Regen issue with Phaserunner and GMAC

titan_rw · Jun 1, 2021

Hello.

I purchased a Phaserunner / Gmac 10T / CA3 setup from Grin back in March. I had them lace the motor into a 26 inch wheel for me. I had my own 14s LiIon battery.

I got everything setup and running on my Kona MTB.

During acceleration everything is fine. No faults.

However during strong regen braking, the PR was tripping Instantaneous Phase Over Current, blink code 2-2. This normally occurs near the 'end' of regen braking, for example, braking from 40 km/h down to 20 km/h is ok, then the over current trips.

I contacted Grin about it at the time, but in over 2 months, the issue still remains. I'm wondering if anybody else has any ideas?

Troubleshooting steps I've taken myself, or as directed by Grin:

Reset PR to defaults, and loaded gmac 10t preset.

Tried changing regen torque engage ramp from 200ms to 500ms.

I tried lowering the current regulator P from 0.75 to 0.3. This made it much worse. Over current tripped within 1/2 second of regen.

Raised P incrementally up to around 3. No change. About 3 seconds after applying regen, over current would trip.

Tried raising I from 300 to 1,000 with no change. Also tried higher P and I simultaneously.

Changed current regulator bandwidth to 1,000 rads instead of 0. I understand this stops using P and I and does things more 'on the fly'. Still tripped over current.

Raised PLL bandwidth from 800 to 1,000. Also tried raising PLL damping from 2 to 5.

Lowered regen phase current from 90A to 62A and it still trips.

I tried lowering battery regen current from 30A to 15A with no help. Didn't expect that to help as the fault normally doesn't occur at high speed where you'd be more likely to be battery current limited, but instead occurs at lower speed where you're probably phase current limited.

I also tried a different rider, as I am around 250 lbs. I had a 160 lb rider try, and they were able to reproduce the fault as well.

Checked stator play by opening up the motor at the suggestion of Grin, but it seems to be within their spec.

I do not believe the cycle analyst has anything to do with this, as I have a separate throttle control wired direct to the PR to command braking, thus bypassing the CA. The CA is still aware of the regen battery current of course, but it's not the one requesting it. Throttle / brake voltage mapping was setup in the PR correctly. Appx 1v -> 4v.

I finally tried lower regen phase current all the way to 40A, and this did help. It no longer triggers phase over current during braking. However this of course has drastically reduced the amount of braking that's possible at medium to low speeds. High speed regen is still battery current limited of course, but low speed braking is rather poor now. I definitely have to use the friction brakes a lot more now, but at least I can rely on the regen not to cutout and the subsequent need to pull over and power cycle the PR to clear the fault.

Aside from making it worse by lowering current regulator P, the fault never occurs 'instantly' or 'quickly'. It was always 2-3 seconds after it had been successfully doing strong regen. If I could see a debug graph of the phase current, or even better, a graph of the P and I terms it would probably help a great deal. I'm somewhat familiar with PID controllers from flying FPV drones, but there you could always look at debug graphs to help determine where the problem was. For example, I'm not sure if the current control loop is too slow to respond, and the error (and therefore phase current) gets too high, or if the control loop is too fast to respond and it takes 2-3 seconds of quick oscillation for it to finally spike too high.

Anybody have anything else I can try changing to get regen phase current back up without over current faults?

Thanks.

goatman · Jun 1, 2021

have you asked about the plug braking transition? that happens at about 10km/h i think

went to bring link from this thread but i guess the new PR's dont have it
https://endless-sphere.com/forums/viewtopic.php?f=2&t=105302#p1539896

titan_rw · Jun 1, 2021

Hi.

That's a good suggestion. I had never thought about that.

However I don't think that's it.

One, With regen phase current at 40A to where I can always regen to a dead stop, I see regen (negative) watts down to probably 2-3 km/h. Whereas over current faults would always occur >10-15 km/h.

Two, I've always seen decent negative watts on the CA whenever there's been an over current fault. I don't remember for sure, but > -500w before the PR trips the fault.

Three, lowing current regulator P from 0.75 to 0.3 made it trip over current within 1/2 second of applying regen, even when speed was > 30 km/h. This would imply regen phase current as opposed to plugging (acceleration) phase current.

