My16M MkIII ECU ASSEMBLY

Assembly

1. Make sure the PCB will fit in the case. Some trimming of the edges may be required. The edge nearest the ECU connector may need trimming to allow the connector to seat properly.
2. Check all the PCB holes are clear. A soldering iron should quickly clear any solder.
3. Check all the PCB tracks for shorts.

Click on the pictures to see larger versions.

The installation of the 10K resistors	The installation of the 47K resistors I've missed R22 and R23 in the photo, do them as well
Now add the 40 pin socket. The notch is at the left. Add the 16 small signal diodes (1N914). Polarity is important. Note D17 is the IN5819, not as pictured. Add the 10uH inductor. It's the green "resistor" Add the single 103 capacitor	Add all the 104 capacitors Add the 4 general purpose diodes(IN4003). Polarity is important.
Add R34 and R35 and the 5 pin header. Add crystal and 2 27pF capacitors. Add the 4 way switch. Set to On,off, on , off. Add the RJ45 connector and 3 way header. Add the 5 BC547 transistors. Note orientation. Add the 2N7000 transistor. Note orientation.
Add the 2 BD139 transistors.They are facing the camera in 2nd pic. Add the BD140.It has back to camera Add the 4 FETs.The centre 2 have heatsinsk. Bolt them in before soldering. Add voltage regulator and the 2 large capacitors. Note orientation.	Add R10 and the 2 inductors for L2. Slight board change - the 2 inductors now each mount to PCB, one where R10 is shown. R10 is now moved up and left and rotated. Add anything else left over. Errata: Some modifications are required. These should be emailed to you when you receive the kit along with the ECU Controller and initial map.

Testing

1. Make sure the microprocessor is not in its socket for these initial tests.
2. Apply the negative of a 12V voltage source to the edge of the board ( the PCB track going around the board is 0 volt ).
3. Apply the positive of the 12V to the left leg of R10 ( the leg that goes to connector 1 ) and check that nothing is getting warm. The voltage drop across R10 should be less than 1 volt.
4. There should be 5V on pins 10,30,32 of the 40pin socket
5. Pin 33 and pin 4 should be 2.5V and pin 3 should be 2.7V.
6. Disconnect the power and connect the RS232 adapter to My16M using the network cable and connect to the PC's COM1 port ( if you need COM2 or other, the ECUController has a configuration dialog that can be used to select the required port). Insert the CPU with pin 1 to the left
7. Start ECUController and apply power to My16M. You should now see ECUController updating.The temperature analogs should be at full scale, the voltage should display correctly. They others will float around 1/2 scale.
8. You should see a 10V square wave on the collector of T5 ( the tacho signal )
9. Check the voltage at the lower leg of R28 (near T7). You should see it go to 5V for 2seconds after connecting power. Check that the gates of the 4 FETs(leftmost pin) are all at 0V
10. Now double check your handywork and fit the PCB into the case and connect the ECU to the bike.Set all switches off except SW1. It would be best to have the ECUController or Optimiser connected.We ARE NOT going to try to start the bike yet. Being careful to monitor for smoke or heat, turn on the ignition. You should hear the fuel pump turn for 2 seconds.The tacho my vibrate a little.Check the analogs with the ECUController or Optimiser. They should all be correct and the throttle should be tracked.
11. Well done, at this stage construction is complete. Proceed to the "First steps" page

RS232 Adapter board

C1 - 10uF or better C2-5 - 1uF U1 - MAX232 The tantalum capacitor is polarized and must be inserted the correct way.