'70 MGB Roadster - 2015 Leaf EM57 powered

[jerrykco]

Purchased this 2 years ago with plans to rebuild the engine (burnt valves).
Saw a post about EV conversions and decided to do this instead.
I'm just getting started.

[jerrykco]

Purchased Johannes' v3 Main board and Leaf interface board.
The kit is amazingly simple for us non EE guys to figure out.

Great instructions......

Finished the through hole parts

Close up of Adapter

Close up of Inverter Controller

[jerrykco]

Purchased a complete 24kWh Leaf Battery from Batteryhookup.com in the USA

Disassembled the battery

[jerrykco]

Watched plenty of youtube videos.
Of interest to me:
Shane at Performance EV. (performance-ev.co.uk) He is using Johannes' Inverter controller and using a Leaf motor in a Porsche 911
See
Also watched Johannes Hubner's Series "Lab Update" (16-27)

and EV Fundamentals

Then because I don't have a way to charge the batteries yet and I wanted to know their shape.....

Wolf created a new connector for a Gen1 Leaf Battery pack. He had a Gen 2 connector but not a gen 1.
I sent him my connector and he created the new plug..

He created this

and this

I ordered a fully wired Gen 1 and Gen 2 cable set. (Gen 1 on right with the through the wall BMS connector.

[jerrykco]

I installed Johannes Inverter controller on the Leaf Adapter and put it into the Leaf inverter.
Gave it 12v and miraculously it's working. (Novice speak for "I'm very happy")
First Test

Second Test

And then I connected via WiFi.
All is good so far.

[johu]

This thread is already text book quality, keep going

[MattsAwesomeStuff]

This is some A+ project logging. Fantastic and fantastic example to set for others.

[Bentto]

Awesome project en very well documentated. This really gives a clear insight in all the steps required! Please continue

Btw that is a VERY good buy on that battery pack right? I don't know the going rate for those is in the USA but 24kWh for 1800 USD seems to me like a steal.

[RE3Rotor]

Very nice. I have MGB GT. This one is staying petrol though.

[jerrykco]

I created this Overview from Shane at Performance EV from his notes.

[damian.lo]

Hi,

According to your schematic - I was speaking also with Shane about this - If small DC12V-DC5V is necessary? I have no idea why to use this. Only because I have 5V coil relays at home maybe. For open collector there is not needed to use small 5V input.
Second: throttle input - you wrote 0-5V, but on Johannes wiki is written 0-3,3V - there is also mine question - we shouldn't to go above 3,3V or can be up to 5V?
What I remember in my BMW I can expect signal 0,8-4,2V so because of this I have doubt.

Regards,
Damian.lo

[RetroZero]

Wow, you make it look so easy. Well done on the compilation, it sets the bar really hight for us who post next. Hope it's advancing, and that Leaf battery Pack was definitely a steal. Good stuff!!

[jerrykco]

Here are the PRIUS Throttle Pedal Pictures of my testing.
It is a DENSO 78110-52053 The other two numbers listed on the Pedal 198800-8402 and 07P09D00143
Using 5 volts input the first sensor output closest to the pedal (Bottom three wires p1 +5v P2 GND, p3 output)
1.648v w/ Zero Depression of pedal

4.64v Fully depressed

Top 3 wires p4 +5v p5 GND p6 output
0.820v w/ Zero Depression of pedal

3.832v Fully depressed

Damian.lo......
I am just learning so I can only show you what I have learned so far. (You may want to ask someone more knowledgeable than me.)
Pedals may vary. Measure to know for sure. Adjust Inverter Throttle Control Parameters as appropriate as specified.
See https://openinverter.org/wiki/Parameter ... Parameters

And for all who have complimented me, thank you. Many came before me and have inspired me to be helpful too.
And yes I will keep documenting.

[jerrykco]

There is also more info here on the Prius Throttle Pedal
viewtopic.php?f=2&t=276

[jerrykco]

Made a little more progress today (well 2 steps forward and one step back).
I wired it but got information after I created the harness that I should have made specific twisted pairs and shielded them.
That is going to be the 1 step back.
I decided to try and make the control wire wire harness for the Inverter and resolver.
The motor I got had the connectors but they had chopped the wire harness. The resolver connector was butchered.

Next I needed to examine available documentation Johannus' and some from zippy500 available here viewtopic.php?f=4&t=619

Originally I showed a picture with all the resolver wires twisted as a family.
That is incorrect. I have since used four individually shielded twisted pairs See correction in a later post.

Based on the info and the wire colors of the connectors everything is right except the two Mtemp wires that seem to be reverse labeled in the picture. However I am not too concerned about those. I can always reverse them later. Note: these are the wires I need to (step back) and remake it into a shielded twisted pairs bundle.

Next I wanted to connect up the throttle. But their is this disturbing note in Johannes' connection document for the Leaf that says that the throttle wires ARE NOT IN THE OEM WIRE HARNESS. Not only that there are no pins in the connector either.

So what to do. I drilled two holes (one for each Throttle wire) through the receptacle soldered onto the leaf adapter board. There are no pins to attach to in the plug even though there are pins in the receptacle. Then wired up the Prius Throttle Pedal. I may only use one. in which case I will have an extra hole if I need it.

