Once I made these changes, I was able to get the output duty cycle to go from 20% to 96.7% as pot on LS122 now changed size of pulse which lets me increase duty cycle.

I collected data in two formats.

First format shows the Pin 4 LS122 clock reference to both Pin 5 Input and M/M1 board output

In the picture the probe on the left straight pin is LS122 pin CH1 Yellow in screen shots.  In this picture CH2 Blue vertical probe is on the M/M1 board output.  Not show in have the CH2 probe on pin 5

Second format shows the Pin 5 LS122 Input and M/M1 board output so you can see output change with input

In the picture the probe on the right straight pin is LS122 pin 5 CH1 Yellow in screen shots.  In this picture CH2 Blue vertical probe is on the M/M1 board output.

Couple of Notes:
TPS on picture name shows input voltage level from pot simulating TPS.
Above 2.99 volts Pin 5 pulse disappears.  Flat line 5V
At higher duty cycles output of board appears to be more stable
If frequency is changed LS122 pot may need to be changed as pulse width is tied to frequency.   Data above was all collected using a LS122 clock cycle of 41.67hz.

I have not yet tied K11 output to see effect on rest of system but K11 and LED-TPS board appears to be working correctly with changes I made.  The cables pin out I am using is document in my report including these pictures.  Will repost updated document after I correct it to include latest information from my testing.

HI Earl Great  nice pics

I have 2 Question
 What Voltage are you  finally using for tps ?
  What frequency of g are you using ?

I read the comprehensive Notes about these questions in thread
I just want to firm answer so no  error in replication
Dan

TPS and LED-TPS board 5.2V
[G] input floats between 1250 and 1316 (I noticed before it hard to get stable frequency out of 555) but the K11 board output is stable at 41.67hz.  I am using the third switch position on K2 to get this.  Keep in mind that K11 divides the input frequency by 32 and creates a new clock.

I am trying to get get this K11 output hooked to other boards.  I am looking at VIC matrix board as something does seem to be right.  Before hooking it up I see a signal on M of VIC Matrix input not sure where it is coming from.

signal goes into matrix and through the k8 voltage control
 to control up down on scope

Video 1

https://youtu.be/1XC2OBu-k1U

Video 2

https://youtu.be/7hCwakBu8hU

Important one showing old k7 tps k11 and k8 voltage
 yellow

Right side is minimum position or low  pedal pressing position slow
left side  is  high speed pedal position

https://youtu.be/rxAXwFLd6YU

Dan,

Next step is to look at how K3 treats the variable gate input from K11.   I could not get the interface to work correct initially turns out I had the Auto/Manual switch wired incorrectly on K3.  Had switched the auto M input and center output posts on K3 front panel.  Moved inputs on switch to correct location fixed problem.
 
Note:  When doing this I noticed the Auto/Manual labels on this version of boards VIC Matrix and K3 do not match schematic.  They should be B/Manual and M/Auto.  For testing this is not a problem as B and M connections are in correct location just the Auto/Manual information is incorrect.

Tests of K3 output to see what the variable duty cycles does to output.

In two photos below
CH1 Yellow is the K3 output gate [A]
CH2 Blue is the [M] input from K11

As you can see the K3 gate output Yellow duty cycle does not change with the variable duty cycle input [M].
 
I expected this as the K3 board version I have is different than the schematic.  K3 board from you has the chips on it to merge 2 wave trains with different duty cycles.  Result with be a signal [A] with the duty cycle that match the largest of the two inputs.

As you can see from above picture one of the waves will be the one from the schematic part where duty cycles is set by pot on board.   I did to a test using input [M] from K11 to verify that this is true by changing pot K3 from 10% duty cycle to 20% shown in screen shots. (Note: 10% not show in pictures)

I also checked what will happen to K8 as [M] also goes to it.   K8 does not care about duty cycle only frequency as its function is triggered by falling edge.

I believe we can fix [A] output by feeding [M] to other side of K3. I am looking at how to do but wanted to provide an update showing signal is getting to K3 correctly.

Dan,

 Can you post the K3 Gerber File with the 37 pin connector one K3 I have does not show connector information.

 
Hi 

OK We got the tps and k11 replicated working send video soon here
Question did you have minimum gate  of 20%?

Here is Gerber  K3
Attached , if any label change please advise i make change
Dan

It Seams We  Breezed over the K3 Fast as at that time we were focused on Vic
I am reviewing to see if we made the changed to the k3 db 37 version or mistakenly did it too the old version

I attached both here and Notes from that
You main comments were at the time labels and that board worked.


NOTES  ( Previous  / we skimmed over k3)
It looks good couple of label corrections

The 2 Q1 chips are labeled 2N3094 them should be 2N3904.

