Resolver configuration guide

EC-C1200-450

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The content of this document is confidential and proprietary to Danfoss Editron Oy. The use of the information
contained herein is restricted solely to the recipient. Use for any other purpose without the written prior permission of
Danfoss Editron Oy is expressly prohibited.

Revision history
2021/10/29 Simo Janhunen 4.1
2021/04/06 Simo Janhunen 4.0
2019/11/04 Jussi Karttunen 3.0
2018/11/19 Tuukka Falkenberg 2.3
2014/02/03 Antti Summanen 1.0

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Contents
1 Introduction .............................................................................................................................................. 4
2 Wiring instructions.................................................................................................................................... 4
3 Resolver parameters ................................................................................................................................. 5
4 Resolver offset identification .................................................................................................................... 6
4.1 Setting the motor control for sensorless operation .......................................................................... 6
4.2 Local control of the inverter using PowerUSER ................................................................................. 6
4.3 Verifying the resolver direction ......................................................................................................... 7
4.4 Different offset identification methods .......................................................................................... 11
4.4.1 DC-magnetization methods ..................................................................................................... 12
4.4.2 Pulses ....................................................................................................................................... 13
4.4.3 Rotating ................................................................................................................................... 13
4.4.4 Injection ................................................................................................................................... 14
5 Activating the use of resolver feedback ................................................................................................. 14
6 Troubleshooting tips ............................................................................................................................... 15
7 References .............................................................................................................................................. 15

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1 Introduction
Controlling permanent magnet synchronous machines (PMSMs) requires knowing the rotor position in
relation to the stator. The rotor position can be estimated by the inverter control software, but it is difficult
especially in low-speed-high-torque situations. To improve the low-speed performance, an additional sensor,
a resolver, is used for measuring the position. This document describes the resolver set up procedure for
Danfoss EC-C1200 inverter with a PMSM.
The configuration of the rotor position feedback is divided into three sub-tasks. First, the resolver must be
connected and configured so that its signals are correctly read by the software. Next, the resolver offset must
be identified so that the resolver angle matches to that of the motor stator coils. Finally, the control system
must be instructed to use the measured resolver angle instead of the estimated value.

2 Wiring instructions
Table 1 shows the pin order for resolver signals on the 35-pin signal connector of the EC-C1200 inverter.

Table 1. Resolver pin order

Signal Description Pin number
RES_EXCP Excitation + for resolver 5
RES_EXCN Excitation - for resolver 4
RES_SINP Resolver Sine + output signal 28
RES_SINN Resolver Sine - output signal 16
RES_COSP Resolver Cosine + output signal 27
RES_COSN Resolver Cosine - output signal 26

Resolver wiring should be done with a shielded wire with twisted pairs, as shown in Figure 1. The cable shield
should be connected to frame/chassis ground from both ends. Pin #35 can be used for connecting the shield
in the EC-C1200 inverter.

Figure 1. Resolver wiring

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3 Resolver parameters
Figure 2 and Table 2 shows the most commonly required parameters for the resolver configuration. These
parameters can be found from the group 2.5 Resolver. Note that Resolver offset does not have any predefined
value in Danfoss motors and thus must be identified separately for every individual motor. Note also that
Resolver pole pair count is motor type dependent and thus the value of this parameter may not be correct
by default.

Figure 2. Resolver configuration parameters.

Table 2. Resolver parameters.

Name Description
Enables the use of the resolver measurement feedback for the motor
control operation. Setting this parameter FALSE means that the rotor angle
Use resolver feedback
is estimated by the control system instead of using the resolver feedback
(typically referred to as sensorless control).
Inverts the direction of the resolver angle measurement. Resolver angle
measurement must rotate in the same direction as the inverter is rotating
the motor. In Danfoss motors, the resolver direction is correct by default
Invert resolver direction
when motor cables are connected as specified in the user manual. When
cables are connected in a non-standard way, the resolver direction must
be checked and possibly changed with this parameter if necessary.
Resolver offset Resolver offset value used by the motor control software.
Selected type of the resolver error reaction. Resolver signal quality is
continuously monitored. Reaction of the motor control to detection of the
signal quality error is defined by this parameter. When resolver error is
detected, possible actions are:
Resolver error reaction 1) Try to continue as is and do nothing.
2) Give warning and switch the motor control to sensorless operation.
3) Give warning but continue to use the resolver feedback for the motor
control operation.
4) Generate trip to stop the operation immediately.

