EV Conversion using prius gen 2 inverter/transaxle

[voti]

Is this what you used as reference?
viewtopic.php?p=14153#p14153

I connected my resolver the way Damien did in the tutorial video. Is it correct or should I change to
pin 1 = yellow ( enc b)
pin 2= green and brown (sin a and cos a)
pin 3= red ( enc a)
pin 4 = black r1
pin 5 = white r2

For excitation I have blue and pink not black and white.

[voti]

I changed my resolver connection today and connected it as pair discussed in the screenshot attached below.
I tested first without it connected and I got the same results of having the Delta connected light bulbs connected on the inverters three phase output light up and turn off again continuously. The inverter goes into run mode when I set udcsw to 0 and this blinking behavior then starts even before I put any numbers in the manualid. Please see video attached in comment above. On angle when the light bulbs started blinking an angle of 63 degrees showed up even without the resolver connected.

Then after I connected the resolver and shortly after setting udcsw to 0, the light bulbs turn on and they stay lit. This time around they don't blink but they say lit. When testing with a scope the PWM wave shows but it doesn't move. It stays in one position. On angle under spot values the angle was 239 degrees but kept changing by a value of 1 either increasing or decreasing when I pressed refresh even without turning the drive shaft.

I went on to connect the throttle pedal also with the discussed instructions on the screenshot below and tested with both the resolver and the pedal connected. Now the light bulbs didn't turn on and the inverter didn't go to Runmode it stay off even after setting udcsw to 0. While on previous tests I set udcsw to 0 because that was the only way I could get the inverter to go Runmode because even with manual start turned on, the inverter would still be on opmode> OFF.

When I had the throttle connected STATUS on spot values first showed "PotPressed" and on another test it said "UdcBelowUdcSw|PotPressed" .

Please see attached pictures.

[RetroZero]

Just to be sure.
You have 2 seperate batteries. 1 for 12v circuit, & another for High Voltage circuit. Can you check that they are well charged.
In spot values, please report back on UDC voltage & Pot1/Pot2.
The pedal should read 0 , if not, it requires setting. I think there is a set-up in the adapter board thread. Once set up correctly, check by pressing the pedal all the way and verify you have 100%
UDC should read the same as your battery ' HV'

[voti]

Below I've attached my entire spot values, please go through and check for all the settings you want to see pot1 and pot2 and any other that are important for testinh stage.. Also please check for faults that might appear.

I'm planning on connecting a high Amp 12v battery for my next test to my HV supply. On UDC now it says 11.87v.

I forgot to mention that now that I have connected both the resolver and the throttle, I cannot get the inverter to go on manualRun. Even after setting udcsw to 0, It stays off.

[RetroZero]

Is your start signal connected directly to 12v, or is it a button? It needs to be a button, not permanent 12v.... When you press accelerator pedal, do you get steady % value under Potnom?

[johu]

@voti: the screenshots are hard to read. Please just attach the contents of http://192.168.4.1/cmd?cmd=json instead

UdcBelowUdcSw means bus voltage (udc) is smaller than udcsw . So at this point it cannot have been at 0

[voti]

I pressed my pedal and Potnom remained 0% all the time. What changed was the values on pot1 and pot2 the valus kept increasing until they reached 4095 when fully pressed. I could only see the changes of this values by refreshing everything I press harder and harder.

I also changed start and add it a switch rather than having it hooked to 12v all the time.

I also put in a fully charged 12v car battery for my HV input and disconnected the 55w ligjt connected in series with the positive line of the battery.

I still couldn't get the inverter to go into Runmode. I even disconnected the resolver cable but still not going for Runmode. Does it mean my pedal is not correctly configured because like I said, potnom didn't show any reading when the pedal was pressed.?

Below I've attached json files.

[johu]

The pedal is not configured correctly. If the dump contains the "not pressed" value then potmin must be 2090. Also you will a series resistor (viewtopic.php?t=5075) but that is for later.
For the current test you can also disconnect it

[voti]

OK. So I swapped pin 3 and 6 and happened to might have happened to get it right for the pedal. I disconnected my resolver because I think that's where the problem is but I'll get to that shortly. I had my inverter in Runmode and the Delta connected light bulbs lit up. When I pressed the pedal, they started blinking and the motor jerked like it did prior. Below I've attached a link to a video of this whole process.

By the way potnom was always on 0 % throught out this test. Is that OK?

Coming to the resolver. Each time I connect it, everything just stops working, the light bulbs turn on but the pedal then stops working and when I press it nothing happens.

I disconnected the HV and tested pins 1 to 5 which are the resolver pins and tested for AC waveforms. I've attached pictures below of these waveforms for each pin. I've also attached a picture of the pins configuration that i also found on other topics.

