1971 GMCe Lexus GS450H BMW 530e Tesla Model S Electruck

[Gregski]

This *is* absolutely fascinating. And thanks for the laughs. Having partially dipped into this myself before this is very relatable and useful.

thanks for the positive feedback, and please don't encourage me, ha ha

[Gregski]

Keep up the good work! I wish people covered other topics as thoroughly.

Yeah, we would have curred Insomnia, that's for sure.

[Gregski]

Keep up the good work! I wish people covered other topics as thoroughly.

Yeah, we would have curred Insomnia, that's for sure, and let's just put it this way you guys are getting the abridged Cliff Notes version the guys on DIY Electric Car Forum are getting the whole nine yards!

[johu]

Now there's one thing that puzzles me. I'm trying to read the numbers upside-down, or backwards or insert random commas. It doesn't compute... Is one sub-harness actually seven thousand US dollars?!

[Gregski]

Now there's one thing that puzzles me. I'm trying to read the numbers upside-down, or backwards or insert random commas. It doesn't compute... Is one sub-harness actually seven thousand US dollars?!

Yes $7,000 American dollars if you buy it brand new from one of our official Lexus dealers.

[Gregski]

[Gregski]

new video much less crappier than the last one (I promise)

[Gregski]

I am certain All Data the online car manual company will be refunding me my money for all the days I went to their website and it was down, ha ha

[Gregski]

Fun Fact: among the 3,754 different and I mean completely different plugs and connectors on this vehicle (the Lexus GS450h) apparently their designers ran out of steam and decided to use three identical ones, and I mean absolutely samesies for the following three components, which mind you live within a foot of each other

• Power Steering ECU

• Oil Pump Motor Controller

• Front Stabilizer Control ECU

no I am not taking the time to post this because I chased down and pulled the wrong harness [ahem] three times

[Gregski]

so here's a mechanical video, where I actually turn a wrench, spin a spanner, and swing a hammer, (no electricity or wire harness talk I promise)

[Gregski]

well I just wasted a couple days wiring the four temp sensors on the gray A Connector only to find out these don't work do to the wrong resistors on the PCB?

#define OilpumpTemp A7
#define TransTemp A4
#define MG1Temp A5
#define MG2Temp A6

so we totally do not need to run these 8 temp wires on Pins 1-8

[Gregski]

which means these two virtual gauges are a lie, lol (now technically they do work they just don't report what they say, instead as the code reads "Using water temp for now")

[Gregski]

but I'm pretty sure you much rather see things spinning

[Gregski]

slightly irked by this latest finding, I decided to unpin the unnecessary temp sensor wires from both resolver cables Sumitomo plugs for that clean slick look

Fun Level: -2

[PatrcioEV-ATX]

Since I completed my entire wire harness before I realized that none of those work, I've left it all. It's easier than undoing it and maybe someone will eventually work out the temp issues. I am considering removing PB1-3 however to use those as auxillary 5v inputs. Maybe for cruise control. I really don't think I'm going to bother with shifting gears and I pretty much ruined two of my four mosfets when trying to replace the incorrect ones on the board. The more I think about it, the entire transmission connector (SLs, PBs, etc) can probably be repurposed.

[Gregski]

Since I completed my entire wire harness before I realized that none of those work, I've left it all. It's easier than undoing it and maybe someone will eventually work out the temp issues. I am considering removing PB1-3 however to use those as auxillary 5v inputs. Maybe for cruise control. I really don't think I'm going to bother with shifting gears and I pretty much ruined two of my four mosfets when trying to replace the incorrect ones on the board. The more I think about it, the entire transmission connector (SLs, PBs, etc) can probably be repurposed.

I hear you, that was the very next thing I did I ditched all the Transmission Shift Solenoid wires on Pins 9- 14 saying good by to that gray transmission plug all together

#define TransPB1 40
#define TransPB2 43
#define TransPB3 42

#define TransSL1 47
#define TransSL2 44
#define TransSP 45

[Gregski]

So my not doing continued and I was not doing anything just fine until I came across the Oil Pump wiring/pin out, I know I can ditch the Oil Pump relay on pin 15 on the gray A Connector, but as one forum member suggested, can I repurpose Pin #6 on the black B Connector for the Oil Pump PWM ? Thoughts and comments appreciated

#define OilPumpPower 33
#define OilPumpPWM 2

A COMMENT FROM MY FUTURE SELF:

Pin #15 is not OIL PUMP Power by any means it is the MOST IMPORTANT Pin in the whole setup it is the "Pre-Charge" circuit

[PatrcioEV-ATX]

So my not doing continued and I was not doing anything just fine until I came across the Oil Pump wiring/pin out, I know I can ditch the Oil Pump relay on pin 15 on the gray A Connector, but as one forum member suggested, can I repurpose Pin #6 on the black B Connector for the Oil Pump PWM ? Thoughts and comments appreciated

VCU Wiring A Connector - Oil Pump.jpg

Well as far as I know, the Inverter relay is a digital output (on/off) where the Oil Pump Pwm is an analog output (0-5v) so unless you want your pump running at 100% that won't work. I don't know how to interpret what the different microchip pins are capable of, however. I don't know if anyone is running the pump over 50%. Is it possible to re#Define the Inverter relay pin to a different analog pin? Maybe.

