Assembling the PCB v3

8/11/2019 Assembling the PCB v3

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Assembling Your MegaSquirt V3.0 Main Board

When you purchase a MegaSquirt kit you receive a PCB (the printed circuit board), plussome essential components, called a partial kit (MSP!"# or MSP!"#), as $ell as theremaining components to complete the assmebly% #he partial kit includes&

printed circuit board ('),

preprogrammed *+C-.+/P processor (U1) 01 MegaSquirt"" daughter

card (MS2), and the MP234.5P M5P sensor (U2) various resistors, capacitors, diodes, inductors, connectors, etc%%

Note: For stim assembly instructions, BOM, etc., see the v2.2 assembly guide here:

www.megamanual.com/v22manual/v1stim.htm

he instructions here are !or building the "# board !or the $%&'()% with the standard

B*+ code or !or Mega-uirt. ! you are 0lanning to use Mn code on a

$%&'()%3 with the "# board, there may be a number o! additions, alterations, and

omissions you need to 0er!orm in building the "# main board. ee theMn site!or

instructions on these changes.

When you purchase a MegaSquirt kit, the components typically arrive individuallypacked, $ith part numbers% 5s a result, $hile you should veri6y that you have receivedall you ordered, it is not necessary to identi6y each item by color, markings, etc%

"6 you have questions about the speci6ication or appearance o6 any item, check the partnumber at the 7igi!ey site ($$$%digikey%com) 6irst% 8ntering the part number in theirsearch engine $ill give you access to both the catalog in6ormation and the data sheet6rom the manu6acturer%

#o assemble any o6 these electronic kits, you $ill need a soldering iron, some solder,and a 6e$ other use6ul accessories% 5 94 $att pencil iron $ill $ork 6ine, ho$ever a 4$att iron heats up 6aster% /et some small solder% :or e;ample, you can use .%) $hich really helps to put ?ust the right amount o6 solder in ?ust the right

places% @ou do not need to use silver solder 6or MegaSquirt% Make sure to let thesoldering iron get hot be6ore using it% 5 hotter tip makes 6or quicker cleaner ?oints, andless heat in the components, because the temperature o6 the lead reaches the melting

point o6 the solder be6ore the component has had much time to heat up (though lettingthe iron heat 6or a $hile also tends to shorten the use6ul li6e o6 the tip)% Aet it sitpo$eredup 6or 9.94 minutes be6ore trying to use it% #he solder should melt nearlyinstantly i6 touched to the tip%

ever try to paste solder on a ?oint using e;cess solder on the tip% !eep the tip clean,and heat the ?oint (try to get the tip right at the ?oint bet$een the lead and the PCB) andhold the solder against the other side o6 the ?oint until it starts to melt% :eed in ?ustenough solder to get a bit o6 a cone on the ?oint, and you are done% /et a solder $ick as$ell you $ill be glad you didD "t is very use6ul 6or removing components% Be6ore

plugging in your soldering iron, be sure you read and understand the assemblyinstructions that 6ollo$%

Note that there is also an e4cellent tutorial !or the assembly o! general electronic 5its

here: www.mtechnologies.com/building/ato6.htm.3
http://www.megamanual.com/v22manual/v1stim.htmhttp://megasquirt.sourceforge.net/extra/http://megasquirt.sourceforge.net/extra/http://www.digikey.com/http://www.mtechnologies.com/building/atoz.htmhttp://www.megamanual.com/v22manual/v1stim.htmhttp://megasquirt.sourceforge.net/extra/http://www.digikey.com/http://www.mtechnologies.com/building/atoz.htm


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ote& #he semiconductor components in MegaSquirt are sensitive to electrostaticdischargeE8S7)% #o reduce the potential 6or damage 6rom 8S7, some care is needed%"nterestingly, you cannot even 6eel an 8S7 shock unless the voltage e;ceeds ,...volts, 6ar more than enough to destroy some o6 the MegaSquirt components% 8S7 eventsdo not al$ays destroy an electronic component immediately on the 6irst occurrence,making the eventual 6ailure o6 your MegaSquirt very di66icult to troubleshoot% Where

possible, make use o6 antistatic controls and material handling techniques, i%e%, $ristband grounding straps, antistatic 6oam and antistatic bags, grounded $orkbenches,

antistatic mats, etc% 5void handling semiconductor components more than necessary% "6you are not $earing a $ristband grounding strap, discharge yoursel6 by touchinggrounded metal be6ore handling "Cs and equipment% #his is especially important in the$inter a6ter taking o66 or putting on any garments, 6or e;ample, s$eaters and coats% #hematerial o6 your clothing also has an e66ect, as materials like silk and some arti6icial6ibers produce a lot o6 >static electricity>% Most commercial carpets contain a high

percentage o6 arti6icial 6ibers, $hich are prone to producing static% Where possible, tryto keep the room humidity at 4.F or higher to reduce static problems, or use a productsuch as >Static /uard>%

5ssembly /uide 6or MegaSquirt Main Board 'ersion '%.

