The Cycle Analyst
Contents
1. As well vehicles with a freewheel in the drive could regenerate for brief periods from the energy stored in the motor s inertia The formula used for computing this percentage is RegenAh FwdAh RegenAh sng Regen Fwd Ah and Regen Ah The actual forward amp hours and regen negative amps hours to the nearest 0 0001 Ah alternate on the right side of the screen The net amp hours shown on the main display is the difference between these two 4 3 Display Screen 5 Peak Statistics The peak electrical statistics yield information that is useful to understanding the electrical limits that the battery is subject to Amin Peak negative or regen current that was captured by the meter Amax Maximum amperage that was drawn from the battery Vmin The voltage of a battery pack will sag sometimes considerably when it is under heavy load Vmin is a local minimum measurement that shows by how much your pack s voltage droops under load Typically Vmin and Amax occur at the same point and the maximum power draw can be computed from Vmin Amax 4 4 Display Screen 6 Speeds and Time Smax and Savg The maximum and average speed of the vehicle in the programmed units of km hr or mi hr 0h00m00s This is the trip time in hours minutes and seconds It counts only the time that the vehicle is in motion and stops incrementing once the speed falls to zero 4 4 Display Screen 7 Lifecycle Statistics The final display screen pr2. a TECHNOLOGIES The Cycle Analyst V2 3 User Manual The Cycle Analyst 2 3 The Cycle Analyst is designed and produced in Canada by Grin Technologies Ltd 20 E 4th Ave Vancouver BC Canada V5T 1E8 ph 604 569 0902 email info ebikes ca web http www ebikes ca Author and Illustrator Justin Lemire Elmore Copyright 2013 10 11 12 Table of Contents Basic USAGE oi bcd ae bee eee bebe ee Oe 3 Device Summary 22 055 4 Installation aaa ved sed ences ened de 6 Display Information 8 Additional Resetting Options 10 Setup MENU 244454444544 544634004 lt 64 11 Using the Limiting Features 13 Advanced Setup Menu 15 Using Advanced Features 19 Operation in Wet and Cold Conditions 21 Circuitboard Connections 22 Specifications 23 Congratulations on your purchase of a Cycle Analyst the original digital dashboard and battery monitor designed to meet the specific requirements of electric bicycles scooters and other small electric vehicles This device measures the energy consumption and speed of a vehicle and displays this information and related statistics on an easy to read backlit LCD screen When appropriately wired to a motor controller it is also capable of imposing a custom speed current or low voltage limit by regulating the throttle signal We hope that you
3. motor controller The Direct Plug in models already have this appropriately connected but the Stand Alone and High Current version require additional wiring for these settings to have any effect 6 3 Speed Limit Set the maximum speed beyond which the motor controller will cease to provide useful output power The Cycle Analyst will vary the throttle signal such that the vehicle will continue to cruise at this set point speed 6 4 Volts Limit Program the low voltage rollback point for your battery pack The Cycle Analyst will reduce power drawn from the controller in order to keep the battery voltage from dropping below this limit 6 5 MaxAmps Set the upper current limit If the Cycle Analyst senses current above this value it will scale down the throttle appropriately to reduce the amperage draw 12 6 6 Main Display Finally the last setup option allows the user to select whether the primary display screen shows watts or amps in the bottom left corner depending on the user preference The 2 display screen will always show both quantities 7 Using the Limiting Features There are many situations when it is desirable to limit the amount of power that the controller is able to draw from the battery pack For instance you might want a current limit in order to A Protect the cells in a battery pack from delivering more than their rated amperage B Extend the range of your vehicle by reducing current d
