Prius Gen2 Adapter Board for CHARGING

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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Well, progress slow my side. Trying to understand all parts of the process.
I managed to wire up the AC side in a relay box today. I used Prius HV Relays to switch Live and Neutral seperately.
I will connect the low side tomorrow to the Openinverter Board, with CSDN openning Two seconds after plugging in the AC Plug .
The Inverter will be set to Buck Mode (and be SAVED in settings) prior to connecting.
The HV DC connections will be connected as per the standard setup - NO Jumper wire bypassing the Buck Convertor.
I undertsatnd that as long as CSDN is HIGH (12v), the IGBT's are all OFF, therefore Precharge and Main Contact on AC and DC can be activated at the same time.
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Schema Relays MG1 Charger.JPG
Ralays MG1 Charger.JPG
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

It may not be the best idea to "blindfold" the charger PI controller. It will try to create a current during those 2 s which it can't because the IGBT is disabled. By the time the IGBT is enabled the controller might have wound up too much. That said, with low chargeki you can make the controller pretty slow.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

So should I rather set it to One second?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

Finally setup the entire battery to attempt to charge. Had one scary moment on the first attempt when a busbar wasn't securely bolted on. A little but of sparking and I think I might have killed a BMS slave board. But all ok now.

When I hook it up to the heater element simulation battery it pulls a steady 3.5 amps and the voltage on the battery inputs sits at whatever pwmmin is.

However with the battery hooked up I am getting charge current into battery go up to around 3 amps to start, then slowly decrease and then invert and start pushing amps into the inverter. The HV Bus was increasing voltage and was at 400v when switched it off.

Not sure what is happening here. I have charge current set to 1.5 amps, kp at 40, ki at 10 and flt at 2 as per my settings before.

charge current.png
Edit: Tried one last time before I went home. This time it started at 3 amps then reduced charge current to 0.5amps and was stable.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

If you mix up buck/boost chargemode it will regulate in the wrong direction, maybe that's what happens?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

I haven't changed the settings from buck all week now.
Just out of interest what do chargekp, chargeki and chargeflt do? I don't feel like I can adjust them much as I don't know what they do.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

chargekp - proportional controller gain - how much does the controller counter-act momentary errors between desired and actual current. Mostly important if you want to quickly react to the sinusoidal shape of the grid input current.

chargeki - integral controller gain - how fast does the controller react to long term errors between desired and actual current, i.e. how fast does it ramp up charge current

chargeflt - how much is the measured current low-pass filtered before being fed into the PI-controller. Dampens down noise on the current sensor but also increases reaction time to the grid sinus
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Can someone explain why the precharge resistor should stay in series during charging please?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

johu wrote: Thu Mar 31, 2022 3:41 pm It may not be the best idea to "blindfold" the charger PI controller. It will try to create a current during those 2 s which it can't because the IGBT is disabled. By the time the IGBT is enabled the controller might have wound up too much. That said, with low chargeki you can make the controller pretty slow.
I decided to pull CSDN to GND with DCSW signal. Will update my schema.

Do we still require Precharge resistor in AC Circuit to remain ON during CHARGING?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

RetroZero wrote: Fri Apr 01, 2022 2:36 pm Do we still require Precharge resistor in AC Circuit to remain ON during CHARGING?
No, who said that? It can be on if that makes it easier but it's certainly not required.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Thanks for the reply.
It was in the discussions at the beginning of this thread, along with your diagram I butchered from Wiki.
Going into the details I picked it up and couldn't understand why it was needed once AC precharge was complete.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

It works! I think the current sensor on the inverter needs to be calibrated a little.

I started to just up the charge current and it had some effect on current going into the battery. Started to adjust the other parameters which also helped.

Settled on this, which was pushing in 4.5 amps.
Screenshot_20220402-121224.jpg
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

The odd thing now is that I can't get anymore than about 4.5 amps. The charge current setting on the inverter VCU has no effect beyond 15 amps.

Increasing chargekp beyond 20 lowers the amps I get into the battery which seems odd.

Whats the max amps you have managed to get into your batteries?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

Maybe hitting udcmax? Or, less likely, tmphsmax
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Well done LRBen!! I'm at testing with heating element at the moment. Bravo
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

udcmax was set to 5000, moved it to 500 amps just to make sure.
I thought tmphsmax could have been a good idea, since I have no coolant on the inverter yet. But that's set to 150c and tmphs is sitting at around 57c.

I'll settle for this for now. Already found a dead cell I think, shot up from 3.7 to 4v while the rest of that module are still at 3.8v.

I think I'm going to remove a module anyway now and run 70s1p. I should be able to fit that all in one layer of the battery box and I can actually charge that to 100% through buck charging.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

70S would be 280V @4V per cell. Maybe you're just running out of voltage to push more amps?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

I guess so, at the moment its been charging at around 295v which is the current SoC of the battery. I do notice the HVbus is dropping down to 315v though so that does make sense.

Wouldn't I be able to push around the same or more amps as the input amps if I am bucking? Since voltage goes down amps needs to increase to keep the same Wattage. So I would expect around 10-12 amps at least, minus some inefficiencies of charging.

It's also pretty cold right now, around 4'C.

Are the slave boards ok with only 2 cells? If I take away a module I will have an odd number of cells per slave board.

Edit: Sorry we are getting mixed up with the 4 cell BMS details now.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

So finally wired up Relay Setup as per my scetch.
Updated software as per Johu's update in previous post.
Chargemode is already in BOOST.
No AC or HV-DC connected.
Simulated AC connection, which pulls CPWM and CSDN HIGH (+12v) via 470 OHM resistors on each line, F and R to +12V.
Set time delay switch to Pull CSDN floating after 0.5s.

Inverter (Opmode) remains in OFF Mode
lastterr = HIRESOFS
status = PotPressed
udc (with only +12v to inverter) = 51.46V

Do I need to have START signal as well?
Inverter not going into ChargeMode....

What am I missing?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

I use the start signal on startup same as when I want to drive.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by johu »

RetroZero wrote: Sat Apr 02, 2022 6:20 pm lastterr = HIRESOFS
status = PotPressed
udc (with only +12v to inverter) = 51.46V

Do I need to have START signal as well?
Inverter not going into ChargeMode....

What am I missing?
Seems like some issue on the analog inputs... HIRESOFS and PotPressed. 51V could also mean wrong udcofs.

You don't need the start signal, just forward+reverse and of course udcsw < udc
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

OK, will look into analog inputs again.
Just trying to get start mode initiated before connecting any voltage.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

Dropped the pack down to 60s. Had to change the settings a little again. Found that chargeflt had the most affect this time. Managed to charge at around 8 amps this time, if increased chargeflt anymore the EVSE errored out.
chrager 8 mp settings.png
chrager 8 mp settings.png (11.37 KiB) Viewed 2334 times
I'm planning to keep the pack at 60s for now since it makes battery install easier.

Next step is to add the additional contactor so I can split the battery positive to the inverter. The charge contactor to battery inputs will be activated by the same signal as the AC contactor, then my main contactor will connect to the HV bus and run as normal.
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Re: Prius Gen2 Adapter Board for CHARGING

Post by RetroZero »

Are you splitting because you will bypass boost inverter when in drive mode to not be limited by 20kW?
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Re: Prius Gen2 Adapter Board for CHARGING

Post by LRBen »

RetroZero wrote: Fri Apr 08, 2022 6:45 am Are you splitting because you will bypass boost inverter when in drive mode to not be limited by 20kW?
That's the plan yes.
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