MegaSquirt uses a number o6 components% #hese components are installed on thesilkscreen side o6 the PCB, and in most case it $ill be easiest to solder them 6rom theother side o6 the board% 8lectrically, the soldering $orks 6ine 6rom either side, but as youget more components on the board, it gets harder to solder on the components side,6orcing you to use the other side 6or soldering% #here are three $ays you can be sure o6

putting the right components in the right places $ith the right orientation% Mostelectronic parts have a standardiGed scheme 6or identi6ication%

#here are a large number o6 cryptic designations in building a MegaSquirt% Many o6these have the 6orm o6 a capital letter 6ollo$ed by a one or t$o digit number% #hese

indicate components that are installed on the MegaSquirt main board (or stim, etc%) andare speci6ic to each PCB% So 1- means resistor (1) number -% ote that the main boardhas a 1-, as does the stim, and they are di66erent% ere are some e;amples&

79 H 7iode 9,

C9 H Capacitor 9,

19 H 1esistor 9,

I9 H "C (chip) 9,

A9 H "nductor 9,

:9 H :use 9,

P9 H Connector 9, J9 (sometimes #9) H #ransistor 9,

etc%%%%%%

#here are also a number o6 2 ?umper locations (29, 2, etc%)% #hese generally speci6y alocation on the board to solder a ?umper, i6 you look at the board $ith all thecomponents installed you should see a 29, 2, etc%%% still visible% #hey can also haveother designations, such as KS3, or KS9%

#he components themselves have a designation as $ell, and con6usingly, these alsoo6ten have the 6orm or capital letters 6ollo$ed by numbers% :or e;ample, "1:L33 H a

speci6ic component the in?ector driver :8#s%
http://www.mnsi.net/~boucher/ESD.htmhttp://www.mnsi.net/~boucher/ESD.htmhttp://www.mnsi.net/~boucher/ESD.htmhttp://www.mnsi.net/~boucher/ESD.htm


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:inally, there is the component part number, used to order the part 6rom a supplier, andthis can be di66erent again%

:or e;ample, the in?ector driver :8# 6or bank 9 is&

J9 the component "7 on the ' main board,

"1:"L3/PB:7 the 7igi!ey part number,

the general term 6or this type o6 transistor is a :8#, or 6ield e66ect transistor%

When you arent sure, a search o6 the manual, andor a quick look through the B0Mshould help you sort it out% ere are the parts used to assemble the '%. main board&

Color Code egend

BasicComponents

5ctive:lyback

'1Sensor"gnition#rigger

allCoil() "gnition#rigger

ighcurrentdriver

CurrentAimiting

Sockets Spares Cables

Please note that a 6e$ component values may have been t$eaked especially in the '1input circuit, but possibly others as $ell% :ollo$ the 7igi!ey B0M values6or thecurrent component speci6ications and use these over the values listed belo$%

78

Neede

d

78

Ordere

d

Mega-uirt

9e!erences

igi;ey


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Components

#5# 3%


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#7Components

*' 9W 4F7039

:9, : 128:.4.7 .%3+ SparesPolys$itch128 Series.%4.5 0A7

A9,A M+++7 9%.9BasicComponent

s

Choke 1:'arnished

9I .F

9 9 M0'9 P


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< 9.19*,19-,1*,1

s

1esistor 49!0hm 9+W

4F Carbon:ilm


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1

9 9 I3"27"3.3P"

7%.*

BasicComponents

M0S:8#7river AS 357I5A +7"P

9 9 I4AM-


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9 9 558


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5MegaSquirt PCBand all associated BR/ and 7igi!ey parts,

5 digital multimeter (7MM) or a voltmeter and 0hmmeter,

5 7B- serial cable that is straightthroughT (not a nullmodem cable, see step

a)% Most computer shops $ill have these% @ou need a 6emale connector on oneend and a male connector on the other end%

5 Windo$s -;M82P PC $hich has yperterminal (hyperterm%e;e)% #his is

normally supplied $ith the Windo$s operating systems), and is also available atilgreave,

Mega#une do$nload it, and install it on your computer% ote that MegaSquirt"" require Mega#une%4b33< or higher (all version $ork $ith MegaSquirt i%e%,a *+C-.+ processor)%

5MegaStimulator$ill make these checks, and several other tasks, much easier%

/eneral electronic kit assembly tools (scre$drivers, pliers, soldering iron, etc%)%

@ou may need a magni6ying glass% Many o6 the components on the ' boards

are small and tightly packed, and this requires much better vision than the '%boards% #he magni6ying glasses that come on an articulated arm are convenient,but can be e;pensive (though they can sometimes be had 6or under U.)% 06ten asimple hand held glass $ill su66ice%

Proper mounting o6 the larger heatproducing components requires the use o6

heatsink compound% @ou can 6ind a small tube o6 it at your local electronicsstore 6or under U%

5 drill, hack sa$, 6ile, and 9+T and OT drill bits 6or cutting the end plates and

heat sink%

7o not let MegaSquirt be your 6irst attempt at assembling an electronics kit% "6 you havenot assembled such a kit be6ore, go purchase another simple kit (like 6rom'elleman)and practice, or assemble the MegaStim or relay board 6irst% #his $ill help you practiceyour soldering skills be6ore attempting the tougher assembly o6 the '%. main board%

/etting Juestions 5ns$ered

When you have problems $ith assembly or testing, post your questions to&

MegaSquirt :orums(must be registered to post)

Make sure to mention the step number and be as speci6ic as you can $ith regards tocomponents, voltages or resistance values, temperatures, Mega#une gauge readings,A87 6lashing rates or any other in6ormation that you think might be related% "6 you haveall o6 the above items on hand, and a 6e$ hours o6 spare time, you can begin to assembleyour MegaSquirt% 5ssembly proceeds in 6unctional blocks, $ith testing a6ter each block%

#hese blocks are&

!o"er Su##l$ Construction and %esting (steps 9)

Serial Communications Construction and %esting (steps 3*)