4. 85 6 02 17 52 8 9268 3 308 49 36 1 43 17 17 8 9317 3 8 307 49 55 3 69 16 05 9365 The data is at 0 5V CMOS voltage levels making it easy to interface directly to other microcontrollers In order to log the data to a regular computer or laptop it is necessary to either level shift the signal to be compatible with RS 232 voltages and run it to the computer serial port or use a TTL gt USB converter for feeding into the USB port J PC or Laptop TTL gt USB Adapter Alternately the data can also be saved while riding directly to an SD memory card using the separate Cycle Analogger device E Data on MicroSD cara 9 2 On the fly Current or Speed Limit There are situations where it may be desirable to adjust the speed or current limit of the Cycle Analyst without having to change the settings in the setup menu This can be accomplished by wiring a potentiometer such that it sends a voltage signal to the POT pad R2 2K7 Cycle Analyst 2 Rev13 ebikes ca R1 5K Pot Aux Signal Gnd The optional resistor R2 is used to reduce the potentiometer wiper range from 0 5V to just 0 3V so that the entire turn range is utilized In the advanced setup menu you can select whether this voltage regulates the current limit or the speed limit and it will scale the limit between 0 and the speed current limit programmed in the setup menu 9 3 Current Thr
5. cap on the throttle output signal It can be used to simulate a lower speed motor by simply clamping the throttle signal to a value between 0 to 5V Be aware that the majority of hall effect throttles only operate from 1V to 4V and so the desired setting to reduce the speed would fall in this range less the diode voltage drop 17 8 14 SetRatio Default 0 100 This is the amplification ratio between the high gain and low gain current amplifiers on the circuit board It is usually around 0 10 is factory calibrated and should not be changed 8 15 Serial Output Default 1Hz This allows you to select between either a 1Hz or a 5Hz transmission rate on the Tx serial data output pad 1Hz is good for general purpose datalogging while the faster 5Hz rate can be useful for dynamic analysis of vehicle performance 8 16 Set TotDist Set TotAhrs Set TotCyc The next three screens enable you to preload or edit your life cycle usage statistics the total odometer distance the total amp hours you have taken from the pack and the total number of discharge and charge cycles on the battery 8 17 Aux Voltage Function Default OFF This allows you to set the function of the auxiliary input voltage line Pad labeled POT on the Cycle Analyst circuit board You can choose whether this line is ignored default or if it is used for on the fly regulation of either the speed limit or the current limit via a potentiometer or other variable voltage sourc
6. correlates to 0 02 seconds to 1 3 seconds between display updates The default setting is 5 0 28 sec 8 3 SetRshunt The Cycle Analyst is calibrated by programming a resistance value for the current sensing shunt If you are using a known shunt resistor then as a first estimate this value can be programmed directly in mOhm This will usually get the meter accurate to within 3 For highest accuracy the shunt value should be calibrated so that the displayed amperage matches that of a known current reference which may not be precisely the same as the mOhm rating on the resistor If the current is reading too low then the shunt resistance value needs to be decreased and vice versa Allowed values are 0 78 to 9 999 mOhm in Low Range Mode 0 078 to 0 9999 mOhm in High Range Mode 15 8 4 ZeroAmps Over time and with temperature fluctuations it is possible for the zero point to drift such that even when no current is flowing through the shunt a small number like 0 03A is displayed This can be reset to zero by holding down the button after the zero amps screen until the _OK flashes on the bottom right Note though that the wire shunts used in motor controllers are prone to generating small thermoelectric voltages for a short while after being used This produces the appearance of a lingering current that slowly decays back to zero and it should not be confused for a current offset in the Cycle Analyst 8 5 Volts Sense Changin
7. ded then the calculated values such as Wh km and average speed will be incorrect Be sure to reset after each battery recharge CA DP S Connector Pinout Controller Side Cycle Analyst Side oa 1 Vbatt Red are o 2 Ground Black E 4 3 Shunt Blue E 4 Shunt White v 5 Speed Yellow 6 Pin JST SM Series Connector 6 Throttle Over ride Green In CA DPS devices the yellow wire is not soldered on the circuitboard as the external speedo sensor uses the Sp pad 23