I also forgot to mention in the original post that this is nothing to do with the BMS. I've tested this without any BMS (PR wired directly to battery cells) and had the same issue. I had originally maybe thought some weird interaction with the charge fets in the bms might cause current spikes, but that didn't seem to be the case.

goatman · Jun 1, 2021

will the dashboard screen appear on the phone app.
ive never used the app but the dashboard has the graph for battery and phase current and can export the file

ive never tried it hooked up to a laptop while watching the graph but maybe raise the back wheel, go full throttle to max speed and hit your regen, see what happens

anyways, good luck

titan_rw · Jun 1, 2021

I haven't tried the android app, as I don't have the capability to connect that way right now. I understand you need a usb otg adapter, and also the 20-ish foot long regular usb type A cord? I wonder if the sampling rate of this logging is enough. Maybe I'll check amazon for a usb C to type A OTG adapter.

I have had it hooked up to my desktop computer while in a bike stand with no issue. Full throttle, then immediately applying full regen will simply stop the wheel very quickly, to the point the pedals spin backwards with the kick. I don't think it spends long enough at high enough regen phase amps to trigger the fault condition.

goatman · Jun 1, 2021

maybe try it slower at 40km/h speed

your regen is at 0.8v and throttle at 1.2v to 4.0v

are both throttles going into the ca3

titan_rw · Jun 1, 2021

Do you mean free spinning at 40 km/h? Tried that with no difference.

If you mean a riding test at 40 km/h, then I'd argue that's not a valid test as full speed without field weakening is around 50 km/h. Regen should handle this.

Regarding the regen voltage and setup, I had tried to mention that in the original post:

titan_rw said:
I do not believe the cycle analyst has anything to do with this, as I have a separate throttle control wired direct to the PR to command braking, thus bypassing the CA. The CA is still aware of the regen battery current of course, but it's not the one requesting it. Throttle / brake voltage mapping was setup in the PR correctly. Appx 1v -> 4v.

Maybe I wasn't clear enough. I've gathered full screenshots from PR and CA:

PR basic setup:

Mostly defaults I think besides power and volt limits.

PR advanced setup:

Throttle and brake voltages set accordingly. I think everything else is on default.

For the PR dashboard screen, I have 3 screenshots, showing voltages based on control position on the bike.

Voltages upon power on. No throttle applied, no friction brake pulled, and no regen brake:

Note Throttle 1.02v and Brake 2 0.87v. Bike is ready to ride. Applying throttle control (filtered through CA) will spin wheel.

Voltages upon pulling friction brakes regardless of throttle input:

Note Throttle voltage driven down to 0.96v to ensure throttle is disabled. Brake voltage still 0.87v, brake flag still cleared. Friction brake sensor acting as throttle disable / cutoff only.

Friction brake released, but full regen commanded. As mentioned, regen 'throttle' is wired directly into PR separating / splitting out throttle / brake wires as per Grin's documentation. Actual throttle voltage from the CA doesn't matter here as the PR is smart enough to prioritize brake over throttle. Brake software flag is showing active as well.

Attached for reference are the cycle analyst configs. I did recently setup 2 presets. Preset 1 (at power on) is a 'road legal' default. Preset 2 is 'offroad'. Other than that I think it's pretty standard. As the regen control commands the PR directly, I don't think the CA has any hand in what's going on here.

As a side note, before I setup the second 'throttle' to act as a regen control, I had done the default 'single throttle and friction brake cut-off' using additional actual throttle control during slight friction brake activation to command > default regen braking. I hated it. It required relatively fine muscle movements in order to activate the friction brake cut-off without actually engaging friction brakes. Then rolling on throttle at that point to enable more than default regen was very unnatural.

Instead of having a fine muscle movement (barely activating the e-brake sensor), then an unnatural one (applying throttle) to control regen, I opted for two separate controls. A half twist right handed throttle as normal. And a left hand thumb regen brake. Any application of left thumb brake disables throttle and activates proportional braking depending on how much you push your thumb. No need to slightly apply brake with one hand then roll on throttle with the other.

