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This page contains my notes and questions regarding the assembly of my V3.1 Genboard. My board is nr 81.
15.02.2006: Question regarding the flyback set-up
Looking at what was in my Rescue kit 1 (came with the V3.1) I'm now having problems finding out which is which of the flyback diodes. 2 types found in the kit but non of them looks or have similar names/measured values of those found in GenBoard/VerThree/RescueKit
Edit: 17.02.2006 '
- measurements over today by applying 24V through a 1k ohm resistor in series with the diode.
- Diode "Mo 16 LV" showed a reading of 0.73V (with DWM on diode setting to be 0.630V)
- In reverse direction the measurement was 24v, similar to my power source (SOP 23.02.2006)
- "M 724 B14 ZP" 0.234v. ( DVM measured to be 0.130V)
- sounds like fast diode, similar to ES2J. At 0.1A it's likely >0.5V. Plenty would be needed to raise the flyback voltage.
- In reverse direction the measurement was 24v, similar to my power source. (SOP 23.02.2006)
- Diode "Mo 16 LV" showed a reading of 0.73V (with DWM on diode setting to be 0.630V)
Note that in forward direction all diodes (the zeners and transient protection diodes too) measure small (typically <0.7V) voltage.
I need flyback control for my high ohm injectors and the Idle control output (Idle control need a 12v PWM signal to operate the spring loaded butterfly)
Possible solution 1:
Utilize the GenBoard/Manual/DDFlyback for both injectors and the Idle control output if I have the correct parts in the Rescue kit.
Possible solution 2:
Install low voltage flyback diodes from Rescue kit 1 together with the new GenBoard/Manual/PowerFlyback
- Q: Is it possible use the GenBoard/Manual/PowerFlyback on the V3.1 ?
- yes ! ask in WebShop for a 35% discount on this part if you chooses this. :)
- Do I need to install or remove any parts if I install a DD low voltage flyback together with the PowerFlyback ?
- if you have a v3.3 (shipped before 2006 Jan), you need to remove D100. Remove the endplate to do this GenBoard/Manual/PowerFlyback/RemoveD
- Q: Do I need to install the PWM kit (remember this is a V3.1 board)for PWM the Idle control output?
- NO. The PWM-ing is only for injector-FET PWMing that is 64usec (15625 Hz). Other power outputs are controlled at lower frequency, from software. Actually, we had to slow down the freq to about 1/10th for some the idle solenoids to work well.
Q: Which of the two solutions is the best from my set-up?
- without PWM-ing, you can use a few diodes in series, in the flyback path (either side of EC36pin23, inside the box or in the loom). If you don't have PWM-ing capability in the box, there is no chance for (a possible future user) to accidentally enable PWM (and ruin something).
Turbo comments
Is the K03 => K04 stepup significant?
No, The K03 is rated to approx 210-230hp on my engine while the K04 should be able to give me between 260-300hp
Flow maps for [K03-2072] and [K04-0025] turbo. [More Flow maps here]
![[K03-2072]](http://not2fast.wryday.com/turbo/maps/k03_2072.gif){kind=link}
![[K04-0025]](http://not2fast.wryday.com/turbo/maps/k04-0025.jpg){kind=link}
A question from MembersPage/DeanPavlekovic
Hi Stein, can you possibly give the part number and the diameter of you crank trigger wheel if the engine is still not assembled?
TIA
PS I can be emailed at dpavlekovic at gmail dot com, or just add to MembersPage/DeanPavlekovic
- The engine is still in bits. I'll look into the part number and diameter when I'm back in the garage (I'm moving appartments at the moment)
- The AEB Crank trigger wheel has part # 050 105 198 (The crack is installed in the block so I couldn't meassure the diameter today.
Questions 19.12.04
If you have a stepper chip, check GenBoard/BuildProcedures/Stepper.
Info from Jörgen:
This is the Elfa part# for the fuseholder: 33-153-48
You find fuses here: http://www.elfa.se/elfa-bin/dyndok.pl?vat=0&dok=2013505.htm
Good news 29.08.04
I got a "Hello" in Bray terminal, finally.
After I tried to use Hyperterm, I got contact with the GenBoard with Bray terminal.
The reason for my initial problems was all down to bad wiring and bad reading of diagrams.
I somehow managed to switch the pins on the PS2 connector. (sendt + to gnd pin...) and forgot to attach the contrast wire on the LCD.
Question: (29.08.04)
Nothing on the list today (yet)
To do list
- Start planing the soldering of wanted components on the GenBoard
More to come.
