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Old 04-10-2010, 22:46   #1
technozen
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Pektron SCU/BCU

Recently I have had some time to "play" with the Pektron SCU as fitted to the facelift models.



It suffers from problems that can be categorised roughly as follows..

Water ingress (25, ZR and Streetwise only).

Water enters where the wiring loom passes through the bulkhead, it trickles along the loom straight into the SCU. If the SCU had not been mounted with the connectors facing upwards you would simply have ended up with a damp patch on the footwell carpet!

Corrosion will be visible on the pins of the SCU connector. The first item to fail in the SCU when water enters is the radio receiver circuit board. It is mounted at right angles to the main board
and water will rest on it, symptoms include low fob operating range or no fob operation whatsoever.

If caught early the water ingress can simply be dried out and the SCU re-fitted.

If the SCU is damaged beyond repair then it is possible to copy the data from it and program this information into a new or used SCU, this process creates an identical clone of the original
unit and retains all features along with the original fobs.

With a bit of dexterity the SCU can be rotated so that the connectors face downwards and I would suggest that all owners of a ZR, 25 or Streetwise do this.

Fob and immobiliser faults....

A peculiarity of the SCU is that it will not allow diagnostics to communicate with it while it is in the armed state, therefore new fobs cannot be coded if it is armed and you have lost the originals or they don't work. I would assume that this was "designed" as a security feature, it's a pity that the dealer T4 diagnostics were not provided with a method of dealing with armed SCU's.

The MG-R solution when faced with this was to fit a new SCU and code new fobs, rather expensive.

Using a specialist diagnostic tool it is possible to program new fob to an existing SCU that is armed.


A design problem means that fobs that were programmed and working can become corrupted, this was a known problem when MG-Rover existed. The corruption is caused when the fobs are on the same keyring as those from the following manufacturers;

Any BMW vehicle.

BMW Mini.

Rover 75/MG ZT (Immobiliser is a BMW based system).

These vehicles use a transponder based system to communicate with their fobs, the transmissions corrupt the
Pektron fobs rendering them useless.
DO NOT keep MG-Rover Pektron fobs on the same keyring with any of the above.

In these instances the only solution is to program new fob(s).



Please take note of the following!

If buying replacement fobs please be aware that they MUST be supplied with a barcode label, the data on this label is required for programming.

Used or secondhand fobs that do not have this data are USELESS and cannot be programmed to the SCU, even if they are supplied with barcode information they still maybe unusable, see below.


When programmed the barcode data identifies the fob to the SCU, it also contains information regarding the rolling code that will be exchanged. As the fob buttons are pressed the code rolls forward but in a pseudo-random sequence that the SCU can follow. There is a "window" within which the barcode will still allow the fob to be programmed even after the fob has been used and the code has rolled forward. However if the fob has been in use for several years the code will have rolled forward so far that the barcode will no longer represent the valid starting point, it will program fine but not operate.

The fob data contained in the SCU memory changes as the code rolls forward, if this data is extracted and used to program fobs they will work fine as it represents the current "window" for
that fob.



Memory Loss...

I have seen quite a few units which have suffered loss or corruption of the configuration data stored in the SCU memory, depending on the severity of the problem you will be faced with one or more of the following problems;

Fobs are transmitting but they do not operate the central locking and/or immobiliser.

The engine starts and only runs for a few seconds.

None of the SCU based circuits operate correctly, for instance the drivers window operates in reverse etc.

Usually these problems arise after one of the following has happened...

The battery has gone flat.

The car was jump-started.

The SCU was disconnected/re-connected while the battery was still connected to the vehicle.

Solutions..

If the fob data is corrupt in the SCU memory there is usually no option other than to code new fobs, unless you are lucky enough to have a memory dump taken before the SCU became corrupt.

The engine running for a few seconds is a definite sign that the immobiliser code shared between the SCU and engine ECU is no longer correct. The two units must be security matched again to rectify this problem.

Inoperative options or circuits controlled by the SCU can be re-enabled if it is a software fault. In severe cases I rebuild the file using a known good base file and then add fob codes, immobiliser code and VIN details.


Circuit failures 1....

Circuits that cannot be switched off ie. horn or foglamps will not switch off, is caused by an electronic fault that keeps the relevant relay switched on constantly.

