Cycle Analyst V3 preview and first beta release

This no boot-up bug happened to me for the first time today. Kind of freaked me out there for a second.. but reboot it worked fine right away. Ironically, this happened when I stopped at the hardware store today and parked the bike in the sun in the parking lot for the first time, really.

also I'm finding my Top speed spikes most rides...PreLim5. Think I read something somewhere that this was being fixed.

maybe not the CA to fault.. but it seems when I turn on the bike (main pack to kellys, CA on, then kellys on), it takes a while before I get full throttle range from the CA. Using a magura with a range restrictor resistor. Pass thru mode.
 
hillzofvalp said:
This no boot-up bug happened to me for the first time today. Kind of freaked me out there for a second.. but reboot it worked fine right away. Ironically, this happened when I stopped at the hardware store today and parked the bike in the sun in the parking lot for the first time, really.

also I'm finding my Top speed spikes most rides...PreLim5. Think I read something somewhere that this was being fixed.

The only two problems I have with it currently...
 
I had a little trouble getting Grin's PAS ring and sensor installed correctly, and since there is not yet any documentation available on correct installation of the PAS disk and sensor I would like to share what I learned.

At first I installed the sensor so that it was tangent and at an angle to the working side of the PAS disk.

DSC04375.jpg

I was getting no pickup signal. After some consultation with Justin L-E at Grin, I learned that the sensor must be perpendicular to the disk, not tangential. I also discovered that the sensor does best when the pickup end (opposite the red LED) is close to parallel to the disk surface. Confirmation of correct installation is given by the red LED flashing twice for each magnet that passes in front of the sensor when pedaling forward.

DSC04476.jpg
 
Help. My CAV3 gives me strange readings when using prelim6. I get normal readings when flashing to Cab319. I've been trying to email Ebikes but I'm not really getting a response except for asking what hardware was sent to me. I was mailed the hardware a few weeks ago. I really want to get this up and running but they don't respond to my emails anymore. I thought they had a reputation for responding in a timely manner.
 
Mackerel said:
I've been trying to email Ebikes but I'm not really getting a response except for asking what hardware was sent to me. I was mailed the hardware a few weeks ago. I really want to get this up and running but they don't respond to my emails anymore. I thought they had a reputation for responding in a timely manner.
Well, gee - it sounds like they did respond and were trying to get details of the installation. But - let's move on from your unhappiness with Grin Tech...

Mackerel said:
Help. My CAV3 gives me strange readings when using prelim6. I get normal readings when flashing to Cab319.
So - here's some questions to try to clarify the situation:
  1. Which readings in particular are strange, what are the strange values, and under what circumstances does the strangeness happen?
  2. Did you install and setup the CA by following all the steps in the Guide?
  3. How is your CA connected to the controller and is this a Grin Tech, EM3EV, or Lyen controller?
  4. Did you do a Zero Amps calibration?
  5. Are you running in normal or legacy mode?
  6. Are these strange readings apparent using the basic configuration for basic setup in the Guide or have you configured other options?
  7. Please post back with these Calibration values under Prelim6: Cal->Range, Cal->RShunt, Cal->VScale
 
1. Voltage displays at 4x what it should be (330 volts, with Cab319 it displays 80 volts)
3. Lyen controller
4. Yes
5. normal
6. Strange readings come without any modifications.
7. RShunt value is zero. When I enter the controller shunt value it defaults back to zero, not saving the entered value. Will post other values when I get off of work.
 
Mackerel said:
1. Voltage displays at 4x what it should be (330 volts instead of 80)
2. Guide was followed to the letter
3. Lyen controller
4. Yes
5. normal
6. Strange readings come without any modifications.
7. RShunt value is zero. When I enter the controller shunt value it defaults back to zero, not saving the entered value. Will post other values when I get off of work.
Okay - good stuff - With a recent Lyen controller your 'normal' hookup should have simply required plugging the CA into the controller to get normal mode, so wiring issues are pretty much off the table (assuming no external shunt). Doing the Guide setup is good - so the many config parameters are probably fine as well. Bad behavior with only basic setup rules out fancy interactions of advanced features.

The 4x voltage suggests the factory calibration of VScale is wrong and the inability to set RShunt seems to indicate that you have a wonky RShunt value in memory that is giving the firmware a hissy fit. So - you seem to have corrupted calibration values in EEPROM - these are not initialized when you flash Prelim 6 and can only be reset by flashing B19. You did mention running B19 and that it worked (which is confusing), but let's give that another go...

