Grin Technologies Frankenrunner Manual de usuario
Frankenrunner User Manual
Rev 1.0
The Frankenrunner
Motor Controller
User Manual – Rev 1.0
Grin Technologies Ltd
Vancouver, BC, Canada
ph: (60 ) 569-0902
email: [email protected]
web: www.ebikes.ca
Copyright © 2022
Frankenrunner User Manual
Rev 1.0
Table of Contents
1 Introduction.........................................................................1
2 Connectors...........................................................................2
2.1 Battery Power..................................................................................................2
2.2 Motor Cable – L10 Model..............................................................................2
2.3 Motor Cable – MT Model..............................................................................3
2.4 Cycle Analyst WP8 Pl g.................................................................................3
2.5 Mains Signals Pl g..........................................................................................4
2.6 PAS / Torq e Pl g...........................................................................................4
2.7 Comm nication Port.......................................................................................4
3 Wiring Strategies..................................................................5
3.1 Cycle Analyst Based Hook p.........................................................................5
3.2 3rd Party Display Hook p.............................................................................5
3.3 Headless System..............................................................................................6
4 Controller Mounting............................................................7
5 Parameter Tuning ...............................................................7
5.1 Importing Defa lt Motor Parameters..........................................................8
5.2 Motor A tot ne...............................................................................................9
5.3 Battery Limits................................................................................................13
5.4 Motor Phase C rrent and Power Settings.................................................13
5.5 T ning the Sensorless Self Start..................................................................15
5.6 Throttle and Regen Voltage Maps..............................................................16
5.7 Field Weakening for Speed Boost................................................................17
5.8 Virt al Electronic Freewheeling..................................................................18
5.9 Motor Temperat re Sensing........................................................................18
6 Additional etails: ............................................................19
6.1 Signal Mapping.............................................................................................19
6.2 Reverse Mode................................................................................................20
6.3 Wheel Speed Sensing....................................................................................20
6.4 Combined Temp / Speed Signal...................................................................21
6.5 Independent Regenerative Braking............................................................21
7 Cycle Analyst Settings........................................................22
8 LE Flash Codes...............................................................23
9 Specifications.....................................................................25
Frankenrunner User Manual
Rev 1.0
1 Introduction
Thank you for purchasing the Frankenrunner, a temporary alternative to the
Phaseunner motor controller based on Accelerated Systems Inc. ASI)'s BAC800
device.
This manual covers two production models: the Frankenrunner_L10 and the
Frankenrunner_MT. The L10 model is intended for motors already using the
L1019 connector, while the MT model employs a cable harness between the
controller and motor for accommodating various other connector standards.
Features of the Frankenrunner include:
Compact form factor
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 forwards/reverse input
Field weakening to boost top speed
Sensorless operation with high eRPM motors
Unlike standard trapezoidal or sine wave controllers, the Frankenrunner is a field
oriented controller that must be tuned to your motor, battery, and performance
requirements for proper operation. This process is detailed in Section 5
Parameter Tuning .
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2 Connectors
The controller has been connectorized to achieve maximum versatility with
minimal wiring, using a combination of waterproof overmolded ebike plugs for
signals and popular compact connectors for high current.
2.1 Battery Power
DC Power Pinout
The embedded plug on the back of the device provides a
reliable hookup to DC battery power through the compact
and popular XT60 plug interface.
A 30cm XT60 to Anderson cable is provided with each
device to match the Anderson standard used on 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-tube, or to a front hub motor with the controller on
the stem. Both 60cm and 100cm L10 extension cables are available when
longer lengths are required.
L10 Motor Plug Pinout
The Higo L1019 cable has three
motor phase pins capable of 80
amps peak, along with 7 small
signal wires for Hall position, speed
encoder, and motor temperature.
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2.3 Motor Cable – MT Model
The motor connection on the MT model uses an MT60 plug for the 3 phase
power, and both 5 pin and 2 pin JST-SM plugs for Hall sensor and temp/speed
signals. These leads coming from the controller are short, with an expectation
that a separate cable harness will be employed to reach the motor terminals.
Motor Harness Phase Pinout
The MT60 connector supports 3 phase
power in a single plug. These connectors
can be readily soldered for making custom
harnesses.
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 Plu
WP8 Pinout
The connector for the Cycle Analyst cable uses
the waterproof 8-pin Z812 Higo standard.
