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Frankenrunner User Manual

Rev 1.0

-12-

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Summary of Contents for Frankenrunner

Page 1: ...Frankenrunner User Manual Rev 1 0 The Frankenrunner Motor Controller User Manual Rev 1 0 Grin Technologies Ltd Vancouver BC Canada ph 604 569 0902 email info ebikes ca web www ebikes ca Copyright 2022 ...

Page 2: ...unting 7 5 Parameter Tuning 7 5 1 Importing Default Motor Parameters 8 5 2 Motor Autotune 9 5 3 Battery Limits 13 5 4 Motor Phase Current and Power Settings 13 5 5 Tuning the Sensorless Self Start 15 5 6 Throttle and Regen Voltage Maps 16 5 7 Field Weakening for Speed Boost 17 5 8 Virtual Electronic Freewheeling 18 5 9 Motor Temperature Sensing 18 6 Additional Details 19 6 1 Signal Mapping 19 6 2 ...

Page 3: ...r User programmable parameters for customized tuning Wide operating voltage 24V 72V nominal batteries Compatible with both Cycle Analyst and 3rd party displays Supports Throttle PAS and Torque sensor control Waterproof design with potted electronics Proportional and powerful regenerative braking Smooth and quiet field oriented drive Supports thermal rollback in thermistor equipped motors Remote fo...

Page 4: ...n many ebike batteries Warning The controller may suffer irreparable damage if leads are hooked up in reverse polarity Always check the polarity of the connector before applying power 2 2 Motor Cable L10 Model The L10 model has a 40cm lead to a Higo L1019 connector for direct hookup to a compatible motor This length is sufficient to reach a rear hub motor with the controller mounted on the seat tu...

Page 5: ...arnesses Motor Harness Hall Pinout The 3 Hall signals and 5V Hall power are provided through the 5 pin female JST SM connector This is a user crimpable plug Motor Harness Signal Pinout If the motor has a temperature and or wheel speed sensor these signals can be passed to the controller via the 2 pin plug Both of these signals must be referenced to the Hall ground pin 2 4 Cycle Analyst WP8 Plug WP...

Page 6: ...pin HiGo MiniB Z609 plug for connection of a PAS sensor or Torque Sensor Note that the PAS 2 pin shares the same signal as the Fwd Rev input of the Mains cable and can be configured for either function See section 6 2 2 7 Communication Port A TRRS jack embedded in the controller can be used for connecting to a computer Android smart phone or potential Bluetooth dongle future product The communicat...

Page 7: ...ents on the road In this arrangement all throttle ebrake and PAS or torque sensors are plugged in directly to the Cycle Analyst The Cycle Analyst is responsible for determining the desired ebike behavior and sending a suitable throttle command to the controller The 6 pin PAS plug of the controller is typically not used in this arrangement except as a possible Fwd Rev input source The 9 pin Mains c...

Page 8: ...WP8 Cycle Analyst plug is not needed but it can be used as a convenient tap point to power a rear bike light as well At present Grin only provides support for this third party display hookup to OEM customers and does not offer support or the components for this at the retail level Configuration and additional controller settings will be detailed in a separate document to this manual 3 3 Headless S...

Page 9: ...ler that is in still air The controller casing includes two threaded M5 holes 60mm apart on the narrow edge to facilitate installation Grin offers a tube mounting bracket that converts this into a channel that securely attaches to bicycle tubing with either zip ties or hose clamps 5 Parameter Tuning If you purchased the Frankenrunner as part of a complete conversion kit that includes a battery a m...

Page 10: ... Controller is not connected check that the selected serial port is correct and that the USB TTL device shows up in your device manager as a COM port Windows ttyUSB Linux or cu usbserial MacOS If your system does not recognize the USB serial adapter or has frequent COM timeouts then you may need to download and install the latest virtual COM port drivers directly from FTDI http www ftdichip com Dr...

Page 11: ... smoothly If it does you can now skip over the Motor Autotune section and continue with Battery Limits If your motor is not listed on the Import Defaults window try choosing Download Latest Defaults from Grin and follow the prompts If your motor model is still not listed proceed to the Motor Autotune section that follows 5 2 Motor Autotune Basic Setup tab 9 ...

Page 12: ...ne will usually work fine even if your initial guess for the kV value is incorrect Most ebike hub motors fall within 7 12 rpm V and an initial guess of 10 will usually work The effective pole pairs is a count of how many electrical cycles corresponds to one mechanical revolution of the motor and must be set correctly The Frankenrunner needs this information to correlate it s electrical output freq...

Page 13: ...c Test This test will produce three short buzzing sounds and determine the inductance and resistance of the motor windings The resulting values will be shown on the screen Next launch the Spinning Motor Test which will cause the motor to rotate at about half speed for 15 seconds During this test the controller will determine the actual kV winding constant for the hub as well as the pinout and timi...

Page 14: ...Frankenrunner User Manual Rev 1 0 12 ...

