[darreng]

PSIG, thank for replying.

Tune file not available, I have made so many adjustments just to try and 1) get it running and 2) keep it running.
The engine was bed-in on the kart under load using the brake, I have been building engines for around 40years. I currently have a Ferrari f430 replica with an Audi v8 controlled by a vems ECU, wired and programmed myself, final finshing touches on ecu with the help of Gunni (Vems enthusiast and programmer for Aston Martin), I'm leaning on that project to help me understand this one.
I ran the kart engine up to 9500rpm, the clutch spider cracked, I thought that was the problem, but it seems I was to look elsewhere, hence the C2C.

I was led to the coils because I was trying to set the timing, I thought my timing light was faulty until I checked the spark, I then changed the coil, I then changed the coil again. I then moved onto the Hall sensor, I changed that. I checked both with a multimeter.
I have no trigger recognition from the C2C, Channel 1 is faulty, Channel 2 is perfect. Tunerstudio is configured for No2C single cylinder.
I'm going to go through some stuff with the oscilloscope over the weekend, I want to see if there's any interference on the 5&12v line while the coil is running, I can get it to last longer when the C2C is cold.
I will load up a video over the weekend, this will help explain and show issues I have. I'm also going to try running off a 12v lead acid battery instead of a dewalt 12v powerpack.
I want to get back to a healthy setup so I can start having fun with the tune, let's see what I find over the weekend.
Cheers

[PSIG]

Then I will regard these as background status reports until then, yes? BTW, do not take my posts personally, as I respond to everyone that may read this (or any posts) looking for information or answers, and we cannot know their knowledge or skill levels. My responses are directed to you, but written for them, often with more context or background to 'fill-in the blanks'. If you are already ahead of the game, that's great, and ignore any additional info added for informing those future readers.

[darreng]

No offense taken, I have seen that you've posted for years on this forum, only happy to have you chip in with some helpful info. It's how we all learn.
I'm an automation engineer, but every day I'm surprised by manufacturers claims. We test the control boards out in the real world only to have the same component fail time and time again. We've found that they are sourcing inferior parts for their circuit boards.
Cheers
Darren

[darreng]

Traced trigger pulse back to ATmega2560 chip.
I have a schematic of a speeduino, the 1kohm pullup resistor has failed to 600ohms, just need to check it's not the ATmega 2560 that shorted to ground, I'll check it and reference against channel 2.
I have a couple of the 2560 chips laying around, there's an electronics engineer local to me that repairs games consoles, I'll drop the board off to him later this week. It will either just have the 01B resistor or a new ATmega chip.

The C2C is a small intricate board, the problem is it's size. I don't have a hot air work station, so I can't replace any components. If this board fails again I'm going to move to a No2C through board, I can replace damaged components, if the mega fails, it's just a matter of plugging in a new one.
I'll report back when the board is repaired.
D

[darreng]

The 1k pullup resistor was pulled from the board and was okay. Installed a new mega2560 chip. Bootloaded new chip using another arduino mega as an ISP.
Loaded up speedyloader, now back to where I started. RPM1 led half light.
I've purchased an electric microscope and re-workstation. Traced actual fault to the 0402 0.01uf capacitor shorting to ground at around 6kohms, should be in the milli ohms range. I've purchased a strip of 0402 and 0603 caps, the pad can hold a 0402 or 0603. I can now repair the board at my leisure, aswell as lift components for further testing. The low pass filter set up can deal with just over 15khz, I hope the slight larger cap is fast enough to dissipate the charge.
I guess it's just a learning experience at the moment

[PSIG]

[darreng]

Set about tracing the 2.1v bleed on the rpm1 circuit, found it on the 7002 mosfet led controller. Changed for new mosfet, initial testing is good, half light has gone and I now have a ON-OFF trigger input to the 2560 chip, I've carried out preliminary coil output tests and again no problems observed. The board had been on for around half an hour I felt the voltage regulator a few times, happily it was just warm, beforehand it was quite a bit warmer.
Testing will continue next week, I'm away for a few days.