Please flash B19, then without doing any setup, flash 3.0Prelim 6 immediately on top of it. This should load the unit with 'Good' calibration values from B19 and then plop working Prelim 6 firmware around those values without altering them. A quick check should show the Rshunt to be 1.000 mOhm and VScale to be 31.05 V/V. If so, you should be good to set RShunt, do a Zero Amps calibration, then reconfigure everything else normally. Please advise how this works out.
 
I have now installed and tested both of my hybrid-electric bikes with the latest CAV3 (prelim6). I have also added PAS options to both of these bikes and would like to share my observations.

Bike 1 is a modified Easy Racer's Gold Rush. Motor power is added at the crank, and the chainrings are mounted on a freewheel (J&B's IPS crank, stoker's model). The bottom bracket (BB) is a Thun X-Cell RT that is wired directly to the CA.
http://mrbill.homeip.net/hybridBike.php#power_gold_rush_build

Bike 2 is a modified Rotator (now-defunct) Pursuit. Motor power is added at a mid-drive. Due to the required long spindle on this bike I was unable to use Thun BB, but I was able to install a PAS ring and sensor from Grin.
http://mrbill.homeip.net/hybridBike.php#power_pursuit_build

Both bikes use a modified BMC "600 watt" motor, externally controlled, similar to the PowerPack motor and the Lyen 12FET3077MK2 controller run between 22 and 30 volts. Both bikes have installed an Aux Pot that adjusts PAS Level when either bike is in one of the PAS modes.

On both bikes the CAV3 has been set with the following relevant parameters:

ThrI->CntrlMode = "Pass-thru"
ThrI->AutoCruis = "3 Sec"
ThrI->CruiseHld = 0.10 Volts

ThrO->UpRate = 2.00 V/sec
ThrO->FastRate = 5.00 V/sec
ThrO->DownRate = 5.00 V/sec
ThrO->FastThrsh = 2.00 Amps

SLim->MaxSpeed = 35 mph
SLim->StrtSpeed = 0.0 mph
SLim->IntSGain = 200
SLim->PSGain = 0.85 V/mph
SLim->DSGain = 200

PLim->MaxCurrent = 45 Amps
PLim->AGain = 50
PLim->MaxPower = 1000 watts
PLim->WGain = 50

PAS->PASPoles = 8 (on Gold Rush with Thun BB)
PAS->PASPoles = 12 (on Pursuit with Grin 12-pole PAS ring)
PAS->PASWatts = 1000 watts (when using "AutoPAS")
PAS->MaxThrotSpd = 99.0 mph

Gold Rush Trq Sensor Settings:
Trq->SensorType = "Thun BB"
Trq->TrqScale = -200.0 Nm/V
Trq->TrqOffst = 2.44 2.44 V
Trq->AsstFactr = 8.00 Times
Trq->AsstStart = +065 Watts
Trq->AsstAvg = 16

Pursuit Trq Sensor Settings:
Trq->SensorType = "Custom"
Trq->TrqScale = 35.7 Nm/V
Trq->TrqOffst = 0.00 4.87 V
Trq->AsstFactr = 1.00 Times
Trq->AsstStart = +0 Watts
Trq->AsstAvg = 12

Aux->Function = "Limits"
Aux->ScaleLim = "PAS Level"

On the Gold Rush the TorqPAS mode works nicely. There is a bit of delay between initiation of pedaling effort and application of motor power. Likewise there is a short overhang of motor power after pedaling effort has ceased. The delay is about one crank rotation or one second. It would be nice to reduce this delay/overhang, but the mode is still usable. Using TorqPAS the motor amplifies pedaling effort. This leads to the rider getting a good workout, since slacking off pedaling results in less motor power and lower speed. So, the rider is encouraged to keep up the pedaling effort.

On the Pursuit and Gold Rush the AutoPAS mode works well, too. There is a short delay/overhang, about half a second or so. Motor power is constant when applied, as long as the cranks are turning, even if they're being "soft-pedaled". This aspect makes it easier to ride in a manner where motor power complements human power rather than amplifies it.