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 If the parameter is selected to generate a trip, the resulting fault is
“Resolver error”.
Number of magnetic pole pairs of the resolver. For one mechanical
revolution of the rotor, resolver produces pole pair number of cycles.
Typically, the resolver pole pair count is the same as the motor winding
Resolver pole pair count*
pole pair count. Note that EC-C1200 motor control software only supports
configurations where the motor winding pole pair count is integer multiple
of the resolver pole pair count.
Selected type of resolver offset identification method. See detailed
Resolver ID method
description of available methods later in this document.
Resolver ID time, DC Time duration that DC-magnetization current is applied when resolver
magnetization offset identification is performed.
Time duration that resolver offset identification is performed when
Resolver ID time, injection
injection is used as the method.
Magnitude of the current during DC-magnetization when resolver offset
Resolver ID current, DC
identification is performed. Value is given in motor’s per-units (1.0 pu
magnetization
equals nominal current of the motor).
*For Danfoss EM-PMI -motors the resolver pole pair count is the same as the motor winding pole pair count.
Some older motors and EM-PME -motors might have differences in pole pair counts, in this case the
specification must be checked from Danfoss.

4 Resolver offset identification

This section describes how to identify and configure the resolver offset when using the local control of the
inverter using PowerUSER diagnostic tool. There are several methods to identify the resolver offset,
described in chapter 4.4. After the offset has been configured, the inverter can be switched to use the
resolver feedback for motor control operation as described in chapter 5.
Note that resolver offset identification can also be performed using CANopen, for further information see
[1].

4.1 Setting the motor control for sensorless operation

Sensorless control refers to the situation where the rotor angle is estimated by the control system instead of
using the resolver measurement feedback. Running the motor before the resolver offset has been configured
must be done with sensorless control. To set the inverter into sensorless control, parameter 2.5.1 Use
resolver feedback must be set to FALSE. Setting the inverter for sensorless control is not required if the motor
is not intended to be rotated before the resolver offset is configured.

4.2 Local control of the inverter using PowerUSER

The commands to activate the local control of the inverter with PowerUSER is located in the 2.50.2 Diagnostic
commands signal group, this is highlighted in Figure 3.

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Figure 3. Motor converter diagnostic commands.
Local control is taken when 2.50.2.1 Request command is set to TRUE, this changes the used command
configuration to 0. The command configuration 0 is described in [1]. Used reference settings, limits, run
command and control mode can be seen in 2.50.1 Used commands signal group.

4.3 Verifying the resolver direction

Before configuring the angle offset of the resolver, it needs to be verified that the positive direction of the
motor control is the same as the positive direction of the resolver. This is required because the positive
direction of the motor control depends on the order of which the motor cables are connected. When cables
are connected in a non-standard way, the resolver direction must be checked and possibly changed with the
parameter if necessary. In Danfoss motors, the resolver direction is correct by default when motor cables are
connected as specified in the user manual. Default positive direction is motor rotating clockwise viewed from
the drive end.

Resolver rotation direction can be verified in two ways. The first way is to use a resolver identification method
to perform the verification. The second way is to run the motor with sensorless control. First way is suitable
if the motor is not connected to anything and can rotate freely. The identification method very slowly rotates
(default is 10 rpm) the motor by applying slowly turning phase currents to machine and letting the rotor to
align with the phase currents. The advantage of this method is that the motor is not operated with actual
speed or torque control, so it works even in cases where the motor fails to run with sensorless control, for
example, because of severe motor parameter errors.

To verify the resolver direction with resolver identification process, the parameter 2.5.6 Resolver ID method
should be set to Resolver direction and poles (see Figure 4).

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Figure 4. Parameter to select resolver identification method for resolver direction verification.
Then, identification is requested by setting a signal 2.6.1 Request resolver ID to TRUE (see Figure 5).

Figure 5. Signal to request starting resolver identification when next run command is given.
When the request signal has been set, the next run command for the motor control initiates the identification
process. If local control has been enabled, the run command must be given as shown in Figure 6 by setting a
signal 2.50.2.2 Run command to TRUE.

Figure 6. Signal to set motor control run command when local control is enabled.
The resolver identification process starts rotating the motor and analysing the angle measurement
information of the resolver. When the identification is ready, the signal 2.6.2 Resolver ID finished gets value
TRUE (see Figure 7). The result of the identification can be seen from the signal 2.6.6 Direction check result.
Value Correct means that the direction is correct and value Error means that the direction is wrong, or the
resolver measurement was otherwise unexpected. In case of wrong resolver direction, inverter the direction

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(see Figure 2 and Table 2). The resolver identification with the method Resolver direction and poles also
checks the resolver pole pair number. The result for this can be seen from the signal 2.6.7 Pole pair check
result.

Figure 7. Signals to read the results of the resolver identification.