While correcting those it would be helpful to label GND and Signal on test landing pads (GND is closest to board edge).

The Cell ON/OFF needs to have GND going to switch as closing switch connects the circuit to GND which turns off cell.  I used a simple on/off switch and connect it to the GND lug on the Test Point on the panel.  Then turned switch upside down to match label on front panel with up being on and down off. A cleaner fix would be to do this connection on the landing pad.  See circuit trace below to see what I mean.  Adding this wire is the only change I made to get card to work and I did that while wiring up the front panel.
 
While I am still waiting for a new SH74122N I wanted to test board, so I took the one out my test K3.  I can report that the board works.  I did test all the front panel controls (still need to label and mount the trim pot) but as I mentioned above the only thing, I change was to add the missing connection to GND on the Cell ON/OFF switch which I did on front panel.  NOTE: Input signal is from K2 and K3 is in manual mode for these tests.

I did notice that the [A] signal on the test point was not what I expected.  It was a square wave at 5-volt levels.  It does change as expected with the pot controls.  See picture K3 test point Signal.  I also checked [A] on screw terminal and it is the same signal but at 10-volts, which is the level required by K21.  I actually expected this as VEE pulls it up and powers the LED.  See picture K3 [A] on screw connector.  Note: ( [A] is the basic gate frequency and duty cycle used by the rest of the system.  If it is not at 10-volt level it will not trigger the chip that combines the gate with the high frequency digital signal. If gate is turned off no digital signal will be sent to the cell.)

There are a few other chips on the board that are not in original schematic and they use the [A] signal that goes the test connector.  The [A] signal gets combined with another signal that comes in on one of the board pins.  The additions chips AND the 2 signals and route results back off on another board pin. (This means the combined signal can never be larger that gate pulse, but it can be smaller and is at 5-volt levels).

Having the 5V level signal on the test point is not a problem as what is being checked is gate information mainly frequency and duty cycle.  There just should be a note some where it is not exactly the [A] signal being sent to rest of the system.

K3 Note   I am Reviewing gerber again

so welcome correction and changes to ensure we did not skip it

Dan

Video
 
Here is Us Testing the doc changes 
Got it firing  our minimum is 20% lowest setting
is that your lowest setting also ?
  ( Stan Said voltage should not drop to zero )
 I guess unless gas feed back cuts it of totally
or safety power cuts it

so  makes sense duty would not go to zero

Dan

https://youtu.be/N0BOxA92xA8

Current things
1 Testing K8 and K3 ( status) Into Matrix
2 Testing tps and k11 into k8 and k3  for tps movement up raising or lowering voltage through k8.

Merging & Gerbers
1 Checking status review Gerber K3 for any mistakes we missed or changes.
2 Starting Merge simplification of K11 tps board moving them into 1 hard trace board  and gerber.

all will be checked discussed posted here
Excellent progress documenting the k11 and tps and getting it to function.

DD :)

Yes 20% duty cycle was as low as I could get it to go.

Thanks for the Gerber file with the connector.  Did not have that one had the other one.

Have been looking at K3 Gerber and found couple of things will mark them up and post.

Labels by Connector  should be:  Labels only does not effect function
   B/Manual
   M/Auto
 
Trace going to Pin 3 of DM74LS21N should go to Pin 2 (Pin 3 is unused) I add jumper it to test though it did not change anything.

Now the good new I did get the variable duty cycle to work.  I need to add a missing trace to Pins 4 and 5 of DM74342N from the output feed of the Accel/Man Switch.  Once I did that I was able to change the duty cycle using TPS input.   I will post a picture showing the easiest way to make this fix. Just wanted to let everyone know I got it to work actually minor change to K3.  Note: There is a feed though connect just to the right of these pins that is not hooked to anything.  Connecting it to Pin 1 of MC14001BCP will make the needed connection. 

Added Pictures of board corrections.  Going straight down maybe the best route to make connection to pin 1 will leave that to you.   Also added Label changes for Matrix board to match these changes (do not effect function)

I will also post some screen shots showing it working. 

Earl

Working on the merge gerber K11 /tps shrinking size whilst keeping method

Dan

ok for changes I am editing all and will post here soon

re this one  you mean just expand the description label right to be this
both on same pin

No B and M are both needed and are correct and in the right location but Manual and Auto labels need to be switched.   

Tests of variable output from K11 to check K3 Output

I added a jumper from LS122N pin 1 to DM7432N pins 4 & 5 (trace was missing from this version of board.  The feed to Pin 1 comes from the Auto/Manual data select switch.  With the trace added K3 functions as before in manual mode.  In auto mode K3 output now tracks the variable duty cycle pulse from K11.

