HPM5000B motorcycle application; questions, quandries and quibbles

[Bikemad]

The posted users manual is rather vague about the wiring of the HPC100B controller. They show the unit, a wiring diagram, but, there is no connection to the two.
I'd like an explanation of what plugs in where. The five post plugs, and the multi-pin connector.

Bob, here's my explanation of the connections:
Ref. Page 2 of the User guide.
(Motor wires are shown in bold)

Screw terminal Connections

    B+     Battery Positive/Supply (Heavy duty Red)
    B-     Battery Negative/Ground (Heavy Duty Black)
    U      Motor Phase Wire (Thick Blue)
    V      Motor Phase Wire (Thick Yellow)
    W     Motor Phase Wire (Thick Green)

14 Pin Plug connections
  Pin  1   Battery Positive (Red) Supply (Presumably through a switch)
  Pin  2   Battery Negative (Black) Ground
  Pin  3   Not used
  Pin  4   Not used
  Pin  5   Not used
  Pin  6   Throttle Control Signal Wire (White?)
  Pin  7   Throttle Control 5V supply (Red)
  Pin  8   To Ground via Brake Switch
  Pin  9   To Ground via Fwd/Rev Switch
  Pin 10   Motor Hall Sensor 5V Supply Wire (Thin Red)
  Pin 11   Motor Hall Sensor Wire (Thin Blue)
  Pin 12   Motor Hall Sensor Wire (Thin Yellow)
  Pin 13   Motor Hall Sensor Wire (Thin Green)
  Pin 14   Not used

Both the Throttle Device and Motor Hall Sensor Black leads must also be grounded.

Pin layout

    (1)  (2)  (3)   (4)   (5)

      (6)   (7)   (8)   (9)

   (10) (11) (12) (13) (14)

Plug Part No: 776273-1
Click Here for more details.

Hopefully the connections will be a little bit clearer now.

Alan
 

[Bikemad]

Should the black wire from the motor then go to the B- post as well?

That would be as good a place as any to ensure a well grounded connection.

Also, I'm assuming the brake switch activates regenerative braking, correct?

Doubtful, as regenerative braking is not mentioned, I would assume it's not a function of this controller.
I expect the brake switch is used purely for power cut-off purposes. (Unless Yao or TOM tell us otherwise.)

And, where is this "hall sensor", I don't see it pictured anywhere.

There are three hall sensors (one for each phase of the motor), located inside the motor casing (usually fitted between the windings).
These are probably not visible externally, but they will be in there somewhere!

Alan
 

[gestalt]

I ended up going with this controller, it is a mod on a infineon controller done by a member of another forum. I don't think he made much more than ten of these guys.







Whats Inside
Genuine IRFB4110 Mosfets
Precision Calibrated 4W shunt
10AWG Teflon coated tinned copper cabling
6AWG equivalent traces
Precision 1% Reference

Reliability
100% Testing
Cleaned and inspected
Conformal coated
Glued Capacitors
Large Heat Dissipating Case
High Pedal Lockout
Reverse Lockout


Modifications
90V Regen Mod
100V Power Resistor Mod
3K Base Mod
250uOhm Shunt Mod
50V / 100V Switch Mod
Programming Mod
10AWG Wire Mod
4110 Fet Mod


It's pretty burly and will probably fit quite nicely into the frame of my cruiser right where the "gas tank" is going. Well it will be less of a gas tank and more of a brain basket.

Though I must admit I am a bit sad they didn't have this program module available when I was out controller shopping.



It is mated to the hpc100b controller and looks like a touchscreen interface to adjust the parameters of the controller. I must say that it is really slick and wish there was more info on it. Probably still no regen though, booo

[gestalt]

here's the basic idea of what I'm going for

[Bikemad]

Gestalt,

If you were unfortunate enough to be involved in a collision, impaling certain parts of your anatomy on those switches would result in severe pain. You might want to consider relocating them somewhere safer.

With such a large container of Methamphetamine, you should also consider its long-term effects, these can include chronic fatigue, paranoid or delusional thinking, and permanent psychological damage.
That space in the frame would be far better used to house a conventional speed controller or a breakdown repair kit etc.

I'm not convinced that spokeless wheels are going to work very well, and the addition of some footrests might help to reduce excessive wear on your shoes as your leg muscles get tired.

On a more serious note, it's looking good so far and I look forward to seeing some more photos of your project as it progresses.

Alan
 

[gestalt]

I got my controller in the mail finally, and wouldn't you know it the damn thing didn't fit in the enclosure that I had spent so much time shaping out of styrofoam. time for plan b. A nice big sheet of 1/8th inch steel was donated to the cause and I will be ditching the soft curves of the fiberglass housing for some rough and tough steel angles.

here's the frame with the controller placed in it



with the "tank" overlayed



and finished

[Mabman]

A little late to the party here but that motor is similar to the eTek (except in $) used by Thunderstruck to construct the Jackal. I rode one of them about 5 years ago and it would 

http://www.thunderstruck-ev.com/jackal_home.htm

[gestalt]

got some work done in the shop recently, it's amazing what you can do with a plasma torch, angle grinder and a tig. It's my first time using a tig, so take it easy on me.









think I'm going to go with a wood top on it.

[Freesiderxl]

Hi Gestalt & all,

I've been looking at the HPM5000B for a while too.  If you had it to do over again, would you still go with the Infineon controller?  Would you want that touchscreen model instead?   The beefy HPC100B is the easy choice, but price is a big factor for me.  Is there anything cheaper out there?  Could you run 2 in parallel?

Thanks, I'm a real n00b.