-23 <code> function output = VEtable(dummy) %values taken from my log file req_fuel = 12.5 rpm = 4621 rps = rpm./60 effrps = rps./2 effperiodms = 1./effrps.*1e3 gamma = .98 pw = 2.8 VEelementraw = pw./ ((req_fuel).*(gamma)) output = VEelementraw.*100 return </code> If the VEtable is configured (at WOT) well with what a dyno HP plot would look like, the VE table relates the of TPS% to air flow. For example if 1% throttle is 10% flow the VE table would reflect that. I'll be posting some matlab code soon that takes RPM,HP, displacement, airtemp, and outputs various VE tables: * linear throttle * exponential throttle * the above are far from realistic, the airflow(TPS,RPM) depends on RPM and opening (~cross sectional area), ** opening(TPS)=sin(TPS * const2) but oval linkage changes this somewhat (but 0 for TPS=0 and 1.0 for TPS=255 most of the time so you can calculate const2) ** at low RPM we know that pressure drop across the throttle (which is appr 1.0 - airfill) is roughly proportional to RPM*airfill * (1.01/opening - 1.0); *** that is 1.0 - airfill(RPM, TPS) = airfill(RPM, TPS) * const3 * RPM * (1.01 /opening - 1.0) so sg. like airfill(RPM,TPS) = 1/(1+(const3 * RPM * (1.01 /opening(TPS) - 1.0))) TODO: review,check, propose reasonable const values *** At 1200 RPM 2..6% TPS is enough for 90% airfill (that is usually called VE; I intentionally don't use VE term here, so noone thinks this directly goes into the j[] table) ** at high RPM close to linear with the opening(TPS); appr 90% opening needed for 90% airfill with some modifications we can also do the same for AirDensityControl maps as MAP is supposed to determine % throttle open with some non-linear effects already included. Notes: *with config13 = 0x06, Baro indicator in MegaTune goes up and down with TPS. The config has full AlphaN * For FULL AlphaN you need to manually edit config13 in the config file (typically value 02, needs to be changed to 06, it masks bit-2 true changes the binary from 0000 0010 to 0000 0110 ) it eliminates the loadmultiplication from the fueling math becoming: PulseWidth = ReqFuel * tps (0..1) * VE (0..1) $2005 Challenge Car not going this year. A multituide of last minute problems has conspired to prevent the two planned cars from attending. * Odd problem #1 unless the serial port loaded or grounded the Fuel Pump wont run. -- Do NOT use EMI serial ports.. * Odd problem #2 Bad ignition switch caused intermittent starting Not really bad ignition switch, bad grounding of ignition module * Odd problem #3 Unknown coolant system after winter freeze -- ejected freeze plug -- yep this one did us in.. * misc other stuff. Anyway plans are already underway for next year. And the cars/engines are partially built. ------ Physical Setups * '''Plans Turbo car ''' ** '''VEMS v3.1''' **2.0L ABA with a 20V AUG head ( variable valve timing) *** Stock KO3 from VW 1.8T *** Stock 1.8T fuel injectors 241cc/min and ~10-11ohms **60-2 crank trigger (VR) - aba **hall sensor on cam for #1 TDC ( very optional ) ** wasted spark setup with ABA coil ** or Coil on Plug from 1.8T ** LSU4 WBO2 sensor ** Nitrous activation ** Water injection -- maybe * '''Plans for NA car ''' ** '''VEMS v3.2''' ** 2.0L PL block with Port & polish 16v Head ** GSXR 750 ITBs ** Nitrous -- triggered this time ** move from v2.2 to v3.1 with proper PWM ** LSU4 WBO2 sensor ** Stock Distributor and Hall sender ** Bosch 008 module for coil. ** Drive ingition THRU distributor ---- VEMS needs/checklist '''STICKERS ! ''' '''STICKERS !!''' '''Hardware''' * StepByStepGuide ''done'' ** Basic Assembly Instructions for putting in a Alubos case *** ''Power'' *** ''Serial Port / Communications'' *** LCD Hookup *** ''Injector Drivers: Flyback and FETs (Low Z injectors)'' - VERIFY *** ''Ignition Drivers: FETs for driving ABA coil pack - Wasted spark '' - VERIFY **** May possibly need setup for GM packs Lost module in garage *** Ignition Drivers: Drving Bosch 008 Module (NA car) *** ''WBO2: Heater/Driver setup'' **** Will this work with wasted spark setup? *** Trigger setups **** ''VR trigger 60-2 wheel VW ABA block (Red VR+) (Black VR-)'' R30 Removed, D14 to be installed.. **** ''[http://www.vems.hu/wiki/index.php?page=StepByStepGuide%2FNotes HALL] trigger'' 4 window *****Hall sensor connected to primary trigger *****Solder wire between JP2 (top row middle of the trigger jumper section) and JP7 (top row to the right) *****''Use D14 '' *****''Bridge SJ2 (Leftmost in the LM1815 grouping) '' *****''Leave SJ6 open (found below LM1815 on component side) '' *****The Hall GND lead is connected near Pin26 on the EC36 connector. *****The Hall signal lead is to be connected to Pin 27. *****The Hall supply is connected to pin 28. *****''Install 270ohm resistor at R142. (solder