Suzuki RF400E, now with Enertrac MHM602

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Rovii
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by Rovii » Fri Aug 11, 2017 2:43 am

Put the motor phase current on 90-100% and the batterie current on 58%, than it should work.
Had the same problems with KHB14601. If both currents are standing on 100% and I go on full throttle position the controller cut out at speed of 65kph.
You will also state that if you go back a little bit with your throttle position (when the cut out starts) and than go back to full position slowly the acceleration begins again.
Check out my threat and you will see it.

On no load conditions (rear wheel in air, away from bottom) you will have no problems during acceleration phase.
But on load conditions (high current flow) you will get it.
Maybe also your battery can not feed the controller fast enough and therefore the capacitors inside the controller will get a voltage drop down or the cabeling is not big enough to get the high current from battery to controller.

I also split hall cables from power cables of motor because I got the information that due to the reason of high current the magnetic field can influence the signal cables.

Have you readouted red-led-blinking code?
Do you have problems with the throttle setup?

Now I changed to KLS controller, this one should work better and also motor noise is history!
If you want I can send you my KHB601 setup parameters. Than you can compare it.

BTW: Nice build, nice movie!

And if you are interested in KHB14601C, I want to sell it, so you can PM me (waterproof version)!

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Fri Aug 11, 2017 6:02 am

Danke, that's encouraging :)

Preliminary to-do list:
- reroute sensor cable away from phase wires
- re-terminate phase wires with hydraulic crimper
- add CA to wiring to show voltage at least

- sink screws "behind" brake disk on torque arm
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Sat Aug 26, 2017 3:14 pm

OK, did the above, minus the CA and spent the afternoon fiddling with the settings:
- 95% phase & 68% battery current
- wider throttle active range (1.2V-3.8V now) & smaller delay (0.3s)
- combined mode

One finding about the Kelly 24V requirement - I couldn't find any difference between 4 and 6S, so I left it at 4 :wink:
140mA idle, 250 when running. Idle drops to 110 on 6S

Also picked another of the 4 promising Hall/phase combinations from doing "the spreadsheet" - the methodical work paid off, have it attached for convenience.

The result:

Then I changed the brake fluid for the front (it should better be roadworthy for the next test drive :)).
The controller wiring is back on the workbench now to add another relay for the brake (remember that I have 2 4S packs for the LV circuits) plus some mounting.
Thanks again Rovii!
Attachments
Phase-Hall-Wire-Combinations-Bafang-Infineon.xls
(14 KiB) Downloaded 26 times
Last edited by marcexec on Wed Aug 30, 2017 6:09 am, edited 1 time in total.
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

Rovii
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by Rovii » Sat Aug 26, 2017 11:48 pm

You are welcome!
Fine, when everything works now.
But did you test it already on load conditions?
Look for a straight long street and go in full throttle position. Then you will find out it works correctly.
On no load conditions it's always no problem because of less current flow!
As I wrote if you want to have more acceleration, you can get my 14601C.

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Wed Aug 30, 2017 4:18 pm

OK, some more tinkering with the settings tonight.
I couldn't get the "conking out" away with either "Combined" or "Torque" mode, even though I went down to 60% battery and 80% phase amps :cry:
I was able to carefully accelerate bit by bit, but that's not workable - too distracting.
On the "Speed" mode I have it now to 85/100% without issues. Acceleration from startup is "meh", once she's rolling it's OK. Top speed for tonight 80km/h, not an issue getting there even on the local hill (about 6% incline).

Performance is good enough IMO for the commute, I will focus on other things now, like:
- Find a spot on the wiring loom to connect the "brake" relay on the controller, should be black/white. This is essential for safety, I got the occasional "shove" while maneuvering on the driveway - Done, see below.
- Get the seat re-covered. There's a local shop around the corner.
- Mirrors. They come in handy in traffic. I have the polygonal ones with LEDs, maybe I'll swap at some point.
- BMS. One wire from the ATX connector came loose. Some balancing left to do after I had a creeping current/short on the OEM connector due to moisture. - fixed, need to mount BMS
- 12V /4S charging x2 - not sure yet, packs should last for more time than the main pack.
- CA, will have to steal connector from broken controller :), any idea how to avoid a shunt and use the Kelly Ammeter output? - Installed. I still need to calibrate as I just used a length of cable for the shunt (but have believable readings already :)). Need to find the magnet for the pickup.
- LED H4 headlight, already ordered, should be brighter
- front forks need new seals & oil, standing too long, feel squishy
- fairings, need adaption due to front battery box, needed for efficiency and weather protection - In progress
- making everything shiny and fitting well, maybe save some weight - tank re fitted for narrower gap, expect it to be fine against some 1mm Neoprene self-adhesive tape for sealing.

I also put her on the scale: 94kg front / 84kg rear - 178kg is not too bad without fairing, rear foot pegs, BMS and charger. Original dry weight was 186kg, or around 207kg wet.
Last edited by marcexec on Wed Sep 06, 2017 7:55 am, edited 1 time in total.
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

Rovii
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by Rovii » Wed Aug 30, 2017 10:39 pm

Change to KLS 8080i 14401 or another controller!
That's my personally view.
The big problem is KHB type!!!
In every run I got power cut out but by knowing to go back a little bit with acceleration and then continue I know it's working but that is not solving the problem to get a smooth and powerful acceleration!
Check out my threat (https://endless-sphere.com/forums/viewt ... 12&t=82155)
same problems and really frustrated!
With KLS controller I did the first run (100% phase / 100% battery current @ 175V) without any interruption from 0-200 kph!
But if you go higher than 144VDC battery voltage you have to switch off regen!
Ok 400A are under current for my motor, therefore the acceleration could be better and that's the reason I will change controller again to Emsiso emDrive500 (The costs are a little bit higher than Kelly, Sevcon and Co. And you need watercooling system)
My GSXR 1000 weight is 167kg but I only have 20Ah and no lighting system.
Regards Andre