[Gregski]

So my not doing continued and I was not doing anything just fine until I came across the Oil Pump wiring/pin out, I know I can ditch the Oil Pump relay on pin 15 on the gray A Connector, but as one forum member suggested, can I repurpose Pin #6 on the black B Connector for the Oil Pump PWM ? Thoughts and comments appreciated

VCU Wiring A Connector - Oil Pump.jpg

Well as far as I know, the Inverter relay is a digital output (on/off) where the Oil Pump Pwm is an analog output (0-5v) so unless you want your pump running at 100% that won't work. I don't know how to interpret what the different microchip pins are capable of, however. I don't know if anyone is running the pump over 50%. Is it possible to re#Define the Inverter relay pin to a different analog pin? Maybe.

it is my understanding that PWM is a fake analog signal so it would make sense that it runs on a digital line

here is how they are defined in the code (they look similar just on different numbers):

#define OilPumpPWM 2
#define InvPower 34

and here is how analog pins are defined:

int Throt1Pin = A0; //throttle pedal analog inputs
int Throt2Pin = A1;

[Gregski]

alright moving down the list, next is Pin #17 on the gray A Connector, in the code aka Sketch it is defined like so on pin 50 (can someone explain to me how it can be on pin 50 out of 40 total pins between the two 20 pin connectors? ha ha)

#define Out1 50


this one controls the HV battery Main Contactor, and by controls I mean turns it off at startup (I really don't get it yet as no where in the code it turns it back on)

digitalWrite(Out1,LOW); //turn off at startup

[mayes8229]

So my not doing continued and I was not doing anything just fine until I came across the Oil Pump wiring/pin out, I know I can ditch the Oil Pump relay on pin 15 on the gray A Connector, but as one forum member suggested, can I repurpose Pin #6 on the black B Connector for the Oil Pump PWM ? Thoughts and comments appreciated

VCU Wiring A Connector - Oil Pump.jpg

Well as far as I know, the Inverter relay is a digital output (on/off) where the Oil Pump Pwm is an analog output (0-5v) so unless you want your pump running at 100% that won't work. I don't know how to interpret what the different microchip pins are capable of, however. I don't know if anyone is running the pump over 50%. Is it possible to re#Define the Inverter relay pin to a different analog pin? Maybe.

it is my understanding that PWM is a fake analog signal so it would make sense that it runs on a digital line

here is how they are defined in the code (they look similar just on different numbers):

#define OilPumpPWM 2
#define InvPower 34

and here is how analog pins are defined:

int Throt1Pin = A0; //throttle pedal analog inputs
int Throt2Pin = A1;

Looks like the design uses a power switch (https://www.onsemi.com/pdf/datasheet/ncv8401-d.pdf) for the Inverter Power signal and an N-FET (https://www.onsemi.com/pdf/datasheet/fdt457n-d.pdf) for the Oil Pump PWM. Both are digital pins on the processor, but I don't think you can PWM that power switch unless the PWM frequency is less than 1KHz which is not likely.

[mayes8229]

alright moving down the list, next is Pin #17 on the gray A Connector, in the code aka Sketch it is defined like so on pin 50 (can someone explain to me how it can be on pin 50 out of 40 total pins between the two 20 pin connectors? ha ha)

#define Out1 50


this one controls the HV battery Main Contactor, and by controls I mean turns it off at startup (I really don't get it yet as no where in the code it turns it back on)

digitalWrite(Out1,LOW); //turn off at startup



VCU Wiring A Connector - Contactor Question.jpg

The pin numbers in firmware don't relate to the pin numbers on the connectors. They map the signals in firmware to the correct port pin on the microcontroller (there are way more than 50 pins on the MCU). Also it looks to me like pin #17 on that connector is "IN1" when I read the schematic.

Are you using a V1 or a V2 board?

[Gregski]

The pin numbers in firmware don't relate to the pin numbers on the connectors. They map the signals in firmware to the correct port pin on the microcontroller (there are way more than 50 pins on the MCU). Also it looks to me like pin #17 on that connector is "IN1" when I read the schematic.

Are you using a V1 or a V2 board?

First thank you so much for your help, you are offering a lot of good information so let me respond to you and address your points one by one.