On the Pursuit I also tried the "AutoTorqPAS" mode. This mode worked, but I found the delay/overhang of applied power to be on the order of two seconds. Also, as I increased my cadence (pedaling RPM) power increased, but this rate of increase exhibited a similar delay, about two seconds. Overall I found the behavior to be over-damped, but I found no way to change this with the CAV3 parameter settings. Also, because I set up the Torque Sensor on the Pursuit as a virtual sensor, I get spurious "human watts" reading of around 1350 watts. Not a big deal since I can suppress display of the "human watts" screen.

In all cases I retained use of the throttle. I still find throttle use necessary when starting from a stop, especially when starting on a hill, and when pulling out of high-speed sweeping corners since counter-steer on my long wheelbase bikes is less effective (or more dangerous if the road surface grip is poor) under these conditions.

Initial indications are that riding in any PAS mode is slightly less efficient than smart use of the throttle-only mode. Energy loss can occur when slowing on flat terrain as before a traffic signal or on downhills on which I might soft-pedal to keep my legs moving while the motor works lightly or free-spins in PAS mode. This consumes power that doesn't contribute meaningfully to forward progress. I can dial down the Aux Pot to avoid this waste, but the appeal of PAS is not to have to manage motor control explicitly, to make it an extension of my pedaling.

Of the PAS modes I have a slight preference for AutoPAS. I like the complementarity of human power and motor power. It fits better with the way I like to ride, to be able to ease up on pedaling and have the motor take up the slack, for example, when I'm trying to snap a photo from a moving bike while I minimize my own body motion.

The TorqPAS mode on the Gold Rush makes for a good workout, and it's nice to have motor power reflect true pedaling effort, either when spinning fast or when grinding slowly. Use of the TorqPAS mode leads to a more intense physical workout since one's incentive is to pedal as hard as possible to maintain the highest forward speed, and speed is fun.

I might like AutoTorqPAS mode better if the long delay/overhang could be shortened. Perhaps there is a parameter combination I did not consider--suggestions are welcome--or perhaps this mode and an appropriate gain parameter or two could be added to a future CAV3 firmware release.

I don't want to forget to mention that the Auto Cruise function appears to be working well and as expected. I no longer have difficulty holding the thumb throttle steady while the cruise control circuit locks.
 
mrbill said:
On both bikes the CAV3 has been set with the following relevant parameters:

ThrO->UpRate = 2.00 V/sec
ThrO->FastRate = 5.00 V/sec
ThrO->DownRate = 5.00 V/sec
ThrO->FastThrsh = 2.00 Amps

Gold Rush Trq Sensor Settings:
...
Trq->AsstAvg = 16

Pursuit Trq Sensor Settings:
...
Trq->AsstAvg = 12

...
On the Gold Rush the TorqPAS mode works nicely. There is a bit of delay between initiation of pedaling effort and application of motor power. Likewise there is a short overhang of motor power after pedaling effort has ceased. The delay is about one crank rotation or one second. It would be nice to reduce this delay/overhang, but the mode is still usable.
...
On the Pursuit I also tried the "AutoTorqPAS" mode. This mode worked, but I found the delay/overhang of applied power to be on the order of two seconds. Also, as I increased my cadence (pedaling RPM) power increased, but this rate of increase exhibited a similar delay, about two seconds. Overall I found the behavior to be over-damped, but I found no way to change this with the CAV3 parameter settings.
...
I might like AutoTorqPAS mode better if the long delay/overhang could be shortened. Perhaps there is a parameter combination I did not consider--suggestions are welcome--or perhaps this mode and an appropriate gain parameter or two could be added to a future CAV3 firmware release.
Regarding delays in power increase for AutoTorqPAS and TorqPAS:

justin_le said:
3) There is an additional option to set the averaging of the torque sensor when running in torque assist mode. So if you have say a THUN sensor with 8 PAS poles, you could set the averaging to 8, 16, or 24, depending on if you want to average over the last 1, 2, or 3 full pedal rotations. Averaging over 3 rotations will naturally be the smoothest, but then also a bit slower to respond to changes in your pedal force. If you are just starting to pedal from a stop, then it ... is consistently responsive and unaffected by the longer average.
For AutoTorqPAS, please try reducing Trq->AsstAvg to 1.0 - since the virtual torque is constant, there is no need to average it. As it is set now (12), it requires an entire crank rotation for the full effect of power changes to be felt - My Bad - this is in the draft of the next Guide version, but not yet published.
  • EDIT - Actually this shouldn't have an effect - reducing this to 1 affects the time the adjustment takes effect when using a pot on the TRQ input so you can dial in a power level and see the effect immediately on the screen - I see you are using Aux Pot to control torque instead.
A lesser reduction for TorqPAS mode might also be worth some experiments to see if you can find a better balance of responsiveness and smoothness.

