Teppo Kalske from Finland, born 1972
My daily drive is a 1986 VW jetta into wich I couple of years ago transpalnted a full 16v drivetrain. Used it for about a year until head cracked. Then it was quite natural to take engine to pieces and make a total rebuild wich included 1,5mm oversize piston and getting rid of CIS to make place for Megasquirt.
After 7 months of driving with MS Miska talked me over to swap it for VEMS. Main reason was internal UEGO for WB-lambda.
Specs:
- 1.85L 16v, 136Hp stock + tube header, base engine KR, with ABF intake and very light (3,5kg) flywheel
- 4 cyl fuel injection, Hi-Z injectors about 200cc, INJA, B, F, G
- Ignition with distributor, IGN03
- PWM controlled idle valve, INJE
- 1xWBo2
- trigger from hall in distributor, 1 pulse/cylinder
- Running with firmware v12, vemsv3.ini r017
Shopping list:
- 1 x GenBoard v3.2
- 1 x Econoseal36-PCB
- 1 x Econoseal36-Wire
- 1 x Econoseal18-PCB
- 1 x Econoseal18-Wire
- 1 x Alubos1600
- 1 x Alubos EC frontplate transparant
- 1 x Alubos Endplate transparant
- 2 x Alubos gasket
- 9 x FETs Injector driver, WBO2 heater driver (FQFP..)
- 5 x Ignition driver (IGBT)
- 1 x Ignition driver insulator sheet
- 1 x 2.5 bar MAP sensor
- 1 x Wideband connector
Information hunting
Let's assume one who never before has browsed through wiki has just got his V3.2 order. He might end up wondering what to do next? Does he need to solder something by hand? A little searching brings following pages:
- BuildProcedures/SectionThree
- GenBoard/Manual/InitialTesting/VerThree contains some information about the hardware to check
- GenBoard/VerThree/Testing contains same kind of information
- GenBoard/Manual/WBSensorControllerCompleting
- Some information is collected to the StepByStep page
So there is something to start. Maybe a proper step-by-step guid is needed, I'll try collecting the issues to a separate page from this exercise.
29.08.2005
Copied this page from here: http://www.vems.hu/wiki/index.php?page=MembersPage%2FMiskaPeippo%2FJettaGT
Due to the too light flywheel I'm having quite a head ache with idle setup. For last 5 months I've been trying infinite number of various idle settings and never seem to get a setup wich works in all engine temps. Main problem seems to be with warm or almost warm engine. Ecu starts Idle stabilation too late, after revs drop under idle rpm setting that is. Due to light flywheel revs drop so fast that enigine dies before ign. adv. and isv changes have any effect on it. Has anybody any hints?
14.06.2005
Idle is now close to perfect with cold and half-warm engine. Also previous RPM undershooting (RPM falls down to ~500rpm when releasing throttle rapidly from high RPM) problems are gone. The trick was to set IAC ref position table a few steps over needed values and limiting iac_integral_limit_dec to very small value.
With warm engine there is still a problem with rapidly falling RPM. Ref position table ends to 77C, does this affect to all temperatures above 77C?
07.06.2005
CLT and MAP readings are incorrectly, at +7C outside temp after night CLT says -16C MAT -6C. Incs are generated using EasyTherm using 2k7 bias resistor and following measured values:
100C, 350ohm
23C, 5400ohm
0C, 16000ohm
and
100C, 343ohm
6.4C, 12600ohm
-16C, 37300ohm
Note that resistance is appr. double compared to standard GM sensor. This is not a problem, just good to know.
Generated thermfactor.inc is [here]
Verify that inc file has following "firmware_temp_value" at given "adc" indexes:
- adc=29.26 firmware_temp_value=252 temp=100 celsius_or_fahrenheit=C ohm=350
- adc=170 firmware_temp_value=113.4 temp=23 celsius_or_fahrenheit=C ohm=5400
- adc=218.18 firmware_temp_value=72 temp=0 celsius_or_fahrenheit=C ohm=16000
- adc=28.74 firmware_temp_value=252 temp=100 celsius_or_fahrenheit=C ohm=343
- adc=210 firmware_temp_value=83.52 temp=6.4 celsius_or_fahrenheit=C ohm=12600
- adc=237.79 firmware_temp_value=43.2 temp=-16 celsius_or_fahrenheit=C ohm=37300
These were made with firmware/bin/therminc.pl (in CVS head).
