Schematics and Instructions - Revision history

Timelord: Formatting

2025-07-09T08:12:57Z

Formatting

← Older revision		Revision as of 08:12, 9 July 2025
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	If you have a kit with the large sensor board, look here for instructions.		If you have a kit with the large sensor board, look here for instructions.

	== General ~~instructions~~ ==		== General Instructions ==
	Check out the assembly video.		Check out the assembly video.

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	3. On Windows you might need an older version of the serial port driver, [https://www.openinverter.org/forum/viewtopic.php?f=2&t=57 if you're having issues].		3. On Windows you might need an older version of the serial port driver, [https://www.openinverter.org/forum/viewtopic.php?f=2&t=57 if you're having issues].

	== Using the ~~web interface~~ ==		== Using the Web Interface ==
	The included Olimex MOD-WIFI-ESP8266 is preloaded with an easy to use [[Web Interface]]. Connect to mainboard JP6 like so		The included Olimex MOD-WIFI-ESP8266 is preloaded with an easy to use [[Web Interface]]. Connect to mainboard JP6 like so
	* Pin 1 of Wifi to Pin 2 on mainboard (3.3V) ~~(note~~ Pin 1 is now 5V!, schematic not yet updated)
			* Pin 1 of Wifi to Pin 2 on mainboard <s>(3.3V)</s>
			** Note: '''Pin 1 is now 5V''', schematic not yet updated)
	* Pin 2 of Wifi to Pin 5 on mainboard (GND, next to inductor)		* Pin 2 of Wifi to Pin 5 on mainboard (GND, next to inductor)
	* Pin 3 of Wifi to Pin 3 on main board		* Pin 3 of Wifi to Pin 3 on main board
	* Pin 4 of Wifi to Pin 4 on main board		* Pin 4 of Wifi to Pin 4 on main board

	The ESP8266 acts as a wifi access point. SSID and password are printed on the instructions sheet included with you kit. Connect to the access point, then open your browser and type 192.168.4.1 to open the web interface.		The ESP8266 acts as a wifi access point. SSID and password are printed on the instructions sheet included with you kit. Connect to the access point, then open your browser and type 192.168.4.1 to open the web interface.

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	The STM32-H103 comes with a bootloader and a current software version. Both configuration and software updates are done via the Wifi interface. To update the inverter firmware extract the stm32_sine.bin and upload it via the "Update" form of the web interface. The update takes about 2s and when it is finished the green LED should flash.		The STM32-H103 comes with a bootloader and a current software version. Both configuration and software updates are done via the Wifi interface. To update the inverter firmware extract the stm32_sine.bin and upload it via the "Update" form of the web interface. The update takes about 2s and when it is finished the green LED should flash.

	Make sure you're not running a plot or gauges during firmware upgrade!		'''Make sure you're not running a plot or gauges during firmware upgrade!'''

	You can also customize the web interface itself by replacing the respective files like index.html, index.js etc. Upload them with the same form as the firmware.		You can also customize the web interface itself by replacing the respective files like index.html, index.js etc. Upload them with the same form as the firmware.

	== Connecting the ~~sensor boards~~ ==		== Connecting the Sensor Boards ==
	The sensor boards are connected to JP4. The provided 10-pole ribbon cable must be inserted into the socket as shown. 3 slots must be blank on either side of the 16-pole socket. Connect the boards like so:		The sensor boards are connected to JP4. The provided 10-pole ribbon cable must be inserted into the socket as shown. 3 slots must be blank on either side of the 16-pole socket. Connect the boards like so:
	# Current sensor module 1: JP4 Pin 6 to J1 Pin 1, JP4 Pin 7 to J1 Pin 2 and JP4 Pin 8 to J1 Pin 3		# Current sensor module 1: JP4 Pin 6 to J1 Pin 1, JP4 Pin 7 to J1 Pin 2 and JP4 Pin 8 to J1 Pin 3
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	# Voltage sense module: JP4 Pin 13 to JP2 Pin 1, JP4 Pin Pin 4 to JP2 Pin 2, JP4 Pin 5 to JP2 Pin 3, JP4 Pin 12 to JP2 Pin 4		# Voltage sense module: JP4 Pin 13 to JP2 Pin 1, JP4 Pin Pin 4 to JP2 Pin 2, JP4 Pin 5 to JP2 Pin 3, JP4 Pin 12 to JP2 Pin 4
	# Temperature sensor: Connect to voltage sense board JP1		# Temperature sensor: Connect to voltage sense board JP1


	Current values are only measured in Run mode, so tie Pin 11 and 17 to 12V and type		Current values are only measured in Run mode, so tie Pin 11 and 17 to 12V and type
	start 2		start 2
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	save		save

	== Connecting the ~~gate drivers~~ ==		== Connecting the Gate Drivers ==
	'''The steps from here on will only work with the "sine" software, not the FOC software'''. So temporarily flash that, you can revert later on.		'''The steps from here on will only work with the "sine" software, not the FOC software'''. So temporarily flash that, you can revert later on.