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Wed Sep 06, 2017 7:31 am

Thanks mate.
I'll need the bike for commuting (as my VFR got stolen - decided not to buy a petrol bike again :)).
Thus the "cleanup" jobs as above. Maybe some sine wave controller in the future, but as they say here, it needs to be "used in anger" :mrgreen:

I wanted to expand on the brake wiring as I decided only to activate regen through the rear brake.
Cable colour codes should be the same on most (at least Japanese) bikes:
- both front and back switches get power from an orange/green cable
- when pressed a the black/white cable goes high to light up the brake lights
- for rear-brake only regen I cut the BK/WH from the rear switch, put in a Schottky Diode and pulled a cable to the front to connect to my now 3 pole "controller relay connector"

Works a treat, but made me realize I still have a lot of cabling to tidy up/remove. :(
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Tue Sep 26, 2017 8:45 am

Made some crucial progress here.
20170924_141802.jpg
wiring
20170924_141607.jpg
stands, open
Fairings were fixed in place around the front box, thanks to some IKEA PE (Legitim cutting boards :))
20170924_141727.jpg
front
20170924_141643.jpg
controller
20170924_141623.jpg
left
20170924_141615.jpg
right
will have to rework them somewhat, they are a bit low on cornering.
20170924_141713.jpg
lower fairing
20170925_214034.jpg
I did a "shakedown" test ride last night - 9.5km @8.5Ah
Assuming 86.4V (24S), that's ~77Wh/km, not too bad I think. Top speed was 90km/h, feels like it's voltage limited.
20170925_221034.jpg
CA
(138.68 KiB) Downloaded 3 times
I'm calling V1.0 - will take her to work later this week :D.
Edit: pictures added
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Tue Oct 10, 2017 5:32 am

A quick update after 2 weeks of commuting:
- Failed on the first day :( - forgot to charge the 4S aux battery for the controller. I got home just fine after "jump starting" from the big 4S for the lights... :mrgreen:
It's doubled up now to 2P, ~4Ah should be plenty
- Uphill starts ( I have a hilly commute) from a dead stop are a bit slow, the amps are ramping up slowly. Red lights are thus becoming fun - I stay behind the first car if I judge them to go quickly (single/young/hot hatch/BMW driver) :lol:
I still have to go from 90 to 100% battery amps
- Fairings need more work to allow for cornering at higher speeds, bike feels pretty nice, though

Best of all, the CA shows 950Wh for the 16km round trip, which would give me a range of 100km! :D
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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Lebowski
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by Lebowski » Tue Oct 10, 2017 6:41 am

Marc, didn't you have one of my chips ? Volttan seems to have good results on his bike:
https://endless-sphere.com/forums/viewt ... 9#p1320779

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Tue Oct 10, 2017 7:47 am

Yep, 2 actually :D. I blew the DC/DC on the one board I had working :(.

That's the long-term plan (and why I passed on the bigger Kelly above). At the moment I am getting the secondary functions on the bike sorted as it's my daily driver - weather protection, heated grips & other conveniences, put the chargers and BMS on board, tidy up the wiring etc.
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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marcexec
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Fri Oct 20, 2017 9:14 am

I spent some time replacing the insert that's plugging the hole the filler cap left (with PP/"corruboard") and spent some time sanding/de-rusting the inner part of the tank:
20171013_204647.jpg
20171013_212452.jpg
Maybe I'll add a LED to illuminate the "boot" :D
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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marcexec
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Location: Dublin, Ireland

Re: Suzuki RF400E, now with Enertrac MHM602

Post by marcexec » Wed Nov 01, 2017 8:27 am

I got a semi-cheap H4 LED headlight, fitting was a breeze - no tools required ;).
US$ 7 on Banggood

The light pattern is more than OK, there's a clear cutoff, no glare, just an area that's not lighted directly in front of the bike. I'm not sure if that's good or bad, will report if I ever ride outside of the city light's :D.

Measured the current on 4S (~16.0V):
0: "ignition" on, essentially just the contactor, pre-charge and controller power relays: 0.2A
1: 0 + tail lights & instrument ligting 0.7A
2: 1+ low beam: 1.6A
3: 1+ high beam (switches over on high and pass): 1.9A

Altogether I'm quite happy, money well spent as far my needs go.

Also started stripping back the wiring loom, lots of stuff not needed any more....
A motorcyclist is never late, Frodo Baggins. Nor is he early. He arrives precisely when he means to.
My Suzuki RF400 build: now with Enertrac MHM602 and 6kWh AESC modules protected by a Zephyr BMS
Renault Equation modded to 10S6P recycled laptop 18650s & 1kW controller.
Master of Electric Motor Selection: "Adopt a motor" (PM me if you have trouble editing)
All the gear, all the time!

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SplinterOz
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Re: Suzuki RF400E, now with Enertrac MHM602

Post by SplinterOz » Wed Nov 01, 2017 3:42 pm

marcexec wrote: ...
The light pattern is more than OK, there's a clear cutoff, no glare, just an area that's not lighted directly in front of the bike. I'm not sure if that's good or bad, will report if I ever ride outside of the city light's :D.
...
Looking at the "bulb" how does the cutoff change when you switch to high beam, do you get more light spread and also forward and up?
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