I would recommend increasing ThrO->DownRate to 20.0 V/s or more to minimize shutdown delays across the board.

The PAS start/stop thresholds have a noticeable effect on the startup/shutdown times and might be worth a little tinkering...

These modes rely on Watts limiting, so WGain controls the responsiveness (see limit flags), but your setting is already fairly high and shouldn't be slowing things down. However, you might try switching to Current throttle, increasing the up ramping V/sec values to get them a little more out of the picture, then using AGain to get the desired throttle response and WGain to control the PAS response. ...Just a thought...

Anyhow - some things to try ... :D
 
teklektik said:
For AutoTorqPAS, please try reducing Trq->AsstAvg to 1.0 - since the virtual torque is constant, there is no need to average it. As it is set now (12), it requires an entire crank rotation for the full effect of power changes to be felt - My Bad - this is in the draft of the next Guide version, but not yet published.
  • EDIT - Actually this shouldn't have an effect - reducing this to 1 affects the time the adjustment takes effect when using a pot on the TRQ input so you can dial in a power level and see the effect immediately on the screen - I see you are using Aux Pot to control torque instead.
A lesser reduction for TorqPAS mode might also be worth some experiments to see if you can find a better balance of responsiveness and smoothness.

I set Trq->AsstAvg to 1 on the Pursuit, where I'm using "AutoTorqPAS" mode. As you thought, the change had no effect.

teklektik said:
I would recommend increasing ThrO->DownRate to 20.0 V/s or more to minimize shutdown delays across the board.

I set ThrO->DownRate to 50.00 V/sec. This had the effect of increasing the slope of the down rate ramp, but not of shortening the overhang.

teklektik said:
The PAS start/stop thresholds have a noticeable effect on the startup/shutdown times and might be worth a little tinkering...

I spent quite a bit of time settling on +65 watts as the start threshold. Lower power led to spurious "surging" when soft-pedaling--the Thun BB sensor indicates brief spikes of power often when soft-pedaling or when spinning the cranks under no load--, and higher power increased the start delay too much. I still get an occasional surge of power when soft-pedaling or when not intending to add power, but these incidents are infrequent enough that I can live with them.

Side note: Setting the Aux Pot to 0% in any PAS mode does not completely shut off PAS-mediated motor power. I do occasionally see the motor spinning unloaded and occasionally get surging. I would call this a bug, since setting the pot to 0% should effectively turn off the selected PAS mode.

teklektik said:
These modes rely on Watts limiting, so WGain controls the responsiveness (see limit flags), but your setting is already fairly high and shouldn't be slowing things down. However, you might try switching to Current throttle, increasing the up ramping V/sec values to get them a little more out of the picture, then using AGain to get the desired throttle response and WGain to control the PAS response. ...Just a thought...

I tried lowering AGain but found throttle and PAS response to be damped too much. I tried raising both AGain and WGain, but this lead to too much drivetrain "slam" and underdamped initial power application. These along with the Speed gain parameters were set according to your Unofficial User Guide--thank you for this effort, btw--, and I think they're pretty well dialed in for this motor/controller/drivetrain/bike.

On the Gold Rush I started with Trq->AsstAvg = 8, but I found this caused the motor power to surge with pedaling force too much. I prefer smoother motor power delivery and went with Trq->AsstAvg = 16. In any case, changing the AsstAvg does not seem to affect noticeably the delay/overhang of motor power delivery.

teklektik said:
Anyhow - some things to try ... :D

Thanks for your suggestions. I kept a few of them such as ThrO->DownRate = 50 V/sec when in a PAS mode, but it makes only a slight difference. Maybe I'm just being too fussy. The PAS modes are certainly usable and offer an alternate mode of operation that might work well when riding with others or when wanting to be free from managing a throttle (sort of like an automatic transmission vs. a manual on a car), even if they do end up being slightly less energy efficient overall than manual throttle control.
 
mrbill said:
teklektik said:
Anyhow - some things to try ... :D
Thanks for your suggestions. I kept a few of them ... Maybe I'm just being too fussy.
Well, glad we made a little progress. There are definitely some oddities with PAS, so I don't think you are being too fussy - anyhow - it's good to get feedback of all kinds...