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	Now you are ready for some more power. Connect the gate drivers to the IGBTs and repeat the steps above. The slope of the PWM will be less steep as to show that the gate driver is really working against the gates capacity. Connect a small voltage (like 30V) to the DC bus and verify that the PWM shows on the IGBT modules outputs and looks the same on all outputs. This circuit is completely symmetrical so the output should be symmectrical as well. If its not, there might be something wrong. There must be absolutely 0 current flow on the DC bus, otherwise you are experiencing shoot-through, i.e. the top and bottom IGBT of one leg are on at the same time. Correct this before continuing!		Now you are ready for some more power. Connect the gate drivers to the IGBTs and repeat the steps above. The slope of the PWM will be less steep as to show that the gate driver is really working against the gates capacity. Connect a small voltage (like 30V) to the DC bus and verify that the PWM shows on the IGBT modules outputs and looks the same on all outputs. This circuit is completely symmetrical so the output should be symmectrical as well. If its not, there might be something wrong. There must be absolutely 0 current flow on the DC bus, otherwise you are experiencing shoot-through, i.e. the top and bottom IGBT of one leg are on at the same time. Correct this before continuing!

	== Connecting the ~~motor~~ ==		== Connecting the Motor ==
	Now comes the big one. Connect a motor to the three output phases. Leave the DC voltage at a small value but make sure it can supply enough current (more than 10A). But also make sure to limit the possible current e.g. with a fuse. Now type		Now comes the big one. Connect a motor to the three output phases. Leave the DC voltage at a small value but make sure it can supply enough current (more than 10A). But also make sure to limit the possible current e.g. with a fuse. Now type
	set fweak 10		set fweak 10
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	python tuning.py -d /dev/ttyUSB0		python tuning.py -d /dev/ttyUSB0

	== Connecting the ~~speed sensor~~ ==		== Connecting the Speed Sensor ==
	[[File:PulseEncoder.jpg\|thumb\|227x227px\|Pulse Encoder]]		[[File:PulseEncoder.jpg\|thumb\|227x227px\|Pulse Encoder]]
	This board has been designed with optical encoders in mind. So it supplies 30mA on pin 2 for an IR diode. Pin 3 expects an open collector pulse signal. The picture shows a very exposed version of such a sensor which explains the principle very well though. The controller needs to know how many pulses it gets per turn of the shaft. It also needs to know the number of pole pairs of your motor. You can deduce that from the nameplate or data sheet. Type		This board has been designed with optical encoders in mind. So it supplies 30mA on pin 2 for an IR diode. Pin 3 expects an open collector pulse signal. The picture shows a very exposed version of such a sensor which explains the principle very well though. The controller needs to know how many pulses it gets per turn of the shaft. It also needs to know the number of pole pairs of your motor. You can deduce that from the nameplate or data sheet. Type
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	Some encoders require more than the provided 30mA. In that case replace R2 by a bridge.		Some encoders require more than the provided 30mA. In that case replace R2 by a bridge.

	== Connecting the ~~throttle pot~~ ==		== Connecting the Throttle Pot ==
	The throttle needs a 5V source. It depends on your encoder type. If you have a simple 1-channel encoder you can populate R1 with a wire and use Pin 1 as 5V. If you use an advanced quadrature encoder, replace R7 with a wire and use Pin 2 as 5V for both throttle and encoder. Connect pot GND to Pin 23 (or some other GND source) and the slider to pin 6. Type		The throttle needs a 5V source. It depends on your encoder type. If you have a simple 1-channel encoder you can populate R1 with a wire and use Pin 1 as 5V. If you use an advanced quadrature encoder, replace R7 with a wire and use Pin 2 as 5V for both throttle and encoder. Connect pot GND to Pin 23 (or some other GND source) and the slider to pin 6. Type
	get pot		get pot
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	If the pot value leaves the window defined by potmin and potmax the throttle command is set to 0 and the error light is triggered.		If the pot value leaves the window defined by potmin and potmax the throttle command is set to 0 and the error light is triggered.

