Nissan Leaf Gen2 Board: Difference between revisions

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* OTA software updates and parameters  
* OTA software updates and parameters  
* regen and cruise control
* regen and cruise control
Swap video: https://www.youtube.com/watch?v=T_6hw6vGzfM


== The Kit ==
== The Kit ==
Line 16: Line 14:
* adapter board  
* adapter board  
* various connectors   
* various connectors   
* a handful of some basic components     The kit is designed to drop in place of the original Nissan logic board.  The adapter board is designed to re-use the large proprietary connector that is mounted on the original logic board.  
 
Shop link: https://openinverter.org/shop/index.php?route=product/product&product_id=57
* a handful of some basic components  
 
The kit is designed to drop in place of the original Nissan logic board.  The adapter board is designed to re-use the large proprietary connector that is mounted on the original logic board.
 
Kit shop link: https://openinverter.org/shop/index.php?route=product/product&product_id=57


== Nissan Board Removal ==
== Nissan Board Removal ==
[[File:Nissan inverter board.jpg|alt=Nissan board, yet to be removed. The large connector on the left must be salvaged and re-used.|thumb|OEM Nissan logic board, yet to be removed. The large connector on the left must be salvaged and re-used.]]The inverter casing attaches directly to the motor and may be opened by removing the 10mm hex head bolts underneath the top lip along with the waterproof guard for the large connector.
[[File:Nissan inverter board.jpg|alt=Nissan board, yet to be removed. The large connector on the left must be salvaged and re-used.|thumb|OEM Nissan logic board, yet to be removed. The large connector on the left must be salvaged and re-used.


Once opened the board with the controller is easily distinguished as it has the large connector attached. It is on it's own carrier attached to the lid by 3 allen head bolts. Start by disconnecting the plugs from the four connectors at the top of the board, then remove the allen bolts to free the carrier.
3 allen head bolts can be see in bottom half of photo
]]The inverter casing attaches directly to the motor.
* remove the inverter from the motor:
# remove the 2 torrox screws holding the inverter/motor phase wire connection cover on.
# remove the 3 exposed hex head bolts. each bolt is a phase connections, keep these separate from the rest of the bolts
# lift the inverter off the motor, be carful not to bend or nock the coper phase connections.
* taking the inverter apart
# remove the 4 10mm hex head bolts around the connector(?)
# remove the connector(?) cover
# remove all the hex head bolts around the inverter
# with a mallet tap around the seam in the inverter casing to loosen the sealant
# pry the case open, carefully lift the 2 case half's apart.
* removing the mother board
the oem mother board is easly distinguished as it has the large proprietary connector attached. It is on it's own aluminum bracket attached to the case by 3 allen head bolts.  
# disconnect the plugs from the four connectors at the top of the board.
# remove the allen bolts to free the bracket and board.
# remove the screws holding the board to the bracket <u>'''Nissan uses some very strong thread lock'''</u> so be prepared for some of the screw heads to shear.*carefully heating the screw will help break down the thread lock
[[File:Nissan Proprietary connector.jpg|alt=Nissan Proprietary connector as seen from outside the housing.|thumb|Nissan Proprietary connector as seen from outside the housing.]][[File:Leaf adapter pin map.png|alt=Pin function descriptions, pins as seen from outside the housing|thumb|Proprietary connector pin function descriptions, pins as seen from outside the housing.]]
Once the board has been removed from the carrier,the large connector must be salvaged from it. One method is shown in the swap video, a vacuum soldering iron is also known to work.


Next remove the screws holding the board to the carrier. <u>'''Nissan uses some very strong thread lock'''</u> so be prepared for some of the screw heads to shear, the sheared stubs can be removed afterwards using heat to burn off the thread lock.
Swap video: https://www.youtube.com/watch?v=T_6hw6vGzfM
[[File:Nissan Proprietary connector.jpg|alt=Nissan Proprietary connector as seen from outside the housing.|thumb|Nissan Proprietary connector as seen from outside the housing.]][[File:Leaf adapter pin map.png|alt=Pin function descriptions, pins as seen from outside the housing|thumb|Proprietary connector pin function descriptions, pins as seen from outside the housing.]]
Once the board has been removed from the carrier the large connector must be salvaged from it. One method is shown in the swap video, a vacuum soldering iron is also known to work.