Please remember that the only parameters I'm putting In are changing udcsw to 0, DefaultForward and adding values on manualid only. Should I still set ocurlim -1 even on the new FOC firmwares updated version that i'm using now ?

[johu]

Yes ocurlim can stay at -1
Have you tried swapping resolver sin and cos input?
Are you still on FOC firmware? The behaviour is a bit unexpected.

Light bulbs are in parallel to motor, right?

[voti]

Yes I'm still on the FOC firmware, and yes the ligjt bulbs are in parallel with the motor. Ibhave them connected to monitor output PWM.

If i change resolver sin and cos, should I replace them with the ENC A or B. On the tutorials video, Damien had brown and red for his sin and cos. Is that what you mean?

[johu]

Swap the brown and the red.
Also try completely disconnecting the phase cables and check if you get a steady 0-360 sawtooth pattern when turning the shaft by hand. Plot setting is burst length 1000, data points 1000

[voti]

I swapped and connected the brown and red. On pin 2 I'm reading a straight line and pin 3 nothing. My yellow is still connected to pin 1 and my green is now connected on pin 3

I've also attached pictures of the patterns I got when spinning the motor manually.
I had my resolver disconnected when doing this test.

[voti]

Anyone please come through

[MattsAwesomeStuff]

I can't do much except offer encouragement.

FYI, Johannes is transitioning away from openinverter, and mentioned he'll be stepping back from forum support on inverter-related topics. Not that it was ever something he was expected to do, but, just if you're curious why troubleshooting might become quieter.

There's still lots of other people in the community, and, this is supposed to be community-supported anyways, so, hopefully others step up to help where they can. You're not the first person to spin a synchronous motor with OI software/hardware.

Perhaps since you're stalled, it would be helpful to re-group. So that a knowledgeable community member who stops by to read this might get caught up on where you're stalled. Is there a procedure you're currently following, and if so, what step are you stuck on?

Can you briefly summarize the problem and why you can't progress further?

[RetroZero]

Haven't looked under the bonnet for 2 years, as I have been stupidly focusing on the most complicated of chargers I would like to get working....
I popped the hood ( remove dusty cover first) and went to look at resolver wires, as I can't remember what was done and how.

Resolver - Pin 1 - (Blue) = Adapter board pin 4
Resolver - Pin 2 - (Green) = Adapter board pin 1
Resolver - Pin 3 - (Yellow) = Adapter board pin 3
Resolver - Pin ? - (Pink) = Adapter board pin 5
Resolver - Pin 5 - (Red) = Adapter board pin 2
Resolver - Pin ? - (Brown) = Adapter board pin 2

I had the car running with this config....hope it helps

[MattsAwesomeStuff]

Resolver - Pin 5 - (Red) = Adapter board pin 2
Resolver - Pin ? - (Brown) = Adapter board pin 2

Is that a typo or do they both go to the same pin?

[RetroZero]

They both go to the same ground référence.

[voti]

Thank you Retro, I'll definitely test this configuration when I get home.
I was on leave for the whole on June hoping I'd get the motor spinning before I come back to work and sadly I wasn't able to due to delayed responses from the forum. I'm not complaining, I'm just appreciating you guys being here. Might have not got the motor spinning yet but I'm 100 positive it will spin eventually

[voti]

I

They both go to the same ground référence

I was able to do a bit of testing today.

First things first, when the resolver is connected, the transaxle doesn't jitter when I put in the parameters and press the throttle pedal. But when I disconnect it and press the pedal it jitters. So I'm guessing my resolver cable is messed up.

I tested each strad from the resolver cable and also tested the combos (Green and brown) and also (red and brown). Please see attached pictures and tell me what you think.

[RetroZero]

Can you connect the resolver back and turn the transaxke by hand, replotting the angles in the User Interface as you did in earlier post?

[voti]

Can you connect the resolver back and turn the transaxke by hand, replotting the angles in the User Interface as you did in earlier post?

I did, just that I didn't post the outcome. What I noticed was that the straight line that appeared on the scope when I had connected brown and red to pin 2 of control board, when I turned the transaxle by hand the straight line didn't change but the faint waveform that appears noisy on the background of it seemed to be moving when the transaxle was also moving.
Should I connect the brown and green or Brown and red.
Below I've attached a screenshot of the pattern that appeared on the plotter

My big problem is I don't know which of the two is correct.

Why is it that when not connected to pin 2 the Sin/Cos does show a waveform but once connected to the control board it fades and only a straight line appears on the scope. It's a bit visible at the background of the straight line but faded out. I hope you understand what I mean.