In a panic situation, the regen brake just doesn't get used. You grab friction brakes, forcing throttle disable, and just friction brake to a stop.

Hope all this made sense.

goatman · Jun 1, 2021

did you snip the green wire off the throttle jst that comes out of the PR?
page 2, V3 updates
https://ebikes.ca/amfile/file/download/file/118/

the blue(regen) and green (throttle) are on the same pin, i wonder if thats messing with things

but how does the PR differentiate between the two if theyre connected together?

other than that ive no clue

titan_rw · Jun 1, 2021

Yes, they're separate.

Page 14, section 5.3:

https://ebikes.ca/documents/Phaserunner_Manual_Rev2.0.pdf

Rev 2 manual but I think it's identical.

The throttle signal still comes through on the CA connector. Regen (brake) signal comes through on the jst 3 pin connector once green (throttle) is disconnected.

goatman · Jun 1, 2021

your regen phase current is at 40amps
battery phase amps is at 30amps
60% of 40 phase amps is 24 battery amps

i looked at the motor cable for the gmac and it can handle 100 phase amps

have you checked the pins on the mt60 or did you get the L10?

i see youre running 3000 watts

PR temp is 29 celsius
did you heatsink the PR?
if not you must be going into thermal rollback
i wonder if regen phase amps going into a controller is endothermic

goatman · Jun 1, 2021

you could try heating up the phaserunner with a hair dryer
on the dash board screen you can watch the temperature rise, if i remember correctly at 80 celsius it goes into thermal rollback, then spin up fullthrottle and hit full regen and see if it faults

titan_rw · Jun 1, 2021

The controller is at 29c because that's the ambient temperature in the living room where the bike lives between rides. We don't have air conditioning, so it is what it is. I haven't used the bike in a few days, so it's not sitting at outdoor temperature, which was only 23 or 24 when I took those screenshots.

This has been a problem back in March where ambient outside temperatures have been single digits and basically almost snowing. I've done testing where all I could manage was 5 minutes and I had to come back in from the cold. I don't think it's warming up too much in the first 30 seconds to cause instantaneous phase over current during the very first regen braking.

With the lower regen phase amps, you're right, I'm only seeing a little over 24 amps regen battery amps. The 60 amps max battery discharge current is giving me 59.2 actual battery discharge amps.

This is the L10 connector on both controller, and motor as supplied by Grin. I have to assume it can handle > 40 amps of regen current. Keep in mind I've never had a problem with 90 phase amps of acceleration current.

I have the controller zip-tied to the center post (seat tube?) on the bike, and otherwise unencumbered by anything else.

Even if the controller was instantly getting hot from regen phase current, it should thermal throttle and limit current accordingly, instead of unexpectedly disabling all regen braking, and halting operation until a power cycle. That's not great thermal throttling behavior.

To be clear, I'm not taking issue with your suggestions. The brake plugging one made me think about it. However as I summarized to grin at the end of March, this is a Grin branded motor, a Grin branded controller, on THE most common size MTB wheel (26") that they even laced up for me, on a very common (52v) battery. I'm just frustrated it's been over 2 months and even the manufacturer doesn't seem to be able to help (last communication from Grin was May 5). That combined with the terrible pre-sales experience has definitely made me rethink my choice to spend almost $2,000 on a local company instead of rolling the dice on China. I came to ask help here because I'm out of 1st party options.

Other than the regen braking issue, the motor and controller seem great. I get a top speed of 50 km/h, which is all I'd ever want on a MTB. More than enough hill climb (did a 500m 10% grade no pedaling at 36 km/h and 3,000 watts). The thermal throttling of the CA let me push the motor into some really strong headwinds where DESCENDING a 6% hill took 200 watts (head wind more than overrode gravity helping) and riding straight and level at a max of 35 km/h took almost 2,000 watts. Even with this intermittent head wind I still pushed the bike to 72 km total range starting at a charge of 4.07 and the LVC set to 3.00 / cell.

goatman · Jun 1, 2021

ya when i was on my way to grin the other day to get the replacement PR i thought i should grab a couple spare throttles,
there was lots of busy workers running all over the place looking swamped

store was closed and they wouldnt let me in :lol: :lol: :lol:

i never had thermal roll back issues til it was about 20 celsius outside.

whys the ohms set to 1.004 mohm instead of 1.000 in the ca3

im in the same boat as you, my old V2 PR works good, the new V3 PR is acting up???

im done bugging ya

titan_rw · Jun 2, 2021

The 1.004 is default. I think the PR itself is actually labeled 1.004 as well. I'd have to remove it from the bike to check as I think the printing of the shunt value was on the very bottom.