Test setup:  Output frequency of K11 has been set to 41.67hz.  I did set the duty cycle of K3 in Manual mode to 36% high as it would go with a 12hz signal. (I would need to adjust the K2 frequency to get it higher and I did not want to do that for this test).

Scope settings
CH1 Yellow is on output of K3
CH2 Blue is on the input [M] to the board
Scope is set to display duty cycle for both channels and frequency is output of K3

Pictures below show 5 different duty cycles low of 20% and high of 96.7%.   K3 duty cycle now tracks K11 exactly.

I did switch to Manual mode to verify I get still get K3 output from K2 and I still can manually set the duty cycle using pot on K3 front panel.

ok looks like  very clean signal now

  i guess see if it raise the voltage in k8?

K11 LED-TPS Test Installed on VIC Matrix

As I have been doing all my testing on the K11 and TPS LED boards using my test bread out board and jumpers I installed K11 on the VIC Matrix to verify that the Matrix and K11 interface work correctly, and they did.  While I was doing the interface check I also capture a couple of screen shots showing the effect of varying duty cycle on the VIC output to the coils.

The first picture shows the board mounted on the VIC Matrix.  I plan on build a mount for the LED TPS board and that will also hold the pot I am using to simulate the TPS. I will also replace the jumpers I am using to power the board and TPS when I do that.

The next three pictures show the output K3 Yellow and the output of the VIC board at the input to the VIC coils. 
CH1 Yellow is on K3 output as I wanted to see duty cycle of gate.
CH2 Blue is on the VIC test point which show input to VIC Coils

The first scope is at 50% duty cycle as that is my standard setup.  I have set the gain and offset to provide a minimum level signal.  Analog frequency is set to 41.67hz. I think the digital frequency was 1Khz

What I found interesting was to watch the analog signal fill in more when I increased duty cycle which you can see in picture with 63.3% duty cycle.
What I did not expect was that the analog signal disappeared when I lowered the duty cycle below 50%.  You can see this in picture with 46.7% duty cycle.  In both cases all I change was duty cycle.  I guess this is because I had set outset and gains level using a 50% duty cycle.

Dan,

I updated the K3 document to include the above test results so it now shows the results from using the [M]/Auto input .  I also added note that the added trace reduces the manual mode front panel adjustment to a max value of 50%.  This is due to the manual mode input to be a 50% square wave.  Front panel can adjust it lower just not higher than 50%.   Original schematic did not have this limitation.   Note:  I did test the manual mode to verify it now works this way.

Still checking the K11 document but planning on including the series of test results in both documents.

The K3 Update is attached.

Earl

Dan,

I went though the K11 LED-TPS document and clean it up to remove incorrect information.  I did leave a few items I tested that were wrong with an explanation of why configuration was wrong.  Update document is attached.

Earl

 Great Stuff great to see Reading doc and working on merged board now will post soon
DD

Dan

Found labeling error on BNC pads on K11 they are backwards should be like picture below.  Silk screen fix as long as you are doing board.

Earl

Dan,

New Problem fix below

I put KSF1 back on the Vic Matrix board and it corrupted the M/M1 gate signal.   I believe the fix is to remove the trace on Vic Matrix board go to KSF1 see picture below.  I believe the M1 label in the Gas Feedback circuit is not the same M1 (gate signal) instead it goes from KSF1 board to one of the gages.  See M1 in top of second picture.

Missed this when I reviewed Gas Feedback circuit.  I can fix my Matrix board by cutting trace.

Another case of Stanley re-using labels.

Earl

Ok I have noted these corrections  and making changes

Dan

Dan

I took time to complete the front panels for the Power card and the KGF1 Gas Feedback card so I could properly mount them on matrix board.  I also mounted the VIC daughter board.  With this change this is the first time I powered everything using Stanley’s Power board.  Currently only using side B but I did check side A to see it was working.  To make It active I will need to add a couple of jumpers we have fixed for future board versions.

First picture show all the cards mounted.  Second is a close up of the scope Yellow trace is the gate output from K3 and Blue trace the input to VIC Coils.

I did notice that with the isolation diodes on the power card the 5V level is around 4.75V.  With the power card you can adjust the 10V level but not the 5V.

At this point all the cards I have built and tested are installed even though I am not using KGF1 at this point.  Wanted to verify KGf1 did not interfere with system operation and after I cut the M/M1 trace on Matrix is does not.  I have already verified when it is in system it will shut cell off with over pressure.

Earl

Great work , Dan
I will post gerbers soon,  is the k11 controlling k8 voltage level up down ok?