	== Running ~~slip control~~ ==		== Running Slip Control ==
	Now start the controller in slip control mode by typing		Now start the controller in slip control mode by typing
	start 1		start 1
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	Once the whole setup is inside your car you can play with various parameters for fine tuning.		Once the whole setup is inside your car you can play with various parameters for fine tuning.

	== Connecting ~~precharge~~ and ~~main contactor~~ ==		== Connecting Precharge and Main Contactor ==
	[[File:Precharge.png\|thumb\|Contactor connection]]		[[File:Precharge.png\|thumb\|Contactor connection]]
	Connect the precharge relay and the main contactor as depicted in the diagram. It is recommended to disconnect both battery poles. The inverter controls the two contactors by means of the DC bus voltage. When udc < udcsw then the precharge relay is closed, the main contactor is inhibited. When udc > udcsw the main contactor is closed as soon has the start signal (pin 7) goes high. The precharge relay is opened at the same time. udcsw should be set to about 80% of your nominal pack voltage. So if the latter is 360V set udcsw to 300V by typing		Connect the precharge relay and the main contactor as depicted in the diagram. It is recommended to disconnect both battery poles. The inverter controls the two contactors by means of the DC bus voltage. When udc < udcsw then the precharge relay is closed, the main contactor is inhibited. When udc > udcsw the main contactor is closed as soon has the start signal (pin 7) goes high. The precharge relay is opened at the same time. udcsw should be set to about 80% of your nominal pack voltage. So if the latter is 360V set udcsw to 300V by typing
	set udcsw 300		set udcsw 300

	== Connecting ~~motor temperature sensor~~, ~~emergency stop~~ and ~~motor protection switch~~ ==		== Connecting Motor Temperature Sensor, Emergency Stop, and Motor Protection Switch ==
	The software supports the KTY83 and KTY84 temperature sensor. Other types might be supported in upcoming releases. Note that the sensor has a polarity. When connected the wrong way it will saturate at 120°C. So even if the temperature rises above 120°C it will be displayed as 120°C. Connect it to pin 21 (negative) and pin 22 (positive).		The software supports the KTY83 and KTY84 temperature sensor. Other types might be supported in upcoming releases. Note that the sensor has a polarity. When connected the wrong way it will saturate at 120°C. So even if the temperature rises above 120°C it will be displayed as 120°C. Connect it to pin 21 (negative) and pin 22 (positive).

Timelord: /* Errata */

2025-07-09T07:52:37Z

Errata

← Older revision		Revision as of 07:52, 9 July 2025
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	2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25		2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25
	[[File:Errata Voltage Sense 2.jpg\|thumb\|205x205px\|Connect JP1.2 to VCC]]		[[File:Errata Voltage Sense 2.jpg\|thumb\|205x205px\|Connect JP1.2 to VCC]]
	2. There is a glitch on the new ~~Voltagse~~ Sense Board. The temp sensor polarity is sort of swapped. So connect resistor R9 to the closest GND source (instead of VCC). Connect Pin 2 of JP1 to the closest VCC source. See pictures on the right for details.		2. There is a glitch on the new Voltage Sense Board. The temp sensor polarity is sort of swapped. So connect resistor R9 to the closest GND source (instead of VCC). Connect Pin 2 of JP1 to the closest VCC source. See pictures on the right for details.

	3. On Windows you might need an older version of the serial port driver, [https://www.openinverter.org/forum/viewtopic.php?f=2&t=57 if you're having issues].		3. On Windows you might need an older version of the serial port driver, [https://www.openinverter.org/forum/viewtopic.php?f=2&t=57 if you're having issues].

Marcexec at 10:53, 14 June 2023

2023-06-14T10:53:13Z

← Older revision		Revision as of 10:53, 14 June 2023
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	In-depth information can be found on the [[Hardware Theory of Operation\|Hardware Principles]] and [[Software Theory of Operation\|Software Principles page]].		In-depth information can be found on the [[Hardware Theory of Operation\|Hardware Principles]] and [[Software Theory of Operation\|Software Principles page]].
			[[Category:OpenInverter]] [[Category:Tutorial]]

Romale: /* Forward and reverse */

2022-06-24T12:33:58Z

Forward and reverse

← Older revision		Revision as of 12:33, 24 June 2022
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	== Forward and reverse ==		== Forward and reverse ==
	You can connect a 3-position switch for selecting the drive mode. Forward (pin 13) turns the motor in one direction, reverse (pin 15) in the other. If they are both low, no current is fed to the motor making this essentially the neutral position.		You can connect a 3-position switch for selecting the drive mode. Forward (pin 13) turns the motor in one direction, reverse (pin 15) in the other. If they are both low, no current is fed to the motor making this essentially the neutral position.

