Mainboard V2 troubleshooting

[Esbro]

Hi Everyone, I need a bit of help troubleshooting my V2 mainboard. Way back in 2018, I built my kit etc and it ran my Enova motor on the bench. Then 2 years later, with the motor installed and running freely by hand, I found that after connecting up to the inverter....Nothing ! To cut a long story short .... since then I've ripped the inverter to bits and rebuilt it - twice - all I got is a slight hum from motor - have checked phases with lamps and get flicker. Today I stripped it back to the boards - It seems that I have sort of sine wave at board output.. and at outputs to drivers. The waves all seem to be in phase with each other (ie superimpose on each other) No clean waveforms. How do I troubleshoot this board please - before I'm too old the drive the car
Any ideas would be really great . Thanks

[johu]

You know many things that we don't know so it is impossible to help by just these few lines of text. Please don't be lazy and attach:
- Scope screenshots
- Parameter dump
- json dump
- Pictures of your setup

[Esbro]

Hi johu, thanks for your quick reply. There is an update to my post. Now, it seems as if I have No output from anywhere on the board and, it looks like I've been picking up some hum. Having grounded the probe properly, there is no signal even at 500mV/div.
Yesterday, I loaded the latest firmware, got an ok from the interface and the usual flashing green light and steady red on thebboard. I have attached photos of the setup and scope screens. I'm obviously doing something wrong, but I can't see it.

[Esbro]

My apologies - I forgot to add.... fslipsnt 1, ampnom 1. (I'm starting from scratch). Parameters as per latest firmware- don't know how to get parameter or json dumps.

[johu]

Ok, you've got an Olimex module. So json dump is obtained by getting http://192.168.4.1/cmd?cmd=json

[Esbro]

