Gen Board/Ver Three/Installation - VEMS wiki www.vems.hu

GenBoard/VerThree/Installation (2006-03-16 04:43:08)

Please see GenBoard/Manual/InitialTesting/VerThree.

This page describes the standard procedure to make an assembled v3 from a genboardv3.x

Resistor codes are in [] where appropriate. This saves some time for new people/non-experts.

only needed for v3.1

solder the other 2 FETdrivers (from rescue1 kit).
solder the WBO2 pump resistors: 2*510R [511]; and 8*100k [1003 or 104] that are pairwise matched.. (The 8 100K pump resistors in the old circuits were 510k value, but 100k is better). If you make lotsof boards, easiest to classify a set of 100k resistors (80% goes to 5 bins that are 0.1% apart) and populate a board from same values; If you make just one board, you can put the exact matches into pairs: (r33-r34)(r28-r31)(r35-r49) and (r32-r46): this requires slightly more attention, but just as good. (Note that we are overprecise here, the circuit would be fine without any matching).
solder the 0805 FET gate resistors (33 Ohm [330] preferred, but 10..100 Ohm [100..101] OK)
solder the 10k SIL5 R-net. Take care: it has a direction (why do people tend to get this wrong). The dot is the common net of the R-s, it must be connected to the pad near the edge of the PCB. The R-net is best soldered on the bottom of the PCB, as it doesn't conflict with anything there mechanically (if one wants onboard MPX2450AP, SIL5 is better on the bottom side).
solder a few C-s under the OPA rail (C52,C53).

needed on v3.2 too:

Solder the flyback rail airwire! The airwire should be soldered to the middle of the flyback trace (not to the end closest to EC36) so that 4 diodes are on one side and 4 diodes are on the other side. This means 1/2 current load for the onboard trace, which is 1/4 heat. Very nice when it's flowing 8A flyback current.
solder 3 lines of switches: 6 + 4 FETs and 2 + 6 IGBTs. An align tool, [similar to the clamping plate, but has 6 screws].
the pack includes some insulation material for the IGBTs: SILPAD-900S
solder the EC36 and EC18 PCB side connectors, with the EC frontplate already on and matching to the Alubos.
some more testing (eg wbo2 nernst, pump)
the pack includes 8..10 screws so the frontplate, endplate can be firmed
the pack includes 3 clamping plates (72 mm hole distance) and 6+ 3x10mm screws so they can be fastened.
the pack includes the Alubos (the PCB with the EC frontplate and EC connectors on is slided in), 2 gaskets. Up to now, the sent out Alubos had 6x 3 mm [holes drilled] so the clamping is easy.
the pack includes the complete rescue2 kit, and at least the parts from the rescue1 kit that are not soldered (the FETdrivers are soldered, and often the 5.4A inductor too).
MPX4250AP not soldered, not even included by default! Ask customer. (we should have 3 shop options for this !!! electronic connection with no MAP / electronic connection with included MAP / onboard MAP sensor with pressure connector. We should add option to shop. )
DDFlyBack: earlier we used 1.4V or 6V8 or 20V flyback (asked the customer), but today we use low voltage 0.7V + 0.7V since we have the precise GenBoard/Manual/Config/InjectorOpening.
2nd lm1815 No need for soldering 2nd LM1815. Not even included by default.
solder a 10uF 35V 1210 size cap at supply input
I think we should solder R112=33k and R169=22k (or maybe R112=10k and R169=10k ?). Slightly different setup than on GenBoard/BuildProcedures/LCDconnect) to make -4V contrast voltage possible. The user could simply solder a high resistor value to GND to move the contrast voltage towards GND
if knock is included (as usually. we will add an option to shop) complete the knock part according to GenBoard/Manual/KnockSensor (which EC18 pin is used? pin 3 cannot be MAP and knock at the same time ...)
if stepper is included (as usually. we will add an option to shop) check GenBoard/BuildProcedures/Stepper. Don't forget the mdh.6 tests to enable the stepper and drive outputs to +12V and GND

The EC18 and EC36 wire parts are not included, but we warn customers if they forget to order those when ordering assembled controller.

note: if the customer asks to include some 30..40 Euro of extras, (like MPX4250AP, 2nd LM1815, NTC) in the pack, don't charge if they have paid already.

100k is very precise

Why are there no "1003" (100k 1%) resistors in the resc1 packs?

I found some 104's and they were suprisingly precise. I was searching for the more precise 1003, but looks like we have great luck with 104 5% precision. They were all within .7 ohms, and I found 8 that were all the same 100.1k ohms. Yes, my girlfriend measured several hundred 104 resistors and it's obvious that their precision would be suitable for soldering them blind.