Anyhow, I've had some overrun issues myself but they occurred in very specific circumstances - not as broadly as your experiences. So, here's a couple more thoughts.

First, I am wondering if you are using the CA display as an indication of overrun or the actual sound of the motors. If using the display, it's a good plan to adjust Pref->Averaging = 0.02 sec (short as possible) so there is no delay in the display reflecting the actual readings. This might be worth a try if you haven't already, just to be sure that the actual CA activity is distinct from other mechanical noise cues.

mrbill said:
teklektik said:
The PAS start/stop thresholds have a noticeable effect on the startup/shutdown times and might be worth a little tinkering...
I spent quite a bit of time settling on +65 watts as the start threshold. Lower power led to spurious "surging" when soft-pedaling--the Thun BB sensor indicates brief spikes of power often when soft-pedaling or when spinning the cranks under no load--, and higher power increased the start delay too much. I still get an occasional surge of power when soft-pedaling or when not intending to add power, but these incidents are infrequent enough that I can live with them.
Here we seem to have gotten our wires crossed. I was referring to PAS->StrtThrsh and PAS->StopThrsh, not Trq->AsstStart.

PasStartStopTimes7.png
This start and stop rpm stuff can be a little hard to figure out. The Guide suggests a Start rpm that is lower than the Stop rpm and has a little table of suggested rpms for different pole counts. Actually, the start rpm can be set to higher rpm than the Stop and things will still work. In fact, you can set these all over the place and the PAS will still operate although certain weirdnesses can crop up in different situations. So here's the deal: Justin had some ideas about acceptable time delays for determining starting and stopping (0.75s for startup detection and 0.5s for shutdown detection). At the end of the day, these times map into the PAS pole inter-pulse period. The Guide table and CA built-in defaults show the rpms that are required to achieve these suggested inter-pulse delays.

However, after messing with the settings on the bike, I'm not entirely certain that this 'suggested detect period' is a better means to pick good responsive settings than 'rpm as a percentage of cadence' - to a certain extent, it defeats the advantage of having additional magnets on the wheel to get quidker response. On my bike with a 16 magnet PAS wheel I use Start/Stop rpms of 20/24. I have a nominal cadence close to 70, so these rpm settings are tripping the PAS logic at less than 1/3 of normal cadence which seems to give the CA a pretty early cue on shutdown and an acceptable lag in start-up. The start delay on resuming pedaling while rolling is very quick. With a relatively high start rpm setting, there are no false engagements while fiddling the pedals at low or walking speeds.

  • I'm thinking you might try these 20/24 or similar settings instead of the Guide recommendations - this might noticeably shorten your overrun times. You might lower the Start rpm if it seems too demanding, but starting in a sufficiently low gear so initial cadence is high or goosing the throttle on getaway should offset a higher Start setting...
It might be worth noting again that having the Start/Stop values far apart can lead to occasional surging when stopping as minor cadence fluctuations in this 'start/stop overlap region' cause brief detection snafus. The closer these parameters are together, the quicker a rider will transition the hiccup range.

mrbill said:
Side note: Setting the Aux Pot to 0% in any PAS mode does not completely shut off PAS-mediated motor power. I do occasionally see the motor spinning unloaded and occasionally get surging. I would call this a bug, since setting the pot to 0% should effectively turn off the selected PAS mode.
I cannot duplicate this on the bench (my bike isn't wired to be able to try this), but there are certain failure modes that are difficult to achieve with my little simulator thingie. I'm wondering if raising Aux->MinAuxIn a tenth of a volt will help ensure that things are really off in all situations.

mrbill said:
teklektik said:
These modes rely on Watts limiting, ... However, you might try switching to Current throttle, increasing the up ramping V/sec values to get them a little more out of the picture, then using AGain to get the desired throttle response and WGain to control the PAS response. ...Just a thought...
I tried lowering AGain but found throttle and PAS response to be damped too much. I tried raising both AGain and WGain, but this lead to too much drivetrain "slam" and underdamped initial power application. These along with the Speed gain parameters were set according to your Unofficial User Guide--thank you for this effort, btw--, and I think they're pretty well dialed in for this motor/controller/drivetrain/bike.
Okay - I was going after minimizing the ramp times here by taking over some of the damping with the Gain settings. Seems like that didn't work out for you.