Hi johu, thanks for that. Here is json
"boost": {"unit":"dig","id":1,"value":1700.00,"isparam":true,"minimum":0.00,"maximum":37813.00,"default":1700.00,"category":"Motor","i":0},
"fweak": {"unit":"Hz","id":2,"value":1.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":90.00,"category":"Motor","i":1},
"fweakstrt": {"unit":"Hz","id":134,"value":400.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":400.00,"category":"Motor","i":2},
"fconst": {"unit":"Hz","id":99,"value":180.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":180.00,"category":"Motor","i":3},
"udcnom": {"unit":"V","id":78,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":0.00,"category":"Motor","i":4},
"fslipmin": {"unit":"Hz","id":37,"value":1.00,"isparam":true,"minimum":0.28,"maximum":10.00,"default":1.00,"category":"Motor","i":5},
"fslipmax": {"unit":"Hz","id":33,"value":3.00,"isparam":true,"minimum":0.28,"maximum":10.00,"default":3.00,"category":"Motor","i":6},
"fslipconstmax": {"unit":"Hz","id":100,"value":5.00,"isparam":true,"minimum":0.00,"maximum":10.00,"default":5.00,"category":"Motor","i":7},
"polepairs": {"unit":"","id":32,"value":2.00,"isparam":true,"minimum":1.00,"maximum":16.00,"default":2.00,"category":"Motor","i":8},
"respolepairs": {"unit":"","id":93,"value":1.00,"isparam":true,"minimum":1.00,"maximum":16.00,"default":1.00,"category":"Motor","i":9},
"sincosofs": {"unit":"dig","id":131,"value":2048.00,"isparam":true,"minimum":1.00,"maximum":4096.00,"default":2048.00,"category":"Motor","i":10},
"encmode": {"unit":"0=Single, 1=AB, 2=ABZ, 3=SPI, 4=Resolver, 5=SinCos","id":75,"value":0.00,"isparam":true,"minimum":0.00,"maximum":5.00,"default":0.00,"category":"Motor","i":11},
"fmax": {"unit":"Hz","id":9,"value":200.00,"isparam":true,"minimum":21.00,"maximum":1000.00,"default":200.00,"category":"Motor","i":12},
"numimp": {"unit":"ppr","id":15,"value":60.00,"isparam":true,"minimum":8.00,"maximum":8192.00,"default":60.00,"category":"Motor","i":13},
"dirchrpm": {"unit":"rpm","id":87,"value":100.00,"isparam":true,"minimum":0.00,"maximum":20000.00,"default":100.00,"category":"Motor","i":14},
"dirmode": {"unit":"0=Button, 1=Switch, 2=ButtonReversed, 3=SwitchReversed, 4=DefaultForward","id":95,"value":1.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":1.00,"category":"Motor","i":15},
"snsm": {"unit":"12=KTY83-110, 13=KTY84-130, 14=Leaf, 15=KTY81-110, 16=Toyota, 21=OutlanderFront, 22=EpcosB57861-S, 23=ToyotaGen2","id":46,"value":12.00,"isparam":true,"minimum":12.00,"maximum":23.00,"default":12.00,"category":"Motor","i":16},
"pwmfrq": {"unit":"0=17.6kHz, 1=8.8kHz, 2=4.4KHz","id":13,"value":1.00,"isparam":true,"minimum":0.00,"maximum":2.00,"default":1.00,"category":"Inverter","i":17},
"pwmpol": {"unit":"0=ActHigh, 1=ActLow","id":52,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Inverter","i":18},
"deadtime": {"unit":"dig","id":14,"value":63.00,"isparam":true,"minimum":0.00,"maximum":255.00,"default":63.00,"category":"Inverter","i":19},
"ocurlim": {"unit":"A","id":22,"value":1000.00,"isparam":true,"minimum":-65536.00,"maximum":65536.00,"default":100.00,"category":"Inverter","i":20},
"il1gain": {"unit":"dig/A","id":27,"value":0.15,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":4.68,"category":"Inverter","i":21},
"il2gain": {"unit":"dig/A","id":28,"value":0.09,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":4.68,"category":"Inverter","i":22},
"udcgain": {"unit":"dig/V","id":29,"value":43.56,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":6.15,"category":"Inverter","i":23},
"udcofs": {"unit":"dig","id":77,"value":0.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":0.00,"category":"Inverter","i":24},
"udclim": {"unit":"V","id":48,"value":540.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":540.00,"category":"Inverter","i":25},
"snshs": {"unit":"0=JCurve, 1=Semikron, 2=MBB600, 3=KTY81, 4=PT1000, 5=NTCK45_2k2, 6=Leaf, 7=BMW-i3","id":45,"value":0.00,"isparam":true,"minimum":0.00,"maximum":7.00,"default":0.00,"category":"Inverter","i":26},
"pinswap": {"unit":"0=None, 1=Currents12, 2=SinCos, 4=PWMOutput13, 8=PWMOutput23","id":109,"value":0.00,"isparam":true,"minimum":0.00,"maximum":15.00,"default":0.00,"category":"Inverter","i":27},
"potmin": {"unit":"dig","id":17,"value":0.00,"isparam":true,"minimum":0.00,"maximum":3500.00,"default":0.00,"category":"Throttle","i":28},