Cloc& Circuit Construction and %esting (steps


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? ti0 !or those about to assemble their Mega-uirt: whenever 0ossible, orient the

numbers on the com0onents such as diodes3 so that you can read the @im0ortant@ 0art

o! them when it>s all assembled. For e4am0le, with a diode 1NAC#, try to ma5e sure

you can read the AC# 0art o! the number when the diode is installed in the


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Po$er Supply Construction R #esting

9% /et ready 6or assembling your MegaSquirt% Plan on taking * to + hours 6or theaverage person $ith average skills doing a 6irst time assembly%

a% :amiliariGe yoursel6 $ith the PCB, schematic, B0M, and this assembly guide

make sure you have everything available to assemble your MegaSquirt%

#he above diagram can be a use6ul guide to locate components as you assemble% #oprint it, click this link& components%gi6, and print it 6rom your bro$ser%

b% ote that i6 you bought a complete kit 6rom a distributor, some componentsmay be di66erent in appearance or markings than those listed in theseinstructions% #ake care6ul note o6 any additional instructions and clari6icationsthat came $ith your kit%

c% Ise an 0hmmeter (digital multimeter set on resistance) to check the resistancebet$een the three voltage regulator holes% #he voltage regulator is I4, near the

7B- connector in the top le6t side o6 the board (on the heat sink)% #he resistancebet$een any t$o o6 these three holes should be in6inite% "6 it is not, contact thesupplier you bought the kit 6rom% (#his test ensures that the 9 'olt supply, 4'olt internal supply, and ground are not shorted together%)

d% #rial 6it your PCB in the enclosure be6ore soldering anything to it% @our printedcircuit board (PCB) might be slightly too $ide and too long to 6it into the case

properly% "t is designed to be *%..T long by 3%..T $ide (94%3mm 9.9%*mm)%#he PCB manu6acturer allo$s some tolerance, so some boards might not quite6it $ithout a little 6iling% Check the $idth 6irst% ote that you have to slide the

board in per6ectly straight or it $ill bind, even i6 it is the correct siGe% "6 you stillcannot slide the board in, deburring the bo; sometimes makes all the di66erence%

#he boards bind i6 the edges are sharp, but slip right in $hen cleaned up% "6 thisstill does not $ork, then be6ore soldering anything to the boards 6ile the sidesdo$n a bit% Ise a 9> (.cm) 6inishing 6ile% Slide the board back and 6orth on

both long sides 6or about . seconds% ("6 you do not have your case yet, you canproceed and check the siGes later, it $ill ?ust be a more delicate ?ob)% ote& youshould also check the length o6 the board in the case% Slide the board into thecase% #he < pin sub 7 connector mounting sur6ace should be 6lush $ith the

back o6 the case, look at the other side o6 the board (7B- connector side) andsee ho$ much needs to be 6iled o66 so the cover can be mounted 6lush $ith thecase% @ou may need to take as much as .%.4> (.%*mm) o66 o6 this side, $hichmay take up to *. seconds o6 $ork $ith the 6ile% When you are done the boardshould 6it nice and snug%

e% Prepare the heat sink% @ou $ill make this out o6 9+> (mm) aluminum 6latstrapping, X> $ide (9- mm) by *%.. inches (94%3mm) long% @ou $ill drill +holes in it to match the PCB heat sink area% U)* +12* +11* +)* +,* +3* +1and+1-9# and 9#% do not need holes3mount to the heat sink% #he easiest $ay toget the hole spacing right is to trans6er the holes 6rom the PCB to the aluminumstrip by placing them together and using a 6elt pen to mark the hole locations onthe aluminum strip through the PCB%
http://www.megamanual.com/ms2/v3components.gifhttp://www.megamanual.com/v22manual/mintro.htm#grouphttp://www.megamanual.com/ms2/v3components.gifhttp://www.megamanual.com/v22manual/mintro.htm#group


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Be sure to allo$ enough room 6or the aluminum strip to 6it in the case, and allo$enough room so that it $ont contact the component leads% Make sure the heatsink rests up against the case $hen installed to get the thermal contact bet$eenthe case and the heat sink% Sand both sides o6 the heat sink to ensure there are no

burrs%


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#he $ider lip o6 the case side is near the heat sink side o6 the board% #his is to allo$ thetop lid case to close% Mock it up by ?ust sliding the board in the case $ith the end capso66, put on the top case hal6 and slide the heat sink along the top, you $ill see $hy youneed the 6atter lip side o6 the bottom case hal6 on the heat sink end% #he aluminumshould 6it against the case lip 6or a little e;tra heat trans6er%

% o$ $e $ill install the t$o e;ternal connectors, the 7B- and 7B


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near the 7B< connector, and does not have a polarity, it can go either $ay around% #hispart protects the MegaSquirt 6rom surges on the 9 volt line%

4% "nstall the capacitor C1)E#((A2)2N, .%..9 N:, 9. markingY% #his goes near theM0'9 you ?ust installed, bet$een it and >/rippo> in the copyright notice% ote that the9 night be obscured by a via%

his com0onent, and many o! the remaining ones, such as resistors, ca0acitors and

diodes3 has long leads. n general, you want to install and solder the com0onent as

close as convenient to the


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94% "nstall and solder 12E1NAA(?'N, 3 volt LenerY make sure banded endis installed correctly as sho$n on the printed circuit board% #his installs very near 79.and 799%