side between pin 28 and 29 on EC36) '' *****''Install 220n capacitor at C69 (solder side between pin 28 and 29 on EC36) '' *** *Knock setup for using stock VW sensor for a 2.0L [http://scirocco.org/engine/ PL] block *Knock setup for using stock VW sensor for a 2.0L [http://scirocco.org/engine/ ABA] block *WBO2 setup using VW LSU4 for 3.1 *WBO2 setup using VW LSU4 for 3.2 '''Software/ configuration''' Assuming that all my needs are already implemented in firmware setups Please correct if not done.. Current firmware version you want me to run '''Turbo VEMS v3.1''' * Autolearning * 60-2 Trigger (VR) * Nitrous Activation * VVT output (solenoid activation) RPM and load maybe (very optional) * Knock for 2.0L [http://scirocco.org/engine/ ABA] block * LSU4 setup (V3.2) * Basic instructions on changing and viewing values for table entries * CLT for Bosch temp sensor MembersPage/GrmRacer/BoschCltSensor * map stuff? * Air Temp sensor GM '''Naturally Asprirated car -- VEMS v3.2 ''' * Autolearning * 4 window trigger (Hall) -- no other choice * Nitrous Activation -- RPM based * Knock for 2.0L [http://scirocco.org/engine/ PL] block * LSU4 setup (v3.1) * Basic instructions on changing and viewing values for table entries * CLT setup for Bosch temp sensor * map stuff? * Air Temp sensor GM * I'll try for a wasted spark setup from a VW or GM ---- For $2004 challenge So we placed 29th overall in the $2004 challenge our 1/4mi time was 14.6 after 1/2 hour of tuning on a turbo Yugo MEgasquirt fuel map, a bad coolant sensor, and no nitrous.. oh well. Yes that PVC works. http://www.vems.hu/files/GRMenginebay.jpg Lots of pics and snippets.. http://BustedKnuckleRacing.com GRM = Grassroots motorsports (www.grmotorsports.com) '''Documentation and History''' : This is to document any changes or addons that are made to MS-AVR (GenBoard or AfreshBoard) during the building of the 1988 scirocco http://www.scirocco.org : Starting point ''BasicInstallation'' ------ : The plans 2.0L ABA 16v Turbo Triggered via the hall sender built into the block :nitrous injection :water injection :ignition control :traction control ----- Whats happening this year no time for turbo. 2.0L 9A 1.8L 16v head P&P nitrous direct port injection water injection via cold start in ''custom'' intake manifold MS-AVR for ignition and fuel <insert stuff for car setup> MembersPage/GrmRacer/GrmCircuits EGT's on the cheap using raw thermocouple and Dupont LTCC tape. Stuff Im going to document :MembersPage/GrmRacer/HowToSwapIntoCIS :MembersPage/GrmRacer/GrmIgnition :MembersPage/GrmRacer/GrmWiring This one is hard to read, but pretty complete :MembersPage/GrmRacer/GrmCircuits This one is easier to read and follow, but not complete yet :MembersPage/GrmRacer/Grm2005RaceQuestions -- Need help here. :InputTrigger/MultitoothTriggerWheel -- Page describing how to implement this :NitrousController -- Page describing adding nitrous to control stuff :TractionControl -- Used specifically to cut off fuel and air to reduce HP output to stop the tires from spinning :GearSelect -- Circuit to show what gear you are in for an early A1 VW transmission with the big reverse gear connector and the upshift light :IgnitionVW -- information on adapting the stock VW ignition circuit to the MS-AVR system with minimal changes to the system. It should be a fully mappable ignition, by replacing the Typical Hall sender output from the Hall sender on the distributor to the Ignition controller. Ideas abound for a cheap and easy replacement. WaterInjectionController - This page will describe adding water injection to the racecar.. Please dont try this at home you can seriously damage your car. MembersPage/GrmRacer/GrmInjectorSetup -- what I have to do to get the car running.. Disclaimer: I'm trying all this stuff at once. None, some, or all of it may work to some degree or other. This '''STUFF''' is developed for off-road use, and the car only has to last about 5 drag runs and 2 autocrosses. So think about that before you do any of this. to the stock ignition box from the distributor or The 2.5 bar MAP sensor that you asked: MPX4250AP (MembersPage/MarcellGal) http://www.x-dsl.hu/genboard/ --------------------- ArmProcessorSubsitution Im working on the lpc2119 library for the possible ARM processor use. Take a look at the library and see if I got it right. http://www.vems.hu/files/grmracer/LPC2119_arm.lbr a possible source for connectors http://www.fciconnect.com/markets/m_auto.asp ----- [http://cyco.ataxxia.com/gallery/GenboardV3 Genboard pics] ----- Notes for assembly * L2014 LCD must have Contrast to boot * PS2 pinout in manual is wrong and needs fixed * LCD Manufacturer found! ------ GrmRacer/TestHarnessSetup
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