"potmax": {"unit":"dig","id":18,"value":3500.00,"isparam":true,"minimum":0.00,"maximum":3500.00,"default":3500.00,"category":"Throttle","i":29},
"pot2min": {"unit":"dig","id":63,"value":4095.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":4095.00,"category":"Throttle","i":30},
"pot2max": {"unit":"dig","id":64,"value":4095.00,"isparam":true,"minimum":0.00,"maximum":4095.00,"default":4095.00,"category":"Throttle","i":31},
"potmode": {"unit":"0=SingleRegen, 1=DualChannel, 2=CAN, 3=CANDual, 4=BiDir, 6=CANBiDir","id":82,"value":0.00,"isparam":true,"minimum":0.00,"maximum":6.00,"default":0.00,"category":"Throttle","i":32},
"throtramp": {"unit":"%/10ms","id":81,"value":100.00,"isparam":true,"minimum":0.09,"maximum":100.00,"default":100.00,"category":"Throttle","i":33},
"throtramprpm": {"unit":"rpm","id":85,"value":20000.00,"isparam":true,"minimum":0.00,"maximum":20000.00,"default":20000.00,"category":"Throttle","i":34},
"ampmin": {"unit":"%","id":4,"value":10.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":10.00,"category":"Throttle","i":35},
"slipstart": {"unit":"%","id":90,"value":50.00,"isparam":true,"minimum":10.00,"maximum":100.00,"default":50.00,"category":"Throttle","i":36},
"sinecurve": {"unit":"0=VoltageSlip, 1=Simultaneous","id":146,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Throttle","i":37},
"throtfilter": {"unit":"dig","id":147,"value":4.00,"isparam":true,"minimum":0.00,"maximum":10.00,"default":4.00,"category":"Throttle","i":38},
"brakeregen": {"unit":"%","id":38,"value":-50.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-50.00,"category":"Regen","i":39},
"regenramp": {"unit":"%/10ms","id":68,"value":100.00,"isparam":true,"minimum":0.09,"maximum":100.00,"default":100.00,"category":"Regen","i":40},
"regentravel": {"unit":"%","id":19,"value":30.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":30.00,"category":"Regen","i":41},
"offthrotregen": {"unit":"%","id":49,"value":-30.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-30.00,"category":"Regen","i":42},
"cruiseregen": {"unit":"%","id":124,"value":-30.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-30.00,"category":"Regen","i":43},
"regenrampstr": {"unit":"Hz","id":39,"value":10.00,"isparam":true,"minimum":0.00,"maximum":400.00,"default":10.00,"category":"Regen","i":44},
"maxregentravelhz": {"unit":"Hz","id":158,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":0.00,"category":"Regen","i":45},
"brklightout": {"unit":"%","id":67,"value":-50.00,"isparam":true,"minimum":-100.00,"maximum":-1.00,"default":-50.00,"category":"Regen","i":46},
"bmslimhigh": {"unit":"%","id":55,"value":50.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":50.00,"category":"Derating","i":47},
"bmslimlow": {"unit":"%","id":56,"value":-1.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-1.00,"category":"Derating","i":48},
"udcmin": {"unit":"V","id":42,"value":450.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":450.00,"category":"Derating","i":49},
"udcmax": {"unit":"V","id":43,"value":520.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":520.00,"category":"Derating","i":50},
"idcmax": {"unit":"A","id":96,"value":5000.00,"isparam":true,"minimum":0.00,"maximum":5000.00,"default":5000.00,"category":"Derating","i":51},
"idcmin": {"unit":"A","id":98,"value":-5000.00,"isparam":true,"minimum":-5000.00,"maximum":0.00,"default":-5000.00,"category":"Derating","i":52},
"idckp": {"unit":"dig","id":130,"value":2.00,"isparam":true,"minimum":0.09,"maximum":20.00,"default":2.00,"category":"Derating","i":53},
"idcflt": {"unit":"dig","id":132,"value":9.00,"isparam":true,"minimum":0.00,"maximum":11.00,"default":9.00,"category":"Derating","i":54},
"tmphsmax": {"unit":"°C","id":125,"value":85.00,"isparam":true,"minimum":50.00,"maximum":150.00,"default":85.00,"category":"Derating","i":55},
"tmpmmax": {"unit":"°C","id":127,"value":300.00,"isparam":true,"minimum":70.00,"maximum":300.00,"default":300.00,"category":"Derating","i":56},
"throtmax": {"unit":"%","id":97,"value":100.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":100.00,"category":"Derating","i":57},
"throtmin": {"unit":"%","id":119,"value":-100.00,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-100.00,"category":"Derating","i":58},
"accelmax": {"unit":"rpm/10ms","id":153,"value":1000.00,"isparam":true,"minimum":1.00,"maximum":1000.00,"default":1000.00,"category":"Derating","i":59},
