18 fet lyen controller regen issues SOLVED!!

[Ebikebert]

I was finally able to use this controller for the first time this morning. It was fantastic! Incredible power (The front tire was rarely on the ground). However, I noticed when I needed to slow down the regenerative braking was not working. I have checked and did a continuity test on the GND and BK on the board and they are in fact joined together with the included regen jumper wires lyen attached to the controller. This controller is brand new and has never been wired incorrectly, it has run great from the start minus the regen. When I press on the momentary switch that is connected to the e-brake it cuts out the power to the motor and I do hear a very slight regen sound. This sound is absent when the jumper wire is disconnected. If there is any regen it must be incredibly small because the Cycle Analyst picks up no regen amperage and there seems to be no actual slowing down of the hub motor. I ran a test where I would go at a moderate speed both static and myself actually riding the bike around (20-30 mph) to see if the regen would pick up there but it did not. I am not sure what else to do. I need this regen function to work otherwise my build has almost no stopping power at high speeds. I have attached two pictures of where the white jumper leads run to and the continuity test shows they are connected. I have confirmed with lyen that the wires are connected correctly however he has not given me a solution to my problem. Anybody's help would be greatly appreciated. Thanks.

 

[Nobuo]

My question will sound quite dumb, but just in case, did you tried controller regen without the CA connected?

 

[Ebikebert]

I have not tried it without the CA connected.

 

[teklektik]

Please read these sections of the V3 Unofficial Guide relating to ebrake hookup:

• "3.4 Important Conflicts with Controller Features"
• "5.3 eBrakes"

Also, see this post for a summary of Xie Chang (Infineon) controller Regen modes, wiring, and configuration.

 

[Ebikebert]

I just tested and the miniscule amount of regen noise (with no opposing torque) is the same with the cycle analyst connected and disconnected. Will still read the articles.

 

[Ebikebert]

It was interesting reading on the various new features of the v3 CA. However, I have a 2.25 version of the analyst that has none of these features. I think the problem is that lyen forgot to program the controller with the correct regen voltage when he shipped the controller out to me. Please correct me if i'm wrong.

 

[teklektik]

My mistake. The remarks about disconnecting the CA made me jump to the conclusion that you had a V3 - since unlike the V3, the V2 has no ebrake connections and not only cannot affect regen but has no ebrake functionality at all. The referenced V3 Guide sections were to ensure you had that feature properly wired, which is a little custom when using controller regen.

The last referenced post mentions two relevant controller settings - Regen Voltage and EBS Level. You are correct - either may require adjustment and there are no means to read the present settings. You will need to program the whole kit and kaboodle to get those two parameters set as you desire.

 

[Ebikebert]

Im guessing the regen voltage should be the same as charging voltage? I am not familiar with EBS level can you tell me what that is? Could you guide me to where I can download the software to program. Thank you very much for your help.

 

[wesnewell]

The LVC has to be set properly for the battery pack used for regen to work on my controllers.With LVC at 61V, regen won't work above 78V. So when I went to 24s lipo I had to change the LVC to 84V to get it to work.

 

[kiwiev]

I have the same problem the most regen I get is 7watt Lyen is helpful and he did program the controller for my 22 cell headway pack I think the problem is my pack only goes from 72.9 volts full to around 70 volts when I have used 10Ah or BMS cuts ignition wire. So there isn't much voltage difference.
I haven't ridden another bike to compare and don't really know what it feels like but there isn't much braking. :?

 

[Bigbikebob]

I have the same problem, I see that some of you talk about the connection between battery voltage, charger voltage and regen voltage.

My battery voltage is 52.3V after it has been charged with a 58.4V 5A charger. the cutoff charge voltage of the battery is 62.4V

At the lyen softwere I see 3 options for regen voltage 55V,60V and 75V

Now if I choose the 55 option it will be below the charge voltage and nothing will happen?
If I choose 75V I guess my battery will just cutoff?

if I go with the 60V option it should work? and what will be the theoretical difference between 60V and 61V in regards to the regen power?

 

[kiwiev]

Surely

Some of the ES members have had success with Regen or are we expecting too much?

Cheers

 

[RideTheLine]

I ran my ebrake connections (hall sensors mounted on my brake levers) directly to lyens controller. When I pull the brake a little (the discs don't even engage) I have seen up to -650watts when I'm over 20mph which slows me down in a rush! decreasing to maybe 100w @ 5mph

I ran my ebrake button (on the twist throttle) directly to my CA V3, which shows a depressed brake lever on the screen when the button is depressed and cuts out the motor like a kill switch. But I have yet to trigger regen through the CA.. I haven't spent much time working it out though...

I think the sound your hearing is cogging.

I haven't touched v2.25 so I don't have much info for you.
Maybe its the type of switch? Is it wired through CA? Can you post a wiring diagram?

 

[kiwiev]

What batteries are you running? Ed lyen said you need a big voltage drop to kick in Regen I have e brake lever above rear brake lever which kills the motor doesn't do much more.

 

[Ebikebert]

I am almost certain that this is a programming problem. Our regen voltage is not high enough to kick in regen it seems. I have ordered the programming cable yesterday and will report back if I can program the controller and fix this issue. The regen voltage needs to be as high as charging voltage. The reason being if the regen voltage is set below the pack voltage or is the same as pack voltage there is no potential for current to flow. There always has to be a difference in voltage in order for current to flow. In this case we want a positive voltage difference in order for current to flow back into the battery pack and achieve deceleration as a result.

 

[Ebikebert]

I am almost certain that this is a programming problem. Our regen voltage is not high enough to kick in regen it seems. I have ordered the programming cable yesterday and will report back if I can program the controller and fix this issue. The regen voltage needs to be as high as charging voltage. The reason being if the regen voltage is set below the pack voltage or is the same as pack voltage there is no potential for current to flow. There always has to be a difference in voltage in order for current to flow. In this case we want a positive voltage difference in order for current to flow back into the battery pack and achieve deceleration as a result.

It was in fact a programming issue. The changed parameters i did that made the difference were the regen voltage which went from 60v to 75v. The ebs was changed from 0 (low regen) to 2 (high regen). The regen is now very powerful while doing a static test holding the bike up off the ground. I will report back on an actual ride once it stops raining.

 

[Ebikebert]

Lyen helped me with these formulas for programming the low voltage cutoff and regen voltage.


The low voltage cutoff formula for your high voltage controller (24s). Program LVC = real (LVC + 2) x 0.75. For example, real LVC for 24S lipo is 67.2 (24 x 2.8, then program LVC = (67.2+2)x 0.75 = 51.9. The maximum program regen voltage formula is (real regen x 0.75). Therefore, you should set the regen to 75V in the program for 100V actual (real world) regen voltage.

Regards,
Edward Lyen