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I'm going to help in conversion from B&G MS to VEMS in friend's n/a Jetta 16v. * 1.85L 16v, 136Hp stock + tube header, base engine KR, with ABF intake * 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. ---- '''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 [http://www.vems.hu/files/MembersPage/MiskaPeippo/Jetta/thermfactor.inc 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.. * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mcd.txt mcd.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mct.txt mct.txt] 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) * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mcd.txt mcd.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/mct.txt mct.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/datalog200505212239.zip logfile] from a small test ride. '''09.05.2005''' It's alive. Engine was running yesterday, board was only delivering fuel. Latest config files: * [http://www.vems.hu/files/MembersPage/MiskaPeippo/config.txt config.txt] * [http://www.vems.hu/files/MembersPage/MiskaPeippo/tables.txt tables.txt] '''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 <code> "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. </code> 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. ** [http://www.vems.hu/files/MembersPage/MiskaPeippo/config.txt config.txt] ** [http://www.vems.hu/files/MembersPage/MiskaPeippo/tables.txt tables.txt] '''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..
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