Circuit failures 2....
Horn doesn't operate.
Drivers window only travels in one direction or doesn't operate at all.
Rear foglamps do not operate.
Central locking only locks or unlocks... or does neither.
Intermittent wiper function does not operate.
Doors are deadlocked (superlocked).
Windscreen washers do not operate.

The last category is usually the fault of the Pektron branded relays, of which there are five.

The OEM (Original Equipment Manufacturer) relays fail because there coil winding goes open circuit which means that the relay will no longer operate when power is applied. I have dismantled many relays and
each time I have found that the very fine wire in the coil winding has fractured, closer inspection shows that it has corroded.

The wire used seems to be of poor quality with inconsistent enamel insulation coating, where the enamel is missing the wire corrodes.

Some OEM batches are worse than others, with various production weeks in 2004 being extremely prone to failure. I have seen replacement SCU's that were manufactured in 2008 and 2010 which still exhibit
relay failure so the problem still exists!

These relays are unusual by the fact that each single unit contains two separate relays. In instances where one physical relay controls two circuits, ie. one side controls the horn and the other the rear fog lights,
it is common where the horn side fails but the other side continues to work.




This picture shows the SCU circuit board and each relay has it's function shown...



10/2011: I now have stock of the exact replacement and much better quality relay, the Fujitsu relay that I previously
had stock of is no longer manufactured.



SCU Removal.

On all vehicles the SCU module was relocated or secured to withstand the Thatcham "5 minute" attack criteria, however it is relatively easy to access on some vehicle but a complete pain
on others.

The biggest challenge is when the SCU has to be removed from a 25 or ZR that has aircon fitted.

The SCU is fitted on the bulkhead behind the aircon evaporator housing. This is accessed by removing the glovebox,
the evaporator housing is towards the right with a metal retaining strap either side. The housing cannot be fully removed
as the evaporator contained within is connected by pipework to the AC system in the engine bay.

The original removal instructions were based on the fact that the early SCU bracket had a "hook" at its top which simply hung on a stud welded to the bulkhead.
All that was needed was for the lower housing nut to be removed, the housing pulled away from the bulkhead and the SCU lifted off the stud.

All change! The bracket was obviously modified at some point but the removal procedure was never updated.

The new design has a hole for the fixing rather than the previous hook and the bracket is now retained on the stud with a plastic cap. The aircon evaporator and housing has to be removed to allow access and SCU removal, this requires the system to be de-gassed and the pipework disconnected.

Here is the new bracket design...



Some people have managed to loosen the various clips and brackets securing the pipework in the engine bay, this allows more movement of the evaporator housing and slightly better
access to the SCU.

If the car does not have aircon fitted then it is easier to remove the plastic evaporator housing completely.

The procedure is as follows;

Remove the glovebox, two 8mm bolts secure the hinges to the metal framework.

Remove the metal strengthening strap that runs horizontally, one bolt either side.

The evaporator housing is to the right hand side.

Remove the two vertical metal straps. One bolt at the top of each strap and it is hooked in place at the bottom.

The housing is held in place with two 11mm nuts, one at the top and one at the bottom.

With these removed the housing can be pulled forward and removed.


Here is the SCU with the later type bracket in its position on the bulkhead, the hole on the left is where the aircon pipes enter.




On the 45/ZS the SCU is fitted behind the centre console, none of the above troubles here but there is a lot of dismantling required.

When the console has been removed you will need to unscrew the heater control assembly and the lower black plastic assembly from the metal framework, the SCU is located behind these.

The MGTF SCU location is also behind the centre console, roughly in line with the lower row of switches.
Remove the console side panel, drivers or passenger, it doesn't matter which.

The SCU retaining bracket only has to be removed on one side but the screw head is obscured by the bracket which is bent at 90 degrees.

Undo the screw, open the bracket and slide the SCU out.

The screws used are a variation on the TORX design, these are TORX-Plus Security which are a 5 lobe design with the pin in the centre.

The bit required is TORX-Plus 25.

Standard 6 lobe TORX security bits will not fit!

Here's a close-up of the screw head...



The correct bit can be difficult to source, if you cannot find one then get in touch as I have stock of the correct size.