"accelflt": {"unit":"dig","id":154,"value":3.00,"isparam":true,"minimum":1.00,"maximum":5.00,"default":3.00,"category":"Derating","i":60},
"iacmax": {"unit":"A","id":89,"value":5000.00,"isparam":true,"minimum":0.00,"maximum":5000.00,"default":5000.00,"category":"Derating","i":61},
"ifltrise": {"unit":"dig","id":91,"value":10.00,"isparam":true,"minimum":0.00,"maximum":32.00,"default":10.00,"category":"Derating","i":62},
"ifltfall": {"unit":"dig","id":92,"value":3.00,"isparam":true,"minimum":0.00,"maximum":32.00,"default":3.00,"category":"Derating","i":63},
"chargemode": {"unit":"0=Off, 3=Boost, 4=Buck","id":74,"value":0.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":0.00,"category":"Charger","i":64},
"chargecur": {"unit":"A","id":71,"value":0.00,"isparam":true,"minimum":0.00,"maximum":50.00,"default":0.00,"category":"Charger","i":65},
"chargekp": {"unit":"dig","id":72,"value":80.00,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":80.00,"category":"Charger","i":66},
"chargeki": {"unit":"dig","id":126,"value":10.00,"isparam":true,"minimum":-100.00,"maximum":100.00,"default":10.00,"category":"Charger","i":67},
"chargeflt": {"unit":"dig","id":73,"value":8.00,"isparam":true,"minimum":0.00,"maximum":10.00,"default":8.00,"category":"Charger","i":68},
"chargepwmin": {"unit":"%","id":128,"value":0.00,"isparam":true,"minimum":0.00,"maximum":99.00,"default":0.00,"category":"Charger","i":69},
"chargepwmax": {"unit":"%","id":79,"value":90.00,"isparam":true,"minimum":0.00,"maximum":99.00,"default":90.00,"category":"Charger","i":70},
"idlespeed": {"unit":"rpm","id":54,"value":-100.00,"isparam":true,"minimum":-100.00,"maximum":10000.00,"default":-100.00,"category":"Automation","i":71},
"idlethrotlim": {"unit":"%","id":65,"value":50.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":50.00,"category":"Automation","i":72},
"idlemode": {"unit":"0=Always, 1=NoBrake, 2=Cruise, 3=Off, 4=HillHold","id":66,"value":3.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":3.00,"category":"Automation","i":73},
"holdkp": {"unit":"","id":138,"value":-0.25,"isparam":true,"minimum":-100.00,"maximum":0.00,"default":-0.25,"category":"Automation","i":74},
"speedkp": {"unit":"","id":53,"value":0.25,"isparam":true,"minimum":0.00,"maximum":100.00,"default":0.25,"category":"Automation","i":75},
"speedflt": {"unit":"","id":57,"value":5.00,"isparam":true,"minimum":0.00,"maximum":16.00,"default":5.00,"category":"Automation","i":76},
"cruisemode": {"unit":"0=Off, 1=Switch, 2=CAN, 3=ThrottlePot, 4=Limiter","id":62,"value":0.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":0.00,"category":"Automation","i":77},
"cruisethrotlim": {"unit":"%","id":155,"value":50.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":50.00,"category":"Automation","i":78},
"udcsw": {"unit":"V","id":20,"value":330.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":330.00,"category":"Contactor Control","i":79},
"udcswbuck": {"unit":"V","id":80,"value":540.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":540.00,"category":"Contactor Control","i":80},
"tripmode": {"unit":"0=AllOff, 1=DcSwOn, 2=PrechargeOn, 3=AutoResume","id":86,"value":0.00,"isparam":true,"minimum":0.00,"maximum":3.00,"default":0.00,"category":"Contactor Control","i":81},
"bootprec": {"unit":"0=Off, 1=On, 2=na","id":135,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Contactor Control","i":82},
"pwmfunc": {"unit":"0=tmpm, 1=tmphs, 2=speed, 3=speedfrq","id":58,"value":0.00,"isparam":true,"minimum":0.00,"maximum":3.00,"default":0.00,"category":"Aux PWM","i":83},
"pwmgain": {"unit":"","id":40,"value":100.00,"isparam":true,"minimum":-100000.00,"maximum":100000.00,"default":100.00,"category":"Aux PWM","i":84},
"pwmofs": {"unit":"dig","id":41,"value":0.00,"isparam":true,"minimum":-65535.00,"maximum":65535.00,"default":0.00,"category":"Aux PWM","i":85},
"canspeed": {"unit":"0=125k, 1=250k, 2=500k, 3=800k, 4=1M","id":83,"value":2.00,"isparam":true,"minimum":0.00,"maximum":4.00,"default":2.00,"category":"Communication","i":86},
"canperiod": {"unit":"0=100ms, 1=10ms","id":88,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Communication","i":87},
"nodeid": {"unit":"","id":129,"value":1.00,"isparam":true,"minimum":1.00,"maximum":63.00,"default":1.00,"category":"Communication","i":88},
"controlid": {"unit":"","id":156,"value":63.00,"isparam":true,"minimum":1.00,"maximum":2047.00,"default":63.00,"category":"Communication","i":89},
