Leaf DC-DC Not Working with Zombiverter Topic is solved

[maiks]

Hello,
I am using a Zombiverter with a Leaf drivetrain. I have provided both 12V and switched 12V power to the PDM and Inverter and other connections as explained by Damienm, but the DC-DC converter is not charging the car's 12V battery as expected. When I start the car, it moves, but the PDM is not sending voltage to the 12V battery. What could be the problem? Below are my params

[tom91]

Please provide pictures of your installation.

What version of Zombie firmware.

Also it is NOT failed, it just is not working... Please use accurate thread titles.

[maiks]

Please provide pictures of your installation.

What version of Zombie firmware.

Also it is NOT failed, it just is not working... Please use accurate thread titles.

thank for replying. its V2.20A

[arber333]

Hello,
I am using a Zombiverter with a Leaf drivetrain. I have provided both 12V and switched 12V power to the PDM and Inverter and other connections as explained by Damienm, but the DC-DC converter is not charging the car's 12V battery as expected. When I start the car, it moves, but the PDM is not sending voltage to the 12V battery. What could be the problem? Below are my params

See here for start protocol...
viewtopic.php?t=1532

This should get you at least 14V. See if you have your pins connected correctly.

[Bratitude]

See here for start protocol...
viewtopic.php?t=1532

This is for the gen1, said user has a pdm.


Is the pdm case grounded to the 12v battery?

This is key

[tom91]

Please provide pictures of your installation.

[J0hannes]

Got the same question in mind

Is the pdm case grounded to the 12v battery?
This is key

These highlighted connect DIRECTLY to 12V battery

[Jack Bauer]

V2.20A

Headlights, heater blower and rear window heater on.

[maiks]

Got the same question in mind


PDM_battery_connections.jpg

These highlighted connect DIRECTLY to 12V battery

yes I connected it like that.
I have spent the entire day trying to fix it but still it has not worked, i opened the pdm top cover to confirm if 12v is reaching

Here are my connection details
Connection Details:
CAN Bus Connections:

PDM and Inverter VCU can connection:
Green wire (CAN H) → VCU CAN Ext 2 H
Blue wire (CAN L) → VCU CAN Ext 2 L

ISA Shunt CAN connection to VCU:
CAN H→VCU CAN Ext 2 H
CAN L→ VCU CAN Ext 2 L
ISA Shunt to VCU:

Power Supply Connections:
Permanent +12V:
Red wire from leaf harness → Connected to permanent +12V
Dark Green wire from leaf harness → Connected to permanent +12V

Switched +12V:
Purple wire from leaf harness → Connected to switched +12V
Light Green wire from leaf harness → Connected to switched +12V

EV Relay Connections (4-pin relay):
Pin 1 → Connected to permanent +12V
Pin 2 → Connected to permanent +12V
Pin 3 → Connected to VCU's Inverter Power LS switch (for control)
Pin 4 → Provides switched +12V

[maiks]

This is for the gen1, said user has a pdm.


Is the pdm case grounded to the 12v battery?

This is key

yes l provided 12V and grounded pdm case to the 12v battery

[tom91]

PDM and Inverter VCU can connection:
Green wire (CAN H) → VCU CAN Ext 2 H
Blue wire (CAN L) → VCU CAN Ext 2 L

So to CAN2, why is your chargercan and invertercan set to '0' better known as CAN 1 ?!?!?!?!?!?!?

Also no idea on wire colours so cannot help you there.

[maiks]

So to CAN2, why is your chargercan and invertercan set to '0' better known as CAN 1 ?!?!?!?!?!?!?

Also no idea on wire colours so cannot help you there.