== Kit Build ==
== Kit Build ==
# Solder the components to the board as per the instructions.  
# Solder the components to the board as per the instructions.  
# The large proprietary connector must be salvaged from the original Nissan logic board. as it is not available on the open market. once salvaged, solder it onto the adapter board.
# The large proprietary connector must be salvaged from the original Nissan logic board. as it is not available on the open market. once salvaged, solder it onto the adapter board.
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There are multiple part numbers for the large 35 way Ampseal through hole socket, with small mating differences, be sure to get a matching pair.
There are multiple part numbers for the large 35 way Ampseal through hole socket, with small mating differences, be sure to get a matching pair.


TE connectivity '''776164-1''' and '''776163-1''' are a matched pair. Look for the male connector that comes with a gasket.
TE connectivity '''776164-1''' and '''776163-1''' are a matched pair. Look for the male connector that comes with a gasket. ( these are a right angle pin connector, the straight pin might be a better option)
 
== Wiring ==
 
the adapter board in the kit is set up so the original oem wiring harness works with the open inverter board.
 
The following connections are populated on the OEM wire harness:
* resolver
* motor temp
* power
* main contactor
* can high/low
 
Diagram found here: <nowiki>http://productions.8dromeda.net/c55-leaf-inverter-protocol.html</nowiki>
 
<pre style="white-space: pre;">
+-----------------------------------+  +------------+
| 47  46  21 20 19 18 17 16 15 14 |  |      x  x |
|          29 28 27 26 25  x 23 22 |  |  6 x  x  x |
| 49  48    x  x  x  x  x  x  x  x |  | 10 x  x  x |
|          45 44 43 42 41 40 39 38 |  |    x  x  x |
+-----------------------------------+  +------------+
</pre>
{|
|-
| - 6 = OUT_BRAKE
|-
| - 10 = IN_BMS
|-
| - 14 = CANH *
|-
| - 15 = CANL *
|-
| - 16 = IN_FORWARD
|-
| - 17 = RES_S2 *
|-
| - 18 = RES_S4 *
|-
| - 19 = RES_R1 *
|-
| - 20 = RES_S1 *
|-
| - 21 = RES_S3 *
|-
| - 22 = IN_START
|-
| - 23 = IN_BRAKE
|-
| - 25 = IN_REVERSE
|-
| - 26 = 5V
|-
| - 27 = RES_R2 (GND) *
|-
| - 28 = THROTTLE2
|-
| - 29 = THROTTLE1
|-
| - 38 = IN_CRUISE
|-
| - 39 = OUT_PWM
|-
| - 40 = OUT_ERR
|-
| - 41 = OUT_OVTG
|-
| - 42 = OUT_DCSW * (! 12V input on original harness, make sure not to connect to 12V but to DC switch!)
|-
| - 43 = OUT_PRE
|-
| - 44 = MTEMP1 *
|-
| - 45 = MTEMP2 *
|-
| - 46 = 12V *
|-
| - 47 = GND *
|-
| - 48 = 12V *
|-
| - 49 = GND *
|-
|Only pins with * are populated on the OEM wire harness
|}

Revision as of 10:30, 11 January 2021

open inverter replacement mother board kit. Assembled and installed in a gen 2 nissan leaf inverter

The Nissan Leaf gen 2 board is a replacement mother board for the gen 2 leaf inverters. it utilizes a adapter board to fit a rev 3 openinverter board in into the leaf inverter.

  • Full control over the nissan power stage.
  • power beyond the stock 80kw. (up to140kw (or more?))
  • wifi interface + tuning
  • OTA software updates and parameters
  • regen and cruise control

The Kit

Gen2 leaf inverter mother board replacement kit. Including revv3 open inverter brain board

The kit comprises of:

  • openinverter rev3 board pre programmed with leaf motor tune
  • Esp8266 wifi board
  • adapter board
  • various connectors
  • a handful of some basic components

The kit is designed to drop in place of the original Nissan logic board. The adapter board is designed to re-use the large proprietary connector that is mounted on the original logic board.

Kit shop link: https://openinverter.org/shop/index.php?route=product/product&product_id=57

Nissan Board Removal

Nissan board, yet to be removed. The large connector on the left must be salvaged and re-used.
OEM Nissan logic board, yet to be removed. The large connector on the left must be salvaged and re-used. 3 allen head bolts can be see in bottom half of photo

The inverter casing attaches directly to the motor.