"controlcheck": {"unit":"0=CounterOnly, 1=StmCrc8","id":157,"value":1.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":1.00,"category":"Communication","i":90},
"manualstart": {"unit":"0=Off, 1=On, 2=na","id":150,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1.00,"default":0.00,"category":"Testing","i":91},
"fslipspnt": {"unit":"Hz","id":151,"value":0.00,"isparam":true,"minimum":-100.00,"maximum":1000.00,"default":0.00,"category":"Testing","i":92},
"ampnom": {"unit":"%","id":152,"value":0.00,"isparam":true,"minimum":0.00,"maximum":100.00,"default":0.00,"category":"Testing","i":93},
"version": {"unit":"4=5.35.R-sine","id":2039,"value":4.00,"isparam":false},
"hwver": {"unit":"0=Rev1, 1=Rev2, 2=Rev3, 3=Tesla, 4=BluePill, 5=Prius, 6=MiniMainboard, 7=Leaf2, 8=Leaf3, 9=BMWi3","id":2036,"value":1.00,"isparam":false},
"opmode": {"unit":"0=Off, 1=Run, 2=ManualRun, 3=Boost, 4=Buck, 5=Sine, 6=AcHeat","id":2000,"value":0.00,"isparam":false},
"lasterr": {"unit":"0=NONE, 1=OVERCURRENT, 2=THROTTLE1, 3=THROTTLE2, 4=CANTIMEOUT, 5=EMCYSTOP, 6=MPROT, 7=DESAT, 8=OVERVOLTAGE, 9=ENCODER, 10=PRECHARGE, 11=TMPHSMAX, 12=CURRENTLIMIT, 13=PWMSTUCK, 14=HICUROFS1, 15=HICUROFS2, 16=HIRESOFS, 17=LORESAMP, 18=TMPMMAX, 19=CANCRC, 20=CANCOUNTER,","id":2038,"value":10.00,"isparam":false},
"status": {"unit":"0=None, 1=UdcLow, 2=UdcHigh, 4=UdcBelowUdcSw, 8=UdcLim, 16=EmcyStop, 32=MProt, 64=PotPressed, 128=TmpHs, 256=WaitStart, 512=BrakeCheck","id":2044,"value":4.00,"isparam":false},
"udc": {"unit":"V","id":2001,"value":37.71,"isparam":false},
"idc": {"unit":"A","id":2002,"value":0.00,"isparam":false},
"il1": {"unit":"A","id":2003,"value":0.00,"isparam":false},
"il2": {"unit":"A","id":2004,"value":0.00,"isparam":false},
"ilmax": {"unit":"A","id":2005,"value":0.00,"isparam":false},
"uac": {"unit":"V","id":2006,"value":0.00,"isparam":false},
"il1rms": {"unit":"A","id":2007,"value":0.00,"isparam":false},
"il2rms": {"unit":"A","id":2008,"value":0.00,"isparam":false},
"boostcalc": {"unit":"dig","id":2009,"value":1700.00,"isparam":false},
"fweakcalc": {"unit":"Hz","id":2010,"value":400.00,"isparam":false},
"fstat": {"unit":"Hz","id":2011,"value":0.00,"isparam":false},
"speed": {"unit":"rpm","id":2012,"value":0.00,"isparam":false},
"cruisespeed": {"unit":"rpm","id":2041,"value":-1.00,"isparam":false},
"turns": {"unit":"","id":2037,"value":0.00,"isparam":false},
"amp": {"unit":"dig","id":2013,"value":0.00,"isparam":false},
"angle": {"unit":"°","id":2014,"value":0.00,"isparam":false},
"pot": {"unit":"dig","id":2015,"value":68.00,"isparam":false},
"pot2": {"unit":"dig","id":2016,"value":101.00,"isparam":false},
"regenpreset": {"unit":"%","id":2051,"value":100.00,"isparam":false},
"potnom": {"unit":"%","id":2017,"value":-1.25,"isparam":false},
"seldir": {"unit":"-1=Reverse, 0=Neutral, 1=Forward","id":2018,"value":1.00,"isparam":false},
"rotordir": {"unit":"-1=Reverse, 0=Neutral, 1=Forward","id":2053,"value":0.00,"isparam":false},
"tmphs": {"unit":"°C","id":2019,"value":85.46,"isparam":false},
"tmpm": {"unit":"°C","id":2020,"value":170.00,"isparam":false},
"uaux": {"unit":"V","id":2021,"value":12.34,"isparam":false},
"pwmio": {"unit":"","id":2045,"value":59136.00,"isparam":false},
"canio": {"unit":"1=Cruise, 2=Start, 4=Brake, 8=Fwd, 16=Rev, 32=Bms","id":2022,"value":0.00,"isparam":false},
"din_cruise": {"unit":"0=Off, 1=On, 2=na","id":2023,"value":0.00,"isparam":false},
"din_start": {"unit":"0=Off, 1=On, 2=na","id":2024,"value":0.00,"isparam":false},
"din_brake": {"unit":"0=Off, 1=On, 2=na","id":2025,"value":0.00,"isparam":false},
"din_mprot": {"unit":"0=Error, 1=Ok, 2=na","id":2026,"value":1.00,"isparam":false},
"din_forward": {"unit":"0=Off, 1=On, 2=na","id":2027,"value":1.00,"isparam":false},
"din_reverse": {"unit":"0=Off, 1=On, 2=na","id":2028,"value":0.00,"isparam":false},
"din_emcystop": {"unit":"0=Error, 1=Ok, 2=na","id":2029,"value":1.00,"isparam":false},
"din_ocur": {"unit":"0=Error, 1=Ok, 2=na","id":2030,"value":0.00,"isparam":false},
"din_desat": {"unit":"0=Error, 1=Ok, 2=na","id":2031,"value":1.00,"isparam":false},
"din_bms": {"unit":"0=Off, 1=On, 2=na","id":2032,"value":0.00,"isparam":false},
"uptime": {"unit":"10ms","id":2054,"value":52434.00,"isparam":false},
"cpuload": {"unit":"%","id":2035,"value":2.28,"isparam":false},
"serial": {"unit":"","value":"43212848","isparam":false}
}

