Grin Technologies C4820 User Manual Download

Page: 19 / 19

SINEWAVE GRINFINEON CONTROLLER MANUAL

Rev 2.1

-19-

Specifications

5.1

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

Nominal Battery Voltage

36V-52V

36V-72V

12x

MOSFETs

AOT460

IRFB4110

AOT460

IRFB4110

Max Regen Voltage (+/- 2%)

58 V

88 V

Low Voltage Cutoff (+/- 2%)

27 V

31 V

Control Chip

XCKJ3232C

eRPM Limit Sensorless

~28,000

5.2

Mechanical

C4820

C4825

C4835

C7240

Dimensions (mm)

110x71x34

154x87x46

Weight (kg)

0.47

0.49

0.75

0.78

Chassis Material

Extruded Aluminum

DC Battery Connector

Genuine Anderson Power Poles

Motor Phase Connector

Genuine Anderson Power Poles

Hall Sensor Connector

JST-SM Series

Other Signal Connectors

JST-SM Series

Waterproofing

Gasketed at end plates and wire exits, sealed switch

5.3

Connector Pinout

* White wire in sheath is for FWD/REV - Jump to GND to enable
** Leave hall sensors unplugged for sensorless operation
***

Caution with Old Small Screen Cycle Analysts

(will go full throttle

unless additional diode wired inline with green throttle-override wire)

Summary of Contents for C4820

Page 2: ...LED Indicator 11 3 3 On Off Switch 12 3 4 Regenerative Braking via Ebrake 12 3 5 Proportional Regen via 0 0 8V Throttle Signal 13 3 6 Fwd Rev 14 3 7 Fault Tolerant Hall 15 4 Limitations 15 4 1 eRPM Sensorless Sensored 15 4 2 Power Oscillations at Full Throttle when Sensored 16 4 3 60 Degree Hall Timing 17 4 4 No Change to Internal Settings 17 4 5 Max Regen Voltage 17 4 6 Won t Show CA Accessory Cu...

Page 3: ...about any geared or direct drive brushless motor in the 500 3000 watt power range 1 1 Key Features Here are some of the features that make this controller stand out which you won t usually find with most 3 rd party ebike motor controllers Long phase leads 120cm On Off Switch Proportional Regenerative Braking Dual Mode works With and Without Hall Sensors Silent Sine Wave Operation in Sensored Mode ...

Page 4: ...ations and orientations Although it is tempting we do not recommend putting the controller inside a bag or enclosure box that blocks exposure to air flow as it will be more susceptible to overheating The silicone grommets on the controller end plates do an excellent job of keeping water out so there is little concern about having the controller exposed to the elements and the orientation of the in...

Page 5: ...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 Throttle signal voltages higher than 4 0V are considered a fault condition so if a potentiometer based throttle is used then appropriate resistors are needed to keep the voltage swing within range Figure 4 Controller Throttle Pinout ...

Page 6: ...u are running the motor sensorless then it is only these 3 wires you need to connect and the color pairing does not really matter If the motor spins backwards then simply swap any pair of wires to reverse it Figure 5 Example of Motor Direction Change by Swapping Phase Wires If you want regenerative braking in a basic setup then you can connect either an ebrake cutoff lever or other momentary push ...

Page 7: ...ay 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 Figure 6 CA V2 Hookup Throttle and eBrake Plug into Controller motor and battery not Shown ...

Page 8: ... 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 Throttle and eBrake Plug into CA not controller The V3 Cycle Analyst is useful when much more advanced control features are desired like PAS operation motor over temperature protection torque sensing pedalec mode presets etc ...

Page 9: ...ommend connecting them to the controller as well so that you can benefit from sensored sinusoidal operation The hall sensor plug has 5 wires red and black supply power to the hall sensors in the motor and the yellow green and blue wires carry the resulting hall signals Figure 8 Hall Signal Plug 2 4 Hall Phase Mapping Procedure Previous generations of Grinfineon controller had the ability to automa...

Page 10: ...e connectors through the first 3 positions as shown below Figure 9 Systematic Approach to Phase Pinout Mapping Then swap any pair of plugs yellow and blue swapped in above example and rotate through the 3 positions again This will cover all 6 possible phase pinouts and one of those 6 should allow the motor to run smoothly If that one position spins the motor backwards then you can swap a pair of t...

Page 11: ...state it s in and most importantly if there are any fault conditions that would cause things not to work The following are normal operating modes LED Off No power to controller either battery is disconnected or ON OFF switch is OFF LED Slow Flash Controller powered up throttle is not pressed or it is running but in sensorless mode LED Steady On Controller is running the motor in sensored mode The ...

Page 12: ...g at least 20 AWG 3 4 Regenerative Braking via Ebrake The Grinfineon controllers have regenerative braking capabilities allowing you to use the hub motor as a brake and return kinetic energy back into the battery pack This can be achieved either with the ebrake lever for a constant 50 braking force or with a 0 0 to 0 8V throttle signal for variable 0 100 braking In the first method you connect an ...

Page 13: ... 0 0V to 4 0V Figure 13 Regen intensity for throttle 0V 0 8V The test was done with the motor spinning at 100 200 and 300 rpm You can see that at lower RPMs the breaking intensity was higher for a given throttle voltage Even though the regenerative braking intensity is reduced at higher speeds the actual regen current flowing into the battery pack increases at high speeds as there is more mechanic...

Page 14: ...e throttle line If you have a geared motor or mid drive motor then the regen won t have much effect It will cause the motor to quickly stop spinning when you squeeze the brakes but it won t be able to help slow the bike down due to the intrinsic freewheel of these systems There is no need to disable controller regen in this situation it is harmless 3 6 Fwd Rev If you have an application where the ...

Page 15: ...e tried to make this controller fairly universal there are also more than a few limitations that can affect its use in some applications 4 1 eRPM Sensorless Sensored The maximum commutation frequency in sensorless mode is about 28000 eRPM This is substantially higher than previous Grinfineon controllers 13000 eRPM and will work with most geared hub motors just fine at typical ebike speeds but may ...

Page 16: ...utation timing can be off and motor performance will suffer 4 2 Power Oscillations at Full Throttle when Sensored In sensored sine wave mode the motor controller is always attempting to interpolate the exact motor position at any given moment in between hall sensor events With certain geared hub motor installations the controller can be prone to having large power fluctuations at full throttle whi...

Page 17: ...ower limits then either a V2 or V3 Cycle Analyst will provide that functionality and a lot more just via modulation of the throttle signal 4 5 Max Regen Voltage The maximum regen voltage is set to 58V for the 25A and 35A controllers allowing them to work with up to 14s 52V lithium batteries but without risk of high voltage spikes if the battery BMS circuit trips The 40A controllers have a maximum ...

Page 18: ... 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 If you want the Cycle Analyst to show auxiliary device current then the controller can be opened up and the black wire from the CA DP cable moved from the side of the shunt adjacent to the blue wire to the side of the shunt adjacent to white wire ...

Page 19: ...echanical C4820 C4825 C4835 C7240 Dimensions mm 110x71x34 154x87x46 Weight kg 0 47 0 49 0 75 0 78 Chassis Material Extruded Aluminum DC Battery Connector Genuine Anderson Power Poles Motor Phase Connector Genuine Anderson Power Poles Hall Sensor Connector JST SM Series Other Signal Connectors JST SM Series Waterproofing Gasketed at end plates and wire exits sealed switch 5 3 Connector Pinout White...

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