Diagnostic Software

Hi Mik,

had the encoder replaced, but the technician at the shop didn't use any alignment tools. I still have Encodr faults approx once every 25 km, with varying frequency. So Steve Scott suggested the slotted disc might not be positioned correctly in the axial direction, ie not having the proper gaps vis-a-vis mirror and sensor array. Instead of hauling my bike twice more for 300 km in one direction to the same dealer, I'd rather like to take it up myself and get this possible cause corrected. In my view it's a very straightforward task, with the right tools.

By the way it would be a tremendous enhancement for a future firmware version to activate the encoder calibration routine without laptop, by some clever keystroke/brake grip sequence.

Meanwhile I hope to somehow acquire a copy of the diagnostic software tool for the PC.

Will post about progress with this tedious issue,

Rgds from Austria
Wolfgang

Hi X Vectrix,

do I understand you correctly that there is a way to invoke the encoder calibration routine without connecting a PC? This would be very convenient as I wouldn't have to purchase any CanBUS/USB adaptor, and chase after the diagnostic software.

Here's want I want to do: Following a series of Encodr faults despite multiple thorough cleaning, I had a new encoder installed at a dealership. However I still get occasisional Encodr faults. According to Steve Scott's advice, the slotted disc might not be properly positioned on the split motor shaft, relative to the mirror-sensor bracket, ie in the a x i a l direction. The r o t a t i o n a l offset of the disc relative to the permanent poles of the motor's rotor has certainly been correctly set on the motor controller, as you pointed out (or else I wouldn't be able to drive at all). What was missing during the installation of the new encoder, are the proper tools for achieving the right gap between disc and mirror, or sensor array, respectively. I imagine that the disc should be positioned exactly in the focal plane of the optics.

From my experience troubleshooting servo drives on machine tools I know there might indeed be other causes. But before I invest more time and money, to remove the rear battery, exchange the motor controller board, the cable to the encoder, or even the whole rear swing arm with motor, I think I should first exclude the more simple points, such as a bad encoder disc seat.

I therefore plan to get those spacers/alignment tool(s) necessary, then loosen the encoder disc and shift it to its correct position on the split shaft. Inevitably I will lose the rotational position in the process. So if you know a way to run the encoder calibration without PC attached, please let me know. This would spare me a lot of trouble.

By the way do you know the type/make/part number of the plastic connector with the crimped contacts, to the encoder board? I might as well replace it just to make sure there is no bad contact on any of the wires.

Regards
Wolfgang

Thanks X Vectrix and Mik,

from your post of post of Mon, 08/17/2009 - 05:23 I gather that I need a shim 0.134" = 3.4 mm thick. I'm traveling this week but when I return on Friday I'll try to carefully check this distance by means of a caliper.

Mik, could you provide a drawing of the tool necessary for positioning the encoder PCB? I can imagine that it must be set at a certain radial distance from the motor shaft, to align its optical sensor array with the tracks on the slotted disc.

Rgds
Wolfgang

Today I carefully measured the distance between the slotted disk and the bottom of the motor&gear casing, using one of my old-fashioned "analogue" calipers. I arrived at a distance of 3.2 mm from the top of the slotted disk to the bottom. Assuming a thickness of 0.1 mm (which I couldn't measure), this would mean 3.1 mm of spacing. This is 0.304 mm too little, according to your shim of 0.134".

Even though this doesn't seem much off, I would like to shift the disc by 0.3 mm towards the end of the motor shaft. It might just be feasible to mark the disk, block the rear wheel, then loosen the split shaft and shift the disc while conserving its readout. However, without diagnostic software it would be quite a gamble (how would I manage to drag a dead bike onto a trailer?). There could be some clearance in the planetary gear, and I might rotate the motor a bit even when the rear brake is tight.

So, anyone out there ready to share the diagnostic software with me? Please give me a message on this board or e-mail (see above). I'd greatly appreciate your help.

By the way, I pulled not so gently on each of the wires in search of loose contacts but found none.

I have a faint memory that a "magic sequence" to initiate the encoder auto-setting routine on the scooter had once been described in an early post in this forum some years ago, but I couldn't locate it and it might just be wishful thinking.

Anyways, thanks to a helpful fellow Vectrix fan, I now have access to the diagnostic software 2.1. Next, I'll mail order the PEARL canbus/usb adapter, and also I'll fabricate or try to obtain both tools (radial alignment and axial shim) necessary.

As the dealer's technician didn't employ any of those while replacing my encoder board and disc, I have high hope that I'll be able to adjusting things by myself and get rid of my Encodr faults.

Rgds
Wolfgang

Yeah of course that's what I'm able to do, since today (24 h after ordering) I received the PEAK canbus adapter PCAN-USB IPEH-002021 and cable PCAN-Kabel 1 IPEK-003000 directly from http://www.peak-system.com/Home.59.0.html for € 262,99 incl sales tax and shipping.

It would however be much more interesting to invoke the encoder setting procedure without diagnostic software, just by pressing certain switches/levers on the bike (aka "magic sequence"). Anyway I suggest to add this feature to a future firmware version.

As soon as I have made or obtained some tools I'll try to improve my encoder situation.

Rgds
Wolfgang

Tonight I serviced my encoder. So far I have a good feeling, but it's yet untested on the road. I'll report in more detail tomorrow.
Wolfgang