This was my first PR. First purchase from Grin at all actually.

titan_rw · Jun 3, 2021

So I got some realtime logging off the PR by tossing a laptop in a backpack.

First I wanted a baseline, so I logged everything with my current setup of 40a regen phase current just to see how it would look without the faults.

Then I changed regen phase current back to 90a, the same as acceleration phase current. This triggered the over current protection again.

Here's a clip from the exported data trimming zeros:

Code:

Time(s)	Interrupted	Controller Temperature(eg C)	Motor Current()	Motor RPM(PM)	Battery Voltage()	Battery Current()	Throttle Voltage()	Brake 2 Voltage()	

89.035	0	29	0.03	2	54.56	0	1.02	0.87	
89.631	0	29	0	17	54.56	0	1.22	0.87	
89.741	0	29	0	17	54.56	0	1.22	0.87	
90.288	0	29	14.06	32	54.5	1.16	1.51	0.87	
90.46	0	29	14.06	32	54.5	1.16	1.51	0.87	
90.975	0	29	16.91	38	54.47	1.66	1.62	0.88	
91.629	0	29	19.44	38	54.47	1.97	1.69	0.88	
92.3	0	29	26.91	42	54.38	3.28	1.96	0.87	
92.994	0	29	28.03	46	54.38	3.66	1.97	0.88	
93.642	0	29	27.75	58	54.31	4.19	2	0.88	
93.705	0	29	27.75	58	54.31	4.19	2	0.88	
94.308	0	29	28.94	66	54.28	4.97	2.01	0.88	
94.417	0	29	28.94	66	54.28	4.97	2.01	0.88	
94.991	0	30	50.31	79	53.94	10.84	2.78	0.87	
95.131	0	30	50.31	79	53.94	10.84	2.78	0.87	
95.623	0	30	55	96	53.75	13.88	2.91	0.87	
96.29	0	30	59.34	114	53.56	17.25	3.06	0.86	
96.971	0	31	58.91	133	53.44	19.38	3.04	0.88	
97.631	0	31	55	154	53.38	19.91	2.91	0.87	
98.304	0	32	60.06	168	53.16	23.94	3.12	0.87	
98.367	0	32	60.06	168	53.16	23.94	3.12	0.87	
98.98	0	33	63.19	186	52.97	27.16	3.2	0.87	
99.089	0	33	63.19	186	52.97	27.16	3.2	0.87	
99.651	0	33	64.72	203	52.75	30	3.24	0.86	
99.807	0	33	64.72	203	52.75	30	3.24	0.86	
100.337	0	34	89.31	224	51.91	44.88	4.08	0.86	
100.981	0	35	89.31	243	51.72	47.69	4.09	0.86	
101.662	0	36	89.16	262	51.5	50.59	4.08	0.86	
102.348	0	37	88.84	284	51.28	54.09	4.08	0.85	
103.058	0	38	86.78	307	51.13	56.69	4.07	0.84	
103.716	0	39	72.22	326	51.47	50.66	4.11	0.88	
103.763	0	39	72.22	326	51.47	50.66	4.11	0.88	
104.397	0	40	63.19	339	51.66	46.31	4.08	0.86	
104.49	0	40	63.19	339	51.66	46.31	4.08	0.86	
105.073	0	40	56.44	350	51.81	42.69	4.08	0.86	
105.198	0	40	56.44	350	51.81	42.69	4.08	0.86	