9*% "nstall and solder diode 13E1NAA2?'N, 9 volt Lener, 93


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% o$ you need to make a decision on the 6irst optional component& i6 you are goingto use an "5C stepper motor $ith MegaSquirt"", you must install a ?umper 6rom thehole marked S12Cto the hole marked @S, 12C% #hese are on the bottom side o6 the

board, on the 7B- side o6 the processor% ( (% 'S%A %?'S @UM!>D 9(D(MegaSquirt'' A!!'CA%'(S '% 4' >S%D(Y %?>

!D(C>SS(D55

"6 you are going to use a stepper style "5C (such as the /M "5C), you need to connect?umpers to bring the controller signals out to the 7B


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Pin grounds

9-

9(4 'olt)

VVVV VVVV VVVV

.(4 'olt) VVVV VVVV VVVV

9(4 'olt)

VVVV VVVV VVVV

"6 you have installed the S9C to KS- ?umper (6or stepper motor "5C control $ith anMegaSquirt"" 0A@), then you should also have stim voltage (typically =- 'olts) on

pin 9* o6 the processor socket%

' $ou dont #ass the abo


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#he 7B- pin 6unctions are&

o !in 1 'CC (4 volts)

o !in 2 #; (0I#)

o !in 3 1; (")

o !in ) ground

o !in , 4 'olts (bluetooth device po$er supply)

"6 your laptop has a 7B4 serial port, rather than a 7B-, you can use a 7B- to7B4 adapter, available 6rom most computer stores% :or the rare 7B4 PC

port, a >straight through> connection has pins , and < (t$o, three and seven)on the 7B4 connected to pins , and 4 (three, t$o and 6ive) on the 7B-,respectively%

"6 you do not have a serial port (some ne$er laptop computers do not), you maybe able to use a ISB port% #he ISB port on your computer cannot be $ired to a7B- connector directly% @ou can buy a ISB adapter, $hich may $ork $ithMegaSquirt% "t is more e;pensive than the simple adapter solution% #here have

been some reports o6 problems $hen using a ISB to 1S adapter, though a

6e$ people have managed to make them $ork% 0ne that some people have hadsuccess $ith is at& $$$%se$elldev%comISBtoSerial%asp"t is only U.%

0thers have 6ound that the !eyspan ISB to Serial 5dapter model number IS59- JW$orks% @ou have to do$nload the ne$ driver and go to the !eyspan Serial5ssistant% "n it you have to change the baud rate to -*.. and the Com port to 9%#he de6ault is *% @ou can get one at CompIS5 6or U3-%--% ' $ou use a USB

ada#ter* be ma$ haD( 0. You can change thisin the Control !anel* loo& under S$stem* ?ard"are* e


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994..)% ote that the con6iguration is set 6or com port ]9, you may have tochange this% (Dyou can set up yperterminal yoursel6&

i% 0n the PC, 6ind and run yper#erminal (yperterminal is usually underStartPrograms5ccessoriesCommunications, but i6 it is not there then search6or a 6ile called hyperterm%e;eT)%

! you do not have &y0ererminal installed, you can get it !rom&ilgraeve, who

wrote the original !or Microso!t Dindows. &y0ererminal megasquirt>)% iii% When the >Connect #o> dialog comes up,select under the >Connect Ising> option the C0M port to $hich the 7B- cableis connected, i%e%, C0M9 or C0M% 7o not $orry about any o6 the othersettings% Click 0!% iv% e;t, a dialog $indo$ opens $ith baud rate, stop bits,etc% Set the values according to the table belo$% ote& the last one, 9lo"Control, is very important ^ be sure to set it to one% Click 0!%

Baud 1ate ,-00!or Mega-uirt11)200!or Mega-uirt

7ata Bits ;

Stop Bits 1

:lo$ Control one

d% yper#erminal no$ is up and >connected%>e% #ype any character it should be echoed back to the screen, i%e% you $ill see it

once i6 you do not have local echo enabled, t$ice i6 you do%Note that the abovecon!iguration !ile has the local echo set to @o!!@."6 the character you typedappears on the screen then the link is $orking% "6 not, then check the cableconnections and try di66erent C0M ports% @ou must see characters echoed

correctly be6ore you move on%6% 0nce the connection is $orking $ith the cable loopback, it is time to connect the

7B- cable to the MegaSquirt 8CI% 1emove the ?umper on the loose end o6 thecable and plug it in to the MegaSquirt 7B- connection%

g% Kumper 6rom pin 12to pin 13on the 3.pin processor socket _near D66`, using asnippedo66 component lead (i%e% the loose end 6rom a resistor or capacitor,smaller is better to avoid damaging the socket)% Be care6ul to count correctly to

?umper the correct pins% Pin number 9 is to the le6t o6 the notch ($hen the notchis >up>) on the chip%o not test the loo0bac5 yet, you have to a00ly 0ower !irst%

h% :inally, #lug in the stimulatorto MegaSquirt to po$er the board up% #hisallo$s a 6ull loopback test, all data sent to pin 9 should be returned back on

pin 9 through the M52 chip and all related communications circuits on theboard% 5gain, type any character and again it should be echoed back to thescreen% "6 characters appear on the screen then everything is 6ine, i6 not, thencheck solder ?oints on the sockets and components, veri6y voltages at theM52 chip connections and so on%

Clock Circuit Construction R #esting


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+% "nstall and solder C20E#((A#$1N, .%. N:, markingY% "t is located in aro$ o6 three capacitors above the A9 inductor you installed (above >%in6o> in thecopyright notice)

