Leaf Invertor DC connections

[jerrykco]

What is the correct polarity for the DC HV connections to the invertor.

[celeron55]

You can always use multimeter diode check.

One polarity will show a diode forward voltage of 0.3 to 1.2V depending on the inverter. This is the reverse polarity and will be a short circuit if you connect the battery this way.

The other polarity will show open circuit after a second of charging the capacitor first. This is the correct polarity for connecting the inverter to a battery.

Measure both ways, make sure you can see both cases and mark accordingly.

That having been said, on the leaf gen2 inverter positive is the one closer to the side, farther from the cooling port. But you don't need to ask.

[jerrykco]

You can always use multimeter diode check.

One polarity will show a diode forward voltage of 0.3 to 1.2V depending on the inverter. This is the reverse polarity and will be a short circuit if you connect the battery this way.

The other polarity will show open circuit after a second of charging the capacitor first. This is the correct polarity for connecting the inverter to a battery.

Measure both ways, make sure you can see both cases and mark accordingly.

That having been said, on the leaf gen2 inverter positive is the one closer to the side, farther from the cooling port. But you don't need to ask.

Thanks Celeron55!
When I took electronics in the Army's Signal Core school after being drafted during the Vietnam war in 1969 for 9 months, this test wasn't part of anything I learned. After the war I pursued a career in Software Development and later Project management. Thanks for the remedial education. I love learning new stuff. I will test it tonight!

[clanger9]

On the course, Damien taught us how to check with a bulb & battery.

A picture might help - hopefully I've got this right!

[zippy500]

Image taken from different site

[doobedoobedo]

Image taken from different site

I can vouch for this being correct. I put similar markings on mine.

[RetroZero]

On the course, Damien taught us how to check with a bulb & battery.

A picture might help - hopefully I've got this right!
23_03_2020, 17_03 Office Lens.jpg

Thanks for being on to it clanger9.

[jerrykco]

Happily and correctly because of your help clanger9 , zippy500, and celeron55, I connected HV to the Leaf Inverter and nothing blew up.
My question is what is the sequence to bring the HV on line with the v3 Controller (I'm and flipping relay switches by hand). I noticed that I can get two different sets of errors, depending on the sequence I try.
If I turn on the Battery after I start the the inverter, I get PRECHARGE-STOP.
If I turn on the Battery before the the powering up the v3 controller then I get LOWRESAMP-DISPLAY.
Searching both errors I did the following.
(LOWRESAMP). Verified that the twisted pair wiring seems correct. Tried to measure EX but I don't know what I need to measure it. (to ground or to !EX?) and am I looking for a dc voltage or a signal? (I don't have a scope).
(PRECHARGE). Verified the R values of R40=509Ω, R41=9.98KΩ, R42=3.31KΩ, R44=3.30KΩ.
And help or advice would be appreciated!

[Isaac96]

LOWRESAMP comes from a bad resolver signal. https://openinverter.org/wiki/Errors
I'm not familiar with resolvers but maybe you could scope the sine and cosine pins? That ought to give a nice signal of some sort assuming you have the resolver connected. Maybe someone with a Leaf motor could chime in?

Precharge error occurs if udc is less than udcsw after 5 seconds.

Do you have a precharge resistor?

[johu]

!EX = GND so yet can scope EX to ground. You should see a 4.4kHz sine with 9V peak-peak amplitude.

But sometimes I get lowresamp in my car, I think the detection might need some work

[damian.lo]

Exactly from time to time I have the same error on beginning - lowresamp, but then if I push throttle, car goes without any problems.

[jerrykco]

!EX = GND so yet can scope EX to ground. You should see a 4.4kHz sine with 9V peak-peak amplitude.
But sometimes I get lowresamp in my car, I think the detection might need some work

Thanks, Johannes!

I have a cheap USB digital scope I can use to test this tonight.

BUT... I still would like to know the proper sequence to power on the INVERTER and connect the HV BATTERY.

1. Power the Inverter and connect to the WiFi Web Interface
2. Connect the BATTERY in Pre-Charge mode (using 100 Ohm Resister)
3. Wait 10 Seconds (and using a Volt Meter measure the DC Voltage into the inverter)
4. Connect the Main Contactor (bypassing the 100 Ohm resister)
5. Apply 12V DC to the Start line
6. Start Manual mode via WiFi
ETC......

This is what I have been doing. But should I have connected the HV DC Battery before ever applying the 12V to power up the Inverter?

[Isaac96]

Step 5 is not necessary if you're starting via the wifi.

You should connect HV first, else you will get the precharge error.
Or if you like you can just change udcsw to avoid the error - set it to 0 or something.
Then connect in any order you like. I believe HV connection is not problematic as long as you let it precharge first?

[jerrykco]

Step 5 is not necessary if you're starting via the wifi.
I believe HV connection is not problematic as long as you let it precharge first?

Yes, I always pre-charge first.,
Thanks for the help Isaac96!

[jerrykco]

!EX = GND so yet can scope EX to ground. You should see a 4.4kHz sine with 9V peak-peak amplitude.

I think it's my resolver wiring.
EX Signal looks good.

[johu]

Yes looks fine to me. What do you get on the sin/cos return lines? Be aware amplitude will change here as you turn the shaft.

[johu]

Just checked the resolver code:

Code: Select all

   int sin = adc_read_injected(ADC1, sinChan);
   int cos = adc_read_injected(ADC1, cosChan);

   minSin = MIN(sin, minSin);
   maxSin = MAX(sin, maxSin);

   //Wait for signal to reach usable amplitude
   if ((maxSin - minSin) > MIN_RES_AMP)
   {
      if (invert)
         return SineCore::Atan2(-sin, -cos);
      return SineCore::Atan2(sin, cos);
   }
   else
   {
      if (0 == startupDelay)
      {
         ErrorMessage::Post(ERR_LORESAMP);
      }
      return 0;
   }
 

So it records the minimum and maximum amplitude of the the sin signal. But if the motor is stationary (which it usually is after startup) and happens to be in a position where the sin-amplitude is low, it will assert the LORESAMP warning for no reason. Gotta work on that...

[jerrykco]

Yes looks fine to me. What do you get on the sin/cos return lines? Be aware amplitude will change here as you turn the shaft.

I'll check that tonight and let you know.