openinverter forum

Failed Initial Setup with the Prius Gen2 board
I have tried multiple time to start the motor with the Initial Set up procedure, but failed.
There is no sign of any movement, no bulb lights are on or blinking.
Everything is set according to the prescribed procedure of the Initial Setup board: 12V lamp and switch + 3bulbs 12V – 55W to the HV connector in delta mode. The VCU communication is smooth without errors.
Any value settings in MANUALID and MANUAL IQ remained without any change in the behavior of motor.
A member of the Forum suggested to change the Inverter/Converter, presuming it was the cause of the failure. The change did not help either.
Besides all this I am missing the 17 ,18 ,19 commands in the program settings (wmpol,deadtime,ocurlim.)
Later the same member of Forum recommended to reprogram the board with newer FOC version. I tried to do this, but there is no chance to solder any wires for connections to the board , because it comes without pin- connectors for the St.Link V2 unit
That is why I decided to renew the VCU board with the hope , that there will be some improvement in the Initial Set Up, and I can turn the motor at last.
Any hints and suggestions are welcomed, to start moving !

Sorry, but picture not too well focused. Which stepd in the initial setup work?
I don't see the 2 pin connector (I9 I think) hooked up to 12v supply.

It would be helpful for you to be more precise about what you're doing and what you've done.

Show pictures or draw diagrams of what you've connected and how (your one photo is blurry and doesn't really show anything).

Link what procedure you're following and where you got stuck, if anywhere.

RetroZero wrote: ↑Thu Dec 15, 2022 8:35 pmI don't see the 2 pin connector (I9 I think) hooked up to 12v supply.

It's there. Left of the i10, black cable with glossy tape wrapped around it.

...

Again though, if you want people to help troubleshoot, they have to tell the difference between "roughly correct" and "exactly correct" to spot your possible mistakes. So, everything you've done needs to be much clearer.

DIETZENBACH wrote: ↑Thu Dec 15, 2022 5:03 pm Besides all this I am missing the 17 ,18 ,19 commands in the program settings (wmpol,deadtime,ocurlim.)

These parameters are hidden on purpose because it makes absolutely no sense to modify them. They are setup correctly when I program the board and then hidden.

RetroZero wrote: ↑Thu Dec 15, 2022 8:35 pm Sorry, but picture not too well focused. Which stepd in the initial setup work?
I don't see the 2 pin connector (I9 I think) hooked up to 12v supply.

From step 9.
The 2pin 12Vconnector +25pin of the32Toyota connector are coneccted via switch and bulb to 12V saurce.
SMD board saperatly connected to 12V battery.
HV 12V with 3 lights in delta form connected to the terminals of the Toyota Inverter. 12V-100A on the supply Toyota terminals.
THe values given tothe commands MANUALID & MANUALIQ remain without
result or improvement.
The motor is still,the 3lights are off.

Pin #25 and I9 positive are connected without a bulb in series. It's 15vdc fused.
The bulb in series is only on the 'HV' line.
Make sure your 12vdc is stable too.

DIETZENBACH wrote: ↑Fri Dec 16, 2022 6:55 pmThe motor is still,the 3lights are off.

Again, very difficult to troubleshoot your setup and identify where you've maybe got things wrong...

... when you don't show us your setup.

Be respectful to people volunteering to help you, give them as much information as possible, as clearly as possible.

]Dear MattsAwesomeStuff,,
I am sorry for the delay of my answer.Here is scheme of my connections.

MattsAwesomeStuff wrote: ↑Fri Dec 16, 2022 9:46 pm Again, very difficult to troubleshoot your setup and identify where you've maybe got things wrong...

... when you don't show us your setup.

Be respectful to people volunteering to help you, give them as much information as possible, as clearly as possible.

Hi Matts, sorry for the delay.Here is the scheme of the connections.

Have you connected GINV (16)?
Also while doing the basic tests you need to flash stm32_sine.bin not foc

Do not connect motor and lightbulbs in parallel. First light bulbs, then motor

With that done and if still no blinking post the contents of 192.168.4.1/cmd?cmd=json%20hidden as a text file here

The 12v supply with the light bulb in series will create a resistance and lower the voltage to the inverter. I would remove it.

RetroZero wrote: ↑Sat Dec 17, 2022 5:14 pm The 12v supply with the light bulb in series will create a resistance and lower the voltage to the inverter. I would remove it.

No, that's part of the instructions. It's a load limiter. Its job is to mostly disappear from the circuit when little power is flowing, but the more power used the more it's going to limit it.

It's not necessary, usually just a one-time check in case the board has a short in it somewhere, this would prevent the whole board from exploding. But I don't think it hurts any to limit the current to the inverter brains. It should only be pulling a few watts, hardly a spec of voltage drop.

johu wrote: ↑Sat Dec 17, 2022 4:21 pmHave you connected GINV (16)?

Should not have to. It's internally tied to ground. If you've got ground on the i9 connector, you've got ground on GINV.

Do not connect motor and lightbulbs in parallel. First light bulbs, then motor

Just FYI, your (presumably) instructions don't indicate that you remove the lightbulbs and put the motor in their place. Not the way I'm reading them. Should probably make that less ambiguous.

"It's not necessary, usually just a one-time check in case the board has a short in it somewhere, this would prevent the whole board from exploding."

That's what I thought it was for as well.
Hope this all helps. Once it's spinning, I'll go back and update the wiki to be more precise

Do You know how to set ==Full boost with 12V ? step9.
There is any simmilar command for this step.

Set 'curki' to 20000 minimum.

Oops, did I somehow clic the wrong button somewhere and changed the status to SOLVED? Or am I missing something?

Just a clarification here, I'm pretty sure the light bulb is supposed to be in the HV circuit, not the 12V supply to the logic board.

> Connect fused 12 volt and Ground to HV Inputs (battery), along with 55 watt light bulb in series (resistor) on the Positive line

I saw that too and went off on a long explanation. If you look closely, it looks like it's the HV circuit that is being pictured with a 2 pin plug with 12 vdc for first test. ... But that's my assumption. Will wait on a reply....

You are both correct ,I just misplaced it by drawing.I saw it later when posted.It is again my error.
Thank You for the reminder !

So, have you got lights flashing?

Thanks again for the request.
Unfortunately could not perform the Inital Setup Test with the newly aquired information . The whole project machines are one other place,some 2000km. away.
As far I got ready and tested the motor , will contact You by myself and inform You.
Merry Xmas and a peacefull and prosperous New Year2023 !!

Took the liberty to update wiki on the few details that were made unclear in this thread. Please check all is correct in step 9.

Thanks, but in step 9 it still says "use stm32_sine.bin" and then full boost "curki=20000". That doesn't add up as the parameter doesn't exist in sine. Whats the intention?

Ahh, now there's a good question. I wrote those steps up quite some time back. Could it be related to OI updates that they are no longer possible for modifications? Or is there a more specific explanation to setting full boost I can put in the wiki?