(TODO: complete it to make complete inc files, and publish some inc files with different resistor values).
If the AVR AREF reference voltage and the pullup voltage are significantly different (they should be roughly the same, appr. 4.86V .. 5.05V. Easy to measure with just endplate off) that would explain things and would be easy to make an inc for.
02.06.2005
With updated ini (r017) and small kpa formula fix also idle is functional and possible to tune with MegaTune.
01.06.2005
Victory in tuning battle! Car runs now pretty well with firmware v12. Almost only thing we missed was idle, because of some bugs in MT profile (r016):
- Idle settings, bits in iac_conf are not ok
- MAP scaling is incorrect (kpaoffs scale)
- battfac is missing from menu, no scaling either
31.05.2005
Severe problems keeping the engine running nicely. Tried STABLE1_0 with config below, engine hardly runs. Same SW & config with older compiler and car runs almost nicely, but ign advance is for some reason limited to ~24degrees and changes in ve table doesn't seem to affect AFR at all..
Please publish
- compiler version avr-gcc -v ( very suspicious )
- compiled zip, that also includes vems.hex (not relese on GenBoard/UnderDevelopment/FirmwareChanges or MegaTune page!) (rm *.o *.asm *.lst *.elf cleans the slate for zipping)
Earlier test were done with release v11 and gcc3.4.1/libc1.0.4 (WinAVR 20040720 distribution). Updated to firmware v12 release and compiled with gcc3.4.3/libc1.2.3 (latest WinAVR) and problems are gone.
22.05.2005
Car is now running, both fuel and ignition (dummy with distributor). Latest config dumps from board with STABLE1_0 firmware (20.05.2005)
09.05.2005
It's alive. Engine was running yesterday, board was only delivering fuel. Latest config files:
12.04.2005
Problem below was solved by updating a perl. With perl v5.8.6 make_ini.pl works smoothly.
Yesterday we made some initial tests in the car. MT configuration started to look somehow acceptable after a couple of hours, basically using old configuration from B&G MS. However TPS readings were not ok, values were either 16% at idle or by adding some throttle value jumped directly to 100%. In the LCD TPS values were ok.
11.04.2005
Some problems with perl. I use a activestate perl under Win: This is perl, v5.6.1 built for MSWin32-x86-multi-thread
When trying to run perl bin\make_ini.pl global.h doc\megatune\config.xml doc\megatune\vemsv3.ini I get an error message\n
"strict" is not defined in %XML::Simple::EXPORT_TAGS at C:/APPS/Perl/lib/Exporter/Heavy.pm line 75
Exporter::heavy_export('XML::Simple', 'main', ':strict') called at C:/APPS/Perl/lib/Exporter.pm line 45
Exporter::import('XML::Simple', ':strict') called at bin\make_ini.pl line 10
main::BEGIN() called at C:/APPS/Perl/site/lib/XML/Simple.pm line 10
eval {...} called at C:/APPS/Perl/site/lib/XML/Simple.pm line 10
Can't continue after import errors at bin\make_ini.pl line 10
BEGIN failed--compilation aborted at bin\make_ini.pl line 10.
I tried to download XML-Simple from activestate and installed it ppm install XML-Simple.ppd without any warnings etc. but obviously something is still wrong. Any hints?
04.04.2005
Board/case assembly is now mostly completed after some not-so-active period.
- Partially commented configuration files added here. These are not in any proper shape yet, mostly copied from GRM's config but will update once I get to the some real business.
03.03.2005
Completing of the controller begins.
Although board has a most of the parts already soldered on it, a few components still needs to soldered by hand.
- Injector driver FETs (TO220)
- Ingition IGBTs (TO220)
- WideBand LSU4 sensor heater driver (we use TO220 FET, same type as for injector drivers; except the WBO2 channel has no onboard place for flyback diodes)
There are also several items to check before even thinking to plug the board to the car.
- items to check listed here..
01.03.2005
Ordered items arrived
more details will follow..