LDU/board troubleshoot help

[wigman]

Hi everyone. Upon the advise of Johannes I'm starting a separate thread here.

I've had a few different issues with getting my board to work and the results were scattered in the LDU support thread. I'm going to consolidate what has happened so far since I got the board and hopefully someone can point me in the right direction. Since it will be a while before I can get a replacement board I figured I would take the time to fault find mine while I'm waiting and maybe solve the mystery. Or if it's the LDU itself, find that out.

Here is what has been done and the results so far-

1. Installed the board (came with v4.71), contactor, precharge, pedal, etc. to a Tesla motor
2. Switched parameters to match my 80V test battery and set pedal pot readings
3. Every time start signal was sent, main contactor would close and open again with overcurrent fault.
4. Traced the error to lack of 5V on one of the two current sensors due to bad solder joint on connector.
5. Resoldered connection. This fixed the overcurrent error and the main contactor would close but motor would not spin- still had tmpmax and current limit codes
6. Updated the firmware to V4.78 and then to the fix v4.79 posted on the MUX fix thread. v4.78 wouldn't spin the motor. V4.79 eliminated the temp error but still had PWM stuck code and would not close the main contactor when applying the start signal.
7. Contacted Jon Volk and used his version (v4.56) and his parameters. Main contactor would not close with start signal.
8. with Jon Volk parameters v4.71 and v4.76 would spin the motor but not correctly. It would accelerate and then the motor would keep spinning at the same speed or even accelerate when let off the throttle.
9. I tried each version with Volk parameters again and once got the motor to spin correctly (quickly stop after letting off the accelerator) with V4.79. 5 minutes later I turned on the system again to try it again and the main contactor wouldn't close again. Still giving PWM stuck error when ignition was turned on.
10. Jon looked at my parameters and noticed that my encoder was set to "single" instead of "AB".
11. Switched the encoder to AB. Motor would run extremely slow and rough/jogging. Would accelerate very slightly with throttle, same jogging/rough running.
12. Also tried Damien's parameters. Motor won't spin at all.
13. Tried a different battery (100V), no difference.
14. Tried swapping AB encoder wires, no difference

spinning motor-

[Kevin Sharpe]

Or if it's the LDU itself, find that out.

Have you considered buying a Toyota Prius inverter and verifying the motor is working in open loop mode? It would allow you to experiment with the open inverter software/hardware and an inverter was purchased recently for 40 euro delivered

[johu]

Can you attach your parameters to the opening post, please (edit). Also some info on your testing environment, most of all DC voltage. A video or screen capture of the non-working situation would help identifying the problem also.

[Boxster EV]

What are you using to power the LV side? Bench PSU or 12v battery?

[MattsAwesomeStuff]

Didn't Damien already give you your money back for the board? Shouldn't you just send it back to him and then perhaps go buy something else?

[wigman]

I’m using a 12v battery for low voltage.

Damien refunded me and told me to contact Johannes to buy a board. Johannes said I should try to get the board I already have working as he is weeks away from having any available and told me to post here.

I would be happy to send the board back if it’s requested. I never asked for a refund, I was offered one. I think the theory was that I could use it to purchase another from Johannes, who said I should at least try to fix this one first.

If this one can be troubleshooted, even if it doesn’t end up spinning the motor because of a bad component, the knowledge that comes from the process will help others in the future on this forum.

[invokeperformance]

Or if it's the LDU itself, find that out.

Have you considered buying a Toyota Prius inverter and verifying the motor is working in open loop mode? It would allow you to experiment with the open inverter software/hardware and an inverter was purchased recently for 40 euro delivered

Hello guys. I have a gen 3 Prius inverter and I'm considering purchasing a LDU from a model s 85 with a blown inverter. I know I can run the ASIM with open loop with my inverter as seen in Damien's video. So my question is does anyone have any information on running the LDU in closed loop full control with resolver feedback to the prius inverter? Also will the current LDU control parameters on the Wiki work directly in the gen 3 power stage and are there any things that I should be aware of with this motor and inverter combo? Thanks