8. e 8 18 Aux Threshold Default 0 99V The auxiliary voltage input is scaled over a 3V input range to be compatible with hall effect throttles You can set the threshold where this voltage kicks in For instance if the threshold is OV then the input range is 0 3V If the threshold is set to 1V then the input range from zero to full scale is 1 4V matching the range of most ebike throttles 8 19 Vshutdown Default 10V This setting controls the voltage point at which the CA saves all data and powers down If the value is too low data may not save correctly It is possible to operate down to a 7V shutdown if the backlighting LED is bypassed with a short 18 9 Using Advanced Features There are several advanced features on the Cycle Analyst but making use of these may require soldering to the circuit board Incorrect wiring can damage the unit and it is only recommended for those who are familiar and comfortable with electronics 9 1 8 Using the Data Output The TRS communications cable transmits a serial data stream with the current stats of the vehicle The format is tab deliminated ASCII text ata 9600 baud rate After power up the CA outputs a header line and then at a rate of once a second or 5 times a second see section 8 15 it transmits the amp hours voltage amperage speed and distance as shown here Ah vV A S D3 3 296 47 62 10 04 15 32 8 9132 3 299 47 49 13 22 16 41 8 9175 3 302 47 43 13 45 17 30 8 9220 3 306 47
9. find it a useful accessory that optimizes the experience of your electric vehicle 1 Basic Usage The Cycle Analyst will turn on automatically when more than 10V appears across the circuit and will turn off when this voltage is removed The default screen shows five pieces of information that are most relevant to the rider This includes three instantaneous quantities the voltage of the battery pack the power output in watts and the speed of the vehicle as well as two accumulated quantities trip distance and net amp hours Ah from the battery Toggles Between Y Ah and Distance n kek Press Buttons to Change Display A quick left or right press of the button will scroll through other display screens of interest while holding the right button will reset trip statistics The second display shows just the electrical information of the battery pack including the currentin amps 2nd Display Screen Additional clicks of the button scroll through a total of seven display screens which are discussed in detailin section 4 1 1 Asa Fuel Gauge Amp hours Ah are the fuel equivalent of a battery pack but rather than behaving like a fuel gauge and estimating how much fuel is left the Cycle Analyst instead tells you exactly how much you have used starting from O and counting upwards For example if you have an 8 Ah battery pack and the Cycle Analyst shows 6 1 amp hours consumed you would know the
10. g this value will change the scaling of the battery voltage displayed on the screen This value can be modified either for calibration or to display a voltage that is proportionally higher or lower than the voltage powering the Cycle Analyst The calibrated value is close to 31 0 8 6 Set Poles For Direct Plug in units this should be set to the number of hall effect transitions per rotation of the wheel Crystalyte 400 series hubs have 8 the 5300 series hubs have 12 while the H series and Crown motors and most generic hubs have 23 poles For units that use a speedometer sensor and spoke magnet poles should be set to 1 unless you have multiple magnets on the wheel Max polesis 99 8 7 PSGain Default 0 08 This is the Proportional Speed Gain for the over ride output It can decrease the response time and reduce overshooting the set point speed but at the risk of causing rapid vibrations if it is too high The range can vary from 0 to 0 99 V kph or V mph 8 8 IntSGain Default 200 This value determines how rapidly the over ride output will ramp down when the speed of the vehicle exceeds the limit speed Increasing this value will speed up the response time for the speed control but at the risk of causing oscillations Too low of a value will allow considerable overshoot of the speed limit The gain value can range from 0 to 999 and the scaling is currently arbitrary 16 8 9 IntAGain Default 300 This value determines
11. hile the Direct Plug in models CA DP or DPS tap into the shunt resistor inside your motor controller The High Current model CA HC is supplied with terminals to connect to a larger user supplied shunt Display Box _ 60 Wire Typical Molded Shunt for CA SA DC Power HP lt Ring Terminals N AG a for CA HC NG JST Connector for CA DP S Communications g Speedometer Pickup Not in CA DP The Cycle Analyst picks up the vehicle speed information using either a spoke magnet or in the case of the CA DP device through the hall sensor signals from a brushless motor controller 2 1 Additional Cables Communication Cable There is a short cable present on all the CA s for communication This can be used both for logging data from the serial data stream using an Analogger or similar device or for reprogramming the CA with new firmware using a USB TTL adapter cable TRS Communication Cable Tip RX into CA 9600 Baud 0 5V Ring TX from CA 9600 Baud 0 5V Sleeve Ground To Analogger ac ES or USB Adapter DC Power Cable There is an additional short cable from the device terminated with a 5 5x2 1mm power plug This is connected to your battery voltage and is protected by a 500mA polyfuse It can be used for powering the Lumenator headlights or other devices such as DC DC converters Analoggers that run off your full battery voltage and draw less than 0 5 amps Itcan not be configured as a 12V