The second way to verify resolver direction is suitable in cases where the motor can be run with sensorless
control. Always set the correct motor parameters (see Figure 8, parameter group 2.3 Motor parameters) and
limits (see Figure 9, parameter group 2.1 Motor limits) before running the motor.

Figure 8. Setting motor parameters.

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Figure 9. Setting motor limits.
In order to verify the direction, one needs to get the motor running. This can be accomplished either by
running the motor with the inverter in speed control mode, or turning the motor externally, for example,
when connected to a diesel engine. In the case of something external turning the motor, it is recommended
to use torque control mode with a reference of 0 Nm.

When the motor is running in a stable operating point with sufficient speed, the correctness of the resolver
direction can be checked from the signal 2.6.6 Direction check result. Value Correct means that the direction
is correct and value Error means that the direction is wrong. The resolver direction can also be verified by
comparing the control system estimated speed (2.1.2.1 Speed) to resolver speed measurement (2.1.2.2
Resolver speed) (see Figure 10, signal group 2.1 Measurements and estimates). The direction is correct if both
have same sign. Additionally, both should have close to equal magnitude if the resolver pole pair number is
correct.

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Figure 10. Monitoring estimated and measured values of the motor control.
In case the motor positive rotation direction is not according to user specifications, the positive motor
rotation direction can be changed. Rotation direction can be changed by swapping any two motor cables or
using the phase order change parameter 1.3.1.1 Phase order from the inverter software. If the resolver was
rotating into the correct direction before changing the phase order, then it rotates into wrong direction after
the change and should be corrected with the parameter 2.5.2 Invert resolver direction. If the order of the
motor cables is physically changed or the phase order parameter value is changed in the inverter software,
it is recommended to verify the resolver direction again using the above described methods.

After the resolver direction has been verified to be correct, the resolver offset should be identified next
before the motor control using resolver feedback can be enabled. Note that also the resolver offset has to
reidentified if the order of the motor cables is physically changed or the phase order parameter value is
changed in the inverter software. Also, if the resolver direction is wrong when the offset identification is
done, the obtained offset value is not correct. For this reason, always first check the resolver direction and
then continue with the offset identification.

4.4 Different offset identification methods

Different methods for identifying the resolver offset for the EC-C1200 inverter are described shortly in Table
3. It is possible to use several different methods to increase the accuracy and eliminate possible errors in the
identification run, by observing the offset values given by each method and comparing them to each other.

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Table 3. Resolver offset identification methods.
Method Description
DC-magnetization simple Default method. The inverter supplies a DC-current to the motor (default
50% of the motors nominal current) to forcefully align the rotor to a known
position. After holding the rotor still (default 6 seconds), the inverter reads
the resolver offset and writes it to the parameter 3.2.6.17 Resolver offset.
Requires motor to be able to spin freely with nothing attached to motor
axis. Cogging and axle inertia might affect the accuracy of this method.
DC-magnetization turning Same as above, but the inverter turns the current vector so that it
approaches the zero position first from clockwise and then from
counterclockwise direction. This is used to minimize the error caused by
cogging torque. Requires motor to be able to spin freely with nothing
attached to motor axis.
Pulses Rotor angle is determined with current pulses. This does not give a very
accurate result but can be used in situations where it is not possible to
rotate the motor freely.
Rotating Determines the offset while the motor is running. Motor can be run e.g. in
speed control mode with the inverter or by external force if connected to
a diesel generator or something similar.
Injection Uses high-frequency current injection to determine the angle of the rotor.
This method can be used in situations where it is not possible to rotate the
motor freely.

Selection between different resolver offset identification methods is done with the parameter 2.5.6 Resolver
ID method shown in Figure 4.

Note that from above mentioned methods, only DC-magnetization simple and DC-magnetization turning
saves the resolver offset angle automatically after performing the identification run. When using other
methods, the user must save the angle manually by setting signal 2.6.4 Save the identified offset to TRUE.
Note that the inverter must be stopped (run command has to be FALSE) when the save request is done.

4.4.1 DC-magnetization methods

When either DC-magnetization simple or DC-magnetization turning is selected, the identification process
requires the user to set signal 2.6.1 Request resolver ID to TRUE while the inverter is not running. After this,
the RUN command can be issued. After the RUN command is set to TRUE, the inverter will do the
configuration procedure and stop running automatically when the procedure is finished. The process is same
as described in figures 5-7.
When using DC-magnetization simple/turning method, the offset is automatically written to parameter 2.5.3
Resolver offset. If any other method is used, the measured offset value is not automatically saved but only
shown in the signal 2.6.3 Measured resolver offset shown in Figure 11 and must be manually saved by setting
signal 2.6.4 Save identified resolver offset to TRUE.

