Phasing Test

23/07/2022

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General

1. Phasing is the process in which the motor rotates 360 degrees in the CW direction once and we can determine the feedback offset angle
2. 4 12V batteries in series connection were used to provide 48V(high voltage) to do the phasing process.
3. RFE and RUN signal were given to the motorcontroller by attaching external push buttons
4. First time testing videos

Steps:

1. Check that the switch in branch K4(discharge relay) is closed and has been closed for at least 15 seconds, once it has been closed for 15 sec, open the switch

2. Changes in the N-Drive software (installation guide attached in the end)

   • Set Speed 2 at Pos-Reference to 100
   • Set Inom eff in settings to 20A
   • Set Mpole in settings to 20
   • Set FB pole in settings to 2
   • Set Mtemp to 32767(to resolve the motor temp issue value, for actual working the value must be set in between 14500-15000 which refers to 90-100 degree celcius)
   • Set Imax pk to 3%

3. Give the RFE signal {It is mentioned in one of the emails that this can be done before applying the HV }

4. Close the switch in K3(negative AIR)

5. To initial Pre-Charge, close the switch in branch K2(Precharge relay)

6. Using the N-Drive Software determine when the DC-BUS is at least 90% of the total applied voltage (Check NDrive->Extra->Vdc-Bus (0xeb).

7. Once the DC-BUS voltage is at least 90% , close the switch in branch K1(Positive AIR) [It was not charged exactly to 90% but was actually showing around 50-51V even though the supply was only 48V]

8. Once the switch in branch K1(positive AIR) has been closed, open the switch in branch K2(Precharge)

9. High voltage is now being supplied to the motor controller and the system is considered live and should be handled carefully and cautiously

10. Changes in N-Drive software

    • Auto ~> Special functions ~> select [fn4] Phasing-Rotating
    • Press START (**The next step must be done before 10 s are over)
    • Switch on X1-G (RUN: Run enable)

11. The motor must then rotate 360° once in CW direction.

12. Disable drive by switching X1-G (RUN) to off (NDrive will tell you) [ Please always deactivate the inverter with the RUN signal before cutting the HV voltage. Even at 48V.The RFE does not need to be disconnected. Disconnecting the RUN input is enough.]

Issues Faced

1. As seen in the EMRAX-RS_V2 Resolver connector pdf , the wire in the 6th pin of the Feedback plug motor is black-white but no black-white wire is there [Resolved(1)]
2. After completing phasing, the N-drive software is supposed to give back the offset angle of our motor, but it gives a garbage value/whatever value you manually set in it
3. As mentioned in the initialisation guide the motor is supposed to run during phasing at an Imax pk value of 5% it should draw a current of 2-3A {mentioned in emails by edward} however at 5% it draws 21.2A {as shown in phasing videos} and motor does not run at 5%[Resolved(3)]

Issues Resolved

1. There were translation issues and the wire is supposed to be yellow-white
2. We have custom made the connector ourselves by soldering the resistor as well as the connections
3. We set the Imax pk value to 3% during our successfull test and the current drawn was 12.7A(as shown in N-drive software)

Circuit Used

1. The normal connections for battery pack(High voltage) connections are replaced by an external battery pack of 4 12V EXIDE batteries kept in series
2. The controlling of the positive AIR which originally is done by a signal from the MASTER PCB(once 90% charging is done of the motor controller capacitor) was replaced by and external push button

Motor Controller connections

1. The RS232 serial interface requires a connector from M8 to D9-S. We have custom made the connector by soldering the wires into the RS232 connector.Special drivers are also required to be installed
2. The resolver connections are as follow

Installing N-drive software

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