83 Hilux
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Still debugging, reaching out for advice if anyone has any.
Just looking at what has changed between the bench test and engine bay test at the minute.-PDM separation from the inverter and its orientation. Anyone else run their system with the PDM mounted vertically as above?
I have connected the inverter and motor castings to 0V since the stack is now separated.-also connected a logic analyser to the OLED CAN H and CAN L, to get a sense of whether can frames are corrupted. With limited success, likely down to test setup.
I intend to go through a process of elimination, and if every node on the bus is chatting, then I'll assume the issue isn't CAN related, since it worked before.
As seen below, no chatter on one of the CAN lines, this I think is down to the logic analyser trigger level. more work to do here.-Another picture shows HV is reaching the inverter, through the pre-charge contactor+resistor, but the system stops there and the second contactor does not close. Anyone think 378 V is too low causing the system to stop there?
-Lastly, the OLED has been through a bit of grief, I separated the boards to add a board to board connector, and re-fitted the can and power connector. This rework could be the culprit and I suspect I will be replacing the OLED soon. I think the OLED CAN board is an STM32 and I know STMs are specifically sensitive to static.
Thanks, any pointers are appreciated.
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Based on old screen grabs of my system as reported by LeafSpy 378v should be about 80% SOC, so that’s not low.
Never seen a PDM like that. Not saying it’s not going to work, but you’d need to check coolant flows ok.
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Thanks Ian. That’s helpful. From what I remember last time the system powered properly it was around 80% which checks out. Good point, I will make sure to check coolant flow in a future test.
Today I lifted the PDM out and mounted it horizontally, the system still didn’t power up properly.
I also recorded some more can frames so will look at the payload and see if isak can shed some light on what is missing from the data.
I still suspect the OLED but prefer to get more facts instead of problem solving just by replacing parts. Let’s see. -
I’ve seen others may have had a failed oled.
If you don’t have LeafSpy setup it’s worth doing that as another way of gaining insight into the system. Having said that mine isn’t working right now after having worked for a year for reasons I don’t understand. -
@ianlighting could you let me know what Bluetooth reader you are using for leafspy so I can make sure I buy a compatible one? Cheers
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LeLink2.
Think there’s a ‘1’ version aswell out there but I bought the prebuilt loom from Resolve and they included the 2 vers. They look similar, but zoom in to see a small 2 in the logo. -
Working on a similar build but with a 1980 pickup. I have not yet tried fitting the stack back in the truck (w transmission). Wondering now if the PDM will clear the firewall! I have seen several builds move the pdm to alternative location and connect with cables so I know it can be done and will take encouragement from your build!
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LeLink2 ordered and will try that likely next week to see what is available on the CAN Bus.
In the meantime, here are some CAN frames if anyone has any wisdom they would like to share on which CAN IDs correspond to what parts of the system.
I found this page https://github.com/dalathegreat/leaf_can_bus_messages but can't seem to link the IDs described to the data I have captured.
@isak if possible it would be great to know if the sequence below indicates what is wrong, I have a text file of the whole sequence I can send you. This is a lot of work so no problem if not, but would be great to know what each ID corresponds to. Thank you
Will see what leafspy says next week, failing that I will be ordering a new OLED.
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The PDM doesn’t clear the firewall lol, at least if your adapter plates are the same thickness as mine. Hence why I removed mine, can send some pictures of the motor and PDM mounts if that helps
@RufusL That is some good info to know in advance thanks. I would love some pictures of your motor and PDM mounts. Always wanted to try welding - this may be the time. As the PDM is mounted I cant tell how the radiator/fan is situated. Are you using the original truck radiator?
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Could there be an issue where the inverter or motor is missing a ground to the chassis? Could the input power to the inverter be hot but something in the controller or BMS not activating because it is missing a pathway to chassis ground in the 12 system that it would normally have through the physical connection with the pdm that is now gone? Not sure if I am thinking this out fully but might be worth establishing a temp route to chassis from the inverter housing just to see if that might be the problem?
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@RufusL That is some good info to know in advance thanks. I would love some pictures of your motor and PDM mounts. Always wanted to try welding - this may be the time. As the PDM is mounted I cant tell how the radiator/fan is situated. Are you using the original truck radiator?
@badkins I’ll get some photos to you soon, my first proper welding job too, pretty simple if you use some thicker material, I’ve got a hobby gas mig welder and that’s doing the job fine.
Good thinking re. the motor ground, I’ve actually got a connection from the inverter casting to battery 0 V so will be sure to check continuity but I don’t think that’s it.
Not using the truck radiator, the PDM is there cos it’s the best space I could find for it with my limited fabrication skills, plan to mount a radiator horizontally above the wheel arch, being EV a small one should do with a decent fan is my thinking. -
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Managed to get leafspy connected. Reads out the cell voltages so I guess BMS CAN working. Unsure how to test PDM and inverter but will look into the app instructions a bit more.
Anyone understand these error messages before I get into the documentation?
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Cleared the codes today to try and power back on but LeLink wouldn’t connect again, gutted. Going to try another reader as it’s connecting fine to another app and read similar issues online between leafspy and lelink.
The first time it did connect and managed to “read ECU versions” but didn’t get much of a readout, bit concerning but not sure until I get a reliable connection. Can anyone share a screenshot of leafspy ecu readout on there resolve setup?
