Nissan Leaf Gen3 inverter

[Jack Bauer]

fyi gen3 leaf current sensors are 5v powered, 2.5v center 0A and 2.5mV/A

[johu]

Can you fit a good old Tamura?
https://www.digikey.de/product-detail/d ... -ND/529412

3.3 mV/A so you would loose some power.

for the bulky 800A L06P which would have the correct coefficient:
https://www.digikey.de/product-detail/d ... ND/3048495

[Dala]

I have now completed my 110kW inverter retrofit! Video on installation:



Now to figure out the missing CAN messages and resolver coding!

[johu]

Early forum release, thanks
You can pull more than 225A short term. I've also tuned my inverter to about 120 kW (with the openinverter board) and ran it on the 24 kWh pack. Even went full throttle for a few minutes doing a speed not allowed in Finland

[Dala]

Good to know!

I now made more progress on the Resolver Offset. I contacted Jim(Leafspy author) as soon as I had the first logs. Jim was able to add the resolver reading to the latest Leafspy Pro release, it looks like this: [76 -- -- -- --]


I then ran my home-made writing, since this is not available in Leafspy yet. This is what my motor plate and the commands looked like:


I then double-checked that the new offset was taken into use with Leafspy. It was. [86 -- -- -- --]


This will all be automated soon, Jim is working hard on adding this as we speak But if you have a custom build that you can't connect Leafspy to, then the above commands I have listed will be mandatory! We need more people on the 110kW inverters

[Dala]

This was mentioned in the video, the ZE1 inverter only needs the two first digits. That is why the rest are just listed as --



But the above commands work for all generations, the extra numbers just get ignored!

[drprox]

Nice. Resolver coding worked, I had got confused trying to get it to send the other numbers which aren't used!

FYI the fuse derate curve is shown here:
https://www.socfuse.com/products/detail/dc500vbt2543/

Btw. I didn't do anything smart with the CAN bridge, I just multiplied demand by 1.4

[Dala]

Great! I will work on getting the fault code cleared now.

My hypothesis is that some 10ms message is missing. The new inverter is sending a 0x120 that is just a heartbeat, so maybe the other similar ones are missing (like 0x1C2 or 0x1ED). I'll let you know if I have any breakthroughs!

[drprox]

Do you have a 40kWh pack? If so I thought it would essentially have a ZE1 BMS and therefore send out the 1C2 etc? Perhaps they flashed special firmware if not.

[drprox]

Did some playing this morning. The missing message is 4B9.

[Dala]

You beat me to it! This is what my battery upgrade software looked like, so I was blocking most new messages:


I have created a repository for the CAN-bridge inverter code: https://github.com/dalathegreat/Nissan- ... r-Upgrade/

I'll add the magic message there

[Dala]

Full video on coding coming soon, here's a teaser:

[bennyr]

Don't you just love that EV grin?

[Dala]

Final video is now out on the 110kW inverter!

[johu]

Very smooth and great that you're making it open source.

That camera effect is familiar

[Bratitude]

Adapter board is all assembled along with the V3 mainboard....

Kelju, would you mind sharing the pcb/ schematic for your adapter board?
Cheers

[Dala]

Just got my hands on a gen4 (technically gen5) inverter! The part number for this 160kW inverter is 291A0-5SN0A. Anything I should check before chucking this into the LEAF?

[drprox]

If you are willing to open her up, i have been curious to know if they are using the same infineon IGBTs in this and therefore it is just a firmware change.

The reason being, my current sensor mod can overcome the firmware issue but not if I'm going to blow the gen4 igbts.

[Isaac96]

If you are willing to open her up, i have been curious to know if they are using the same infineon IGBTs in this and therefore it is just a firmware change.

The reason being, my current sensor mod can overcome the firmware issue but not if I'm going to blow the gen4 igbts.

Are you planning to modify the phase current sensors?
Would that mess up the FOC algorithms?

[drprox]

Yes. Already done it on the 110kW version and it seems to work great.

[Isaac96]

Awesome!

[Bratitude]

The reason being, my current sensor mod can overcome the firmware issue but not if I'm going to blow the gen4 igbts.

Is this mod simply just a purposeful phase shift in the readings? do you mind expanding how / what the mod entails?

[drprox]

Its simply an amplifier circuit to reduce the amplitude of the phase current signals, so the inverter drives more current to achieve its target 'torque'.

[Leo M]

Early forum release, thanks
You can pull more than 225A short term. I've also tuned my inverter to about 120 kW (with the openinverter board) and ran it on the 24 kWh pack. Even went full throttle for a few minutes doing a speed not allowed in Finland

Have you run it in reverse mode? My forward mode works fine, and in reverse mode there is an overcurrent. The settings are all working and tested on other inverters on GEN2 works perfectly! What could be the problem? Please help with advice.....Forward-great! Reverse - overcurrent....(

[Dala]

I couldn't resist, so I installed the 160kW inverter with the 40kWh pack. No fuse problems so far