So lastly, you have mentioned surging a couple of times - perhaps you can leave the present ramping and AGain in place, but reduce WGain to about 8-10. Since only PAS will be using Watts limiting, this should smooth out the PAS operation and damp PAS power surging. I run with WGain at 8 and others have gone as low as 5 - this is by way of example and may not apply to your build or tastes. This should not affect throttle or any other operation - just make sure your PLim->MaxPower is slightly above current limits (SLim->MaxCurrent) you might incur so the overdamped Watts limiting doesn't come into play in 'throttle mode driving'.
 
teklektik said:
Mackerel said:
1. Voltage displays at 4x what it should be (330 volts instead of 80)
2. Guide was followed to the letter
3. Lyen controller
4. Yes
5. normal
6. Strange readings come without any modifications.
7. RShunt value is zero. When I enter the controller shunt value it defaults back to zero, not saving the entered value. Will post other values when I get off of work.
Okay - good stuff - With a recent Lyen controller your 'normal' hookup should have simply required plugging the CA into the controller to get normal mode, so wiring issues are pretty much off the table (assuming no external shunt). Doing the Guide setup is good - so the many config parameters are probably fine as well. Bad behavior with only basic setup rules out fancy interactions of advanced features.

The 4x voltage suggests the factory calibration of VScale is wrong and the inability to set RShunt seems to indicate that you have a wonky RShunt value in memory that is giving the firmware a hissy fit. So - you seem to have corrupted calibration values in EEPROM - these are not initialized when you flash Prelim 6 and can only be reset by flashing B19. You did mention running B19 and that it worked (which is confusing), but let's give that another go...

Please flash B19, then without doing any setup, flash 3.0Prelim 6 immediately on top of it. This should load the unit with 'Good' calibration values from B19 and then plop working Prelim 6 firmware around those values without altering them. A quick check should show the Rshunt to be 1.000 mOhm and VScale to be 31.05 V/V. If so, you should be good to set RShunt, do a Zero Amps calibration, then reconfigure everything else normally. Please advise how this works out.

Not working so well. Still getting funny readings. Thanks for trying to help out though I appreciate it. Not sure what to do now.
 
Mackerel said:
Not working so well. Still getting funny readings. Thanks for trying to help out though I appreciate it. Not sure what to do now.
  • Were you able to to perform the recommended flash operations successfully?
  • Are you able to properly set RShunt?
  • What RShunt value are you using?
  • What is your VScale setting?
  • What does 'funny readings' mean exactly?
You need to provide details about the symptoms and circumstances of the difficulty or no diagnosis is possible... This is a complicated gadget and no one expects you to be a wizard at it - just tell the tale straight up. :D

Your best bet was and still is going to Grin Tech and getting assist, but they are going to want to know the same stuff so they can come up with a plan. If you can post back and answer the questions above, we can see if your unit appears to be behaving properly. If it's not, you can contact Grin, point them to this exchange in this thread so they can see what you have done to address the situation and the results. This should fill in the blanks enough so they can either offer additional strategies or swap out your unit if it looks wonky.
 
teklektik said:
  • Were you able to to perform the recommended flash operations successfully?
  • Are you able to properly set RShunt?
  • What RShunt value are you using?
  • What is your VScale setting?
  • What does 'funny readings' mean exactly?
You need to provide details about the symptoms and circumstances of the difficulty or no diagnosis is possible... This is a complicated gadget and no one expects you to be a wizard at it - just tell the tale straight up. :D
Flashed correctly
Cannot set RShunt (stays at 0) (Can be set when using Cab319)
RShunt should be 1.000
VScale sets to 31.07 when flashing to cab319
Funny reading = Voltage is off
 
Mackerel said:
Flashed correctly
Cannot set RShunt (stays at 0) (Can be set when using Cab319)
RShunt should be 1.000
VScale sets to 31.07 when flashing to cab319
Funny reading = Voltage is off
Okay. From the wonky RShunt reading it looks like your unit is not well.

The firmware files have some small error detection so they are unlikely to be corrupted (they use checksums - not the best error detection method, but...). As a least resort, I might recommend downloading 3.0p6 again just to be sure, then repeat the v3b19 flash with immediate 3.0p6 flash overlay (don't run v3b19). If the shunt value is not 1.0 by default in p6 (you shouldn't have to set anything) then you have a problem.

If so, just email Grin Tech and link them to to the posts here in this thread to describe what's up. Unless they have another test to try, I believe they will replace your unit straightaway - I find they customer support to be outstanding. Sorry you have had a hard time of this, but I'm sure it will be cleared up shortly.
 
