Members Page/Tonci Loncar/Opel Kadett Turbo/Vems Hardware

MembersPage/TonciLoncar/OpelKadettTurbo/VemsHardware

Here is my FETs and IGBTs layout:

notes:

FETs and FET drivers for boost and idle control are not soldered on pic
GenBoard/Manual/DDFlyback (diodes and flyback rail wire) not soldered on pic, although they are very important!!!

Here is config and tables setup for layout from pic:

Injectors:

config.alternate = 03

h[0] = 01 02 04 08 20 40 00 00 (note: 20 is for idle valve and 40 is for boost valve)

h[1] = FF 00 00 00 00 00 00 00 (not used anymore)

Ignition:

config.ignchmax = 01

h[2] = 02 03 02 03 02 03 02 03

Idle:

config.iac_sol_channel=INJFETi_5

Boost:

config.boost_channel=INJFETi_6

Here is wiring for this setup:

V3.1-wiring2.gif

Please check:

Is gnd connected right?

The ground is a bit tricky. This would deserve a page of it's own. Anyone willing? The bad news is that it's not possible to tell from just the schematic if it's good or bad (it should work though). But if the GND wires meet at the battery, it should be OK.

Are fuse values ok?

The 5A WBO2 fuse might be blown in very cold (at 14V VBatt and high abs_limit setting). Unlikely though. 8..10 A should be safe in any case.

Are boost and idle valves connected ok?

Yes, each one on a free FET-output. The DD-flyback (low voltage 0.7V + 0.7V is best, but other types OK too) is hopefully populated on the board for those channels too.

Here is my wbo2 part of config:\n

wbo2_warmup_ramp=A0
wbo2_warmup_target=FF
wbo2_abs_limit=E4
wbo2_limit_maxt=A0
wbo2_fallback=60
wbo2_retry_t=06
wbo2_edgetime_corr=BA
wbo2_edgetime_min=50
wbo2_ri_target=96
wbo2_nernstdc_target=8D
wbo2_pump_pw_zero=66
wbo2_calibration=AE
wbo2_heater_pid_kp=46
wbo2_heater_pid_ki=10
wbo2_heater_pid_kd=1A
wbo2_heater_pid_ilimit=80
wbo2_pump_pid_kp=40
wbo2_pump_pid_ki=2E
wbo2_pump_pid_kd=08
wbo2_pump_pid_ilimit=84
wbo2_ri_confidence_scale=80

Here are measurements around pump OPA:

-Datapoints around the opamp during warmup:

OC3A	2.01
OC3A filtered = After R54 = Before R32	2.02V
After R32 (OPA+)	2.84V
pump+	4.03V
reference 2V = Before R35	1.98V
After R35=expect average of reference 2V and OPAout (OPA-)	3.47V
OPAout	4.00V

This is beautiful. pump+ to pump- is very small (appr 30mV / 10k = 3uA pump current: +-20uA would still be perfect). So wbo2_pump_pw_zero=66 is good for your board (well, for wbo2 channel1). This proves that your pump (current-generator) is working.

-Datapoints around the opamp after warmup:

OC3A	3.26V
OC3A filtered = After R54 = Before R32	3.28V
After R32 (OPA+)	5.77V
pump+	4.03V
reference 2V = Before R35	1.98V
After R35=expect average of reference 2V and OPAout (OPA-)	4.58V or 5.18V
OPAout	7.18V or 8.52V

Questions:

Q: As you can see there are two values in last two rows of second table that are changing during measurement. Is this OK?

A: I don't know for sure: maybe these are not really for simultaneous time-instant: OC3A=3.26V (significantly above 2V) means positive current command, while pump+ == 4.03V is almost 0mA current command. Since the sensor is not connected, it probably just falls back to 0mA from time to time.

It's safe to connect the sensor and do free-air calibration.

My WB02 Measurement and Control

Here are the values I got from LCD screen, afther warmup on free air test:

Ri	91 - A0
Nernst	1168 - 11A0
Heat	6E - 77
Pump	C5 - C6
AFR	?(no value)
C2%	2092 - 2095

Questions:

Q:Are this values OK?

A:Yes, 2092 - 2095 means 20.92 - 20.95% o2 which matches the freee-air o2 percentage, perfect! - DB

Q: When I was testing my sensor on free air (with mde02 command) I got AFR of 1050,61 in Mega Tune and on LCD there was no value just question mark. Is there something wrong or that is OK?

A: Since the free-air o2 percentage is out of afr range (actually no burnt fuel at all) the lcd afr shows questionsmarks (read: out of range) that's also why megatune displays funny values on the afr-gauge. Just ignore that, it will be fine when the engine is running and sensor in exhaust. - DB