-% "nstall and solder C21E#((2)CNor #((A#2$N, .%.9 N:, 9. markingY% "tinstalls beside C.%

.% "nstall and solder C26E#((1(11N, 3< p:, 3


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"s 3%

% "nstall and solder D3EC1;B;N, 49!, greenbro$norangegoldsilver)% #hisinstalls near pin ]9 o6 the CPI socket%

3% "nstall and solder D-E1);B;N, 9.!, bro$nblackorangeY% #his installs near

A, by the Boot ?umper hole%

4% "nstall and solder D21E1);B;N, 9.!, bro$nblackorangeY% #his installsbet$een C. and C4%

*% "nstall and solder D22E9..;B;N, 9..!, bro$nblackyello$Y% #his installsbet$een the pad 6or @9 and the components you have already installed nearby%


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ote that the -;?C,0; #rocessors or standard MegaSquirts and MSnS>

alread$ ha"eri!ication succeeded, ((( records total

A s5i00ed3.>


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+% 1emove po$er 6rom MegaSquirt (disconnect the stim)%-% 1emove the boot ?umper (or put it on ?ust onepin o6 the BA7 header 6or

storage),9.% Start Mega#une and set the C0M port and speed i6 necessary% (Make sure you

have con6igured Mega#une to inter6ace $ith MS"" using the mtC6g%e;e utilityin the Mega#une 6older%)

99% "6 you have changed code version (or loaded code 6or the 6irst time), you mayneed to change the Mega#une "" 6ile to match the ne$ code% #hese are located

in theMegaune22C/mt'!g/6older% #he 6iles have names like >megasquirt''.ini.2.0>, $here %. indicates the code it is to be used $ith% Start up the M#Con6igurator (mt'!g.e4e), $hich opens automatically during the installation

process (it can be opened directly 6rom the Mega#une 6older or the start menu atany later time)% 0pen the Mega#une%4 tree item, and youll see a number o6megasquirt""%ini%% 6iles% Click on the one that matches the version o6embedded code you are running to highlight the %ini 6ile and e;ecute :ile 5ctivate% #his $ill rename it to be >megasquirt''.ini> (deleting the e;istingmegasquirt""%ini 6ile 6irst)% "t $ill then be used by Mega#une $hen it starts up%

See the readme 6ile in the package 6or more details%

#o per6orm the tests at this step, you $ill also need to have Mega#une installed on yourcomputer (this is also the program you $ill use to tune the 6uel in?ection in the vehicle)%#o install the latest version o6 Mega#une on your computer&

a% Click this linkto go to the release site,b% Select Mega%une22)#1Hsetu#.e/e, and click on it%c% Choose Run or 9un 0rogram !rom current location $hen prompted%d% Choose all the de6aults $hen installing the program, and it $ill create a 6older

called ':J


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g% @ou need to tell Mega#une $hich version o6 MegaSquirt you have (MS, MS"",MSnS8, etc%), as $ell as the 8/0 type, etc% #o do this, use the mtC6g program,$hich opens automatically during the installation process (it can be openeddirectly 6rom the Mega#une 6older at any later time)% Aook 6or theC078V'51"5# variable, it $ill be in'ar1/settings.ini/ettings/'OK"?9?N in the directory tree on the le6t sideo6 the mtC6g $indo$% Click on C078V'51"5#% @ou can then use the drop

bo; in the upper right section o6 the $indo$ to select your code variant%

Click the links to 6ind more in6ormation on Con6iguring MS"", and Mega#une%

0n the PC, run Mega#une by clicking on the icon on your desktop% /o into the

>Communications> $indo$ and select the proper C0M port (the >'eri6y 8CIoperation> does not operate, so do not be 6ooled)% 8;it this screen (back to the main$indo$)%

39% Plug the stimulator into the 8CI% 0n the PC, click the >1ealtime 7isplay> under>#uning> on the main menu, $hich brings up a ne$ screen% Aook at the >#ime(s)> nearthe top le6t corner o6 the 1ealtime 7isplay it should be counting up, incrementingevery second (it $ill roll over at the value o6 44, back to Gero)% "6 the seconds count isthere, you are runningD "6 not, check the cable, make sure there is po$er, and check theC0M port% #he only other value on the screen $hich is $orking correctly is the >Batt'> bo; it should be displaying the battery voltage (6rom about


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' $ou dont #ass the abo/rippo> in the copyrightnotice on the silkscreen at the bottom o6 the board%

34% "nstall and solder C6* C-*and C;E#((A2)2N, .%..9 N:, 9. markingY% #heseinstall in the column o6 capacitors ?ust above >/rippo> in the copyright notice on thesilkscreen at the bottom o6 the board%

3*% "nstall and solder C) and C:E#((21)2Nor #((A#%(N, 9%. N:, 9.4markingY% #hese install in the column o6 capacitors ?ust above >/rippo> in the copyrightnotice on the silkscreen at the bottom o6 the board%

3


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3+% "nstall and solder D)and D;E2.2;7B;N, %!, redredredY% #hese install inthe column o6 resistors ?ust above >R> in the copyright notice on the silkscreen at the

bottom o6 the board%

3-% "nstall and solder D11E1.)MB;N, 9M, bro$nblackgreengold)% #his installsin the column o6 resistors ?ust above >R> in the copyright notice on the silkscreen at the

bottom o6 the board%

ote& 199 and 19. 6orm part o6 the 8/0 input circuit ($ith C9.)% "t is very importantthat you do (% install a ca#acitoracross the sensor input be6ore 199 (C9. comesa6ter 19. and 199 and is 6ine)% Some people have recommended adding such acapacitor to smooth the sensor input% #his $ill cause problems, especially $ith $ide

band analog outputs such as you 6ind on "nnovates AC9%

5lso, i6 you have a $ideband sensorcontroller, be sure to ground the controller to thesame #ointas MegaSquirtD

