Prius Gen2 Adapter Board for CHARGING

Topics concerning the Toyota and Lexus inverter drop in boards
LRBen
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

I think I'm going to give up on the charging side of this. It didn't seem to be able to push that much power into the inverter and there are allot more options available now in terms of OEM modules than there were two years ago when I started. I have the space for a charger anyway.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

I find it a good and cheap start for testing my basic setup. A battery pack and suitable charger are on the wish list, however the Mg1 alternative gives me possibilities to continue on other parts of the build and road test.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

I tried charging after putting inverter into run mode a few times. Didn't trip house mains, which confirms inverter needs 'to wake-up' before charging.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by alehandro »

RetroZero wrote: Mon Apr 25, 2022 9:36 am I tried charging after putting inverter into run mode a few times. Didn't trip house mains, which confirms inverter needs 'to wake-up' before charging.
There is a prius 20 inverter in charging mode, video in Russian, you can turn on subtitles. Perhaps some information will be useful for a good result of HV charging.[media]
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Thanks, I will try again in the next few days and post a video if I feel it's working well enough. There are still some clicks on startup that concern me and make me doubt that I have the sequence and timing right. Otherwise, I get the same results as 'our Russian friend'
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Finally got a minute to update with a video. I appologise in advance, I am crap at videos.
Made a few modifications, and haven't tripped the mains since, so good news.
I will check @LRBen's work on the Wiki and apdate where needs be along with my scetch.
This is a huge step forward for me,,thanks to Johannes and company.

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Re: Prius Gen2 Adapter Board for CHARGING

Post by alehandro »

RetroZero wrote: Sun May 01, 2022 12:05 pm Finally got a minute to update with a video. I appologise in advance, I am crap at videos.
Made a few modifications, and haven't tripped the mains since, so good news.
I will check @LRBen's work on the Wiki and apdate where needs be along with my scetch.
This is a huge step forward for me,,thanks to Johannes and company.

This is already a good result that the home network does not suffer ;) . By the way, I would like to know more details about the method of your charging order and the switching scheme.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

I'm working on my schematic and will post my findings soon.
Basically,
1: manually power up adapter board
2: connect 230v ac house mains to 2 white relays
3: relays pull all 12vdc signals for charging high
4: adapter board goes into charge mode (buck mode saved in parameters prior to set-up sequence)
5: precharge dc and ac via precharge signal
6: dcsw signal pulls CSDN to ground along with main contactors (dc and ac)
7: remove ac to switch off charging and manually switch off adapter board.

I'll get to parameter settings tomorrow if I get the time 👍

Parameter wise, I left all charge parameters as per default EXCEPT
1. PWMIN (70) = 70% voltage from 320vdc (rectified 230vac mains)
2. PWMAX (80) = 80% voltage from 320vdc (rectified 230vac mains).

Please be extra careful and start testing from low voltage. Any damages are at your own risk.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Latest Update software means Charge Function requires BUCK MODE when using MG1 as rectifier and have battery connected to stock battery input

Here is my hand drawn scetch - if anyone has an easy software to put this into, let me know as I would like to update the wiki with something more professional .Otherwise, I will use the wiki scematics and modify a copy.
Attachments
Prius Gen2 Mg1 Charge setup.pdf
(273.26 KiB) Downloaded 200 times
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Re: Prius Gen2 Adapter Board for CHARGING

Post by vin »

RetroZero wrote: Mon Apr 11, 2022 4:21 pm Thanks for the reply. I am busy charging 12v battery from 24v DC supply on MG1.
So far, so good...
When working with 12DC on MG1, Didn't you have to use a load on the standard battery input, in order to start charge mode, and do you still hear winding at this voltage?


Also I don't seem to be getting any voltage values on UDC, then there is definitely 12v on the MG1. I get a reading, but it doesn't seem to change, regardless of whether I Input voltage to MG1 or not.

Any ideas would be greatly appreciated.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by vin »

johu wrote: Sat Mar 19, 2022 6:50 pm Shorting CPWM to 12V AND connecting it to the control board can easily blow the output driver. Please check if you still see a valid waveform with CPWM pulled up.

CPWM pulled high and CSDN pulled low (or floating) will close the LOW side transistor, shorting the battery input (the stock one). Pulling CPWM low (or floating) will close the high side transistor thus connecting DC bus to battery input bidirectionally.

CSDN pulled high disables both transistors.

No quite sure what you connected where, schematic would help

Hi John, What are the signs of a blown output driver, would you still be able to initiate charge mode from MG1?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

vin wrote: Sat Aug 20, 2022 5:06 pm When working with 12DC on MG1, Didn't you have to use a load on the standard battery input, in order to start charge mode, and do you still hear winding at this voltage?
No, I didn't load the 12v battery (which was connected to HV battery inputs to inverter)
The 24v pack was connected to the 1st and 3rd AC phase connections.
Even without AC connected, you should see UDC.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by vin »

RetroZero wrote: Sat Aug 20, 2022 9:23 pm No, I didn't load the 12v battery (which was connected to HV battery inputs to inverter)
The 24v pack was connected to the 1st and 3rd AC phase connections.
Even without AC connected, you should see UDC.
Thanks for getting back to me.