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Figure 11. Measured resolver offset signal.
After the configuration is finished, the closed-loop control can be activated as explained in chapter 5.

4.4.2 Pulses

This method uses short current pulses to determine the rotor angle and measure the offset between resolver
measurement and actual rotor position. The theoretical uncertainty of this method is 7,5°, and thus it is only
recommended for getting initial value which will be improved with other identification methods. The method
is based on detecting the magnetic saliency of the rotor and thus it can fail if the inductance difference
between the d- and q-axis of the rotor is very small. The advantage of this method is that is does not require
the rotor to move at all. Thus, it can be used in situations where the motor does not rotate freely and also
cannot be rotated by external force.
The procedure for configuring the offset is similar to the one used with DC-magnetization, and this method
can also only be done when the motor is standstill. First set signal signal 2.6.1 Request resolver ID to TRUE
while the inverter is not running. After this, the RUN command can be issued. After the RUN command is set
to TRUE, the inverter will do the configuration procedure and stop running automatically when the procedure
is finished. See Figure 5, Figure 6 and Figure 7.

With this method, the offset is only shown in the signal 2.6.3 Measured resolver offset shown in Figure 11
and must be manually saved by setting signal 2.6.4 Save the identified offset to TRUE.

4.4.3 Rotating

The rotating method can be used to configure the resolver offset in cases where the motor is rotated by
some external force (e.g. a generator connected to a diesel) or to increase the accuracy of the offset value
after determining it by another method. The rotating method can be used regardless if the motor is running
with resolver feedback or sensorless control. The rotating offset identification method is selected by changing
the parameter 2.5.6 Resolver ID method to Rotating.
When the Rotating method is selected, the offset configuration will only start if the motor is rotating faster
than 25% of its nominal speed in either direction. If the offset identification is triggered at a lower speed,
the control system will wait until the speed exceeds this limit before starting the measurement.

Running the motor can be done as described in chapter 4.3. When the motor is running, offset identification
can be started by setting signal signal 2.6.1 Request resolver ID to TRUE.

It is good practice to perform several consecutive measurements to verify that the measurements give
approximately the same result. If the consecutive measurements show a deviation of > 0.01 pu, there might

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be an issue in the resolver wiring or heavy interference from nearby power cabling. If possible, the offset
should be identified by running the motor in both directions to increase the accuracy of the measurement.

After the offset configuration is finished, signal 2.6.2 Resolver ID finished gets value TRUE. The offset needs
to be manually saved by setting signal 2.6.4 Save the identified offset to TRUE.

4.4.4 Injection

Injection -method uses high frequency current injection to determine the rotor position. Injection can be
used to provide an initial estimate, but it is recommended to use another method, for example DC-
magnetization or Rotating, to increase the accuracy of the offset. The method is based on detecting the
magnetic saliency of the rotor and thus it can fail if the inductance difference between the d- and q-axis of
the rotor is very small. The advantage of this method is that is does not require the rotor to move at all. Thus,
it can be used in situations where the motor does not rotate freely and also cannot be rotated by external
force.
Injection -method can be used only when the motor is standstill. The procedure is similar to using DC-
magnetization simple, explained in chapter 4.4.1. The result needs to be manually saved by setting signal
signal 2.6.4 Save the identified offset to TRUE.

5 Activating the use of resolver feedback

After the resolver offset has been determined by any of the methods described earlier, and the result has
been saved, the resolver feedback can be enabled by setting parameter 2.5.1 Use resolver feedback to TRUE
as shown in Figure 12.

Figure 12. Parameter to enable the use of the resolver feedback for motor control operation.
After enabling the use of the resolver feedback for motor control operation, the inverter will use the
measured rotor angle from the resolver instead of an estimate value for driving the motor. This improves
especially low-speed operation and control.

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6 Troubleshooting tips
Problem Action
Resolver signal not reading correctly / signal at zero Check wiring of resolver signals. Ensure all 6
when motor is rotating wires of EXC, SIN and COS are connected.
Resolver signal fluctuates / motor vibrates excessively Check shielding of resolver cable, shorten the
resolver cable or add/improve shielding.
Connect shield to chassis ground on both ends.
Resolver signal has opposite sign to motor speed Swap motor cables or invert resolver direction
estimate
Motor does not turn at all / motor jerks at standstill Check resolver rotation direction, pole pair
configuration and offset
Resolver speed signal shows consistently smaller or Check resolver pole pair configuration
larger values than the actual motor speed
Poor low-speed performance with resolver feedback Switch to sensorless control and perform
control. Motor keeps running and/or accelerates out of resolver offset identification, preferably with
control. several different methods

7 References
[1] EC-C1200+MC Application Manual. Firmware version 11.1, Document version 1.1.

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