Leaf Invertor Plug SIN/COS Connections

[zippy500]

I have manged to get a salvaged plug from the dismantles they obviously cut the resolver plug part off.

I do have the resolver plug part too just need to reconnect it back to the main plug, I have searched for the connections.

All I am finding is resolver connections are S1 S2 S3 S4 R1 R2.

can someone please tell which pin goes to

SIN
SIN-
COS+
COS-
!EX
EX.

Thanks

[arber333]

SIN........S1
SIN-.......S3
COS+......S2
COS- ......S4

!EX........R2 (ground)
EX ........R1 (exciter)

Sin Cos can be reversed in case of different RST cable configuration.

[zippy500]

Thank you

[Jack Bauer]

viewtopic.php?f=4&t=179&start=20#p2481

[jerrykco]

Thanks Zippy 500 for the pics and comments. The Motor control wire harness consisted of connectors on the 2015 Motor assembly stack I purchased.
It would have been nice if the wires from the Resolver were longer......

[jerrykco]

Questions. A little help please.

Everything seems to match up on my two connectors (matching the colors of the wires) comparing the pin mapping description from Johannes for the external inverter connector and the connector for the resolver.
There is one discrepancy on the label of the resolver. According to the wire colors MTEMP1 and MTEMP2 seem to be reversed. Does this matter?
Because I do not have an original wire harness, should I create twisted pairs of any of the wires?
Which pairs should be twisted?
Should I shield each twisted pair?
Or just shield the bundle?

[jerrykco]

If someone could help me please.
See post above

[zippy500]

Here are my pics of my invertor plug.

the original wiring are in twisted pairs sheathed with a separate ground wire commoned together

Can bus wires (green/blue) are just twisted pair

with regards to the motor temp wires, I think they just go to a thermister so is does not matter which way round they ( I am not a EE so maybe someone can correct me if this is wrong with the temp sensor)

the cable pairs from invertor plug are

44,45
20,21
19,27
17,18


The whole wiring bunch was in plastic ribbed conduit

I still need to attach my resolver plug to the harness

Hope this helps, just finishing up my leaf adaptor board, hope to test power up soon.

[jerrykco]

Thanks Zippy500. That helps a lot.I made the cables this morning not having had an answer yet. I will remake it and twist and shield as appropriate.

[jerrykco]

Obviously I need to rebuild the wire harness to the resolver (making the appropriate shielded twisted pairs - Thanks again Zippy 500) but here are the pics from today.
I had to drill a hole through the receptacle of the inverter plug so I could get the throttle wires into the inverter. I have only attached one (orange to test.

View from the other side

I mounted the Prius pedal to a board and placed it on the floor for bench testing

I managed to get the 8x2 Resolver plug wired up (need to remake to have shielded twisted pairs)

Again thanks!

[slow67]

the original wiring are in twisted pairs sheathed with a separate ground wire commoned together

Which wires were twisted with each other on the resolver? Were the Sin, Cos, and Exciter wires twisted with each other and shielded?

[jerrykco]

As zippy 500 pointed out, twist these pairs and shield the pairs.

the cable pairs from inverte\or plug are

44,45 (MtempP1, MtempP2)
20,21 (Sin+, Sin-)
19,27 (Ex, !Ex)
17,18 (Cos+, Cos-)

[Colm Spain]

Hi Jerrykco, I just started a project to convert a boat to electric.... I have a 2012 leaf motor and inverter, trying to work out the cable colour code for the motor resolver, any ideas...
Thanks Colm.