I connected the PDM and inverter CAN to the VCU CAN EXT 1, and the ISA shunt to CAN EXT 2, as shown in this diagram: https://openinverter.org/wiki/File:Zomb ... iring1.png

I then updated the VCU web interface to reflect these changes (InverterCan to CAN1, ChargerCan to CAN1, and ShuntCan to CAN2). However, this update resulted in a failure with the error "UdcBelowUdcSw" and the operation mode remained in PRECHARGE. When I switched ShuntCan to CAN1, the vcu successfully transitioned to RUN mode, but there is still no 14V output from the DC-DC converter.

[Bratitude]

I connected the PDM and inverter CAN to the VCU CAN EXT 1, and the ISA shunt to CAN EXT 2, as shown in this diagram: https://openinverter.org/wiki/File:Zomb ... iring1.png

I then updated the VCU web interface to reflect these changes (InverterCan to CAN1, ChargerCan to CAN1, and ShuntCan to CAN2). However, this update resulted in a failure with the error "UdcBelowUdcSw" and the operation mode remained in PRECHARGE. When I switched ShuntCan to CAN1, the vcu successfully transitioned to RUN mode, but there is still no 14V output from the DC-DC converter.

when you say the purple is on switched 12v, is that powered by a relay that is controlled via zombie?

Also have you connected the zombie to the correct canbus off the pdm? you may have them swapped or H/L swaped

[maiks]

when you say the purple is on switched 12v, is that powered by a relay that is controlled via zombie?

Also have you connected the zombie to the correct canbus off the pdm? you may have them swapped or H/L swaped

Yes its powered by relay that is controlled via zombie. Does the pdm and inverter run different can wires or both use the same? Am using leaf gen 2 drivetrain (2015)

[maiks]

After carefully reviewing Damien's videos on the Leaf drivetrain, I realized that the wiring for Gen 2 and Gen 3 Leaf drivetrains differs. For instance, in this video link the stack shown is for Gen 3, and Damien mentions that both the inverter and PDM require permanent 12V and switched 12V power. However, in another video link where he uses a Gen 2, he specifies that the PDM requires 12V, and the inverter needs switched 12V.

I have a Gen 2, and I mistakenly wired it according to the Gen 3 configuration, which could be the source of the problem. Could you kindly provide a pinout or wiring diagram for the Nissan Leaf Gen 2?

[J0hannes]

Could you kindly provide a pinout or wiring diagram for the Nissan Leaf Gen 2?

You can’t 100% trust just colors as they have changed between year models and there are a limited number of colors, so multiple wires can be of same color. Also engine harness is super fun as some colors change in the looms between the E8/F1 engine loom connection.
You really need to check correct wiring from connector pinout.

Do you have the engine harness connector in your wiring loom? You could use the pinout for it to find all the needed connections.
If yes, you could use the Leaf main engine loom E8 doc kindly shared by Active automation in their Google https://docs.google.com/document/d/1jQd ... d1CFSV_lEo

If you have a cut loom, I’d trace the connections by measuring continuity from the PDM and inverter terminals to the flying lead end and then mark the corresponding wire with label. Just don’t push anything in the female terminals to avoid damage and continuity problems in the future.

A really good source for information (for hopefully obvious reasons) is the Leaf SM. EVC, TMS and powersupply, ground and circuit elements are probably three most useful manuals to look at. They have also details on diagnostics and signal types and voltage levels which are useful if you need to determine that things work like they shoud.

[Bratitude]

in the latest zombie release, the inverter is now powerd via switched 12v also, that is not a source of your problem.

as j0hannes said, you need to wire according to the connectors, NOT the wire colors. re wire and start again.

[maiks]

You can’t 100% trust just colors as they have changed between year models and there are a limited number of colors, so multiple wires can be of same color. Also engine harness is super fun as some colors change in the looms between the E8/F1 engine loom connection.
You really need to check correct wiring from connector pinout.

