One user back at the end of page 1 of this thread, warns that perhaps Damien's design as-is will blow up the inverter in some cases. Not immediately (as can be shown by Damien using it) but eventually under load. He links a webpage of someone who also figured this out: https://nicjam.es/projects/de...

ahhh yes it has been a while.... I put this project on hold for a while, but I think I'm ready to either finish it or get rid of it lol. I had a cell go bad in my pack due to neglect so I had to pull one of my modules, which is 10s.... So now im only running a 30s pack so hopefully that will help me...

So I’ve been driving the dc gen2 for the last couple of weeks at a much more ear friendly 6khz with no ill effects Just about to clock over 300 miles on the Prius inverter DC controller, I am happy to call it a success, as soon as I get time to finish a schematic on my board I will share it You did...

CapCarCap wrote: ↑Sun Apr 24, 2022 3:09 am I was looking at the files on Github vs the picture of the board Damien had made from JLCPCB and I noticed the board on Github says V1 but the ones he ordered and sold say V3. Has anyone actually gotten the V1 board from Github to work?

I built a few and they do work.

Alright..... I think I'm ready to finish this project...... GE11 did you get your hardware setup and spinning a motor? I've got my truck moving on a simple arduino right now.... so no current limiting or fancy feedback loop control. I need to do some more testing to be sure im not going to blow up a...

Awesome! lets see some pics of the inverter configuration! I think taking out the boost block and inductor is required for this to work as i popped a leg of mg1 trying to spin the motor at 4.4 khz.... I still have one more 100% intact inverter....

first one popped when revving the motor in my garage second one blew about 5 blocks down the road.... Yep, scoped the Damien card and its putting out 8.9khz.... hmmmmmm.....

Yes I did have it running through the boost converter as I had mg1 setup to charge at one point.... I'm running half your voltage at 40s and I've cooked 2 mg2 stages already with them wired up like yours, sounds like the key was dropping the pwm speed? let me grab my scope and see what the Damien ca...

AHA! sounds like you might have found the right setup! How did you set it up exactly so I can do some additional testing? are you running it in a half bridge? which switches are paralleled? how many volts is your pack? and looks like no boost inductor?

Thanks, can wait to get this working!

Ahhhhhh that makes sense, wish i would have known that when i blew MG2 and had to push my truck 5 blocks home..... :lol: I wired up the motor to mg1 in an h bridge with my arduino board and I've got the motor spinning again.... I need to get AAA before I take it out for any testing again. Stay tuned...

Oh and with that scope, connect the red clip to 12v+ and the black clip to one of the outputs of the Damien card.

I've got the same scope, quite a value for the price!
You are almost there!

Well, I had to put this project on hold for a minute as I got tied up with some other new hobbies.... anyway it looks like I'm going to have to sacrifice a few more inverters so we can figure this out...... cooked 2 of the trying the conventional 3 phases bridged to motor positive and negative to in...

Also I dissected my first inverter and there is major damage..... Blew all 6 low side flyback diodes, which resulted in a shoot through condition and exploded 2 of the high side switches..... Looks like the diodes in the gen 2 are not suited for running dc motor?? I wonder if putting external flybac...

Sorry I think I had that backwards, inverter fail pin should be around 6.5v when all is well and it drops low when the inverter is in fault.

Well, lets take the controller out of the picture and test just the inverter. Unhook the motor and all the HV battery lines from the inverter and hook up a 12v power source to the inverter rails, with 12v to pin 25 (MG2 shutdown), ground one of the pwm signal lines and then you should have positive ...

I did start disassembly on my first inverter and I can see some destruction and charred components underneath the main IPM board, I need to snip all the IGBT leads from the board so I can remove it and get a clear look at what's going on in there.

Hey Eric, sounds like you have everything wired up right, is your inverter casing grounded to chassis? you could check the voltage on pin 27 and 22 (MG2 Inverter Fail & MG1 Inverter Fail) IIRC they are around 2.5v when all is well and jump up closer to 12v when the inverter is in fault. Not sure...

I dont know, I was running all three low side/ flybacks when I fried two of my inverters..... I wonder if setting the inverter up as a low side switch would work better?? I wonder if its the switch or the diode that I cooked??

WAIT! I too build one of Damiens DC control boards and I've cooked 2 inverters already.... the first time I thought maybe it was something I did so I put another inverter in and took it around the block, lasted about 1/2 mile before the inverter shutdown and would not restart. After getting it home ...