EM57 Resolver connection, need help

[Razor8]

Hello, friends!

I'm going to install an Nissan EM57 AZEO motor om my boat.

I cant get valid connection of resolver to Open Inverter board.

8 pins of resolver -R1,R2,S1,S2,S3,S4 temp1, Temp2.

on the board I have 4pins + 2 temp pins
temp+, temp-, to temp1, temp 2 on board, here is clear
R1 resolver pin to ENC_IN_Z/RES_R1
S2 resolver pin to ENC_IN_A/RES_S2
S3 resolver pin to ENC_IN_B/RES_S3

R2 resolver pin to? nowhere? to GND?
S1 and S4 conected together and to ENC_5V/RES_S4S1, Should I also add 5dc volts here?

[Razor8]

some information:

S4 and S1 connect to GND?
what about R2 pin from resolver?
should I connect 5v dc to resolver?

[Razor8]

Its seems to me - R2 must be connected to GND

[manny]

Yes. Resolver excitation signal is connected to GND and R1.
S1 and S4 connect to RES_S4S1 pin, the OI board should have 1.5V on this pin

[Razor8]

Yes. Resolver excitation signal is connected to GND and R1.
S1 and S4 connect to RES_S4S1 pin, the OI board should have 1.5V on this pin

Thank you!

Get connected.
R1 resolver pin to ENC_IN_Z/RES_R1
R2 resolver pin to GND
S1 and S4 resolver pin to RES_S1S4
S2 resolver pin to ENC_IN_A/RES_S2
S3 resolver pin to ENC_IN_B/RES_S3

checked the voltage on S1S4 - 1.52 volt

I turn on the board's power supply...
blinking led lamp on - OUT_precherge
and always on - OUT-Error....
HV DC - 300 volts
push IN_Start - starts to burn constantly OUT_DCSW and a quiet squeaking sound of work can be heard
in WEB Interface I can stop Inverter - and the sound disappears


if I press- show last errors - only CANTIMEOUT
pressing the throttle handle does nothing. check thtottle voltage - from 0.8 v to 4v
Error led always ON

If disconnect HV DC - than I cant start Inverter by pressing button

Please give me any ideas. How can I fix this error?

[Zieg]

Did you calibrate the throttle? Also just checking but you did put either the drive or reverse input high, right?

[Razor8]

Did you calibrate the throttle? Also just checking but you did put either the drive or reverse input high, right?

No, I do not calibrate the throttle. How can I do it?
IN_FWD connected to 12V
IN_REV is disconected
IN_REV and IN_FWD connected to switch which switches one of them to 12 volts.

[Razor8]

Calibrating throttle - its potmin, potmax parametrs?
potmin - 950
potmax - 4095

when inverter not started, display memory errors give- - NO errors, bat error led is on
when inverter is started, display memory errors give - CANTIMEOUT 4 times

why error led(OUT_ERR) is always on?
why I cant start the motor?

when I start the inverter - can hear a quiet PWM sound, when stops - the sound is disappear.

[Razor8]

when inverter starts and IN_FWD gets _12V - can hear a pulsating quiet sound
disconecting IN_FWD - sound stops.
motor not spining

How can I check the polarity of HV DC?
is it correct?

[Razor8]

update -
OI - starts, NO ERRORS, OUT_ERR - is ok.
after switching FWD or REVERS - start pwm sound
pressing the thottle - sound increasing, The motor shaft twitches but does not rotate.
HVDC is rectified voltage 220, about 300V DC. Diode rectifier, fuses are of course present.

A friend advises changing the sine and cosine in resolver.
Please share your ideas

[zippy500]

this the drop in board OI board ?

Have you configed the syncoff ?

[Razor8]

this the drop in board OI board ?

Have you configed the syncoff ?

No, I have not.
How can this be done?

[Razor8]

update:
No Errors, OpenInverter starts
select forward or reversr
then pressing throtlle
the motor shaft starts to jerk in different directions!?
resover problem?

[manny]

Please read the wiki.

https://openinverter.org/wiki/Using_FOC_Software

https://youtu.be/1SlL6cEoRBgv

[Zieg]

Polarity on your dc in looks correct. If you hooked it up backwards you would have been.. immediately aware of it.

potmax being 4095 says to me something is wrong with your circuit and you may need to add a resistor in series to the signal. Though I'm not sure if that would cause this issue? As Manny said read those links, and post your parameters too.

[Razor8]

It looks like the problem is only in the resolver.
I triple checked the connection - connection is absolutly correct.

checked the resistance of the windings
R1-R2 -11.9
S1S3 - 27
S2S4- 27.5

I'll try to adjust some parameters.

When turning the shaft manually - value of a variable ANGLE changes randomly

[johu]

Did you ever check for the excitation sine wave on R1?

Also read forum rules on how to ask for support (param file missing)

[Razor8]

Did you ever check for the excitation sine wave on R1?

Also read forum rules on how to ask for support (param file missing)

No, I haven't checked the signal shape yet, I'm waiting for an oscilloscope.

[EVGO1987]

From my experience, you shouldn't trust the resolver signal names, and try some different combinations.

Because even if you look up some drawings of resolvers, you will see different schemes from different sources.

Based on the resistance measurements you know, which coil is which (1x excitation coil, 2x reflection coils).. and then, it is a bit trial and error with a new resolver. Once you will find the right combination / wire order, it is then a known combination which can be replicated.