Below are things I have done
Initial Testing
The first thing I did after I recieved the GenBoard. I checked it for visible damage/short circuits, I couldn't see anything special (But are the SMDs assembled by machines? 95% of the top side was automated with picknplace and reflow-soldering. The bottom side was by human for v3.1. For v3.2 both sides will be automated. )
I made a serial cable, LCD display cable and a PS2 cable with connection. My seriell connection cable has been checked against the 1.8m extension cable and should be ok.
My power supply is an old AT PC supply (gives 11.6V). On the 12V power cable I have an 2A fues.
Problems
For the first power up I connected the Genboard with the seriell cable, LCD and PS2 keyboard. 12v was connected with an alligator clip to the right leg of the 1n4007 diode (diode mounted to the bottom side). GND connected to the GND wire loop.
When I turned on the power nothing happend. I couldn't see any signes of life in the LCD or when trying to connect to the Genboard with Bray terminal at 9600baut, 8n,1.
I have also tried to connect to the Genboard with only the serial cable connected without a possitive result
When I tried to hook up the PS2 keyboard again, a couple of seconds after the GenBoard got power, the powersupply fans stopped. I also felt a slight smell of warm electric components :/ I can't see any damage to the board or components. I have feeling somethings wrong with the PS2 wiring/keyboard?
Q:
Can I have damaged the Genboard the first time I powered it up?
Any hints where I can meassure with a DVM ?
A:
I tried powering mine up last night with similar results, mine is however a very early v3.1 (#30) while I guess that yours is one of the last ones.
I verified that my AVR does nothing by measuring 0v on the pre_inj lines. With some luck mine has accidently been delivered without bootloader or firmware. The FET drivers are inverting and to keep the injectors closed the engine management will turn those lines 'high' as soon as it gets power.
VCC is easy to verify by checking that you have 5v on the topmost pin of the PS2 connector. Also check that you have 5v on the forth pin from the left on the top row of JP_ISPI. This is the reset line.
---
Re:
I measured 5V on both pins and on Pre_Inj lines.
My AVR is alive. :D
Q:
I now get "Connected" with Bray terminal, but get no reply when trying the "Man" command.
A: as we don't use RTS, CTS or flow-control, "Connected" means really nothing.
Pin numbers on MAX232 chip
Where are pin1 and pin 16 on the MAX232 chip?
pin1 is close to EC36, pin16 is close to EC18
pin8 close to LM1815, pin9 close to AVR
Checklist
'My test results are in Italic''
- power consumption of the board. I always use 11 Ohm series to power the board (the WBO2 heater is powered separately) so consumption can be measured and anything nasty can be seen/felt/smelled at once. The 11 Ohm (2x 22 Ohm 1.5W in parallel) is very cheap compared to anything else.
- 5V on AVR VCC and AVCC (at least measure after main regulator)Ok
- appr 2.5 V on both crystal pins (so the crystal is oscillating) Ok
- +8V and -8V (or so) on the relevant capacitors next to the max232 Ok
- double-check you RS232 cable and write the pinout and connectivity measurement result (it is very common mistake to swap directions)Not checked
- AVR pin 2 (RXD) connected with max232 pin12 through a 2k7 resistor ok
- AVR pin 3 (TXD) connected with max232 pin11 Ok
- AVR pin2 and pin3 not shorted Ok
- max232 pin11 and pin12 not shorted Ok
- write down measured voltages on relevant max232 pins, on the 8V side and the 5V side
MAX232 meassurements (only power connected)
Pin1 6.9v
Pin2 8.99v
Pin3 2.4v
Pin4 4.59v
Pin5 -4.4v
Pin6 -8.54v
Pin7 8.59v
Pin8 0v
Pin9 5v
Pin10 0v
Pin11 5v
Pin12 5v
Pin13 0v
Pin14 -8.55v
Pin15 0v
Pin16 5v
The rest is not done as I have to check the com. cable first
This assumes you expect to talk to the test (or real) application (firmware) at 9600,8n1 (not the bootloader):
- sending some reasonable characters (blindly) that are known to do something: Manmdh..
- eg.Manmdh82 and Manmdh02 and measuring ign259 channel 0 = pin4
- or ManmdhB2 and Manmdh32 and measuring ign259 channel 3 = pin7
- pressing some key on PS2Keyboard that are known to say something (eg. mcd)
The above 2 command is meant to determine which direction of the RX,TX has problem. If the indication of action happens (ign259 signal change, or mcd output in terminal) than the other direction has the problem.
If you wiped out your test-application by an unsuccessful bootloader-procedure, you can only talk to bootloader (you can force talking to bootloader by shorting the GenBoards RX,TX while serial cable is disconnected). BootLoader talks 19200,8n1 by default and has no such simple way for testing the directions independently as the firmware has. It emits some very short squarewave at powerup that can be captured on a digital scope with some experience.
please move this to relevant page