EM57 test run with bridge rectifier

[Rcoetzee]

Hi all, I did try and find my specific issue using the search function. I got similar results but not quite what I am experiencing.

Ive got the openinverter board wired up to my gen 1 leaf stack. Throttle calibrated correctly, able to get it into RUN and DRIVE states easily. No matter what I do I cannot seem to get the motor to spin, no noise from motor or inverter. Torque value goes up but current draw stays 0. Ive got 320vdc on the HV side, doing precharge and contactors manually. Ive set the udcsw voltages etc so that it will accept the 320vdc but no luck and no errors.

My main questions are;
Can I run it like this as a test?
Do I need a shunt or current measuring device for the motor to run at all?
If I need a shunt, whats the cheapest and easiest way to set one up.

My project is going really well but Im stuck at this point.

[Rcoetzee]

Ive since setup the contactors and everything to be handled by the openinverter, still no luck.

[tom91]

post your params and spotvalues

[Rcoetzee]

here they are:

[tom91]

Okay you are running a zombieverter?

Parameters are missing please download and post.

Did you calibrate your throttle and plot pot1 and potnom to see if they track?

[tom91]

What diagrams did you follow to wire up the wires to the leaf inverter and zombie? Please post pictures of your setup.

[Rcoetzee]

[Rcoetzee]

Diagram v3.pdf

(273.49 KiB) Downloaded 4 times

Throttle has been calibrated, potnom works as it should, its a zombieverter yes. see diagram and pics

[Bratitude]

you have inverter on can 1 but charger on can 2 in your prams.

which can bus did you wire the stack to?

also reset your general purpose i/o. remove all the DCFC stuff.

is your negative contactor wired up to outfun2?

when you pull t15 high dose precharge function work and goes into run mode?

[Rcoetzee]

Thank you Bratitude everything is wired to CAN1.
When T15 goes on it immediately goes into run mode. Negative contactor wired to pin 31 on zombieverter

[Bratitude]

what is the udc value when in run mode?

have you verified your switch's are working? do you see the values change?

[Rcoetzee]

320-328udc

[Rcoetzee]

Yes the values change, switches are working. Can easily select neutral reverse or drive

[tom91]

So if you wired it as the diagram it should work. good news is your can works as you get invudc.

[Rcoetzee]

So you are saying that I should be able to test it like this without a current measuring device like a shunt?

[Rcoetzee]

Some more information:

I have now confirmed that the Zombieverter doesn't seem to "output" the "pull to ground" signal for the main negative contactor. This is supposed to be from pin
31 on the Zombieverter.

If I manually put the negative main contactor in a. "Always on" state then I get the issue again where I never see opmode precharge, it just goes straight to run and there's almost no delay between precharge contactor and main positive contactor. I suspect this is my issue, it might show "Run" but precharge never happened correctly and that's why I can't get the motor to spin.

I hope this helps? I've been on this for a week with almost no rest. This is a big investment that's not turning out so well so far.

[tom91]

I suspect this is my issue

Nope.

Once in run mode it should work. Check all you wiring. Can you do a capture of CAN of your setup?

Both PDM and Inverter need to be on the same CAN network.

[Rcoetzee]

Both PDM and Inverter are on the same network. I've also since solved my precharge issue.

I've checked everything over may times again, I think I'll have to wire in an ISA shunt.

I'm not sure how to do a CAN capture unfortunately

[Rcoetzee]

It works!!!!

So yes, charger and inverter were connected to CAN1 but with the auto refresh and somewhat buggy interface on the cellphone it looked like charger param was set to CAN1 but it was in fact not.

I'm not sure why charger has to be on CaN1 in params for it to work? I don't fully understand this, is the shunt in the PDU/PDM? I've got the comm connection of PDU unplugg and things still work.

Thanks to everyone, I'm sorry for being so uniformed and inexperienced. I'm trying my best

[Alibro]

Check all your pins in the header are fully pushed home, I had similar issues and it turned out one of the pins hadn't fully clicked in so wasn't connecting. It would be worth double checking your soldering too.
If your precharge is working and the Zombieverter is going into run mode then the Gnd out for the negative contactor will also be working.
Double check your wiring, then assume you made a mess of it and check again.

Edit: I just spotted you got it working but left the post up as it might help someone else.

[Bratitude]

you can have them on can 1 or can2, but if you have the pdm and inverter in the same bus, then you need to have them selected In the interface for that bus.

the inverter measures the voltage, so you can remove the pdm and it will still run precharge.

again, testing and verifying your wiring is important. Just because it’s “wired up” dose not mean it’s correct.

Continuity checks with the multimeter, verifying ever stage eliminates issues like negative contractor not closing.

having issues like that when running high voltage with no resistive load during testing can be damaging to inverters.

I’ll update the wiki on proper bench testing procedures

[Rcoetzee]

Bratitude I`m not really sure what you`re on about?

Not sure why you are telling me again that testing and wiring are important either?

I clearly stated that I checked all my wiring numerous times and the wiring never was at fault. I did all my checks with multimeter as previously stated. My issue was never wiring related.


Some of my questions are still not answered, fairly important ones:

In my original post I asked;
1. "Can i run my setup with no shunt?" No answer. But yes i realised I can.
2. "I'm not sure why charger has to be on CaN1 in params for it to work?" Still no answer

As previously stated both PDM and INV are wired onto CAN1, PDM not yet used.

No need to update the wiki, the diagrams are fine. My wiring and hardware were fine, its a paramter "quirk" that caused the issue.

[Bratitude]

it was a general statement, not towards you.

but yes your question about the shut was answered, even states it in the wiki that a shunt with the leaf inverter is not needed.

and 2 charger dose not need to be on can 1 to work. but the leaf inverter and pdm have to be on the same bus. this ovbsuly needs to be more clearly written in the wiki as its just implied.


happy everything is running!

[Rcoetzee]

This seems to be a bug in the Zombieverter software then. Even with PDU communication connector unplugged my setup WILL NOT run if I select CAN2 under charger parameters. The moment I do that the motor won't spin, still able to get temps and Comms from inverter but the motor doesn't respond to throttle inputs at all.

In the end it was a software bug that made me feel really stupid .

I don't see where my shunt question was answered, I probably just missed it. Luckily it's not relevant at this point.

But yes, V2.22a on Zombieverter has a bug that will cost someone lots of time in the future. I hope they find this post.

Thanks to everyone for trying to assist.

[Bratitude]

perhaps, dose the same behavior happen with 2.30a firmware? i would update as there was a lot of leaf based fixes since