			Correction, this will not be a neutral position. Rather, it will be almost parking, if you turn on neutral at speed, there will be a very hard stop regen!

	== See Also ==		== See Also ==

Mjc506: Couple of typos, mentioning that e-stop is not used on rev3 mainboards

2021-03-26T10:44:52Z

Couple of typos, mentioning that e-stop is not used on rev3 mainboards

← Older revision		Revision as of 10:44, 26 March 2021
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	The software supports the KTY83 and KTY84 temperature sensor. Other types might be supported in upcoming releases. Note that the sensor has a polarity. When connected the wrong way it will saturate at 120°C. So even if the temperature rises above 120°C it will be displayed as 120°C. Connect it to pin 21 (negative) and pin 22 (positive).		The software supports the KTY83 and KTY84 temperature sensor. Other types might be supported in upcoming releases. Note that the sensor has a polarity. When connected the wrong way it will saturate at 120°C. So even if the temperature rises above 120°C it will be displayed as 120°C. Connect it to pin 21 (negative) and pin 22 (positive).

	Some motors have a protection switch that opens at some threshold temperature. You can connect it to 12V and pin 11. It will stop the inverter ~~immediatly~~ if tripped. If your motor does not have this feature, connect pin 11 to 12V.		Some motors have a protection switch that opens at some threshold temperature. You can connect it to 12V and pin 11. It will stop the inverter immediately if tripped. If your motor does not have this feature, connect pin 11 to 12V.

	The emergency stop serves a similar function. It can be installed in the drivers reach and will stop the inverter ~~immediatly~~ when 12V ~~are~~ interrupted (failsafe). Connect it to 12V and pin 17.		The emergency stop serves a similar function. It can be installed in the drivers reach and will stop the inverter immediately when 12V is interrupted (failsafe). Connect it to 12V and pin 17. (Not used on the rev3 mainboard, connect pin 17 to 12V. If you want a separate E-stop button, wire it in series with the motor protection switch)

	== Forward and reverse ==		== Forward and reverse ==

Johu: /* Connecting the gate drivers */

2020-06-09T08:44:54Z

Connecting the gate drivers

← Older revision		Revision as of 08:44, 9 June 2020
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	== Connecting the gate drivers ==		== Connecting the gate drivers ==
			'''The steps from here on will only work with the "sine" software, not the FOC software'''. So temporarily flash that, you can revert later on.

	Connect the gate drivers with a ribbon cable like shown in the picture. Power up the inverter, which will now pull around 300mA @ 12V. If its less, one or more gate drivers are unpowered, if its more, there is an error on the drivers or the connection. Remove power quickly in that case. The inrush current is higher of course, so set the current limit of your power supply to about 1A.		Connect the gate drivers with a ribbon cable like shown in the picture. Power up the inverter, which will now pull around 300mA @ 12V. If its less, one or more gate drivers are unpowered, if its more, there is an error on the drivers or the connection. Remove power quickly in that case. The inrush current is higher of course, so set the current limit of your power supply to about 1A.

Isaac96: /* Connecting the sensor boards */ Update for the Melexis sensor calibration

2020-04-07T18:37:02Z

Connecting the sensor boards: Update for the Melexis sensor calibration

← Older revision		Revision as of 18:37, 7 April 2020
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	The current sensor gain depends on it's distance to the conductor (including the isolation). Your AC cable must run on the underside of the PCB between the pins of the sensor IC. Use a cable tie for mounting. The PCB should be placed far away from other high currents to prevent cross-talk. To increase your current range simple put a spacer between cable and PCB.		The current sensor gain depends on it's distance to the conductor (including the isolation). Your AC cable must run on the underside of the PCB between the pins of the sensor IC. Use a cable tie for mounting. The PCB should be placed far away from other high currents to prevent cross-talk. To increase your current range simple put a spacer between cable and PCB.

	To calibrate the current, set il1gain and il2gain to 1. Then put a known current through the sensors by winding for example a 1.5mm² cable 10 times through both sensors. Then, using you lab power supply run 5A through your wound cable. Type:		To calibrate the current, set il1gain and il2gain to 1. Then put a known current through the sensors by winding for example a 1.5mm² cable 10 times through both sensors. Then, using you lab power supply run 5A through your wound cable.

			The new Melexis sensors cannot have cable wound through them. So you need to attach them in their final positions and then pass current through the phase wire.