Hmmm.... I'm wondering if the difficulty is an outdated downloader app. Are you using the most recent version (1.1) from this page?

Older loaders were incapable of handling new files like v3.0p6 where calibration values are left undisturbed in memory. This seems to fit your present symptoms if VScale is getting clobbered along with RShunt when you flash CA3.0p6 (I can't tell from your response above)...

If you are not using this new loader or are unsure, please grab it up and then try the two CA3B19 + CA3.0P6 flash operations again. If both RShunt and VScale have default values similar to CA3B19 after the final flash, you should be good.
 
I have been installing quite a few Thun BB's, and have found that when you apply force to the left pedal the voltage DROPS and the Torque value RISES.
Also, in Trq -> Asst Start you need a negativ value as a consequence.

SETUP_TRQ_SENSOR-active_display.JPG

Has anyone elso found this to be the case, too?
 
teklektik said:
Hmmm.... I'm wondering if the difficulty is an outdated downloader app. Are you using the most recent version (1.1) from this page?

Older loaders were incapable of handling new files like v3.0p6 where calibration values are left undisturbed in memory. This seems to fit your present symptoms if VScale is getting clobbered along with RShunt when you flash CA3.0p6 (I can't tell from your response above)...

If you are not using this new loader or are unsure, please grab it up and then try the two CA3B19 + CA3.0P6 flash operations again. If both RShunt and VScale have default values similar to CA3B19 after the final flash, you should be good.

I was not using the most recent version. Problem solved. Works now.

Thanks for all the help!
 
electricwheels.de said:
I have been installing quite a few Thun BB's, and have found that when you apply force to the left pedal the voltage DROPS and the Torque value RISES.
Also, in Trq -> Asst Start you need a negativ value as a consequence.

Has anyone elso found this to be the case, too?

I enquired with THUN engineers about this, and they say that when pushing down the left side pedal you get a drop in Voltage (down from the nominal 2.5Volt), as the direction of the shaft turning is counterclockwise.
That means that max torque of (-)200 Nm a Voltage of 0.5V is present.

Teklektik: You state in your operators manual Chapter 6.5.9: 'the max (+) torque is 200Nm at 4.5V'. Was that because you use your simulator and not the THUN sensor itself?
 
electricwheels.de said:
Teklektik: You state in your operators manual Chapter 6.5.9: 'the max (+) torque is 200Nm at 4.5V'. Was that because you use your simulator and not the THUN sensor itself?
The simulator uses a pot to supply the TRQ input, so it's not possible to derive meaningful empirical data about the Thun device.

The Guide information was derived from this table as published in this Thun document:
View attachment 0040_X-CELL_Datenblatt_GB_20120626.pdf
ThunTorqPlot.png
As you can see, the Thun is specified to provide both plus and minus torque values which cause plus and minus voltages relative to the Zero Torque set point (nominally 2.5v). The exact conditions under which these plus/minus voltages arise is not published but may, as you note, have to do with right/left pedal force - I don't know. This is the business of the V3 to handle and it should not be exposed to the user.

As you point out above:

electricwheels.de said:
I have been installing quite a few Thun BB's, and have found that when you apply force to the left pedal the voltage DROPS and the Torque value RISES.
This appears to be the proper action by the V3 - convert the left pedal negative voltage into a positive torque so left and right pedaling have the same effect while hiding the electrical nuances of the Thun device from the user.

  • The Guide struggles to address audiences with vastly different levels of expertise and so the statement you point out is perhaps an inaccurate simplification by way of omission of the negative electrical values. It might more appropriately state: "The Thun output voltage allows the CA to detect pedaling force from 0 to 200Nm." I will make this correction in the next release.
As always - thanks for posting questions and issues - it all (hopefully) helps improve the Guide for others. :D
 
Okay - I normally use the 'Custom' torque sensor setting on the simulator since I can easily set the zero point so turning the 'Torque pot' works nicely. But - I just ran a Thun test with the simulator with a 2.5v zero point and applying a relative negative voltage to the TRQ input results in a negative torque on the Setup preview screen. However, the generated Human Watts reading on the status screen is positive. A positive voltage (torque) results in a negative Human Watts display. Looks like the display is reversed.