Besides, there should be kind of settings for the resolver, like pole-pair count and transformation ratio.

Motor jerking, from my experience, is wrong combination of the wires... because then, for example, you have the excitation right, sine-reflection right, but cosine reflection reversed, which means 180 dg phase offset.. And that can't work.

WARNING!!!

Please, setup a low (!) speed limit / safety shut off while playing with angle sensor settings.
If the offset, which you have to set up, is 120-180 dg wrong, the motor will "run away".

[Razor8]

From my experience, you shouldn't trust the resolver signal names, and try some different combinations.

Because even if you look up some drawings of resolvers, you will see different schemes from different sources.

Based on the resistance measurements you know, which coil is which (1x excitation coil, 2x reflection coils).. and then, it is a bit trial and error with a new resolver. Once you will find the right combination / wire order, it is then a known combination which can be replicated.

Besides, there should be kind of settings for the resolver, like pole-pair count and transformation ratio.

Motor jerking, from my experience, is wrong combination of the wires... because then, for example, you have the excitation right, sine-reflection right, but cosine reflection reversed, which means 180 dg phase offset.. And that can't work.

WARNING!!!

Please, setup a low (!) speed limit / safety shut off while playing with angle sensor settings.
If the offset, which you have to set up, is 120-180 dg wrong, the motor will "run away".

Thanks a lot.

I identified the excitation winding.

I checked the signal with an oscilloscope.
There was a sine wave on the excitation winding, 4.31 kHz. Vmax- 0.44v

The sin and cos windings have a lower amplitude sine wave, and the amplitude changes smoothly as the motor shaft rotates.
Vmax 0.14v

I believe everything is working correctly here.

[Razor8]

UPDATE-
I swapped the sin and cos - physically swapped the S2 and S3 wires—now the engine accelerates clockwise, both in reverse and forward.
and I cant stop it.
The fuse trips, or I turn off the high-voltage power.
The engine itself doesn't stop.

Parametr PINSWAP sincos - did not give such an effect

[manny]

Did you do a syncofs calibration procedure?

I checked the signal with an oscilloscope.
There was a sine wave on the excitation winding, 4.31 kHz. Vmax- 0.44v

The sin and cos windings have a lower amplitude sine wave, and the amplitude changes smoothly as the motor shaft rotates.
Vmax 0.14v

0.44V and 0.14V seems low. But if the OI board does not give a loreamp error the signal is probably fine. Measurement error?

[Razor8]

Did you do a syncofs calibration procedure?


0.44V and 0.14V seems low. But if the OI board does not give a loreamp error the signal is probably fine. Measurement error?

Today I finished watching the tutorial video, I'll be adjusting the parameter tomorrow.
In OI board is NO Errors, mabe osciliscoope give a wrong scale

cant find a "syncosofs" for Nissan EM57, How can I get it?

[manny]

You need to find this yourself

https://openinverter.org/wiki/Using_FOC_Software

Tuning Process:

Start inverter -> start input or "manualrun" on web interface. Select forward direction.
Observe value "angle" and turn rotor by hand -> you should see angle changes between 0 to 360°. If not, check resolver connection and excitation signal.
Start with syncofs=0
enter a positive value for "manualid". Start low, with respect to motor rating. E.g. 5% of rated current
Keep increasing the value until you notice that the motor starts to spin - make sure you hear PWM going
If motor spins, change syncofs in 1000 digit increments until it stops spinning. If you need to go below 0, like -1000 enter 64536 (=65536-1000)
If manualid is less than about max_motor_current/2 go back to 4. When approaching rated_motor_current/2 make your increments/decrements smaller, like down to 300 digits
You have found 1 of 2 possible offsets. Now you can enter a small value for "manualiq" and set "manualid" to 0.1, the motor should spin smooth in both directions
If it behaves differently in forward and reverse, add 32768 to syncofs. If the resulting value is > 65535, subtract 32768 instead (or do modulo addition in the first place)

[Razor8]

You need to find this yourself

https://openinverter.org/wiki/Using_FOC_Software

Tuning Process:

Start inverter -> start input or "manualrun" on web interface. Select forward direction.
Observe value "angle" and turn rotor by hand -> you should see angle changes between 0 to 360°. If not, check resolver connection and excitation signal.
Start with syncofs=0
enter a positive value for "manualid". Start low, with respect to motor rating. E.g. 5% of rated current
Keep increasing the value until you notice that the motor starts to spin - make sure you hear PWM going
If motor spins, change syncofs in 1000 digit increments until it stops spinning. If you need to go below 0, like -1000 enter 64536 (=65536-1000)
If manualid is less than about max_motor_current/2 go back to 4. When approaching rated_motor_current/2 make your increments/decrements smaller, like down to 300 digits
You have found 1 of 2 possible offsets. Now you can enter a small value for "manualiq" and set "manualid" to 0.1, the motor should spin smooth in both directions
If it behaves differently in forward and reverse, add 32768 to syncofs. If the resulting value is > 65535, subtract 32768 instead (or do modulo addition in the first place)

I understood how the offset is configured. about SINCOFS.
but I couldn't find any information about SINCOSOFS. Mid point of sin/cos chip.
Do I need to adjust this midpoint?