4.% e;t you need to make a decision% #here are t$o input circuits 6or the tach signal&

#he ?allIo#ticalIetc.circuit takes the square $ave input 6rom a all sensor,optical sensor, or points% "t can also be used 6or triggering o66 the coil (but only i6you are not controlling ignition timing)%

#he VD circuittakes the 5C signal 6rom a variable reluctor sensor and converts

it to a square $ave 6or use by MegaSquirt%

#he all circuit can be built t$o $ays 6or a digital signal such as a all sensor oroptical sensor (step 4.%a%) or 6or a coil negative terminal (4.%b%)% these are the samecircuit, but di66erent components%

#he '1 circuit is install in step 49, i6 desired%

"n most cases, you should install both circuits, and make the selection bet$een them$ith ?umpers% o$ever, i6 you do not $ant to install the allopticalpoints circuit, skipahead to step ]49%

"6 you arent sure $hat input circuit to use, check to see i6 your ignition is on this list and6ollo$ the instruction in the link i6 it is&

Distributor Pickups& general in6ormation,

GM HEI& use the all0ptical circuit,

GM DIS& use the all0ptical circuit, Ford EDIS& use the all0ptical circuit,

Ford TFI& use the all0ptical circuit,

Bosch 0 227 100 124& depends on trigger type,

MSD 6A& depends on trigger type,

Dirct !oi" !o#tro"& depends on trigger type%

a% #o install the ?allIo#tical input circuit (or points withouta coil connection)&i% "nstall and solder D12E#()&N, -. 0hm, $att, orange$hite

bro$nY% #his is installed bet$een the resistors you have ?ust beeninstalling and the CPI socket% #his resistor should be mounted roughly9+> (mm) above the sur6ace o6 the PCB% 5lso, the value o6 this resistormay have to be changed i6 you trigger 6rom the negative side o6 the coil
http://www.megamanual.com/ms2/pickups.htmhttp://www.megamanual.com/ms2/GM_7pinHEI.htmhttp://www.megamanual.com/ms2/GM_DIS.htmhttp://www.megamanual.com/ms2/EDIS.htmhttp://www.megamanual.com/ms2/TFI.htmhttp://www.megamanual.com/ms2/Bosch_124.htmhttp://www.megamanual.com/ms2/msd6a.htmhttp://www.megamanual.com/ms2/vb921.htmhttp://www.megamanual.com/ms2/pickups.htmhttp://www.megamanual.com/ms2/GM_7pinHEI.htmhttp://www.megamanual.com/ms2/GM_DIS.htmhttp://www.megamanual.com/ms2/EDIS.htmhttp://www.megamanual.com/ms2/TFI.htmhttp://www.megamanual.com/ms2/Bosch_124.htmhttp://www.megamanual.com/ms2/msd6a.htmhttp://www.megamanual.com/ms2/vb921.htm


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depending on application start $ith the supplied value, and i6 gets hot$hile the engine is running, then increase the value, in steps, up to 9.!(like 3Bo$ling> in the copyright notice%

iv% Aeave the C30location empty 70 0# ?umper it%v% "6 you have a all sensor or optical sensor, do not install 1, put a

?umper in its place% "t is located beside 19, 6urther 6rom the heat sink%vi% :or most installations, diode 2E1NA))1'N, the marked

93..9Y is not needed% 7o not install 7, install a ?umper (made 6rom asnipped o66 lead) in its place% "t is located beside 79, closer to the heatsink%

ote& this diode (7) is needed only i6 the ignition system has a largeo66set bias most systems do not have such a bias% So, to start, you caneither solder in a ?umper $ire in this location, or, you can install thediode 7, and then install a ?umper around the t$o leads o6 the diode ine66ect shorting it out% #he latter $ill allo$ you to snip the ?umper later oni6 needed, putting the diode back in circuit% Solder the diode in observingthe banded end as on the board, then solder a $ire ?umper across thediode itsel6%

vii% "nstallsolder optoisolator U3E1$)1#))CN, 34)% #his is located

near the center o6 the PCB% "6 you have bought a socket (?#))Nor?1))21N ) 6or this component, solder it in place instead, then insertI into the socket% 0bserve the proper orientation (notchmatches PCB to$ards the heat sink, or dot6or pin ]9 $hich is the square pad on PCBat the notched end o6 the silk screen)% "6 neither are there, hold the chipso that the $riting is 6acing you and the right $ay around% Pin ]9 is onthe bottom le6t%

viii% Aeave the C12location empty 70 0# ?umper it% #his is locatedabove >Bo$ling> in the copyright notice% #his capacitor may need to beinstalled andor the value increased i6 there are noise problems $ith thetach signal values up to .%9u6 $ill $ork% #he .%..9u6 value is a goodstarting point%

"6 you later 6ind you have an intermittent tach signal on the vehicle, but it doesnt$ork at all speeds or all temperatures in the car, check the all circuitmodi6ications here& all input circuit mods

his in0ut circuit is also used with the modi!ications below i! you want to

trigger o!! the negative side o! the coil, since the 0oints control the negative side

o! the coil>s 0rimary circuit.However, you can only trigger off the coil's

negative terminal if you are !T trying to control ignition timing. o either

C)a or C)b, not both.
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b% :or triggering o66 the coil negati