105.732	0	41	48.63	360	52.06	37.78	4.08	0.85	
105.92	0	41	48.63	360	52.06	37.78	4.08	0.85	
107.123	0	41	39.13	373	52.38	31.34	4.11	0.87	
107.826	0	40	36.38	377	52.5	29.34	4.09	0.86	
108.513	0	40	35.72	378	52.53	28.84	4.1	0.87	
109.178	0	40	33.22	382	52.59	26.97	4.09	0.86	
109.862	0	40	29.47	386	52.72	24.16	4.09	0.86	
110.519	0	40	33.56	382	52.56	27.25	4.09	0.86	
110.597	0	40	33.56	382	52.56	27.25	4.09	0.86	
111.192	0	40	32.78	383	52.59	26.69	4.1	0.87	
111.317	0	40	32.78	383	52.59	26.69	4.1	0.87	
111.865	0	39	32.06	383	52.63	26.16	4.1	0.87	
112.037	0	39	32.06	383	52.63	26.16	4.1	0.87	
112.538	0	39	27.97	389	52.75	23	2.81	1.81	
113.215	0	39	39.94	364	55.22	-23.19	1.02	4.19	
113.889	0	39	39.88	336	55.22	-21.37	1.03	4.19	
114.562	0	39	39.94	313	55.16	-19.97	1.03	4.19	
115.234	0	39	39.97	291	55.13	-18.53	1.03	4.19	
115.265	0	39	39.97	291	55.13	-18.53	1.03	4.19	
115.879	0	39	39.91	272	55.06	-17.25	1.02	4.19	
115.988	0	39	39.91	272	55.06	-17.25	1.02	4.19	
116.554	0	39	39.91	251	55.03	-15.91	1.03	4.19	
116.695	0	39	39.91	251	55.03	-15.91	1.03	4.19	
117.29	0	39	39.97	231	54.97	-14.62	1.02	4.19	
117.415	0	39	39.97	231	54.97	-14.62	1.02	4.19	
117.978	0	39	40	206	54.91	-12.91	1.02	4.19	
118.134	0	39	40	206	54.91	-12.91	1.02	4.19	
118.743	0	39	39.97	187	54.84	-11.62	1.02	4.19	
118.853	0	39	39.97	187	54.84	-11.62	1.02	4.19	
119.403	0	39	39.94	168	54.78	-10	1.01	4.19	
119.575	0	39	39.94	168	54.78	-10	1.01	4.19	
120.071	0	40	40.03	145	54.72	-8.69	1.02	4.19	
120.731	0	40	39.72	122	54.59	-6.41	1.02	4.19	
121.387	0	40	39.81	108	54.56	-5.53	1.02	4.19	
122.042	0	40	40.09	89	54.5	-4.22	1.02	4.19	
122.089	0	40	40.09	89	54.5	-4.22	1.02	4.19	
122.727	0	40	40.03	71	54.44	-3.03	1.01	4.19	
122.805	0	40	40.03	71	54.44	-3.03	1.01	4.19	
123.383	0	40	39.88	49	54.34	-1.53	1.01	4.19	
123.524	0	40	39.88	49	54.34	-1.53	1.01	4.19	
124.058	0	40	39.94	34	54.28	-0.41	1.01	4.19	
124.712	0	40	4.41	14	54.28	0	1.02	0.86	
125.384	0	40	0.19	-2	54.28	0	1.02	0.87	
126.017	0	40	0.16	0	54.28	0	1.02	0.87	
126.712	0	39	0.13	2	54.28	0	1.01	0.87	
126.759	0	39	0.13	2	54.28	0	1.01	0.87

You can see 89 phase amps during acceleration (4v throttle). And 40 phase amps during regen braking (4v brake). Braking was successful down to 0 wheel rpm.

