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Summary of Contents for Grin Technologies C4820-GR
- Page 1 The SineWave Grinfineon Motor Controller User Manual - Rev 2.1 Grin Technologies Ltd Vancouver, BC, Canada (604) 569-0902 email: info@ebikes.ca web: http://www.ebikes.ca Copyright © 2017...
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Page 2: Table Of Contents
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Table of Contents Introduction............. 3 Key Features ................... 3 Installation and Hookup......... 4 Basic Hookup .................. 4 Cycle Analyst Hookup..............7 Sensored vs. Sensorless..............9 Hall / Phase Mapping Procedure........... 9 Core Features ............11 Silent Sine Wave Mode.............. -
Page 3: Introduction
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 1 Introduction The Grinfineon SineWave controller is based around the popular Xie Chang device with the XCKJ3232C control chip, but with custom firmware to allow both sensored and sensorless operation and proportional regenerative braking. The generous cable harness lengths and crimpable connector standards make it broadly useful in aftermarket and DIY ebike applications for just about any geared or direct-drive brushless motor in the 500-3000 watt power range. -
Page 4: Installation And Hookup
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 2 Installation and Hookup The motor controller end plates have a flange with holes to facilitate securing to the vehicle. We recommend locating it in place where the ON/OFF switch is accessible and where it still has good exposure to air flow. Common bicycle locations include on the front of the rear rack support, between the seat tube and the rear wheel, or on the top tube with front motors. - Page 5 SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Figure 3: Basic hookup diagram (motor, throttle, and battery) The throttle is a 3-pin JST-SM plug intended for Hall Effect throttle devices. It supplies 4.3V to power the throttle plug and expects a signal of 0.9V - 3.6V as the throttle is twisted.
- Page 6 SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 The brushless hub motor will have 3 phase wires that need to terminate with the 3 controller wires. Typically these are green, yellow, and blue, but many other possibilities exist. If you are running the motor sensorless, then it is only these 3 wires you need to connect and the color pairing does not really matter.
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Page 7: Cycle Analyst Hookup
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 2.2 Cycle Analyst Hookup You can also add a V2 Cycle Analyst to this basic setup in order to have an informative display of all your vehicle and battery stats. The system still responds the same way to your throttle, but the V2 Cycle Analyst has the ability to over- ride and limit the throttle signal if you are exceeding the CA's programmed current limit, speed limit, or battery low voltage cutoff. - Page 8 SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Finally, if you are using a V3 Cycle Analyst, then your throttle and ebrake signals will connect to the Cycle Analyst rather than to your motor controller. Only the 6- pin CA-DP plug of the controller is used. Figure 7: CA V3 Hookup.
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Page 9: Sensored Vs. Sensorless
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 2.3 Sensored vs. Sensorless While the Grinfineon controller will work sensorless with the hall connector unplugged, there are several limitations to this mode. Starting from a standstill can be a little bit jerky while the controller •... - Page 10 SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Of the 36 possible ways to map the hall and phase wires, only 3 will spin the motor properly in the forwards direction. Another 3 combinations will spin the motor in reverse, and the remaining 30 combinations will either not turn the motor at all, or will turn it with great inefficiency.
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Page 11: Core Features
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 3 Core Features 3.1 Silent Sine Wave Mode When the controller has hall sensors connected, the 3 phase output drive waveform is sinusoidal rather than trapezoidal. On most direct drive hub motors, this means a butter smooth feeling as you apply the throttle rather than the normal buzz or growl you may be used to. -
Page 12: On/Off Switch
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 3.3 On/Off Switch The included ON/OFF toggle switch on the controller end plate allows for conveniently switching your ebike on and off without disconnecting the main battery pack. When the switch is off, both the Controller and the Cycle Analyst (if attached) will power down and cease drawing current from the battery. -
Page 13: Proportional Regen Via 0-0.8V Throttle Signal
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 3.5 Proportional Regen via 0-0.8V Throttle Signal The second method to engage regen is with a throttle signal that is less than 0.8 Volts. Normally a Hall Effect throttle will only swing from 0.9V to about 3.6V, leaving the range of 0.0-0.9V unused. -
Page 14: Fwd / Rev
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Figure 14: Regenerative Braking Torque and Current as a Function of Motor RPM at 4 different throttle regen voltages and also with ebrake lever pressed (Ebk, dashed lines) This throttle mapped regen is handy since it allows for variable braking without any additional wires to the controller, and in principle a small bidirectional throttle would allow you to both accelerate and slow down without the need for any kind of brake sensors. -
Page 15: Fault Tolerant Hall
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 Figure 15: FWD/REV, Remove heatshrink tubing over ebrake connector to expose spare white and black signal wires, and extend those to your reverse switch. 3.7 Fault Tolerant Hall Normally a sensored motor/controller setup is somewhat vulnerable to damage of the hall sensor itself, the hall wires, or the hall connector pins. -
Page 16: Power Oscillations At Full Throttle When Sensored
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 The geared motor in Figure 16 has 32 magnets and a 7:1 gear reduction. In this case, the maximum speed in sensorless mode would be 28000 eRPM / 16 / 7 = 250 rpm. In a 26” wheel that would correspond to 31 kph. Below this speed the bike would run fine but any faster and the controller is liable to shut down in a fault mode. -
Page 17: Degree Hall Timing
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 4.3 60 Degree Hall Timing Most brushless motors use 120 degree hall timing, where at any given point there is always at least 1 hall signal that is high, and 1 hall signal that is low. But some motors use 60 degree hall spacing, where 000 and 111 are also valid hall patterns. -
Page 18: Won't Show Ca Accessory Current Draw
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 4.6 Won't Show CA Accessory Current Draw The CA-DP plug on the motor controller is wired up so that it will show the current draw of the motor and controller, but not the current draw of any other devices (like front lights) that are plugged into the CA's power tap. -
Page 19: Specifications
SINEWAVE GRINFINEON CONTROLLER MANUAL Rev 2.1 5 Specifications Electrical C4820-GR C4825-GR C4835-GR C7240-GR Battery Current ( +2% / - 10%) 20 A 25 A 35 A 40 A Phase Current Limit (+/- 10%) 50 A 75 A 90 A 120 A...
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