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a% "nstall and solder D62and D))E1.);B;N, 1; Ohm, brownblac5redY%13 is located near the 7B< side o6 the @9 pad% 144 is beside it, about 9 inch(4mm) above the dash in the copyright notice (the 144 label may be partlyobscured by a via)%

b% "nstall and solder D66, D)3, and D)6E1);B;N ,1); Ohm, brownblac5orangeY% 133 is bet$een I9 and I< near the center o6 the board% 14 is nearA9, above >%in6o> in the copyright notice% 143 is located directly above the dashin the >$$$%mse6i%commse6i (C) ..4> notice%

c% "nstall and solder D6), D6-, and D6;E9.!JB!7, 9.! 0hm, bro$n, blackorangeY% 134 is located beside 19 (the large resistor you spaced o66 the PCB),closer to the heat sink% 13* is located beside 134, above the >..4> te;t in thecopyright notice% 13+ is located very near the center o6 the PCB%

d% "nstall and solder D6:EA;B;N, A; Ohm, yellowvioletorangeY% 13< islocated very near the center o6 the PCB%

e% "nstall and solder D6,, and D)0E1));B;N, 1)); Ohm, brownblac5yellowY% 14. is beside 139> imprinted on the case, depending on $here yougot your components) on each pot should go in the square pad closest to the heatsink% 14 is used to ad?ust the hysteresis, 14* is used to ad?ust the Gerocrossing

point% :or '1 sensor operation, the pot on the transistor base (14*) needs to beturned to Gero volts and the pot on the opamp 6eedback (14) needs to beturned to ma;imiGe resistance (i%e% give 9..! 6eedback resistance)% #his should

be $ith both scre$s turned 6ully counterclock$ise% :or more on ad?usting the'1 pots, see this link%

h% "nstall and solder C31E#((A#2(N, ).1LF, 1)A mar5ingY% #his is located as

the 3th cap in the ro$ o6 >vertical> capacitors above >Bo$ling> in the copyrightnotice%

i% "nstall and solder C32E#((2)CN or #((A#2$N, ).)1LF, 1)# mar5ingY%#his is belo$ C9, 6urther 6rom the heat sink%

?% "nstall and solder 26E1NA))1'NY% Be sure to match the band on thediode to the band on the silkscreen% #his is located immediately above the>..4> in the copyright notice, beside 14*%

k% "nstall and solder +22and +23EICC#NY% #hese are located beside 73($hich you ?ust installed), closer to the heat sink% #he side o6 J R J $iththe rounded edges (i%e%, the shorter o6 the t$o 6lat sides) is re6erred to as therounded side, and it goes a$ay 6rom the CPI 6or both J and J% "6 youimagined the side that had rounded corners $as completely round, then it $ouldmatch the PCB silkscreen% Be '81@ care6ul $hen soldering these, the pinspacing is very tight% "t is a good idea to clean your solder tip be6ore attemptingthis% "6 you do accidentally bridge the leads $ith solder, you can use a piece o6solder $ick ($hich is a 6ine braided copper ribbon) and a hot soldering iron toremove the e;cess solder% ote= i $ou got $our &it rom a distributor* be sureto ollo" an$ instruction the$ ha


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4% Select the tach input circuit $ith ?umpers&

9or the VD sensor= Kumper VD'to

%AC?S>>C%on thebottom side o6 the PCB(near the 7Bto VD(U%(0r VD(U%'Vi6 you$ant the '1 input to beinverted) on the bottomside o6 the PCB, near thecenter%

(D(7o0#install

both setso6

?umpers,chose one

set or theotherD)

9or the ?all sensor* o#tical

sensor* coil negatiMP234.5P> marking $hen the sensor is installed% #he leads are bent to$ard the

PCB, and soldered on the topside% #he notch on the lead indicates pin ]9 thiscorresponds to the square pad on the PCB%


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#he M5P sensor is held to the PCB $ith t$o nylon scre$s do not tighten the M5Psensor too tight, this $ill distort the case and introduce an o66set in the readings by6le;ing the load cell inside the device% 5nd, yes, solder the leads on the top side o6 thePCB% @ou $ill have to devise a scheme to run a tube 6rom the barbed M5P 6itting toyour intake mani6old%

43% "nstall and solder D6and D:E2.A(;IB;N, %3-!, redyello$$hitebro$nbro$n)% #hese are the temperature sensor >bias> resistors% #hey install above the >R> in

the copyright notice%

"6 you $ant to use other sensors, you can either&

change the trans6er6unction 6iles in the MegaSquirt *+C-.+ processor byusing 8asy#hermto change MegaSquirts code to match your temperaturesensors), or $ith MegaSquirt"" you recalibrate the sensor table in Mega#uneunder #oolsCalibrate #hermistor #ables%%%,

(D s$itch these bias resistors, $hich may be easier in some cases%

ormally, you should use 8asy#herm ($ith MS"), its generally more accurate, as thecurve is based on three points, rather than the one point o6 a resistor s$ap%

Sensor Makes1esistor(ohms)