Here's the 90 amp regen phase amp test, trimming away the zeros:

Code:

Time(s)	Interrupted	Controller Temperature(eg C)	Motor Current()	Motor RPM(PM)	Battery Voltage()	Battery Current()	Throttle Voltage()	Brake 2 Voltage()	

47.297	0	31	0	25	54.47	0	1.02	0.86	
47.877	0	31	8.53	27	54.47	0.5	1.32	0.88	
47.929	0	31	8.53	27	54.47	0.5	1.32	0.88	
48.486	0	31	11.38	30	54.44	0.84	1.42	0.88	
49.067	0	31	14.5	30	54.41	1.16	1.54	0.87	
49.631	0	31	15.19	42	54.41	1.59	1.54	0.86	
50.174	0	31	15.75	44	54.41	1.69	1.56	0.87	
50.721	0	31	17.53	51	54.38	2.19	1.62	0.87	
50.799	0	31	17.53	51	54.38	2.19	1.62	0.87	
51.8	0	31	20.25	75	54.28	3.59	1.72	0.88	
51.878	0	31	20.25	75	54.28	3.59	1.72	0.88	
52.393	0	32	33.44	81	54.09	6.88	2.21	0.87	
52.959	0	32	37.5	90	54	8.53	2.31	0.88	
53.518	0	32	65.56	105	53.44	18.47	3.3	0.86	
54.055	0	32	89.5	127	52.84	29.59	4.1	0.89	
54.611	0	33	89.31	149	52.59	33.41	4.09	0.86	
55.174	0	34	89.44	170	52.41	36.75	4.09	0.86	
55.721	0	35	89.25	195	52.16	40.5	4.1	0.88	
56.29	0	36	89.22	218	51.94	44.19	4.09	0.87	
56.846	0	38	89.25	240	51.72	47.59	4.09	0.88	
56.909	0	38	89.25	240	51.72	47.59	4.09	0.88	
57.412	0	39	89.22	260	51.5	50.59	4.1	0.88	
57.981	0	40	88.91	280	51.31	53.84	4.08	0.85	
58.572	0	41	88.16	299	51.13	56.28	4.11	0.88	
59.133	0	42	77.41	318	51.31	53.19	4.11	0.88	
59.682	0	42	66.28	332	51.59	47.88	4.08	0.85	
60.223	0	43	58.5	345	51.75	43.78	4.08	0.86	
60.797	0	43	52.97	354	51.94	40.56	4.1	0.86	
60.875	0	43	52.97	354	51.94	40.56	4.1	0.86	
61.363	0	43	46.53	362	52.13	36.38	4.09	0.87	
61.915	0	43	40.81	371	52.31	32.47	4.09	0.86	
61.946	0	43	40.81	371	52.31	32.47	4.09	0.86	
62.533	0	43	38.03	374	52.41	30.47	4.09	0.87	
63.093	0	43	34.69	380	52.53	28.09	4.09	0.86	
63.677	0	43	32.06	383	52.63	26.09	4.1	0.86	
63.756	0	43	32.06	383	52.63	26.09	4.1	0.86	
64.25	0	43	28.13	389	52.78	23.06	4.09	0.87	
64.83	0	42	26.66	391	52.84	21.94	4.09	0.86	
65.381	0	42	24.78	393	52.94	20.47	4.09	0.87	
65.949	0	42	23.94	395	52.97	19.81	4.09	0.86	
66.533	0	42	22.81	396	53	18.91	4.09	0.86	
67.096	0	41	22.31	397	53	18.5	4.1	0.87	
67.674	0	41	20.13	399	53.09	16.75	4.1	0.87	
67.736	0	41	20.13	399	53.09	16.75	4.1	0.87	
68.196	0	41	17.16	402	53.25	14.31	4.1	0.87	
68.775	0	41	52.16	384	55.5	-29.97	1.02	4.19	
68.822	0	41	52.16	384	55.5	-29.97	1.02	4.19	
69.307	0	41	56.19	364	55.56	-29.78	1.02	4.19	
69.886	0	41	62.59	340	55.59	-29.78	1.03	4.19	
70.458	0	41	75	311	55.63	-29.72	1.04	4.19	
71.019	0	42	89.75	280	55.5	-27.53	1.02	4.19	
71.581	0	42	89.97	253	55.34	-24.25	1.02	4.19	
72.159	0	43	90	225	55.19	-20.72	1.01	4.19	
72.75	0	44	90.06	198	55	-17.16	1	4.19	
72.787	0	44	90.06	198	55	-17.16	1	4.19	
73.299	0	45	90	169	54.81	-13.37	1.02	4.19	
73.843	0	46	0	164	54.22	0	1.02	4.19	
73.874	0	46	0	164	54.22	0	1.02	4.19	
74.408	0	46	0	164	54.22	0	1.01	4.19	
74.949	0	46	0	163	54.19	0	1.02	4.19	
75.524	0	46	0	163	54.19	0	1.01	4.19	
76.065	0	46	0	159	54.19	0	1.01	3.5	
76.644	0	46	0	157	54.22	0	1.01	0.87	
77.193	0	45	0	155	54.19	0	1.01	0.87	
77.769	0	45	0	152	54.22	0	1.02	0.87	
77.815	0	45	0	152	54.22	0	1.02	0.87	
78.298	0	44	0	153	54.22	0	1.01	0.87	
78.858	0	44	0	155	54.22	0	1.01	0.87	
78.905	0	44	0	155	54.22	0	1.01	0.87	
79.422	0	44	0	153	54.22	0	1.01	0.87	
79.975	0	44	0	151	54.22	0	1.01	0.87	
80.526	0	43	0	149	54.22	0	1.01	0.87	
81.076	0	43	0	150	54.22	0	1.02	0.87	
81.681	0	43	0	152	54.22	0	1.01	0.87	
82.253	0	43	0	143	54.22	0	0.96	0.87	
82.822	0	42	0	125	54.22	0	0.96	0.87	
82.869	0	42	0	125	54.22	0	0.96	0.87	
83.397	0	42	0	113	54.22	0	0.96	0.87	
83.976	0	42	0	95	54.22	0	0.96	0.87	
84.551	0	42	0	76	54.22	0	0.96	0.87	
85.112	0	42	0	59	54.22	0	0.96	0.87	
85.69	0	41	0	48	54.22	0	0.96	0.87	
85.737	0	41	0	48	54.22	0	0.96	0.87	
86.268	0	41	0.03	37	54.22	0	0.96	0.87	
86.809	0	41	0	24	54.22	0	0.96	0.87	
87.353	0	41	0	10	54.25	0	0.96	0.87	
87.924	0	41	0	10	54.25	0	0.96	0.86	
88.468	0	41	0	10	54.25	0	0.96	0.87	
89.018	0	40	0	10	54.25	0	0.96	0.87	
89.581	0	40	0	0	54.25	0	0.96	0.87	
90.136	0	40	0.03	0	54.25	0	0.95	0.87