This connector taps into the controller's shunt
resistor for analog current and power sensing,
passing through the motor's speed and
temperature signals as well. It commands the
controller via the throttle line.
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2.5 Mains Si nals Plu
Mains Pinout
An alternate interface is provided via the 9 pin
Mains cable. This uses uses the Signal D 1109
Connector from Cusmade, and supports
conventional ebike wiring strategies for 3rd party
display consoles. It 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.
2.6 PAS / Torque Plu
PAS Pinout
Finally there is a 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 communication standard uses a 0 to 5V level serial bus. Grin produces a 3m
long TTL->USB adapter cable to connect the unit with the USB port of a standard
computer. This is the same communication cable used with the Cycle Analyst
and Satiator products. Third party USB->Serial cables, such as FTDI’s part
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number TTL-232R-5V-AJ are also compatible.
An additional USB-OTG adapter is needed when connecting to an Android
smartphone via the phone's smaller Micro USB or USB-C port.
3 Wiring Strategies
The Frankenrunner can be hooked up to the controls of an ebike system in one
of three ways. It can be connected under the full control of a V3 Cycle Analyst,
under the control of a 3rd party display, or “headless” with no display at all.
3.1 Cycle Analyst Based Hookup
The setup using the latest V3 Cycle Analyst CA3-WP) provides the most
versatility with mode presets, customizable PAS behavior, advanced regen
features, and easy performance adjustments 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 cable either can be
left unterminated, or it can be used as a power tap for running rear lights, using a
9 to 2 pin Power Adapter cable.
3.2 3rd Party Display Hookup
The Frankenrunner can be used with certain third party displays from King
Meter, Star-Union, Bafang etc.) that communicate using the KM5s digital
protocol. This is achieved with a 9 pin Mains cable harness which splits out the 9
signals into separate plugs for throttle, display, ebrakes, and front light, along
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with an optional) PAS or Torque sensor hooked up to the 6 pin PAS plug as
well.
All the key control signals throttle, ebrake, PAS/Torque) go directly to the
Frankenrunner and not the display, so additional controller parameters must be
set up to achieve desired control response. The display has the on/off power
control and up/down settings to set the assist level, but otherwise plays a passive
role in the actual system behavior.
In this wiring approach, the 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 System
Finally, the Frankenrunner can be run with only a throttle on the Mains plug, or a
PAS / Torque sensor plugged into the 6 pin PAS plug. In these arrangements, it
is essential to wire up the on/off power switch on either the WP8 plug or the
Mains connector for the controller to turn on.
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This minimal approach with a PAS sensor does not provide for any means to
adjust the assist level outside of reprogramming the controller, and for that
reason has limited usefulness. A display unit with up/down buttons is required in
order to vary the amount of assist while riding.
4 Controller Mounting
For optimal performance, the Frankenrunner should be installed such that the
finned heatsink is exposed to airflow to keep the controller cool. This placement
will noticeably improve the maximum power at thermal rollback compared to a
controller 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 motor, and so on, the controller should be pre-configured
and no tuning of the parameters should be necessary. This section can be
skipped entirely.
If you bought the Frankenrunner separately, or are changing your set-up, you
should configure the controller to your motor and battery pack once it is installed
and connected on your bike. You will need a computer, a TTL-USB programming
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cable and the V1.7 or later Phaserunner Software Suite. The V1.6 and earlier
software releases will give an “unrecognized device” error message.
This software is available for Linux, Windows, MacOS and Android from our
webpage:
http://www.ebikes.ca/product-info/phaserunner.html
Please Note: hen configuring your Frankenrunner 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. ith a rear hub motor, also ensure that the
cranks can rotate freely.
With the Frankenrunner powered on, plug in the TTL->USB cable from your
computer to the device. After launching the Phaserunner software, select the
COM port associated with the USB cable and you should see “Frankenrunner is
connected” on the top.
If you see “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/Drivers/VCP.htm
During the setup process we recommend having the controller powered by a
battery pack and not a general power supply, as electrical noise from power
supplies can interfere with stable communication.
5.1 Importin Default Motor Parameters
The Phaserunner Software Suite comes equipped with default settings for many
common motors. With your Frankenrunner connected, click on “Load Default
Parameters” and select your motor’s manufacturer and model number from the
new window. Clicking on “Apply” will return you to the “Basic Setup” tab with all
the motor’s parameter-fields populated to their correct values.
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