How to Unbrick Sevcon controller

Electric Motors and Controllers
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Doctorbass   100 GW

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How to Unbrick Sevcon controller

Post by Doctorbass » May 10 2017 12:33pm

Hello guys

I have a great info to share with you regarding how to recover a bricked Sevcon controller that accidently you sometime brick when attempt to upload a new firmware or have problem with teh right baud rate and IXXAT and red light etc..

It is called using the backdoor methode :wink:

follow the instruction of the image i uploaded called HOW TO UNBRICK SEVCON and use the following

The command line you need to copy and paste is the exact one below as described in the document:

can send "0x7FA 0x48 0x65 0x79 0x73 0x6c 0x69 0x70"




tag:

Sevcon unbrick Brick problem bootloader backdoor ixxat dld firmware
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How to unbrick sevcon.jpg
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kiwifiat   100 W

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Re: How to Unbrick Sevcon controller

Post by kiwifiat » May 11 2017 10:47am

There is a lot of good documentation about the sevcon gen4's on the Heinzmann website, thanks for sharing this. Have you used this method? I have a 10.5kw PMS120W that is fitted with an analog sin/cos encoder that I hope to drive with a gen4, let's hope I don't brick it!
The only source of knowledge is experience.
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Doctorbass   100 GW

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Re: How to Unbrick Sevcon controller

Post by Doctorbass » May 11 2017 11:00am

kiwifiat wrote:There is a lot of good documentation about the sevcon gen4's on the Heinzmann website, thanks for sharing this. Have you used this method? I have a 10.5kw PMS120W that is fitted with an analog sin/cos encoder that I hope to drive with a gen4, let's hope I don't brick it!

What is important is to NOT turn the controller OFF while it is in bootloader.

I have sucessfully used this method a year ago, however i still have one of my size 4 that remain bricked as the IXXAT can't comunicate with it at any baud rate.. it flash red or remain red Solid and sevcon flash one long and two short when power up.
I had bad electrical contact on the positive and moved the wiring a bit while in bootloader witch have briefly cut power to the controller while programming it :roll:

A note to mysef: Always check all connections and battery state before ANY programming ALSO on a Sevcon!

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

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Doctorbass   100 GW

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Re: How to Unbrick Sevcon controller

Post by Doctorbass » May 11 2017 11:01am

kiwifiat wrote:There is a lot of good documentation about the sevcon gen4's on the Heinzmann website, thanks for sharing this. Have you used this method? I have a 10.5kw PMS120W that is fitted with an analog sin/cos encoder that I hope to drive with a gen4, let's hope I don't brick it!

What is important is to NOT turn the controller OFF while it is in bootloader.

I have sucessfully used this method a year ago, however i still have one of my size 4 that remain bricked as the IXXAT can't comunicate with it at any baud rate.. it flash red or remain red Solid and sevcon flash one long and two short when power up.
I had bad electrical contact on the positive and moved the wiring a bit while in bootloader witch have briefly cut power to the controller while programming it :roll:

A note to mysef: Always check all connections and battery state before ANY programming ALSO on a Sevcon!

Doc
CURRENT PROJECT: 2WD duo MXUS/Max-E ebike 32kW
http://endless-sphere.com/forums/viewto ... =3&t=65764
-Fastest speed record 117 km/h on flat
-Fastest 1/4 mile@ 114km/h on flat and 16.316 sec
-Succeded to haul a 19200 pounds schoolbus!
113kmh Gianthttp://www.evalbum.com/3406
Mongoosehttp://www.evalbum.com/1947
YOUTUBE---https://m.youtube.com/user/Doctorbasss
http://twitter.com/DocbassMelancon
I speak FRENCH and english

bernext   100 µW

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Re: How to Unbrick Sevcon controller

Post by bernext » Apr 24 2018 10:36am

Does that come from he "Bootloader" application note from Sevcon ?
Where could I download it ?

There seems to be a bunch of secret files regarding Sevcon drives, which I would like to read. So far this is the secret list:

"Vehicle Setup and Configuration" application note
"Using SCwiz" application note
"256K Host Processor" application note
"Bootloader" application note
"DVT" application note
"Autoconfig setup" application note
"PDO fundamentals" application note
"Driver Demand Pipeline" application note
"Tuning the Speed Control Loop" application note

Does anyone know where to download any of them ? Are they all stored inside Heinzmann site ?

Regards.

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flippy   10 kW

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Re: How to Unbrick Sevcon controller

Post by flippy » Apr 24 2018 12:43pm

making a post here so i can find it if needed.

slightly less relevant: i tried several sevon powerd scooters now and they all have this very annoying "hunting" at the speed limit that is set. the current also goes up and down a lot and never seems to settle at a normal level. its quite uncomfortable and pretty hard on the batteries as well.

does anyone have a clue what can be changed to stop this behaviour?
Lithium beats liquid dinosaurs.

kiwifiat   100 W

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Re: How to Unbrick Sevcon controller

Post by kiwifiat » Apr 24 2018 2:30pm

bernext wrote:
Apr 24 2018 10:36am
Does that come from he "Bootloader" application note from Sevcon ?
Where could I download it ?

There seems to be a bunch of secret files regarding Sevcon drives, which I would like to read. So far this is the secret list:

"Vehicle Setup and Configuration" application note
"Using SCwiz" application note
"256K Host Processor" application note
"Bootloader" application note
"DVT" application note
"Autoconfig setup" application note
"PDO fundamentals" application note
"Driver Demand Pipeline" application note
"Tuning the Speed Control Loop" application note

Does anyone know where to download any of them ? Are they all stored inside Heinzmann site ?

Regards.
Try a search with "Heinzmann login" on this and other EV related sites , I think you will find what you are looking for. Have you asked ElectricMotorSport for a copy of the original DCF that was on the controller you purchased from them? Seems that the first step would be to restore the original DCF if you think you screwed things up by changing settings with DVT. Surely ElectricMotorSport would provide you with all relevant documentation for the Sevcon controller you purchased from them.
The only source of knowledge is experience.
Albert Einstein

bernext   100 µW

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Re: How to Unbrick Sevcon controller

Post by bernext » Apr 24 2018 4:56pm

HI kiwifiat,

This might be a dumb question, but is everyone allowed to register at the Heinzmann site ?
I filled up the registration form, but, somehow the Heinzmann people have not contacted me.

So, I guess, only dealers might be allow to get an account there ?
A username of "software" with its password, was posted on 2015, but it's no longer valid anymore.

Regards.

kiwifiat   100 W

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Posts: 107
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Location: Vancouver, Canada

Re: How to Unbrick Sevcon controller

Post by kiwifiat » Apr 25 2018 1:13pm

bernext wrote:
Apr 24 2018 4:56pm
HI kiwifiat,

This might be a dumb question, but is everyone allowed to register at the Heinzmann site ?
I filled up the registration form, but, somehow the Heinzmann people have not contacted me.

So, I guess, only dealers might be allow to get an account there ?
A username of "software" with its password, was posted on 2015, but it's no longer valid anymore.

Regards.
Your guess is as good as mine.

Have you asked ElectricMotorSport for a copy of the original DCF that was on the controller you purchased from them?
The only source of knowledge is experience.
Albert Einstein

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