Outlander

[seanyt]

Hi
All i just got my hands on a v3.0 board and straight into taking apart my outlander inverter.
So far im contemplating to use the existing outlander inverter board to supply all the voltages needed to the gates driver board etc.

I have powered up the inverter board with the gate driver board disconnected and i get a 10khz signal at 8v on the resolver exciter.
5v to the current sensors and 2.5v out of both current sensors

The current sensors are neatly packed and i hope to keep them, i did trace the signal from each one to the original IC and it still stays at 2.5v
Im hoping there is an easy solution for current sensor and voltage sensor thats somewhat oem looking at least.

Looking at the Leaf daughterboard at a guess the current sensors are 3.3v items not 5v items or does the board use a simple voltage divider to get the correct signal voltage
The power/canbus and resolver wires will be easy to complete, however the motor has two temperature sensors and the v3.0 board only has one input. So that will need looking at.


Also the original cabling on the outlander rear motor is not terribly big 38 is written on the battery terminal and 22 on the phase terminal.
Most of the bus bars used are 15mmx1.5mm except for slightly thicker ones straight from the igbt's


I hope to check the sin/cos peak to peak voltage tomorrow when i get time from the resolver.
I also have a 100v dc pack on standby for testing from my ebike when im ready for light testing.

[pemtek]

The igbt driver pcb has a voltage sense built in that stops the inverter working below about 200v.

You can see an obvious row of 150k series resistors totalling 900k making a potential divider with a 3k3.

Phil

[seanyt]

thanks thats a great help i traced the lines to a DC voltage isolation sensor.
I havent been able to find what wire it terminates to on the IGBT header yet but,

I did find a previous persons work on endless sphere where he traced most of the wires for the header, i doubled checked his work and found some additional wires. So just two left on the header that are possibly voltage sensor.

Inverter Header
1 PWM Cathode OPTO 1 XX
2 5VA XX (T1,2,3+)
3 PWM Cathode OPTO 3 XX
4 FAULT (NOTE: all 6 OPTO outputs connected together) XX
5 PWM Cathode OPTO 5 XX
6 UVLO (NOTE: all 6 OPTO outputs connected together) XX
7 GND
8 Not Connected??
9 GND
10 Temperature?? XX T1
11 PWM Cathode OPTO 2 XX
12 Temperature?? XX T2
13 PWM Cathode OPTO 4 XX
14 Temperature?? XX T3
15 PWM Cathode OPTO 6 XX
16 15V
17 5V
18 15V
19 5V
20 Not Connected??

So when i have it all back together i will test 8 and 20 with some dc voltage behind it. i should at least get a signal with my 24s pack.
I do also have 16 modules of vtc6 that are all 4s6p so i can get a 96s pack together if needed.

I also ordered 1k2 and 2k4 smd resistors to build up a voltage divider for the 5v current sensors.
So progress so far aint too bad.
Im not an electronics engineer so if anyone has any further feedback im happy to take on advice.


This motor, inverter and eventually a 10kw battery of vtc6 are being fitted into the rear of a car im working on to make it a hybrid.
I have outlander driveshaft, wheelbearing etc all ready to go in when i have the motor running.

Everything will be communicated through the canus portion of the v3.0 board also.

[pickmeup]

i have definitely subscrived to this thread as I have the PHEV outlander rear diff nearly mounted into a mini subframe, with the next and most important task of getting the motor to turn.
So are you going to use the v3.0 as a piggyback to the OEM board initially? I havent got the Meiden OEM inverter yet but will purchase one soon.
I look forward to seeing your progress.