In true MG-Rover style I have found the SCU brackets to be fitted with standard Pozidriv screws, 8mm hex bolts and the Torx-Plus screw!





Relay testing and removal.

Despite being a multilayered circuit board with through plated holes the relays are easily removed with a standard soldering iron and either a de-solder pump or de-solder braid.



The relay coil(s) going open circuit is the usual cause of failure. Each relay coil has two connection pins and a simple test is to measure
the coil resistance with a multimeter, a working relay coil has a reading of approx. 220 ohms.

I have yet to see damage or welding together of the relay contacts, despite their small size they seem to be able to cope with the current, especially the central locking and drivers window relay.

The picture below has the circuit board pads associated with the coil connections indicated with coloured dots, one connection (centre) of each
coil is "commoned" with the other coil.
If you put the black lead on the centre pin and alternately place the other meter lead on the pin to the left and then the right you should get
the 220 ohm reading each time.
If you don't then that side of the relay is faulty.




This particular SCU had no drive to the Drivers Window relay, the following picture identifies some of the drive electronics....






A is the driver transistor for the key fob transponder coil, the device is a T2406.

B is the transistor responsible for controlling the courtesy light, it is a BSP77.

The IC marked C is a TPIC6C595, it controls all of the relays with the exception of the relay handling the fogs and horn.

The IC marked D is also a TPIC6C595, it controls the Fogs and Horn relay.

All of these semiconductor devices are readily available components.




..... more to follow soon.

30/5/2012.

I can now offer full programming and repair services for the Pektron SCU/BCU.

Keyfob programming.

Enabling Central Locking, Electric Windows and Foglights.

EKA Code retrieval.

Extracting Key fob data

Unlocking an armed SCU/BCU.

Creating a "memory dump", basically a backup file of the data stored in the SCU, a must have if
you are faced with a corrupt memory at a later date.

Cloning units (ideal if you have purchased a secondhand unit or just want a second unit as a backup).


Forum supporters receive some of these services for free!


18/1/2014

The self test mode is useful if you are having difficulties entering the EKA code, the drivers door lock switches (sill switches) are also the
cause of some central locking faults.

Taken from the original SCU Technical Training course documentation....

SCU Self-Test Mode

Self Test Mode can be entered manually as follows;

* With the driver's door shut, depress the door sill button.
* Turn the ignition on, off and then back on again.
* Lift the driver's door sill button.

This sequence of events must be completed within approximately 5 seconds. On successful entry the horn will sound briefly as confirmation and the vehicle will become immobilised.
Once the self-test mode has been entered, normal functionality of the SCU is suspended and certain alarm related inputs can be tested. A transition on any of the switch inputs will cause the security LED to flash briefly to acknowledge the input.
The following inputs can be tested by manual operation in this fashion.
* Sill up
* Sill down
* Passenger / Rear doors open
* Drivers door open
* Bonnet open
* Boot open
* Key barrel switches
* Inertia switch
Failure to access the self-test mode indicates a problem with the sill up, sill down or ignition switch inputs.
A spare key will be required to test the key barrel switch inputs, as one will already be required to turn the ignition on.





The information in this thread is given freely by me to help others, however I cannot abide by those who take this information and use it both commercially and claim it as their
own - to this end I have, from the very outset, introduced subtle minor technical inaccuracies. They do not take away from the usefulness of the information given but do show
up the idiots who claim to be but aren't technically knowledgeable to spot them!
If you want to use anything - just ask.
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I offer FREE engine/alarm diagnostics and fob coding (incl. Pektron fobs) to mg-rover.org Supporters - details here.
Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.

Last edited by technozen; 28-10-2014 at 00:34. Reason: UPDATED.
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Old 04-10-2010, 22:50   #2
technozen
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I also found this excellent thread posted by harbottle.

It covers the repair of the SCU fitted to an MG TF115, the central locking relay had failed.

Clicky...
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Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.

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Old 05-10-2010, 09:47   #3
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Great stuff technozen!
I've been waiting for some details/diagrams of this unit for a while.

The drivers window on my ZS doesn't go up (only down), so I got round it by fitting a double pole toggle next to the button, which switches the feed to the motor. I then just use the down flick on the original switch in conjunction with up or down on the toggle.
This way I also get 'one touch up"!

