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Baserunner Controller User Manual

Rev 1.0

The regen voltage is mapped by default so that regenerative braking starts at 
0.8V and reaches maximum intensity at 0.0V. This way there is no overlap 
between the throttle region and the braking region and a single wire can control 
both ranges.  

5.7 Field Weakening for Speed Boost

Basic Setup tab

The 

Baserunner

 can boost the top speed of your motor beyond what is normally 

possible from your battery voltage. This is accomplished through injecting a field 
weakening current that is perpendicular to the torque producing current. This 
approach will have the same end effect as advancing the commutation timing.

The amount of boost received for a given field weakening current will depend on 
the characteristics of your particular motor and cannot be easily predicted. A 
conservative trial and error approach of small increments is recommended for 
determining a suitable value.

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 15-20%, the 
additional losses are quite reasonable. 

-18-

Summary of Contents for V4

Page 1: ...erunner Controller User Manual Rev 1 0 The V4 Baserunner 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 2021 ...

Page 2: ...arameter Tuning 10 5 1 Importing Default Parameters 11 5 2 Motor Autotune 11 5 3 Battery Limits 14 5 4 Motor Phase Current and Power Settings 15 5 5 Tuning the Sensorless Self Start 16 5 6 Throttle and Regen Voltage Maps 17 5 7 Field Weakening for Speed Boost 18 5 8 Virtual Electronics Freewheeling 19 6 Additional Details 20 6 1 Throttle Priorities 20 6 2 Reverse Mode 20 6 3 Demux Circuitry 21 6 4...

Page 3: ...rs for customized tuning Wide operating voltage 24V 52V nominal batteries Compatible with both Cycle Analyst display 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 control Protects motors from overheating with thermal rollback Remote forwards reverse inpu...

Page 4: ...one 2 2 Motor Cable The motor connection has 38cm lead to either a HiGo L1019 connector or a Z910 connector depending on the model This length is sufficient to reach a rear hub motor on most bikes with the controller mounted on the downtube or seat tube Front hub installations are supplied with a 60cm motor extension cable Baserunner_L10 Motor Plug Pinout The Higo L1019 cable has three motor phase...

Page 5: ...es for 3rd party display consoles This connector shares many signals with the CA WP plug but rather than using the shunt resistor for current sensing it has TX and RX pins that communicate digitally to the display Generally this connector will pair to a harness that splits out separate lower pin count display throttle and ebrake plugs at the handlebar 2 5 PAS Torque Plug PAS Pinout The V4 Baserunn...

Page 6: ...party USB Serial cables such as FTDI s part number TTL 232R 5V AJ are also compatible A USB OTG adapter then is needed to connect to an Android smartphone via the phone s smaller Micro USB or USB C port 3 Wiring Strategies The V4 Baserunners can be hooked up to to the controls of an ebike system in one of three ways Either under the control of a V3 Cycle Anlayst under the control of a 3rd party di...

Page 7: ... displays King Meter Bafang Eggrider etc that communicate with a range of digital protocols through the use of the 9 pin Mains cable and a custom made cable harness and splitter junction These displays are usually powered from a 5 pin Higo plug while other higo cables for throttle ebakes and front lights would also emerge from the junction This configuration would normally include a PAS or Torque ...

Page 8: ...on off power switch on either the WP8 plug or the Mains connector for the controller to turn on There is limited ability to modulate the PAS power assist level in this minimal approach as the controller does not have a native input for increasing or decreasing the PAS power adjustment without reprogramming For a basic PAS controlled ebike most people would still want a small communicating display ...

Page 9: ...o fit the Baserunner For use in other applications Grin also produces mounts to secure the Baserunner to a flanged plate a round tube and the fender bolt of a Brompton bicycle fork For optimal performance the controller should be installed such that the metal mounting plate is exposed to airflow to keep the controller cool This will noticeably improve the maximum power at thermal rollback compared...

Page 10: ...page http www ebikes ca product info phaserunner html Please Note When configuring your Baserunner via the software suite it is essential that your bike is propped up so that the powered wheel can rotate freely both forwards and backwards With a rear hub motor also ensure that the cranks can rotate freely With the Baserunner powered on plug in the TTL USB cable from your computer to the Baserunner...