And here is the temporary connection to the back side of pin 29 on the adapter board.
(i just stuffed the purple wire through so far. (It's a place holder)

Next steps will be to wire up the HV DC, switches, 100 watt resister (for pre-charge) and relays to pre-charge the caps in the inverter before applying full power and watching the motor spin....... (hope is eternal)

[jerrykco]

I am trying to prepare for putting HV DC power to the motor from the Leaf Inverter.
Here is where I m at.
I have created a small switch panel. On it I have a master on then a key w/off/on/momentary start.
Powering it I have a 12 volt DC switching power supply.
I also have a switch that can be off or used to apply 12v to in_forward or in_reverse
It powers up the the inverter controller.

When powered I can connect via WiFi to the Board.
At this point I havent yet connected DC High voltage to the inverter,
What can I do to test any functionality or to see if the inverter is OK?

The big picture:

Can anyone tell me what the connection point is on the leaf adapter board for JP2 Pin 11 on Main Board v3?
Apparently I need to tie it to 12v.

Advice and instructions gladly accepted.

[johu]

no worries about that pin 11, it is already wired to 12V on the adapter board.

The resolver wires should be twisted pairs, not twisted family So twist sin- and sin+, cos- and cos+, exc- and exc+ . Also in the original harness they are shielded pair-wise. You could run into noise issues otherwise.

With FOC software a basic function test is a bit harder, maybe starting manual mode and commanding 0.1A manualid will create a 50/50 dutycycle. Otherwise you'll have to temporarily flash the sine software and follow the kit instructions.
https://github.com/jsphuebner/stm32-sin ... ses/latest

Keep in mind in any case you'll have to command forward or reverse.

[jerrykco]

no worries about that pin 11, it is already wired to 12V on the adapter board.

The resolver wires should be twisted pairs, not twisted family So twist sin- and sin+, cos- and cos+, exc- and exc+ . Also in the original harness they are shielded pair-wise. You could run into noise issues otherwise.

With FOC software a basic function test is a bit harder, maybe starting manual mode and commanding 0.1A manualid will create a 50/50 dutycycle. Otherwise you'll have to temporarily flash the sine software and follow the kit instructions.
https://github.com/jsphuebner/stm32-sin ... ses/latest

Keep in mind in any case you'll have to command forward or reverse.

Thanks Johannes.
I had read about the resolver needing to be twisted pairs. I had already updated them:

DO I just ground the shield to the Inverter frame?

With that I will add temp wires for the HV DC and Inverter AC to the Motor for Bench testing.

[jerrykco]

Still working on bench testing the motor. (no cigar yet)!
I connected the battery to the inverter with a manually controlled pre-charge.

I downloaded the latest code from Gethub. https://github.com/jsphuebner/stm32-sin ... ses/latest
Tend uploaded it to the Controller.
I couldn't detect the inverter actually starting although it said it was started when I clicked Manual Mode.
The warning/errors I got were
[20469]: WARN - CANTIMEOUT
[20470]: WARN - CANTIMEOUT
[20471]: WARN - CANTIMEOUT
[20472]: WARN - CANTIMEOUT
I am assuming because it's a warning it's not affecting the inverter from actually working.

With FOC software a basic function test is a bit harder, maybe starting manual mode and commanding 0.1A manualid will create a 50/50 dutycycle. Otherwise you'll have to temporarily flash the sine software and follow the kit instructions.

I am at a stopping point I for tonight.
Tomorrow I follow the kit instructions.

[Kevin Sharpe]

I am at a stopping point I for tonight.

If you're not doing so already I recommend you use Damien's HV current limiting technique using a bulb or cooker element. I'm sure one of his videos will show you how

[jerrykco]

If you're not doing so already I recommend you use Damien's HV current limiting technique using a bulb or cooker element. I'm sure one of his videos will show you how

Thanks Kekvin, If you are referring to limiting current during the pre-charge a few seconds, I have created this two relay circuit which I manually control by first closing the pre-charge relay that has a 100 Watt 100 Ohm resister in line to charge the inverter CAPs, closing the High Current/High Voltage Contactor, then opening the pre-charge relay.

[Kevin Sharpe]

Thanks Kekvin, If you are referring to limiting current during the pre-charge a few seconds, I have created this two relay circuit which I manually control by first closing the pre-charge relay that has a 100 Watt 100 Ohm resister in line to charge the inverter CAPs, closing the High Current/High Voltage Contactor, then opening the pre-charge relay.

No, I was referring to testing with a current limiting device in the HV line. This is useful while in the early stages to prevent a calamity if you've got anything wrong with your setup. I'll try to find one of Damien's videos showing the cooker element in use.

[jerrykco]

I made some more progress (Kind of indirect but part of the overall project).
I purchased a used single post lift from a nearby heretofore unknown neighbor who advertised it.

And over the last few weeks I also obtained some parts to build a DC Charger.
Parts were found on Ebay.
I ended up getting a 35AMP 240VAC Variac. I also purchased a 240VAC to 480VAC Transformer. Then I got a Bridge Rectifier and big Cap for a filter.
I assembled the parts and I was able to see I could get OVER 500V DC out at full Variac Voltage in.

Today was first attempt at charging the Leaf 24KWH pack. Success. I set the Variac so output level was 3 volts lower than pack voltage and slowly rased the voltage until I was putting in first 5A then 6.5A. I let it Charge for an hour and raised the Pack voltage 10V from 363 to 373V.

I started out with the Pack at about 21% SOC. And finished (today's short 1 hour charge) here.

[mike77cos]

What a great project

[jerrykco]

What a great project

Thanks. It is a whole learning experience.
Brief video charging.
https://www.dropbox.com/s/hsdiy1jq45oyx ... 0.mp4?dl=0