[johu]

That worked but it's not in run mode. Please post the dump when it's in the very state where you expect PWM

[Esbro]

OK - inverter should be running. start 2, set fslipspnt 10, set ampnom 100, set tweak 10.
json below. If I knew what to look for I could sift through it.

"boost": {"unit":"dig","id":1,"value":1700.00,"isparam":true,"minimum":0.00,"maximum":37813.00,"default":1700.00,"category":"Motor","i":0},
"fweak": {"unit":"Hz","id":2,"value":10.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":90.00,"category":"Motor","i":1},
"fweakstrt": {"unit":"Hz","id":134,"value":400.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":400.00,"category":"Motor","i":2},
"fconst": {"unit":"Hz","id":99,"value":180.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":180.00,"category":"Motor","i":3},
"udcnom": {"unit":"V","id":78,"value":0.00,"isparam":true,"minimum":0.00,"maximum":1000.00,"default":0.00,"category":"Motor","i":4},
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}

[johu]

It's dropped out of manual_run because of an over current error (lasterr). Have you got any current sensors connected? Do so if not or feed 1.6V to both current sensor inputs

[Esbro]

Yes, I have current sensors connected (JP2), as per instruction sheet. Inverter has never drawn more than 15A (ie not blown fuse)

[Esbro]

Just had a thought.... 2 of IGBTs went "bad", so I replaced all 3 with new ones. When they died, could this have damaged board output?

[johu]

Just had a thought.... 2 of IGBTs went "bad", so I replaced all 3 with new ones. When they died, could this have damaged board output?

No, the isolation prevents this.
What voltage do you get across C5 and C7?

[Esbro]

Good morning johu, thanks for your reply. I get 3.6v across C7 and 1.8 across C5.

[johu]

Then something is not right with the current sensor showing 3.6V or sensor board. Measure its output. The voltage at that point should be around 1.7V

[Esbro]

Oh, I see. I'll check the 2 caps again, then check output voltages from sensor boards and report back.
I checked "lasterr" again - get lasterr - and got "10" (precharge) this time.
For some reason, the message box in the interface always misses off the first digit/letter in the first line - so I need to enter command like. get lasterr,lasterr to get a readable answer. Is there something I can do about this?
My sincere thanks for your help, I really do appreciate you looking into the problems with my board.