Are you using a V1 or a V2 board?

Honestly I am still a little bit confused by this, I think I bought V2, I got it from here Lexus GS450H VCU

When I say I am confused, it is because in one place it reads: "V2 controller for the Lexus GS450H inverter" and then you click the link and it reads: "Product Code: gs450h_v1_built" so which is it? ha ha and then on Damien's GitHub he actually has a V3 folder with a HARDWARE sub folder, what ever that is?

as listed

and actual (I understand there is a parts shortage, absolutely no complaints here)

[PatrcioEV-ATX]

The pin numbers in firmware don't relate to the pin numbers on the connectors. They map the signals in firmware to the correct port pin on the microcontroller (there are way more than 50 pins on the MCU). Also it looks to me like pin #17 on that connector is "IN1" when I read the schematic.

Are you using a V1 or a V2 board?

First thank you so much for your help, you are offering a lot of good information so let me respond to you and address your points one by one.

Are you using a V1 or a V2 board?

Honestly I am still a little bit confused by this, I think I bought V2, I got it from here Lexus GS450H VCU

When I say I am confused, it is because in one place it reads: "V2 controller for the Lexus GS450H inverter" and then you click the link and it reads: "Product Code: gs450h_v1_built" so which is it? ha ha and then on Damien's GitHub he actually has a V3 folder with a HARDWARE sub folder, what ever that is?

as listed

2020-05-17 11.29.38-500x500.jpg




and actual (I understand there is a parts shortage, absolutely no complaints here)

IMG_5499.JPG

"it is my understanding that PWM is a fake analog signal so it would make sense that it runs on a digital line"

Yes, sorry... brain lapse. Analog pins are for reading analog signals. As to main positive contactor, you're running V3_User which doesn't have that section in it. I'm using that pin to turn on brake lights over a certain regen value and OilPumpPower pin for HV. You can trigger negative contactor and precharge relay with ignition on. Mine even goes a bit further and won't return torque until the HV void has run:

#define HV_Power 33 //OilPumpPower in other versions
int readyVal;
int HVpreset=10; //I'm still on a 60v power supply


short get_torque() {
//accelerator pedal mapping to torque values here

ThrotVal=analogRead(Throt1Pin);

if (ThrotVal<parameters.Min_throttleVal+10) ThrotVal=parameters.Min_throttleVal; //dead zone at start of throttle travel

if (readyVal==true) {
if(gear==DRIVE) ThrotVal = map(ThrotVal, parameters.Min_throttleVal, parameters.Max_throttleVal, 0, MaxTorque);
if(gear==REVERSE) ThrotVal = map(ThrotVal, parameters.Min_throttleVal, parameters.Max_throttleVal, 0, MaxReverse_Torque);
if(gear==NEUTRAL) ThrotVal = 0;//no torque in neutral
} else {
ThrotVal = 0; //actually this section is much different in my code, but this is specifically to account for the main contactor having closed before we can command torque so that there is no possibility of commanding torque when just the precharge circuit is providing voltage.

void setup()

pinMode(HV_Power, OUTPUT); //OilPumpPOwer in other versions. Main positive contactor ground for relay control after precharge
digitalWrite(HV_Power,LOW); //on oil pump 12v power supply

void HV_On() {
if (Sensor.Voltage>HVpreset) {
digitalWrite(HV_Power,HIGH);
readyVal=true;
} else {
readyVal=false;
}

add to void loop:

HV_On();

Like with everything else, there are many ways to do this - some simpler, some more complex. Most OEM systems turn the precharge relay off once the main contactor closes. We're somewhat limited with the number of in/outputs on this VCU. I currently have Sensor.Voltage going to a 2nd Arduino(Nano) on the CAN line and controlling all three contactors with that. I am only using the HV_On void to update readyVal (which I also sent over CAN to my Arduino(Mega)/Nextion for various purposes).

And I can't stress this enough: There are MUCH, MUCH more knowledgeable, more experienced people on here than me! Take anything I say with that in mind.

[mayes8229]

Honestly I am still a little bit confused by this, I think I bought V2, I got it from here Lexus GS450H VCU

When I say I am confused, it is because in one place it reads: "V2 controller for the Lexus GS450H inverter" and then you click the link and it reads: "Product Code: gs450h_v1_built" so which is it? ha ha and then on Damien's GitHub he actually has a V3 folder with a HARDWARE sub folder, what ever that is?

as listed

2020-05-17 11.29.38-500x500.jpg




and actual (I understand there is a parts shortage, absolutely no complaints here)

IMG_5499.JPG

Your board has V2 in silkscreen, so there's your answer. Because it's a V2 there's a different power switch and a BJT rather than a FET, but that doesn't change the previous comment about not being able to PWM that signal.