Some first assembly notes and what happens when you do some things wrong.
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Hey all, I'm swapping a leaf into my old GTI with the resolve controller and I figured I'd put my notes on here for some findings so that they are documented somewhere. Please let me know if any of these are wrong or there are other things to note.
Background, I'm a mechatronics engineering and have a healthy fear of high voltage electronics. I like to step through things one at a time to make sure all is good before adding power to the mix. This can lead to "problems" if you make some bad assumptions at the start.
Another note, I probably could have done more research but I couldn't easily find much out there on troubleshooting the resolve controller.
What I did first was connect all the 12 V and power things on. If you don't have HV connected, the resolve controller will go to a splash screen that says "resolve" then it will show blank after that. That seems to be a feature. Might be good to put a "No CAN" or some other sort of message here so that people know there isn't something wrong with the screen. I don't think this is noted in any of the controller documentation.
If you want to do just 12V checks and your battery is together, stuff should look pretty normal. If you are like me and have already disassembled your battery and none of the HV lines are hooked up, then the only thing you can see of use with 12V powering the system is if the contactors work. Leafspy will look horrendous with multiple cells stating that they are fully dead. this is not real, they just required the HV lines to be connected to read the actual voltages.
In terms of the Resolve controller and CAN, I'm pretty sure that the inverter and PDM will not send out CAN updates that the Resolve controller needs to light up the screen without HV. Someone correct me if this is wrong.
I saw a blank screen (due to not having HV connected and the motor stack probably not sending out CAN) and started "troubleshooting". I switched the white and yellow wires on the charge controller because someone mentioned that was a problem with theirs that fixed a blank screen. This was a mistake. The Resolve Wiring Documentation is correct, follow that. When I miss-wired the charge port, the system would open the HV contactors with power to the ignition, but would not close them. If you are having this issue, where the ignition powers the contactors but they do not disconnect when you remove power to the ignition, then Charger Port wiring is a likely culprit.
Other notes, you do not need thermocouple wires or battery heater wires in the battery connected. the controller seems to run the motor just fine without them attached.
Battery codes read from from Leafspy also don't seem to stop things from working. Not sure how Resolve handles error codes that aren't the ones noted in the manual. I have a CAN error from my BMS that "should" shut down the system but it doesn't. also doesn't seem to impact battery function as the system still charges and switches between drive, neutral, reverse. P31A4-00 4E HV Battery CAN Error EVB-102. Clearing this does nothing as it comes right back. but I can enter drive just fine. Hopefully doesn't become an issue in the future.
I'll keep updating this as more things come up but here's a video of my motor turning! and the soon to be electrified car in the background.link text