Grin Technologies C4820-GR User manual

The SineWave Grinfineon
Motor Controller
User Manual - Rev 2.1
Grin Technologies Ltd
Vancouver, BC, Canada
ph: (604) 69-0902
email: [e-mail]
web: http://www.ebikes.ca
Copyright © 2017

SINEWAVE GRINFINEON CONTROLLER MANUAL
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Table of Contents
1 Introduction............................................................. 3
1.1 Key Features ................................................................................... 3
2 Installation and Hookup......................................... 4
2.1 Basic Hooku .................................................................................. 4
2.2 Cycle Analyst Hooku .................................................................... 7
2.3 Sensored vs. Sensorless................................................................... 9
2.4 Hall / Phase Ma ing Procedure................................................... 9
3 Core Features........................................................ 11
3.1 Silent Sine Wave Mode................................................................. 11
3.2 LED Indicator............................................................................... 11
3.3 On/Off Switch ............................................................................... 12
3.4 Regenerative Braking via Ebrake ............................................... 12
3.5 Pro ortional 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 Current Draw................................. 18
5 Specifications......................................................... 19
.1 Electrical........................................................................................ 19
.2 Mechanical .................................................................................... 19
.3 Connector Pinout.......................................................................... 19

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1 Introduction
The Grinfineon SineWave controller is based around the popular Xie Chan
device with the XCKJ3232C control chip, but with custom firmware to allow both
sensored and sensorless operation and proportional re enerative brakin . The
enerous cable harness len ths and crimpable connector standards make it
broadly useful in aftermarket and DIY ebike applications for just about any
eared or direct-drive brushless motor in the 500-3000 watt power ran e.
1.1 Key Features
Here are some of the features that make this controller stand out which you won’t
usually find with most 3rd party ebike motor controllers
• Lon phase leads (120cm)
• On/Off Switch
• Proportional Re enerative Brakin
• Dual Mode, works With and Without Hall Sensors
• Silent Sine Wave Operation in Sensored Mode
• Hi h Sensorless eRPM Compatible with Geared Motors
• Fwd/Rev Input
• LED Status Indicator
• Waterti ht Enclosure
• Direct Cycle Analyst Plu
• User Crimpable Connectors (JST-SM and Anderson Powerpoles)
Figure 1: Key Controller Hardware Features

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2 Installation and Hookup
The motor controller end plates have a flan e with holes to facilitate securin to
the vehicle. We recommend locatin it in place where the ON/OFF switch is
accessible and where it still has ood 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.
Figure 2: Common mounting locations and orientations
Althou h it is temptin , we do not recommend puttin the controller inside a ba
or enclosure box that blocks exposure to air flow, as it will be more susceptible to
overheatin . The silicone rommets on the controller end plates do an excellent
job of keepin water out, so there is little concern about havin the controller
exposed to the elements, and the orientation of the installed controller does not
matter.
2.1 Basic Hookup
The controller has 6 cables comin out of it: Battery, Motor Phase, Motor Hall,
Throttle, Ebrake, and Cycle Analyst. At the bare minimum, the controller just
needs a throttle, battery pack, and motor connection in order to work:

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Figure 3: Basic hookup diagram (motor, throttle, and attery)
The throttle is a 3-pin JST-SM plug intended for Hall Effe t throttle devi es. It
supplies 4.3V to power the throttle plug and expe ts a signal of 0.9V - 3.6V as
the throttle is twisted. Throttle signal voltages higher than 4.0V are onsidered a
fault ondition, 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

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The brushless hub motor will have 3 phase wires that need to terminate with the
3 controller wires. Typically these are reen, yellow, and blue, but many other
possibilities exist. If you are runnin the motor sensorless, then it is only these 3
wires you need to connect and the color pairin 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 y Swapping Phase Wires
If you want re enerative brakin in a basic setup, then you can connect either an
ebrake cutoff lever or other momentary push switch to the 4-pin ebrake plu .

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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 si nal if you are exceedin the CA's pro rammed
current limit, speed limit, or battery low volta e cutoff.
Figure 6: CA V2 Hookup. Throttle and eBrake Plug into Controller
(motor and attery not Shown)

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Finally, if you are usin a V3 Cycle Analyst, then your throttle and ebrake si nals
will connect to the Cycle Analyst rather than to your motor controller. Only the 6-
pin CA-DP plu 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 sensin
pedalec, mode presets etc.

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2.3 Sensored vs. Sensorless
While the Grinfineon controller will work sensorless with the hall connector
unplu ed, there are several limitations to this mode.
• Startin from a standstill can be a little bit jerky while the controller
attempts to self start the wheel.
• The controller will operate in a trapezoidal rather than the more silent
sine wave mode, resultin in some audible buzz or hum from the motor.
• With hi h ear reduction eared hub motors, you may hit the sensorless
eRPM limit of the controller (~28000 eRPM, see 4.1)
• When usin a Cycle Analyst, you won't have the option of pickin up the
speed si nal from the motor hall line and will require an external speedo
sensor and spoke ma net (i.e. CA-DPS or CA3-DPS).
If the motor has hall sensor wires, then we recommend connectin them to the
controller as well so that you can benefit from sensored sinusoidal operation.
The hall sensor plu has 5 wires, red and black supply power to the hall sensors
in the motor, and the yellow, reen, and blue wires carry the resultin hall
si nals.
Figure 8: Hall Signal Plug
2.4 Hall / P ase Mapping Procedure
Previous enerations of Grinfineon controller had the ability to automatically map
the hall and phase wires so that the exact pinout details did not matter. This was
very convenient but it is no lon er possible with the addition of sinusoidal
sensored mode. It is essential that the hall and phase pinout is correct.
The hall and phase pinout mappin on the SineWave Grinfineon controller is
consistent with how both eZee and Crystalyte motors choose their colour codin ,
and they can be matched yellow to yellow, reen to reen, and blue to blue.
Other popular motor series use a different colour interpretation, and some trial
and error is usually needed to determine the correct pinout.

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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 remainin 30 combinations will either not turn the motor
at all, or will turn it with reat inefficiency.
We recommend usin a systematic approach to determine the hall and phase
mappin . First, plu to ether the hall wires in any pinout that you like. Then
connect the 3 phase wires to ether and test the motor. If it spins smoothly with
low current draw, then reat. If not, then separate the Anderson phase plu s
(they dovetail slide into each other) and keep cyclin throu h the 6 possible
ali nments testin each one. An easy way to keep track of this is by first ‘rotatin ’
the phase connectors throu h the first 3 positions as shown below.
Figure 9: Systematic Approach to Phase Pinout Mapping
Then swap any pair of plu s (yellow and blue swapped in above example), and
rotate throu h the 3 positions a ain. 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 the
hall sensor wires, repeat the test to find the correct phase pinout and it will spin
the forwards direction.
Be aware that there are some incorrect hall/phase pinouts which will still spin the
motor when you apply throttle, but the motor will turn with reat inefficiency and
draw hi her than normal current, usually with a small ‘kick’ when the throttle is
first applied. You do not want to run the motor under load in this condition.
When the motor is runnin in sensored mode, the LED will be on steady without
blinkin unless there is a fault error. In sensorless mode, the LED will flash at a
slow ~1 Hz rate.