Page 15: ...e Cutoff End values can be set just above the BMS cutoff point of your battery If you are using a V3 Cycle Analyst we recommend leaving these values at the default 19 5 19 0 volts and use the CA3 s low voltage cutoff feature instead That way you can change the cutoff voltage without a computer if you ever need to swap batteries If you are setting up a system with regenerative braking and have a BM...

Page 16: ...nt determines the peak amps and hence torque put through the motor while accelerating at full throttle assuming no other limits are reached The Max Regen Phase Current value directly sets the peak braking torque of the motor at full regen If you want a strong braking effect then set this to the same value as the forward phase current limit If the maximum braking force is too intense then reduce it...

Page 17: ...urrent to half your maximum phase current an Autostart Max RPM between 5 to 10 of the running motor rpm and an Autostart Spinup Time anywhere from 300 to 1500 milliseconds depending on how easily the motor can propel the bike up to speed On bikes that you pedal to help get you underway a short 200 to 300 millisecond ramp will often work best while a much longer ramp is required if you need to star...

Page 18: ...you will get a proportional torque from the motor which will stay constant even as the vehicle speeds up or slows down This is different from standard ebike controllers where the throttle more directly controls motor speed By default the Frankenrunner is configured so that active throttle starts at 1 2V and full throttle is reached at 3 5V which is broadly compatible with Hall Effect ebike throttl...

Page 19: ...in small increments until the desired top speed is achieved Increasing a motor s top speed in this way is less efficient than using a higher voltage pack or a faster motor winding but for a speed boost of 15 to 20 the additional losses are quite reasonable The following graph shows a large direct drive hub motor s rpm as a function of field weakening current The upper black line is the motor s mea...

Page 20: ...ved unloaded motor current The Motor Stall Timeout setting determines when this injection current will stop once the motor comes to a stop Once the values for Virtual Electronic Freewheeling are set the controller will draw about 10 to 40 watts in order to overcome the motor s drag Regenerative braking should recapture more energy than lost due to the injection current Users of mid drive motors ca...

Page 21: ... s thermal rollback features and leaving the controller s rollback unchecked 6 Additional Details 6 1 Signal Mapping The Frankenrunner uses the analog Brake 1 signal input as both the throttle and regenerative brake signal source This differs from the earlier Phaserunner controllers which used separate signals for Throttle Sensor Source and Regen Brake Source which were then shorted externally in ...

Page 22: ...l parameter settings saved from a Phaserunner device are then imported to the Frankenrunner or vice versa unexpected throttle and braking behavior can occur 6 2 Reverse Mode The signal PAS 2 used in the 6 pin PAS plug is electrically equivalent to the FWD REV pin in the Main plug This input is by default configured as a reverse switch input by enabling Reverse on Cruise for applications that requi...

Page 23: ...fault has both the throttle signal source and the regen brake signal source coming from the same line Analog Input 2 which floats at 1V when disconnected This allows for a single wire to control power and braking The signal can be shorted to ground via an ebrake lever to achieve maximum regen braking If completely independent throttle and regen brake signals are desired then the throttle signal so...

Page 24: ...Because the Frankenrunner uses a torque throttle rather than a voltage throttle the entire throttle voltage range is always active Optimal settings for the throttle output on a V3 Cycle Analyst will differ than that for generic ebike controllers The ramp up and ramp down rates as well as the feedback gain settings AGain WGain IntSGain DSGain PSGain can be set much higher than with a conventional c...

Page 25: ...ver Current 1 3 Current Sensor Calibration 1 4 Current Sensor Over Current 1 5 Controller Over Temperature 1 6 Motor Hall Sensor Fault 1 7 Controller Under Voltage 1 8 POST Static Gate Test Outside Range 2 1 Network Communications Timeout 2 2 Instantaneous Phase Over Current 2 3 Motor Over Temperature 2 4 Throttle Voltage Outside of Range 2 5 Instantaneous Controller Over Voltage 2 6 Internal Erro...

Page 26: ... any concern Table 3 LED Warning Flash Codes 5 1 Communication Timeout 5 2 Hall Sensor 5 3 Hall Stall 5 4 Wheel Speed Sensor 5 5 CAN Bus 5 6 Hall Illegal Sector 5 7 Hall Illegal Transition 5 8 Low Voltage Rollback Active 6 1 Max Regen Voltage Rollback Active 6 2 Motor Overtemperature Rollback 6 3 Controller Overtemperature Rollback 6 4 Low SOC Foldback 6 5 Hi SOC Foldback 6 6 I2tFLDBK 6 7 Reserved...

Page 27: ...s Lithium 24s LiFePO4 Min Battery Voltage 19V 6s Lithium 7s LiFePO4 eRPM Limit Not recommended above 60 000 eRPM though it will continue to function beyond this RShunt for Cycle Analyst 1 00 mΩ Thermal rollback will typically kick in after 1 to 2 minutes of peak phase current and then phase current will automatically reduce to maintain controller rollback temperature 9 1 2 Mechanical Dimensions Lx...

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