  • remove the inverter from the motor:
  1. remove the 2 torrox screws holding the inverter/motor phase wire connection cover on.
  2. remove the 3 exposed hex head bolts. each bolt is a phase connections, keep these separate from the rest of the bolts
  3. lift the inverter off the motor, be carful not to bend or nock the coper phase connections.
  • taking the inverter apart
  1. remove the 4 10mm hex head bolts around the connector(?)
  2. remove the connector(?) cover
  3. remove all the hex head bolts around the inverter
  4. with a mallet tap around the seam in the inverter casing to loosen the sealant
  5. pry the case open, carefully lift the 2 case half's apart.
  • removing the mother board

the oem mother board is easly distinguished as it has the large proprietary connector attached. It is on it's own aluminum bracket attached to the case by 3 allen head bolts.

  1. disconnect the plugs from the four connectors at the top of the board.
  2. remove the allen bolts to free the bracket and board.
  3. remove the screws holding the board to the bracket Nissan uses some very strong thread lock so be prepared for some of the screw heads to shear.*carefully heating the screw will help break down the thread lock
Nissan Proprietary connector as seen from outside the housing.
Nissan Proprietary connector as seen from outside the housing.
Pin function descriptions, pins as seen from outside the housing
Proprietary connector pin function descriptions, pins as seen from outside the housing.

Once the board has been removed from the carrier,the large connector must be salvaged from it. One method is shown in the swap video, a vacuum soldering iron is also known to work.

Swap video: https://www.youtube.com/watch?v=T_6hw6vGzfM

Kit Build

  1. Solder the components to the board as per the instructions.
  2. The large proprietary connector must be salvaged from the original Nissan logic board. as it is not available on the open market. once salvaged, solder it onto the adapter board.
  3. plug in the rev 3 board and wifi adapter.
  4. clean up the wiring harness
  5. connect 12v to power up the board and test that it is working. login to the wifi interface.
  6. Use fresh screws to attach the board to the carrier and bolt it back in place using the allen head screws.
  7. connect the gate drivers to the adapter board
  8. see rev3 board page

Proprietary Connector

Not all pins of the connector are available. The top group are blanked off, so the brake and BMS signals are not available.

The resolver and CAN bus signals remain on the same pins as used by Nissan. If other signals are required then they must be added to the female connector.

The Toyota hybrid series car inverters (Gen 3 Prius confirmed) use the same connector.

A 3D printable plug for the 35pin ampseal connector may work in this instance.(originally designed for the Prius gen 3 inverter)

https://openinverter.org/forum/viewtopic.php?f=14&t=836

orginal form post with a set of variants

https://openinverter.org/forum/viewtopic.php?f=14&t=488&start=100#p11671

There are multiple part numbers for the large 35 way Ampseal through hole socket, with small mating differences, be sure to get a matching pair.

TE connectivity 776164-1 and 776163-1 are a matched pair. Look for the male connector that comes with a gasket. ( these are a right angle pin connector, the straight pin might be a better option)

Wiring

the adapter board in the kit is set up so the original oem wiring harness works with the open inverter board.

The following connections are populated on the OEM wire harness:

  • resolver
  • motor temp
  • power
  • main contactor
  • can high/low

Diagram found here: http://productions.8dromeda.net/c55-leaf-inverter-protocol.html

+-----------------------------------+  +------------+
| 47   46   21 20 19 18 17 16 15 14 |  |       x  x |
|           29 28 27 26 25  x 23 22 |  |  6 x  x  x |
| 49   48    x  x  x  x  x  x  x  x |  | 10 x  x  x |
|           45 44 43 42 41 40 39 38 |  |    x  x  x |
+-----------------------------------+  +------------+
- 6 = OUT_BRAKE
- 10 = IN_BMS
- 14 = CANH *
- 15 = CANL *
- 16 = IN_FORWARD
- 17 = RES_S2 *
- 18 = RES_S4 *
- 19 = RES_R1 *
- 20 = RES_S1 *
- 21 = RES_S3 *
- 22 = IN_START
- 23 = IN_BRAKE
- 25 = IN_REVERSE
- 26 = 5V
- 27 = RES_R2 (GND) *
- 28 = THROTTLE2
- 29 = THROTTLE1
- 38 = IN_CRUISE
- 39 = OUT_PWM
- 40 = OUT_ERR
- 41 = OUT_OVTG
- 42 = OUT_DCSW * (! 12V input on original harness, make sure not to connect to 12V but to DC switch!)
- 43 = OUT_PRE
- 44 = MTEMP1 *
- 45 = MTEMP2 *
- 46 = 12V *
- 47 = GND *
- 48 = 12V *
- 49 = GND *
Only pins with * are populated on the OEM wire harness