Here you can see phase amps of 90 during commanded braking down to a wheel rpm of 169. The next sample still shows braking is being commanded, but phase amps go to zero even though wheel rpm is still 164. This is when it threw the phase over current fault. Wheel rpm decreases at this point by use of friction brakes. Controller temperature is a max of about 46c.

Since I had the laptop outside and already hooked up, I figured I'd try upping the regen phase amps to determine how much higher than 40A I could get before it started throwing faults. I tried 50, and did 4 or 5 full regen braking tests and everything was good. I went to 60a, and also didn't have any faults. I didn't want to push my luck, so I just left it at 60. I then went for a short ride to see if it was still stable.

Everything was good until the very end of the ride. About 2 km from home it faulted again. I didn't check the blink codes because I just assumed it was over current. I power cycled and continued home. The final spot I need regen before getting home I noticed that it got really rough sounding once the bike got under about 20 km/h. It then faulted again, but this time because of the rough braking before faulting I checked the blink code. It wasn't just a normal 2-2 showing up. As I was very close to home, I didn't want to power cycle so I could plug it back in and see the actual fault section.

It turns out it did trip phase over current, but also tripped a hall transition warning. I guess that's what was causing the blink code that wasn't the normal 2-2:

I cleared the faults, and with the PR still connected to the computer I tried running the motor. It instantly showed two hall warnings:

I went to the dashboard screen and turned the wheel by hand slowly. The green and yellow halls were changing state, but the blue one was not. It seems like I've got a problem with the hall sensors in the motor. I assume this is why the braking got rough at around 20 km/h. That's probably around where it switches from sensorless to sensored.

I'm going to send another email to grin and hope they respond.

Regen issue with Phaserunner and GMAC

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