sector e1 regen has stopped (mostly) working

[mark walkom]

the regen braking on my e1 has stopped working unless (for eg) I am going down a hill in low and it's slowing things down to stick to the 10kph limit. when I drive and take my foot off the accelerator it's not initiating the regen to slow things down and instead just coasts at whatever speed it is at, or speeds up as the regen is not limiting it. the brake lights work, so it's probably not a fault with the sensor on the brake pedal

 

hoping someone else might be able to provide some suggestions on things to check, as the mob that I bought it off seem to have gone silent on me

[Guest]

The 'brake' regen is triggered by a tiny microswitch on the brake pedal. It's an on or off thing, and can get stuck easily. Have a close look at the pedal and you should see it. I've had to give mine a careful clean a couple of times now, but that seems to sort it. 

[mark walkom]

if that also controls the brake lights then the switch is working, I cleaned it anyway based on your comment and it hasn't helped unfortuantely

[Guest]

If it's still working the brake lights there might be a problem with the connection to the controller/inverter. I couldn't find any other way the braking system talks to the electronics, and joggling the switch a bit made my regen under braking work again. Best of luck with it!

[BuggyBoy]

On 11/8/2024 at 9:08 PM, Osney said:

If it's still working the brake lights there might be a problem with the connection to the controller/inverter. I couldn't find any other way the braking system talks to the electronics, and joggling the switch a bit made my regen under braking work again. Best of luck with it!

 

I'm wanting to easily disable the regen as don't need it and it keeps tripping the battery BMS's when fully charged going down a hill (too much current, nowhere to go).

I've attached two pics - on the one called 'Microswitch' is this the switch you are referring to that activates the regen based on pedal positions (looks like it breaks a circuit when brake pedal is pressed?).

Presumably, if that switch stayed closed the regen wouldn't activate when braking? (assume the speed-based regen would still kick in at some point though).

The other pic is of a what i thought was the wiring/connector from the microswitch. I unplugged it, the ATV went a few meters then stopped. Plugged it in, and it went again. Any idea what this connecter is?

 

 

[mark walkom]

bit of an update here, I managed to get into a discussion with hisun support via wechat and they are telling me that the sevcon needs reflashing. they won't provide the ability for me to do this myself and I am 5-6 hours from my "local" dealer, so I am investigating how to do this

 

https://electricdriveengineering.com.au/wp-content/uploads/2024/10/DVT-Manual.pdf seems like it might work if I can get all the things required

[GNFO]

21 hours ago, mark walkom said:

bit of an update here, I managed to get into a discussion with hisun support via wechat and they are telling me that the sevcon needs reflashing. they won't provide the ability for me to do this myself and I am 5-6 hours from my "local" dealer, so I am investigating how to do this

 

https://electricdriveengineering.com.au/wp-content/uploads/2024/10/DVT-Manual.pdf seems like it might work if I can get all the things required

I hate to keep pointing to @EVSupport in the UK, but he's the only one here with the experience doing that.

That said, he may not want to go down that particular rabbit hole. From what I can gather, it takes the DVT software, a particular USB to CAN converter (both of which could possibly run without a license if you can find old versions), and all the parameters specific to the Hisun setup. Even if you can obtain the correct versions of the first two items, I'm not so sure about the parameters without help from either Hisun or someone who has major experience with these particular UTVs. 

I have a feeling you'd waste less time driving the 5-6 hours.

[EVSupport]

Unless someone has already been changing the parameters , just re flashing the controller isnt likely to solve the issues.  There are two factors with the controllers, they have a basic software version that works with the hardware in the Sevcon(think windows say version 7) and the setup / operating files, that is set up to work with that specific version of operating system. Bit like Office 2000 wont work on Window 10. Also like windows you cant run a newer version of the operating system on an older controller (like you cant run window 11 on say a 486 processor).

If the settings have been messed around by someone in the past then it can simply have the appropriate files flashed. Normally the operating system, doesnt need changing as its the correct one for the controller from the factory.

By using the DVT software you can monitor things like the switch input  throttle voltages etc. So these can be checked to see they are doing what they should, But just reflashing anything isnt going to solve the issue if its not been changed from factory.

What is the battery being used in this vehicle? When did this no regen start to show itself? More details please.

You really do need to access DVT software and use an IXXAT CAN compact  Can tool. Older versions of unlicenced DVT wont work with some later versios of Can Compact. The latest DVT requires 64bit windows  older versions would happily work on 32 bit windows, we used Win 7 starter  on Samsung Netbooks and the were brilliant, small, low cost and adequate. No we had had to shift to WIndows & 64 bit and for other software to Windows 10. We also have software which we need for other things that still runs on Windows XP. Its a laptop nightmare. Even if you can get an Unlicenced version, it may not support the version of files used in your much newer controller. IXXAT CAN Compact seem to go for crazy money on things like ebay. Try getting one from the supplier of DVT, as often they get good deals.

The IXXAT will also require a cable to go from the 9 pin D connector to the Hisun, we dont tend to use they dignostic socket, we have had a few where this has not worked. So we have a general breakout cable , we remove the large ampseal connector on the sevcon and put our cable i between the harness and the Sevcon, our IXXAT has its own connection cable (and also other connections for things like Curtis controllers on different pins). I think sevcon sell the appropriate cable used by Hisun as a std part.

 

[mark walkom]

thanks for replying @EVSupport, I don't expect free support but appreciate any assistance

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What is the battery being used in this vehicle?

4 x 12v 100ah Humsienk LiFePO4s, using the default charger that was reflashed

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When did this no regen start to show itself?

before I changed the batteries! so this was an existing issue with the original sla's.

 

basically there's no regen unless I put it in low and then go down a steep hill, if I do that it'll reduce the speed back down and regen. but using the brakes doesn't trigger regen before the physical brakes kick in like it used to.