I See, Strangely my UDC is showing me 318V however there's no HV connected , even when I supply 12v to MG1 (1st and 3rd AC phase), There doesn't seem to be any change on my UDC. I was expecting son sort of difference to show on the plot, bit nothing. There is some there is some movement, but pretty much millivolt movement , which is definitely less than the 12V Im pushing through it parameters for Inverter and Derating are pretty much set to Default.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Have you set your udc offset value?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

I think this is the link
viewtopic.php?p=42373#p42373
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Re: Prius Gen2 Adapter Board for CHARGING

Post by vin »

johu wrote: Wed Oct 21, 2020 5:28 pm So, I got my wire harness back today and immediately went testing (video maybe later). The most exciting finding is that function of the CSDN pin - Pin 29 of the inverter. So when it is left floating (or grounded?) the converter is ON. When CPWM is HIGH, the LOW side IGBT is on, when CPWM is LOW the HIGH side IGBT is on. When CSDN is HIGH both IGBTs are OFF.

So:
  • I pulled high CSDN and CPWM, the latter via a 500R resistor
  • I connected a 12V battery to the orange DC input and 20V to two phases of MG1.
  • I started BOOST mode (always use boost mode with this converter)
  • 1s later I disconnected CSDN
Now you could see something very interesting (see plot). At first the battery voltage is boosted from 12V to 90V as long as the duty cycle is low. The PI controller ramps up fairly slowly so it takes a while until the current flow reverses and current starts flowing from the power supply to the battery.

So right now the charging sequence looks like described above, maybe future versions of the control board should have the ability to control CSDN as well.

It is now a matter of finding a good time to activate the converter so that it doesn't boost so much. 12V to 90V sounds not so bad but what about 200V to 1kV - lets not. Toyota engineers will probably just click at us but lets not force them to :)

So I have default parameters set on the VCU, I can't seem to get activity registering on the VCU plotting (UDC). Pulling CSDN and CPWM high seems to be working (shutting down the IGBTs) however amending chargrcur makes no difference to the plotting or doesn't appear to be making a difference or recognisable change.

Do I need to make any particular changes to the parameters in order to get some sort of response? Has anyone come across this?

Please see my parameters below.


"curkp": 32,
"curki": 20000,
"curkifrqgain": 50,
"fwkp": -100,
"ffwstart": 200,
"syncofs": 55000,
"syncadv": 10,
"polepairs": 4,
"respolepairs": 2,
"sincosofs": 2048,
"encmode": 4,
"fmax": 500,
"numimp": 256,
"dirchrpm": 2000,
"dirmode": 1,
"snsm": 13,
"pwmfrq": 2,
"pwmpol": 0,
"deadtime": 63,
"ocurlim": 100,
"il1gain": 4.68,
"il2gain": 4.68,
"udcgain": 6.15,
"udcofs": 0,
"udclim": 540,
"snshs": 0,
"pinswap": 5,
"potmin": 1200,
"potmax": 2600,
"pot2min": 0,
"pot2max": 0,
"potmode": 0,
"throtramp": 40,
"throtramprpm": 20000,
"throtcur": 1,
"brakeregen": 0,
"regenramp": 0.25,
"regentravel": 20,
"offthrotregen": -15,
"cruiseregen": -15,
"regenrampstr": 10,
"brklightout": -50,
"bmslimhigh": 50,
"bmslimlow": -1,
"udcmin": 450,
"udcmax": 520,
"idcmax": 5000,
"idcmin": -5000,
"idckp": 2,
"idcflt": 9,
"tmphsmax": 85,
"tmpmmax": 300,
"throtmax": 100,
"throtmin": -100,
"chargemode": 4,
"chargecur": 1.5,
"chargekp": 20,
"chargeki": 10,
"chargeflt": 2,
"chargepwmin": 70,
"chargepwmax": 80,
"idlespeed": -100,
"idlethrotlim": 80,
"idlemode": 3,
"holdkp": -0.25,
"speedkp": 1,
"speedflt": 5,
"cruisemode": 0,
"udcsw": 0,
"udcswbuck": 540,
"tripmode": 3,
"bootprec": 0,
"pwmfunc": 0,
"pwmgain": 100,
"pwmofs": 0,
"canspeed": 1,
"canperiod": 0,
"nodeid": 1,
"manualiq": 0,
"manualid": 0
}
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

If you used the parameters according to the post I tagged, udcofs = 300, and udcgain = 3.5.
With these values and no HV connected to the inverter, is udc close to 0v?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Udcmin and udcmax don't make sense iether (don't know if they could be shutting down your adapter board). Are you trying to charge at 450cvdc?
230vac = 320vdc. This setup is for Buck mode, so less than 320vdc. Am I missing something?
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