Page 11: ...fields populated to their correct values Install these new settings to the Baserunner via the Save Parameters button Apply some throttle and your motor should run smoothly If so you can now skip over the Motor Autotune section and proceed to 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 default set...

Page 12: ...ly The Baserunner needs this information to correlate it s electrical output frequency with the wheel speed In a direct drive DD motor it is the number of magnet pairs in the rotor while in a geared motor you need to multiply the magnet pairs by its gear ratio The following table lists the effective pole pairs for many common motor series Table 1 Effective Pole Pairs of Common DD and Geared Hub Mo...

Page 13: ...ing 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 exact kV winding constant for the hub as well as the pinout and timing advance of the hall sensors if present If the motor spins backwards during this test check the box Flip Motor Spin Direction on Nex...

Page 14: ...mits Basic Setup tab With the controller mapped to your motor and spinning correctly you should now set the battery voltage and current settings to appropriate values for your pack Set Max Current to a value that is equal to or less than the battery s rating Higher battery currents will result in more power but can also stress the battery cells resulting in shorter battery life Excessively high va...

Page 15: ...motor speeds this phase current can be several times higher than the battery current you see on a Cycle Analyst The Max Power Limit sets an upper limit on the total watts that will be allowed to flow into the hub motor This value has a similar effect to a battery current limit but it is dependent on voltage A value of 2000 Watts will limit battery current to 27 amps with a 72V pack while allowing ...

Page 16: ...closed loop It does this by first injecting a static current into the phase windings to orient the motor into a known position The controller then rotates this field faster and faster until reaching the Autostart Max RPM value As initial values set the Autostart Injection Current to half your maximum phase current an Autostart Max RPM to 5 10 of the running motor rpm and an Autostart Spinup Time a...

Page 17: ...just a tiny amount of throttle it will still spin up to full rpm as there is no load on the motor People sometimes mistake this behavior as an all or nothing throttle response If you apply partial throttle while riding 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 th...

Page 18: ... is accomplished through injecting a field weakening current that is perpendicular to the torque producing current This approach will have the same end effect as advancing the commutation timing The amount of boost received for a given field weakening current will depend on the characteristics of your particular motor and cannot be easily predicted A conservative trial and error approach of small ...

Page 19: ... 3 amps 5 8 Virtual Electronics Freewheeling Dashboard Basic Setup tabs The Baserunner controller can be set to inject a small amount of current into the motor even when the throttle is off When properly tuned this current injection can overcome the drag torque present in hub motors capable of regenerative braking allowing them to spin freely when pedaling without any throttle To setup this featur...

Page 20: ...ired with resistors in between them in order to avoid conflict if two or more devices are attempting to drive this throttle voltage The resistor combination gives the throttle signal on the Mains cable the highest priority with the throttle signal on the PAS plug typically used for a torque signal the second priority and finally the throttle signal on the WP8 Cycle Analyst plug has lowest priority...

Page 21: ...d via settings 6 4 Wheel Speed Sensing The V4 Baserunner will automatically select the source of the wheel speed signal for vehicle speed measurement If there are speed pulses present on the wheel speed sensor pin then these will be mapped automatically to the Cycle Analyst plug If no speed pulses are detected even after the motor is spinning then the motor hall signals will get fed to the the spe...

Page 22: ...analog input that provides proportional braking control if desired This is pulled to 5V internally while the throttle signal is pulled low If the throttle and ebrake signal are shorted together then the signal level will sit at 1 0V allowing a single wire bidirectional torque control with 0 0 9V mapped to regenerative braking and 1 1 4 0V mapped to forwards torque If these signals are not shorted ...

Page 23: ...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 controller with a voltage throttle These ...

Page 24: ...1 2 Phase Over 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 In...

Page 25: ...any concern Table 3 Baserunner 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 ...

Page 26: ...ing 70 C Max Battery Voltage 60V 14s Lithium 17s LiFePO4 Min Battery Voltage 19V 6s Lithium 7s LiFePO4 eRPM Limit Not recommended above 60 000 ePRM though it will continue to function beyond this RShunt for Cycle Analyst 1 00 mΩ Thermal rollback will typically kick in after 1 2 minutes of peak phase current and current will then automatically reduce to maintain controller rollback temperature 9 1 ...

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