5C7elco/M

7ae$oo, Buick, Cadillac, Chevrolet, 0ldsmobile, Pontiac,/MC

2.6,7

:ord :ord, Aincoln, Mercury 2:7

Bosch andippon 7enso

5cura, 5udi, BMW, onda, "n6initi,Kaguar, !ia, Ae;us, MaGda, Mitsubishi,

issan, SuGuki, #oyota, 'olks$agen, 'olvo (-*up)2.27

Mopar Chrysler, 7odge, Plymouth ,.317

5lso, it is important to note that cross branding and cross licensing a66ect the sensortype% :or e;ample, the Mercury 'illager is actually a issan Juest% #he :ord Probe is

actually a MaGda% #he Chevy Sprint $as actually a SuGuki S$i6t% #here are many othere;amples% When in doubt, measure the resistance%

#o avoid changing the tables in the MegaSquirt code $ith 8asy#herm, the bias resistorsat 13 and 1< should have a value equal to that o6 the thermistor sensor you $ill beusing $hen it is at ;1L:ahrenheit, 2:Celsius% o$ever, the pre6erred method is to use8asy#herm $henever possible%

44% #ime 6or a little testing% "nstall the processor, hook up the stimulator, hook up the7B- to the board and PC, 6ire up Mega#une, and bring up the >1ealtime 7isplay>$indo$% @ou should be able to see responses $hen you move the knobs on the

stimulator%
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:irst, look at the 1PM it should change $hen you move the 1PM pots on thestimulator%Note that i! you have installed the "9 in0ut circuit Eum0ers in ste0 GC2, the

stim is not currently designed to 0ut out the sort o! signal ?'3 the "9 circuit e40ects.

&owever, by adEusting the 0ots at 9C2 and 9C$, you might be able to get a useable

signal into Mega-uirt. he 9ll 5now that the r0m in0ut

circuit is !unctioning at it should.

5ll sensors should react to the corresponding pots on the stimulator% Be6ore doinganything else, go to #oolsCalibrate 5:1 table and select your sensor% #hen $hen the0 pot is moved, the 0 voltage moves irrespective o6 the other settings% 0n the otherhand, the 8/0 correction bar (or equivalent gauge on the tuning screen) W"AA 0#move a$ay 6rom 9..F unless you have the 8/0 correction parameters set properly andMegaSquirt senses the proper inputs to activate 8/0 correction% ote that i6 you havenot connected a #PS to your MegaSquirt, (testing in car, 6or e;ample) the #PS value$ill slo$ly creep up to a ma;imum value, and 0 correction $ill be disabled% @oushould check that Mega#une reads appro;imately the correct barometric pressure $henno vacuum is applied% Belo$ is a chart o6 the normal barometric pressures 6or variouselevations above sea level% MegaSquirt should generally be $ithin 3 or 4 kPa o6 the

values belo$ at your elevation%

Barometric Pressure vs% 8levation

>le


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*... 9+.. +9%

"6 your M5P sensor reads lo$ and doesnt respond to vacuum or pressure, it is likely inback$ards% 'eri6y that it is in correctly% "6 it isnt, unsolder it, turn it around, and solderit back in% @ou $ill have to bend the pins the other $ay be care6ul not to break them%@ou probably havent damaged any components by installing the M5P sensor

back$ards%"6 you dont pass the above tests, recheck all o6 the assembly steps in this section,

veri6ying the correct components are installed $ith the correct orientation% "6 everythingappears 6ine, check the troubleshooting tipsat the end o6 this assembly manual% @ou no$ have all o6 the inputs $ired up% e;t $e are going to hook up the outputs andmachine the case panels% Inhook the stimulator and 7B- cable 6rom the board, andremove the processor again%

0utput Section Construction R #esting

4*% "nstall and solder D16and D1:E1);B;N, 9.! 0hm, bro$nblackorange)%#hese are located near the center o6 the PCB, in the column o6 components roughlyaligned $ith J- on the heat sink%

4


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"6 you use any other transistor other than P57*LC#7 or L#234.7 6romthe MegaSquirt7igi!ey parts ordering page, you MIS# check the pin orientation, asthe order can be di66erent 6or apparently identical partsD

:or PWM "dle 'alve Isers 0nly

ote i6 you are using a PWM idle valve (:ord or Bosch $ire valve see this link6or more in6ormation), these valves can not be operated $ith a relay% 5s a result, theyneed a higher capacity transistor installed%

70 0# install J3 6or use $ith PWM idle valves it cannot handle the currentdirectly 6or PWM idle valves% (>On/O!!> ty0e idle valves used with a relay are !inewith the de!ault 7A.)

"nstead, 6or a PWM idle valve, use a #"P9.999 transistor (such as 7igi!ey3-


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GM HEI

GM DIS

Ford EDIS

Ford TFI

Bosch 0 227 100 124

MSD 6A

Direct Coil Control

he !ollowing instructions are !or M only. ! you are 0lanning to use Mn, 0leasesee theMn site!or instructions on how to wire the high current circuit.

"6 you are not using the 'KB%high current driver circuit, but $ant to use the

MegaSquirt"" output to control an ignition module (< or + pin 8" 6ore;ample), ?umper @S10to 'Kto bring the signal out on 7B< pin ]*% @ou donot need a pull up, the processor port has one enabled already (at 4 'olts)% Skipahead to step ]**%

"6 you $ish to install the high current ignition dri

bet$een the component and the heat sink%

d% "nstall the appropriate ?umpers&

:or MS"", install ?umpers& 'KB%'(near the heat sink side o6 the 7B< on the

bottom o6 the board) to @S10(under the 3.pin CPIsocket on the bottom o6 the PCB)

'KB%(U%to 'K near the eat sink end o6 the 7B

Assembling the PCB v3

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Transcript of Assembling the PCB v3