tom91 wrote: ↑Sun Sep 14, 2025 10:38 am Just to check.
Are you having the Zombie control the HV system? So it does the precharge and contactors along side the 12V ignition relay to the inverter?
Zombie is controlling the Nissan pack, yes. When I'm using the BMW packs, it is not as involved. There is one dead channel on the ZV that isn't activating the "RL2" which i had attached to the negative contactor. I was having to flip that on after precharge as I showed on the video I sent to you and Damien. I can deal with that and put it on another channel later.
When I use the BMW packs, I have a giant 20 ohm resistor I precharge and manually switch over after a couple of seconds.
I removed the contactors and they're def shorted now (cracked one open to verify). I have some kilovacs on the way.
This still feels alot like a wiring issue, or lack of having the zombie control it all.
I really am starting to believe the ZV isn't jumping in or sending something that the PDM needs. Maybe its a revision thing or some firmware difference from Damien's setup. I don't know. This isn't that complex of a wiring scheme, and Ive checked it with you, Damien, a friend that builds electric yachts, two other EE's and an all-around smart person irl, and everything seems ok to them , too.
I just don't know how i can see the resolver generate sin/cos when i send in an external exciter signal and have it hooked up wrong, I mean I could have sin/cos mixed up, but they appear 90 degrees out of phase on my oscilloscope. Pretty safe to say Im picking the right pairs of wires if that is happening. If i monitor the temp sense, the resistance changes when I shoot a little warm air into the motor.
I can get the ZV to do all of the basic stuff like Run & shift in the UI. The 12v from the relay activates as it should and I see it go high when I press the start button. I also can see the clocks/oscillators on the PDM wake up, and I can see the PWM and signals going in and out of the resolver IC on the PDM.
I can see what looks like proper signals on the CAN bus lines all the way in to the PDM on my scope .
I'll get more info and test whatever anyone would like to see next week when i rebuild the Nissan pack. I just don't know what else to look for at this point. I can rewire it until the cows come home and it doesn't make a difference in operation. I've been very deliberate in my wiring, with labels and triple checks with a continuity meter. I've taken it all out and spread it on the floor and redone it at least 3 times now. I see expected signals, values and ranges in the places they're expected.
The number of things it can be are pretty limited based on these measurements. I know nobody here believes I've correctly wired it, but I haven't shared one photo or video where I've had anyone find a improper connection (including Damien or Tom), and those that have seen in in person have not, either.
The ZV did have broken off components when it arrived, so Im really thinking this is a problem now after all the basic redundant checking Ive done. The wemos clone that was included was dead (unsurprising). My ZV still has a dead relay switching channel, and about every 30 seconds I get the "STM-ESP error" message for 15-20 seconds and the UI is very unreliable with any computer or phone or tablet I've tried. Close up or far away, with different antenna orientations . Ive tried a real Wemos, and two other knockoff types, with the same results. I don't know how normal this is, but I don't see it on videos when others are working on theirs, it would be really hard to make a video with the laggy, error prone UI I have. It makes testing challenging as you can imagine, having to wait for a screen for some times, having it appear and then a big red banner, waiting for that to clear up, then trying quickly to get something changed or saved or logged before it hangs up again.
Ive tried reflashing the ZV with my STlink, Ive updated the ESP, ive looked at the power and signals for noise and spikes, I brought in my RF Explorer to look for traffic or noise issues....nada. Where my shop is is somewhat remote and there isnt a lot of wifi traffic there.
Im open to any more suggestions.
is squished.