Is the problem just down to a blown relay as in your photo?
If so, I might have a look for a dead unit that I can pillage!

One last point, is it safe to just unplug the bcu to work on? will the central locking/alarm etc still work when plugged back in?

Thanks,
P
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Old 05-10-2010, 10:13   #4
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Excellent stuff...I wondered how long it'd be before someone like yourself 'cracked' these units.

I'm not unfamilliar with a soldering iron (with a clutch of electronics qualifications, incl. degree level), but not with the soldering of surface-mount components (it was all the discrete stuff in my day!), so I'm in a good position to attempt repairs to these units.
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Old 05-10-2010, 18:38   #5
technozen
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Quote:
Originally Posted by pablo892 View Post
Is the problem just down to a blown relay as in your photo?

One last point, is it safe to just unplug the bcu to work on? will the central locking/alarm etc still work when plugged back in?

Thanks,
P

Your fault will be caused by the failure of one of the individual relays within the C/L relay on the far right in my photo.

Disconnecting the SCU should not cause any faults or problems, all of the settings are stored in non-volatile memory.

If you need a replacement relay the 5 Pektron relays fitted to this SCU are available.
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Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.
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Old 05-10-2010, 22:21   #6
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Quote:
Originally Posted by technozen View Post
If you need a replacement relay the 5 Pektron relays fitted to this SCU are available.
Technozen, can you supply these or can you advise where I can obtain the Pektron versions?
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Old 09-10-2010, 21:54   #7
technozen
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Did a little bit more work...




The TPIC6A595 (larger IC below the one marked "D" in the above photo)
controls some external relays, the two indicator relays and the wiper relays.




.
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I offer FREE engine/alarm diagnostics and fob coding (incl. Pektron fobs) to mg-rover.org Supporters - details here.
Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.

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Old 16-10-2010, 18:47   #8
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Unlike the earlier 5AS alarm ECU, the SCU will not allow new fobs to be coded if it is armed.

So if you have lost fobs or they suddenly stop working and the car is locked the only option would be to replace the SCU and add new fobs.

Avon Diagnostics developed a tool which reads the SCU memory, mimics a fob and disarms the SCU, this then allows standard diagnostic equipment to code new fobs.
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I offer FREE engine/alarm diagnostics and fob coding (incl. Pektron fobs) to mg-rover.org Supporters - details here.
Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.

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Old 23-10-2010, 16:48   #9
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i believe the info for the fob codes etc are stored in the microwire 93CL66A 4k eeprom just above the microcontroller. this is used in the automotive industry as the transponder chip and can be found in the SRS, ecu and abs units. I have an old scu and are thing of using a on board ic clip and reading the stored data through a MANDATA flasher. By using a default file from a new scu, a old scu can be regenerated by clearing and down loading default file.

The repair is quite simple if hex code is known

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Old 23-10-2010, 16:59   #10
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Unfortunately it isn't that simple. Replacing or wiping the eeprom does not result in an unlocked SCU, the microprocessor remains in the armed state.

Having watched the demo video for the Avon Unlock rig it would seem that the SCU is put in a learn or test mode, an inbuilt "fob" learns one of the vaild codes and this can then be used to disarm the SCU.

New fobs are then programmed in the normal way.
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Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
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Old 23-10-2010, 17:06   #11
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Quote:
Originally Posted by technozen View Post
Unfortunately it isn't that simple. Replacing or wiping the eeprom does not result in an unlocked SCU, the microprocessor remains in the armed state.

Having watched the demo video for the Avon Unlock rig it would seem that the SCU is put in a learn or test mode, an inbuilt "fob" learns one of the vaild codes and this can then be used to disarm the SCU.

New fobs are then programmed in the normal way.
Okay so the eeprom contains the key barcode information, EKA or ecu activation code? There is likely to be a backdoor overiding password which will gives full user access to the microcontroller for the software programmers(as you say inbuilt learn mode for a ghost fob). The microcontroller will have its own eeprom which stores the run programme so when power is applied the microcontroller will run using RAM. Can this particular microcontoller be reprogrammed or would this have to be replaced with a blank?

Usually controllers can be reprogrammed to a fix amount ie 64K times.