My Thun is not mounted up to pursue this, but this may be an artifact of the simulator and non-alternating pedaling behavior - unclear. Viewing the main Watts display shows the left pedal (+Human watts) as contributing but the right pedal (-Human Watts) as ignored. I'll query Justin, but he's off to a bike show and a response may take a bit.

Anyhow - we'll see what's up with this....
 
teklektik said:
Viewing the main Watts display shows the left pedal (+Human watts) as contributing but the right pedal (-Human Watts) as ignored.

To my understanding the torque is only measured when you push your left pedal down. I therefore expected the Voltage to rise (to a max of 4.5V), but no, it drops.
The right pedal I consider 'fixed', as there must be some kind of twist in the axle for it to work.
When I move the left pedal backwards, the Voltage indeed rises (if I keep the right pedal 'fixed').

When you look at table 3 of the Thun Data sheet, the red line run from top right to bottom left - not as it is shown.
And here for a conspiracy theory: Thun has removed both the german and english data sheets from their server, including the links. I pointed this out to their sales manager, but so far they have not been put back. Strange thing, that...

The thing gets interesting when you leave your standard setting Trq->Asst Start +100 Watts. You can pedal until you go blue in the face, it seems to me that pedalling is actually getting harder.
Only when you invert the value to Trq->Asst Start -100 Watts the assist function kicks in as expected.
 
Strange. Booted up the bike today, found that I had left the controllers connected over night (no main contactor, no CA). The CA read -40Ah (despite no voltage change of the 100% SOC battery), indicating flow from the controllers to the CA. The throttle input works, but the throttle output is fixed at the minimum mapped output of .93V. I double checked controllers, they aren't faulting. Looks like something is fried or there is a bug. Thoughts? (I also double checked fault volt setting and throttle in.. all good)

By the way, this CA is about 600 miles past a ground rail jumper procedure from shorting the serial programming cable with something. Another clue is that wheenver I've booted this bike recently, I've had to wait a bit to get full throttle output.. as if I'm charging up a capacitor. Sometimes it helped to reboot the controller a few times. Feels like it's in the CA though.

update: I let it sit for a while, pulled all the fuses on the controller power and other devices. I noticed that it has recovered to a certain point where I can get the CA to output a throttle range.

CA Prelim5 in pass thru mode
1)CA On
2)Contactor On (controller mains)
3)Controller Enable (battery positive)
4)Apply throttle, bike oscillates at really low currents then stops. No controller faults (kellys). CA Throttle Out goes to min (.93V) No flag.
5)Turn off contactor, Throttle out slowly starts to recover to full range .93-3.5.
6)Turn on contactor, throttle out is limited to to set min again (.93V) (pass thru mode)
7) turn on controller, still nothing

BEfore I tear apart my wiring for direct throttle-controller connection I will see if you recommend a CA fix. I don't want to lose my pwoer throttle for eco mode
 
hillzofvalp said:
...Another clue is that wheenver I've booted this bike recently, I've had to wait a bit to get full throttle output.. as if I'm charging up a capacitor. Sometimes it helped to reboot the controller a few times. Feels like it's in the CA though.

Mine does this occasionally too.
Usually happens when i have already ridden the bike, turned it off via Infineon's ignition wire then come back and turn it on via the same method.
 
hi all.

i need an assist in trying to figure out what's going on with my new BB...

about 2 months ago, i got a replacement BB from ebikes.ca, as my THUN BB had failed.
i have only just (today) gotten around to having the LBS install it.

the new BB is made by TDCM.
when ebikes.ca sent it out, i got instructions as below....

"You need to set the PAS to have 12 poles, and you need to set torque scaling somewhere between +50 to +100 N-m/V depending on your particular chainring size.

You'll need to rezero the offset as well.
And if you installed the Prelim6 firmware, set the torq averaging to either 12 or 24."



so, i have re zeroed the offset as instructed. i have set the torque scaling at +65N-m/V set the poles at 12, and averaging at 24.

here's my problem.

as soon as i start to pedal, even with no load, the motor wants to start up. even with the PAS aux limit dial set at zero % assist.
it still wants to take off. if i set the aux dial for power limits, then it will limit the power. but NOT when set as PAS level.

what i really want here, is a setup that will allow me to pedal at around 100-150 watts (human input) and then progressively
assist once i start working harder.

im sure it's a configuration issue somewhere.... it's behaving kind of like RPM PAS, not TRQ PAS.

can anyone here help ?

thanks in advance.

Jason.
 
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