[DRIVING] leaf powered 1983 Subaru BRAT (dual outlander WIP)

[johu]

On a customer project we had various errors on the bus, it was a device presumably running at the wrong baud rate. Also caused counter and timeout errors.

It's not a traffic thing. Tourans bus is super busy and I'm getting no errors (vehicle, isa, charger, inverter, bms, vcu)

[Bratitude]

we had various errors on the bus, it was a device presumably running at the wrong baud rate

makes sense, i put the inverter back on CAN1, dcdc and shunt on CAN2 and still getting timeout. ill play with the inverter can setting tomorrow


new harness is now in the car, water pump and tesla charger controlled via gpo
inverter is switched on via zombie on start

still have yet to confirm if zombie side brake + start will start the inverter or if those are still need to be switch inverter side.

[arber333]

makes sense, i put the inverter back on CAN1, dcdc and shunt on CAN2 and still getting timeout. ill play with the inverter can setting tomorrow

...

I have a similar problem with Teensy VCU and my Outlander setup. I use everything from Outlander in Mazda MX-3 car; Inverter, motor, charger and heater.
I made a new CAN harness and removed or twisted 12V wires which supply inverter and other devices in case i would get EMI from it.

I still have a problem with speedo loosing its information that it receives from inverter RPM reports. It jumps by about 10km/s...
viewtopic.php?p=67750#p67750
Another problem is that charger does not work as its heartbeat msg does not come through at correct speed of 30ms.
It seems that inverter is not so fussy about heartbeat arriving less often at 100ms. Inverter would work just fine and provide torque.

[Bratitude]

okay played around the inverter can setting abit to no effect.

then disconnected the dcdc can from can2

and we are back!
with the transmission in neutral, i slightly pressed the throttle, and the motor spins up... too quick and it takes off. yikes.

pull the for/rev switch to neutral and instant regen slows it down then what i presume an over current event.
not sure as i was logged into the zombie interface, not the inverter.
start everything back up....and precharge fail....hmm okay not getting proper reading in the web interface. opened up the contactor box, the shunt on the negative contactor terminal is a little loose. yikes.

tighten that back up, run the sequence and looks like i killed the shunt. its not providing proper udc data.

2 steps forward 1 step back.

arhhggg.


also the state logic of the OBCenable and coolantPump on GPOs is ambiguous.

with the zombie on permeant 12v, OBCenable just switchs on.

[Bratitude]

Okay so nope! I blew my mid pack fuse

[Bratitude]

took a closer look at how the inverter is functioning when in drive.
current firmware is 5.32

i'm getting pluses /oscillations in the motor rpm when applying a little bit of throttle (with transmission in neutral) and the same (lurching) when in gear.
this happens regardless of throttle over can, or throttle directly connected to the inverter.

i loaded johu leaf prams viewtopic.php?p=63866#p63866 in case i had some strange tune.

made no difference.

ill down grade back to 5.27 to see if theres any change.

[Bratitude]

another stupid mistake. i loaded 5.32 SIN instead of FOC.
loaded up 5.27 FOC. fired it up. click/ pop sound moment i touch the throttle. desat.

lots of noise on everything. doing a full shut down and reset it will slightly spin moment i select drive, then desat.

plots are with inverter on and no HV.

ill take the zombie out of the equation. its currently handling the contactors.

[Scrappyjoe]

Could I ask what an OI board is? I’ve been trying to follow along - very interesting - but I can’t get a full understanding because I can’t figure out what an OI board is.

[Bratitude]

Could I ask what an OI board is? I’ve been trying to follow along - very interesting - but I can’t get a full understanding because I can’t figure out what an OI board is.

OI = openinverter
The logic board In the leaf inverter was replaced with the open inverter board.

[Scrappyjoe]

Thanks! Much appreciated

[Bratitude]

Installed a new rev 3mimi board.

Using the original leaf harness with the additional pins populated.

back in action. sort of.

getting pre charge on boot. Regardless of firmware, Or parameter settings.

so i have pull negative con high befor booting the inverter. or precharge fails and it wont cycle precharge on brake/start again once on.

[johu]

That's odd. It should give you 5 seconds so closing precharge and neg contactor together with inverter powerup should work

[Bratitude]

Just finished a 370km drive. Smooth driving.

And got CHAdeMO working with zombie.

First station (charge hub)charged me for time but provided 0 power.

The bc hydro dc fast charger(abb) worked great!

There’s a remote delta 25kwh fast charger at a rest stop. along with a 48amp level 2….

I feel like I’m cheating

[arber333]

I feel like I’m cheating

I cant see why?

[Bratitude]

When I arrived at the station I immediately thought “oh can I pull an arber and charge with both at the same time?!?” Gave me a good laugh

[marcexec]

I feel like I’m cheating

New profile picture? Looks awesome!

[Bratitude]

Some more CHAdeMO updates:

FLO dc fast chargers result in an over voltage fault.

I’m guessing this is a result of the isolation test?

During the charger start up udc voltage rises up to 650v.

Shortly after starting the charge, the zombie shut it all down.

some of the newer bc hydro station seem to do the same thing!

[Bratitude]

Brat is pretty beat up at this point. I’m slowly gathering the bits for v2.

here’s where I’m at with the new front end:
new subframe to accommodate the outlander drive unit and fixes the suspension geometry.

Packing is definitely getting tight be everything should fit where I’d like.

subframe will be 1.25 od .83 wall dom about 15lbs

Huge weigh reduction from the stamped steel Subaru subframe that’s around 35-40lb

[geduxaz]

That's odd. It should give you 5 seconds so closing precharge and neg contactor together with inverter powerup should work

Could You explain more on those DCSW and DCPRE on boot?
I get DCSW short trip when powering the system from 12V.

[Bratitude]

R160 rear diff is out, outlander DU is in!

Built a jig and welded up the new mounts remotely and then brought the parts to the brat. not perfect but it’s in. Next up axles, then I can pull the original gearbox and leaf motor and loose a couple hundred lbs!

[Jacobsmess]

Wow, you using the same code as EvMacguyver for his dual outlander setup

[maland2]

Dang! This is such a cool build, & pretty inspiring someone who'd considering converting an '06 outback. Eager to see how things go with the outlander drive units, though I think with my more limited fabrication capabilities I'm leaning towards trying to do some R&D to make the TH-2A work. (viewtopic.php?t=1641)

I read through a good bit of this thread and it seems like you do a fair bit of driving in winter, but I didn't see (or maybe missed) mention of battery heating. Do you only charge when ambient temp is above 0C or when the batteries have warmed up from driving?