[Esbro]

Hi again... rechecked voltage across caps - C5 1.45v, C7 1.79v. Similarly, the sensor outputs read the same. Don't know why the difference in readings from before - will check solder joints, as I've been moving caps for access.
The sensor boards have always been difficult to calibrate - my best effort was using a similar piece of 2AWG cable with both sensors on and running a current through. I need to do that again now I've flashed the firmware.

[Esbro]

OK, I've done some repair work on solder joints on both current sensors. Now voltages on their outputs are around 1.7v (1.786 & 1.789v).
I think now, that the current I'm passing through the cable to calibrate is too low - I can only do around 12A DC - I have a bulbs in parallel, using car batteries.
Can AC current be used to calibrate? If so, I can use my stick welder (80-100A, 50/60V, 50Hz). I also have a 150A bridge rectifier that could give DC from welder - no smoothing caps though.

[johu]

calibration can come later. What's your progress otherwise? Good PWM and spinning motor?

[Esbro]

Hi Johu, I have got il1.il2 sensors outputting 1.786/1.789 volts, but still can't calibrate. Neither can I calibrate UDC nor heatsink temp.
I have just replaced the KTY83-120 and get a temp reading of 85 when the heatsink is 17C (just as before). Open circuit, the temp reading is -25C.
Unfortunately, there is still no spinning of the motor yet. My next job is to check again parameters for values on PreCharge, Temp, then see if I can start up the PWM/Driver Boards/IGBTs in that order. If all is ok maybe connect the motor (which I have already tested for continuity and shorts on phases)... I will update post when I've done it ....Steve

[Esbro]

Hi, I have an update on progress - not good. Starting from basic set up once again. Start 2, set fslipspnt 1, set ampnom 1. Voltage supply 12.2v , Amps increase as I attach driver boards 1,2,3 to a total draw of 0.30A. Checked driver board inputs on scope (see photo) all the same form.
Next checked driver board output - nothing an any !! Checked driver boards - DC-DC All producing ~ 9v, 15v . Input to opto same form as before - No output on any. It seems that All of the opto ICs are dead. I have had odd opts go down before but never the whole lot together !
When I had problems before, I built a new set of boards (these I'm using - pic) then 2 of the original IGBTs went bad, so I replaced the whole lot (to Infineon FF600R12KT4 , 600v (1200v peak) 600A). Could it be, that the current draw of the gates of these new IGBTs is too large for the opto? If so, can I upgrade the opto?
It will be interesting to know what you think. .... Steve

[johu]

So far I've only seen IGBT side components go up in smoke when the IGBT blew up. Are you sure it's the opto or could it also be the TVS permanently conducting or the gate resistor blown (it looks quite small)?

[Esbro]

Hi Johu, No, not certain, but there is absolutely no voltage or wave at the output of optos - they seem dead. Similarly, previous opto (1) showed the same symptoms.
I noticed something amiss when I connected the IGBTs, there was no increase in current draw to the power supply.
The normal current draw is around 60mA more at 360mA total.
I can replace the optos, but I need to find why they were damaged, first.
Any ideas are welcome ... Steve

[Esbro]

Hi, Another update, I replaced the driver boards with some that had been repaired. These gave the same results. I lowered scope setting th 200mV/div and got the trace in the photo. Only 400mV peak to trough. Wave is ok maybe ?? I've just been back out to the workshop to check driver input voltages - seems high to me at 11.1v !! Will need to sort it out. ...... and repair both sets of driver boards, if the voltage is that high. Will report back later. Once again any comments are welcome.... Steve

[uhi22]

If I count correctly I see 4•5ms periode time, this is 20ms is 50Hz, which is the grid frequency. If this is true, you have a problem with your scope grounding.

[johu]

You're right uhi, I didn't pay attention to it. The other scope shot also doesn't show a square wave. So something is not right with the scoping. I had a probe with intermittent connection that would also just pick up 50 Hz

I've just been back out to the workshop to check driver input voltages - seems high to me at 11.1v

What is "driver input voltage"?

On the low voltage side you feed in 5V into the small DC/DC converters. On their output they will output -9 and 15V. Now which of these is 11.1V? Maybe provide pictures of what you're measuring.
Have you checked the gate resistors? Have you checked whether the TVSses are short-circuiting? This would also lead to no voltage on the opto.