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Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Tue Jun 17, 2025 8:03 pm
by voti
RetroZero wrote: Tue Jun 17, 2025 7:53 pm Is this what you used as reference?
viewtopic.php?p=14153#p14153
I connected my resolver the way Damien did in the tutorial video. Is it correct or should I change to
pin 1 = yellow ( enc b)
pin 2= green and brown (sin a and cos a)
pin 3= red ( enc a)
pin 4 = black r1
pin 5 = white r2

For excitation I have blue and pink not black and white.

Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Wed Jun 18, 2025 9:07 am
by voti
I changed my resolver connection today and connected it as pair discussed in the screenshot attached below.
I tested first without it connected and I got the same results of having the Delta connected light bulbs connected on the inverters three phase output light up and turn off again continuously. The inverter goes into run mode when I set udcsw to 0 and this blinking behavior then starts even before I put any numbers in the manualid. Please see video attached in comment above. On angle when the light bulbs started blinking an angle of 63 degrees showed up even without the resolver connected.

Then after I connected the resolver and shortly after setting udcsw to 0, the light bulbs turn on and they stay lit. This time around they don't blink but they say lit. When testing with a scope the PWM wave shows but it doesn't move. It stays in one position. On angle under spot values the angle was 239 degrees but kept changing by a value of 1 either increasing or decreasing when I pressed refresh even without turning the drive shaft.

I went on to connect the throttle pedal also with the discussed instructions on the screenshot below and tested with both the resolver and the pedal connected. Now the light bulbs didn't turn on and the inverter didn't go to Runmode it stay off even after setting udcsw to 0. While on previous tests I set udcsw to 0 because that was the only way I could get the inverter to go Runmode because even with manual start turned on, the inverter would still be on opmode> OFF.

When I had the throttle connected STATUS on spot values first showed "PotPressed" and on another test it said "UdcBelowUdcSw|PotPressed" .

Please see attached pictures.

Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Wed Jun 18, 2025 10:06 am
by RetroZero
Just to be sure.
You have 2 seperate batteries. 1 for 12v circuit, & another for High Voltage circuit. Can you check that they are well charged.
In spot values, please report back on UDC voltage & Pot1/Pot2.
The pedal should read 0 , if not, it requires setting. I think there is a set-up in the adapter board thread. Once set up correctly, check by pressing the pedal all the way and verify you have 100%
UDC should read the same as your battery ' HV'

Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Wed Jun 18, 2025 6:28 pm
by voti
Below I've attached my entire spot values, please go through and check for all the settings you want to see pot1 and pot2 and any other that are important for testinh stage.. Also please check for faults that might appear.

I'm planning on connecting a high Amp 12v battery for my next test to my HV supply. On UDC now it says 11.87v.

I forgot to mention that now that I have connected both the resolver and the throttle, I cannot get the inverter to go on manualRun. Even after setting udcsw to 0, It stays off.

Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Thu Jun 19, 2025 4:56 am
by RetroZero
Is your start signal connected directly to 12v, or is it a button? It needs to be a button, not permanent 12v.... When you press accelerator pedal, do you get steady % value under Potnom?

Re: EV Conversion using prius gen 2 inverter/transaxle

Posted: Thu Jun 19, 2025 6:01 am
by johu
@voti: the screenshots are hard to read. Please just attach the contents of http://192.168.4.1/cmd?cmd=json instead

UdcBelowUdcSw means bus voltage (udc) is smaller than udcsw . So at this point it cannot have been at 0