Motor Controller wont update

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eyeinthesky's picture
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I blew a IBTs (PM300CLA060)and thought I might try to replace it with a new one at $400.
After instalation, I jacked up the wheel and switched on the bike, calibrated encoder, then it seemed to accelerate when I turned the throttle.
but no reverse, it was a bit chuncky so proceeded to reload MC firmwware.
but it refused to load and wanted to dump algorithym, did that! now MC box turned red scooter diag stops working each time I try to load.
does anyone know if I have/need to get a factory reset, if so, Where? or can I get around it.
Failing that I NEED ANOTHER MOTOR CONTROLLER
Peter from Tasmania

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slbaker's picture
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Re: Motor Controller wont update

I had a similar problem (see my post on "My Vectrix is now a doorstop (failed firmware update attempt)").
Once the MC firmware is in this state (no flash-resident boot loader) it is no longer possible to load firmware over the CAN bus using the scooterdiag software.
The only way to re-load the firmware at this point is by using the JTAG programming port. I am planning to attempt this, but to do so I need:

a) a JTAG programmer
b) the MC firmware from Vectrix in .out format (.hex format does not work for JTAG programming)

I am still waiting on Vectrix service support to respond to my request for the MC firmware in .out format.
Keep and eye on my "doorstop" post for updates on my progress.

Regards,
Scott

Drew's picture
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Re: Motor Controller wont update

Scott - keep badgering Vectrix won't you? This is something that would be sooooooooo useful to a number of vectrix owners. I think I have access to a JTAG programmer at work - and you'll be the first person I've heard of to successfully re-flash the firmware if you can get the right .out files. If you do get the file, I'd love a copy.

Best wishes - here's to non-doorstep status!
Drew

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Re: Motor Controller wont update

Scott, I've just had another quick look this morning and it might be possible here http://emulators.spectrumdigital.com/utilities/sdxmlgui/Readme_dsk6000_v1.1.pdf
If you look at section 4.2.1 it says the following....

Converting .hex to .out file: The utility AsciiHexLib.exe is used to convert .hex
to .out. This utility is located in our main working directory (See Section 9). Put
post.hex into your main working directory. Point the command window to that
directory and type in
AsciiHexlib -hex post.hex -out posttarget.out
Now point your flash program data file to this directory from the SDXMLGUI
application. This bootable .out file can be programmed into Flash so that the board will
boot it and run POST example in standalone mode when it is powered up independently
of the debug environment.

I haven't looked to see if the AsciiHexLib.exe software is freeware or licensed but it's a start. At least it confirms (if nothing else) that it should be possible!
Best wishes, Drew

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Re: Motor Controller wont update

eyeinthesky wrote:

I blew a IBTs (PM300CLA060)and thought I might try to replace it with a new one at $400.
After instalation, I jacked up the wheel and switched on the bike, calibrated encoder, then it seemed to accelerate when I turned the throttle.
but no reverse, it was a bit chuncky so proceeded to reload MC firmwware.

If the wheel turns but is choppy, it usually means a lost phase

If the IGBT connections are good, the next place to look would be the opto-couplers between the gate drivers and the processor

given the original IBTs failed, there may be other SMD parts on the logic side that may have failed aswell

Matt

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Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah
Vectrix 60Ah Lithium Tyres Fuel Registration Insurance cycle analyst replacement TC Charger
conversion
Spent so far: $5800 + $7000 + $1720 + $960 + $320 + $720 + $140 + $600
Cost to do it again: $2500 + $5600 + $1720 + $960 + $320 + $720 + $140 + $600
Cost for a Petrol bike:$6000 + + $1440 + $6000 + $800 + $1400 + $3200 servicing
Total spent: $17260
Total to do again: $12560
Total to have used a petrol bike: $18840
Total distance travelled so far: 79'120km