What video? or is this top secret only for the eyes in the trade. ( james bond)

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Old 23-10-2010, 17:57   #12
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Quote:
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I have made a few enquiries regarding replacement relays.

Pektron don't really want to know...

Hello Paul
Unfortunately are not able to sell just relays but as this is a spares
product you can still purchase the SCU from Caterpillar Xpart who deals
with Rover spares.

Hope this helps.

Kind Regards

Carole Davies

Customer Service Co-ordinator


Strange that they point me towards XPart when their own spares section lists the SCU as a complete item available for 125.


Willow Electronics have not replied... so annoying.

An American component supplier have been extremely helpful, hopefully it will bear fruit.
Willow electrons ignore emails even with a company name. Its seems that that they will only deal with known customers. Any other zed had succsses?

Last edited by starlight14; 23-10-2010 at 18:23.
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Old 23-10-2010, 19:27   #13
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The microprocessor is an NEC uPD78F0138 with 64K flash ROM and 2048 bytes of RAM.


Avon have a website for existing customers as they are now "trade only".
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Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
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Old 23-10-2010, 19:46   #14
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Quote:
Originally Posted by technozen View Post
the microprocessor is an nec upd78f0138 with 64k flash rom and 2048 bytes of ram.


Avon have a website for existing customers as they are now "trade only".
top secret, trade only!

Most micro controllers are accessable using PC tools and by increasing the supply volts from 2.5v to say 5.5v it puts them in down load/up load mode.

The data sheet tells all, http://www.datasheetcatalog.org/data.../4542731_1.pdf

On the scu board there is a feature which will allow direct connection to be made to the microcontroller to allow read, erase and write operations. The programme stored will be in machine code complied from most likely C, but it is difficult to reverse the prossess without the original code. However, I am sure an experinced bit basher would able to disarm and retrieve the the appropriate disarm code. alternatively Iam sure it would be possible to write a default programme or another file from a part working scu

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Old 19-11-2010, 09:56   #15
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Relays

I have had my Rear Fog Light relay fail in my Rover 25 BCU so I'm trying to source a replacement.

I have tried contacting Willow but so far no reply even thought I work for a large multinational electronics company and they are one of our supplier.

I have also found that Fujitsu also do a replacement which is the FBR512 series

This is the datasheet: http://www.fujitsu.com/downloads/MIC...fbr512-522.pdf

The relay looks identical unless anybody can spot the difference.

I now need to see if I can find a supplier.

If any body has a spare Pektron relay I would be very interested.

Andy.

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Old 19-11-2010, 12:21   #16
technozen
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I have a few original relays, PM me if you need one.
__________________
I offer FREE engine/alarm diagnostics and fob coding (incl. Pektron fobs) to mg-rover.org Supporters - details here.
Fob not working? Common faults and fixes here.
Pektron BCU/SCU Faulty? This may be of some help. Full SCU programming and repair services available.
Discounted SCU/BCU Full Relay Replacement Service - only for Supporters - details here
Replacement relays for the Pektron SCU available - .org Supporters buy 4, 5th is free - PM for details.
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Old 19-11-2010, 13:53   #17
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Fujitsu Relay

Following on from my last post, I have had an email from Fujitsu to say the FBR510 / FBR520 series of relays is been discontinued with a last time buy up March 2011.

The two UK distributors are:
Inelco Hunter, Limited - http://www.inelcohunter.co.uk

Young Electronics Group - http://www.youngelectronics.com

The part number are FBR512ND12-W1 or FBR522ND12-W1 which will both do the same job.

I have also had Willow Technolgies contact me and the HG4508 relay is branded for Pektron only and they cannot supply any, also they are out of stock. So the best option is the Fujitsu relay in the short term.

Andy.

Last edited by andy_thomas; 19-11-2010 at 14:10.
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Old 19-11-2010, 21:15   #18
andy_thomas
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technozen - I have sent you a PM.

Andy.
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Old 08-12-2010, 14:31   #19
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technozen i have send you a message too. I need two of these relays!!! ;-)
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Old 14-02-2011, 19:24   #20
Peapilotreturns
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Thanks for the info. I need 3 of these relays, as my washer jets are playing up too. Do you have any?
Also, if I brought a new SCU, would I have to have new fobs for it too & have them progremmed too?
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