Prius Gen2 bench test

[kon]

Hi,
I have a prius gen 2 board wired up and ready for a test on real hardware (inverter).
Before doing that I want to verify that everything is working correctly.
I have it on the bench, powered with a 12V PSU. See parameters attached. I can start the inverter in manual mode, however get opmode returns 1 and in the Spot Values I can see opmode is run and not manual run.

I probed all pins of the 12pin connector, and none have a PWM signal.
Is there anything I am missing?

Thanks!

[ZooKeeper]

Which board (VCU) are you using?

[kon]

Gen 2 SMD version

[johu]

start pin constantly high? Also set udcnom=0 for testing.

[kon]

20pin connector only has +12 and GND connected, I can see that my opmode switches to RUN when touching +12 to the start pin.
I'm getting the following error msg:
[97950]: DERATE - TMPHSMAX
thmphsmax is already maxed out to 150°C , but tmphs is at 166.28°C

[kon]

Got around the tmphsmax by hard coding it to a random value within limits and recompiling the FW.
I still can't start the inverter in manual mode.
error memory shows
STOP - DESAT
I can get opmode to 1.0 by holding start pin high, but still no PWM out. Starting inverter in manual mode won't change opmode (stays 0)

[johu]

Have you connected ALL inverter pins on the 12 pin connector? That will give you a valid temperature and remove the DESAT error

[kon]

This test was board only (no inverter connected). I wanted to verify the output on the bench first, before connecting it to the inverter.
I was hoping that there is a way of testing outputs without inverter, but I guess it's easier to test with the board connected to the inverter ...

[johu]

oh ok. Well then connect a the desat input (MFIV) to 6V or more.

[kon]

Thanks Johannes! I got it hooked up to the inverter, and was able to spin the motor in manual mode.
I'm using a kollmorgen kbm motor, and a 12V PSU.
The motor itself does not have an encoder, but I could buy one if needed.
Next step is hooking up a TPS (I have a spare e46m3 pedal) and run it in non-manual mode. Do I need an encoder for this to work, or should it work without? This is just for an on-the-bench test setup, I'm planing on using a leaf motor with encoder in the final install.
thanks

[kon]

I got it all running, using a 48V battery, leaf motor/resolver and FOC firmware. only issue I'm having is that the motor won't stop spinning once it started (after throttle input)

[LRBen]

I got it all running, using a 48V battery, leaf motor/resolver and FOC firmware. only issue I'm having is that the motor won't stop spinning once it started (after throttle input)

Sounds like the resolver wires are not in the right combination. The FOC tuning video goes over that pretty well. I had the exact same thing when I was setting mine up.

[ZooKeeper]

I got it all running, using a 48V battery, leaf motor/resolver and FOC firmware. only issue I'm having is that the motor won't stop spinning once it started (after throttle input)

Yea, been there, done that :O

That condition is due to syncoffs not being correct (FOC tuning performed) PRIOR to utilizing the throttle input.

Fortunately there is a FOC tuning video now that does an excellent job of walking one thru the process.

[kon]

thank you, got it tuned and it runs like clockwork now!