			Type:
	set ocurlim 1000		set ocurlim 1000

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	save		save
	Calibration is crucial to ensure correct operation of the over current limit!		Calibration is crucial to ensure correct operation of the over current limit!

			If your current sensor gains are negative then your 'ocurlim' also needs to be negative!

	Likewise you need to calibrate the voltage sensor board. Type (or set on web interface)		Likewise you need to calibrate the voltage sensor board. Type (or set on web interface)
	set udcgain 1		set udcgain 1

Johu: /* Connecting precharge and main contactor */

2020-04-01T20:10:28Z

Connecting precharge and main contactor

← Older revision		Revision as of 20:10, 1 April 2020
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	== Connecting the speed sensor ==		== Connecting the speed sensor ==
			[[File:PulseEncoder.jpg\|thumb\|227x227px\|Pulse Encoder]]
	This board has been designed with optical encoders in mind. So it supplies 30mA on pin 2 for an IR diode. Pin 3 expects an open collector pulse signal. The picture shows a very exposed version of such a sensor which explains the principle very well though. The controller needs to know how many pulses it gets per turn of the shaft. It also needs to know the number of pole pairs of your motor. You can deduce that from the nameplate or data sheet. Type		This board has been designed with optical encoders in mind. So it supplies 30mA on pin 2 for an IR diode. Pin 3 expects an open collector pulse signal. The picture shows a very exposed version of such a sensor which explains the principle very well though. The controller needs to know how many pulses it gets per turn of the shaft. It also needs to know the number of pole pairs of your motor. You can deduce that from the nameplate or data sheet. Type
	set numimp 64		set numimp 64
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	== Connecting precharge and main contactor ==		== Connecting precharge and main contactor ==
			[[File:Precharge.png\|thumb\|Contactor connection]]
	Connect the precharge relay and the main contactor as depicted in the diagram. It is recommended to disconnect both battery poles. The inverter controls the two contactors by means of the DC bus voltage. When udc < udcsw then the precharge relay is closed, the main contactor is inhibited. When udc > udcsw the main contactor is closed as soon has the start signal (pin 7) goes high. The precharge relay is opened at the same time. udcsw should be set to about 80% of your nominal pack voltage. So if the latter is 360V set udcsw to 300V by typing		Connect the precharge relay and the main contactor as depicted in the diagram. It is recommended to disconnect both battery poles. The inverter controls the two contactors by means of the DC bus voltage. When udc < udcsw then the precharge relay is closed, the main contactor is inhibited. When udc > udcsw the main contactor is closed as soon has the start signal (pin 7) goes high. The precharge relay is opened at the same time. udcsw should be set to about 80% of your nominal pack voltage. So if the latter is 360V set udcsw to 300V by typing
	set udcsw 300		set udcsw 300

Johu: /* See Also */

2020-04-01T20:07:44Z

Johu: /* Errata */

2020-04-01T20:05:54Z

Errata

← Older revision		Revision as of 20:05, 1 April 2020
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	== Errata ==		== Errata ==
			[[File:Errata Voltage Sense 1.jpg\|thumb\|203x203px\|Connect R9 to GND]]
	There are some glitches which can be easily fixed.		There are some glitches which can be easily fixed.

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	This results in the ribbon cable map:		This results in the ribbon cable map:
	2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25		2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 22 21 24 23 26 25
			[[File:Errata Voltage Sense 2.jpg\|thumb\|205x205px\|Connect JP1.2 to VCC]]
	2. There is a glitch on the new Voltagse Sense Board. The temp sensor polarity is sort of swapped. So connect resistor R9 to the closest GND source (instead of VCC). Connect Pin 2 of JP1 to the closest VCC source. See pictures on the right for details.		2. There is a glitch on the new Voltagse Sense Board. The temp sensor polarity is sort of swapped. So connect resistor R9 to the closest GND source (instead of VCC). Connect Pin 2 of JP1 to the closest VCC source. See pictures on the right for details.

← Older revision		Revision as of 20:07, 1 April 2020
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	== See Also ==		== See Also ==
	There are detailed pages for main board, and gate drivers.		There are detailed pages for [[Main Board Version 2\|main board]], [[Sense Boards\|sensor boards]] and [[Gate Driver\|gate drivers]].

	Information about the softwares Parameters.		Information about the softwares [[Parameters]].

	In-depth information can be found on the Hardware Principles and Software Principles page.		In-depth information can be found on the [[Hardware Theory of Operation\|Hardware Principles]] and [[Software Theory of Operation\|Software Principles page]].

	~~Forum Post about experimental parameter setup~~.