Do you have the engine harness connector in your wiring loom? You could use the pinout for it to find all the needed connections.
If yes, you could use the Leaf main engine loom E8 doc kindly shared by Active automation in their Google https://docs.google.com/document/d/1jQd ... d1CFSV_lEo

If you have a cut loom, I’d trace the connections by measuring continuity from the PDM and inverter terminals to the flying lead end and then mark the corresponding wire with label. Just don’t push anything in the female terminals to avoid damage and continuity problems in the future.
IMG_1196.jpeg

A really good source for information (for hopefully obvious reasons) is the Leaf SM. EVC, TMS and powersupply, ground and circuit elements are probably three most useful manuals to look at. They have also details on diagnostics and signal types and voltage levels which are useful if you need to determine that things work like they shoud.

Thank you, J0hannes.

I have carefully checked the F18 connectors, and my connections appear to be correct. The pinout is as follows:

Pin 18: 12V permanent
Pin 16: Switched 12V
Pin 11: CAN Low
Pin 27: CAN High
Pins 29 and 30: cp and pp
I have rewired everything according to the diagram here: https://openinverter.org/wiki/images/5/ ... iring1.png. The inverter is working, but the DC-DC converter is still unresponsive.

Additionally, I've noticed that when I change the interface on the VCU from "Unused" to "Chademo," the contactors switch on, and the operation mode changes to "Charge," with the charging type set to "AC."

A couple of questions:

What gauge wire should be used for the negative 12V connection from the 12V battery to the PDM?
How can I verify if the PDM is receiving power?

[maiks]

in the latest zombie release, the inverter is now powerd via switched 12v also, that is not a source of your problem.

as j0hannes said, you need to wire according to the connectors, NOT the wire colors. re wire and start again.

Have tried but still it has failed

[Bratitude]

Have tried but still it has failed

Are the internal lv connections in the pdm properly connected? I’ve had issues in the pass which the connectors not being fully seated.

[maiks]

Are the internal lv connections in the pdm properly connected? I’ve had issues in the pass which the connectors not being fully seated.

Am going to first change the negative cable from the 12v battery to pdm to bigger cable and incase this fails am going to check the internal lv connections

[J0hannes]

What gauge wire should be used for the negative 12V connection from the 12V battery to the PDM?
How can I verify if the PDM is receiving power?

If you match the negative battery cable with same gauge as the positive battery cable.
I think the OEM wire is 35mm2, so choose that or a size thicker.

PDM function is maybe somewhat tricky to determine without looking at CAN messages.
There aren't that many clues to look at, but the PDM will tell it in the CAN messages if it is upset

[maiks]

If you match the negative battery cable with same gauge as the positive battery cable.
I think the OEM wire is 35mm2, so choose that or a size thicker.

PDM function is maybe somewhat tricky to determine without looking at CAN messages.
There aren't that many clues to look at, but the PDM will tell it in the CAN messages if it is upset

I have managed to make it work. Thank you all for your knowledge and guidance

DC-DC Solution: Upon reviewing the CAN messages, I discovered that the PDM wasn't receiving any signals. Upon opening the unit, I identified that low voltage was not reaching the PDM via connectors F18/F23. To resolve this, I implemented a bypass, and the system started functioning correctly.

AC Charging Solution: I connected the PDM's permanent 12V (pin 18 on the F18/F23 connector) to the permanent 12V supply. Then, I routed the PDM's switched 12V (pin 16 on the F18/F23 connector) to the EV relay( controlled by the VCU switched 12V). Additionally, I established the CP and PP connections.

[Bratitude]

DC-DC Solution: Upon reviewing the CAN messages, I discovered that the PDM wasn't receiving any signals. Upon opening the unit, I identified that low voltage was not reaching the PDM via connectors F18/F23. To resolve this, I implemented a bypass, and the system started functioning correctly.

A

Can you provide ore details and photos

Is the connector pinout wrong?

was there a damaged connector?

[maiks]

Can you provide ore details and photos

Is the connector pinout wrong?

was there a damaged connector?

Yes my f18 connector was damaged.
The pinout is correct and l followed it to trace wires inside the pdm, cut them and made a bypass .