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Re: Motor Controller wont update

oops, for a moment there I thought the TI microprocessor was what had failed and was replaced

given there is a new IGBT installed, a failed opto is still the next step

another possibility is one of the 4 x 15v powersupplies for the IGBT have failed

until the Jtag process works, replacing the microprocessor may be necessary

Matt

__________________

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah
Vectrix 60Ah Lithium Tyres Fuel Registration Insurance cycle analyst replacement TC Charger
conversion
Spent so far: $5800 + $7000 + $1720 + $960 + $320 + $720 + $140 + $600
Cost to do it again: $2500 + $5600 + $1720 + $960 + $320 + $720 + $140 + $600
Cost for a Petrol bike:$6000 + + $1440 + $6000 + $800 + $1400 + $3200 servicing
Total spent: $17260
Total to do again: $12560
Total to have used a petrol bike: $18840
Total distance travelled so far: 79'120km

eyeinthesky's picture
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Re: Motor Controller wont update

Change the MC board today,(transfered IGBT)
First thing, the BC and MC are green in the Scooter diag.
I was able the update the BC firmware, the MC has already got the
version I wanted, (not game to reload it again just yet)
Encoder didnt move the wheel, just the speedo needle to 100 four times
Bad news is even thou I have the GO sign, no motor movement, still dead,
no regen braking so its not IGBT
It's like accelerator isnt connected, looks like Its comming out again.
Any clues as to what I can check Matt?
Are you able to test/diagnose/repair the Board yourself if, I send it over Matt?
I will pay you.
Regards Peter

eyeinthesky's picture
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Re: Motor Controller wont update

Another quirky thing, during charge,temp started at 39 dropped later to 36, then up to 44 in 1/2 hr
Bat light stays on, (just changed out two swollen cells day earlier) all temp connectors are in place
All tight, cause I rechecked. if MC still faulty, might be a clue.
Soldering skills are good but when talking electronic components pictures would help.
I was a mechanical fitter now an aerial photographer, forced into electon drive repair.
still learning basic stuff,

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Re: Motor Controller wont update

eyeinthesky wrote:

Encoder didnt move the wheel, just the speedo needle to 100 four times
Bad news is even thou I have the GO sign, no motor movement, still dead,

The wheel barely moves during the encoder calibration process

You do have to turn the power off and on again for the calibration to save, it doesn't work straight away.

I would also see if the MC will pass the motor rotate test:

hold accelerator to full while holding the left brake on, and turn the bike on

The wheel should rotate slowly

If it does that, it would suggest an issue with the encoder

eyeinthesky wrote:

It's like accelerator isnt connected, looks like Its comming out again.

when you have the kill switch on with left brake held
what does the speedo show?
does it change when you change throttle position?

If so, the throttle is working fine
If not, there's your problem

eyeinthesky wrote:

Are you able to test/diagnose/repair the Board yourself if, I send it over Matt?

I can put it in a friends spare Vectrix and see what it does

He's much more skilled and better equipped than I at MC board repair, together we could probably get to the bottom of it

Try the easy tests first before sending it off to me
It may be a few weeks before we can work on your board, but may have another good one ready to ship before then

Matt

__________________

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah
Vectrix 60Ah Lithium Tyres Fuel Registration Insurance cycle analyst replacement TC Charger
conversion
Spent so far: $5800 + $7000 + $1720 + $960 + $320 + $720 + $140 + $600
Cost to do it again: $2500 + $5600 + $1720 + $960 + $320 + $720 + $140 + $600
Cost for a Petrol bike:$6000 + + $1440 + $6000 + $800 + $1400 + $3200 servicing
Total spent: $17260
Total to do again: $12560
Total to have used a petrol bike: $18840
Total distance travelled so far: 79'120km

eyeinthesky's picture
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Joined: 01/05/2008
Posts:
Points: 122
Re: Motor Controller wont update

Checked the kill switch brake test and that shows needle going to 40odd
checked turning on bike with accel and brake, no go.
Both boards had IGBTs blow as I have opened up IGBTs to check
If you Mat or anyone out there has a complete working Motor Controller for sale
Please email me "eyeinthesky (add symbol) dodo dodd com dodd au"

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Joined: 10/20/2008
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Points: 369
Re: Motor Controller wont update

I see you are asking for a new/replacement board.
How far did you get with the repair of the old one

Has matt looked at it ?

PM me if necessary.

Cheers

Chris

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