12. how rapidly the over ride output will ramp down when the current from the battery pack exceeds the programmed current limit Too low of a value will result in considerable overshooting of the set point current while too large of a gain will cause the controller to oscillate above and below the limit The range of allowable values is from 0 to 999 8 10 IntVGain Default 800 This value determines how rapidly the over ride output signal will scale down when the pack voltage falls below the set low voltage cutout The range of allowable values is from 0 to 999 and the scaling is arbitrary 8 11 ITermMax Default 3 79V This puts an upper limit on how high the throttle over ride will drift upwards when none of the limit values are being exceeded Ideally this value is set to the voltage that is considered full throttle by the controller For hall effect throttles full power occurs at about 4V and limiting the ITerm to this value will speed up the response time of the limiting features Allowable values are from O to 4 99V 8 12 ITermMin Default 0 0V This value imposes a lower bound on how low the throttle over ride can drift downwards when one of the limiting values is being exceeded By preventing the over ride signal from going all the way to OV you can decrease the recovery time for the signal to go back upwards Range is from 0 to 4 99V and must be less than ItermMax 8 13 Max Throttle Default 4 99V This value puts a maximum
13. ing battery power that draw under 500mA Advanced Connections Tx Serial data output signal 9600 baud 0 5V CMOS level POT Auxiliary input voltage for amps speed limit 0 5V range 5V 5V source user may draw up to 5mA from this line for powering external device such as a potentiometer or throttle EBK Ebrake cutoff input not yet enabled in V2 3 firmwarel Vex External voltage sensing pad for high voltage applications using a remote voltage divider with the CA powered from a safe 12V source 22 12 Specifications Voltage Range 10 150V Voltage Resolution 0 1V Current Draw 10mA Current Range 200 mV Rshunt For instance with a 2mQ sense resistor the maximum current is 100 amps With a 0 5mQ resistor up to 400 amps and so forth Current Resolution 0 01A in low range mode 0 1A in high range mode Current Accuracy Temperature coefficient and accuracy depend on the shunt and calibration With pre calibrated Stand Alone model it is within 2 0 06A Trip Ah and Wh Up to 1999 Ah and 19999 Wh in low range mode and 10x this in high range mode Trip Distance Up to 1999 km or mi Odometer rolls over at 99999 km or mi Wheel Size 0 to 9999 mm Speed Range Up to 600 kph or mph There is an upper limit of about 500 Hz for the speed sensor input which can be increased by removing C12 Note that if any Ah Wh or Distance limits are excee
14. k well for ebike setups in the 300 600 watt power range For more powerful systems they will usually lead to the vehicle oscillating around the programmed set point rather than holding steady In this case it is necessary to tone down the appropriate feedback gains in the advanced setup menu 14 8 Advanced Setup Menu The advanced setup menu is accessed by pressing and holding the button when the message advanced shows up at the end of the regular setup menu and allows for setting less frequently changed parameters 8 1 RangeMode There are two mode settings that are available to accommodate the wide scope of electric vehicles The high range mode should be used with shunts that are under 1mOhm such as in electric motorcycles and small electric cars that draw hundreds of amps In this mode the Cycle Analyst will display current to the nearest 0 1 A and will show power in kW For shunts that are over 1 mOhm butless than 10 mOhm the LowRange mode must be selected This will increase the resolution to 0 01 A and shows your power in Watts 8 2 Averaging In an electric vehicle the current and voltage can fluctuate rapidly under normal use making the instantaneous values difficult to read These values are averaged before being display Short averaging times allow you to get a better real time feel for the power fluctuations while longer averaging times produce a stable reading that is easier to record The range is 1 7 which
15. ottle or Cruise Control In other cases it may be advantageous to use the Cycle Analyst to directly regulate the motor controller rather than just limiting the power Via a throttle over ride function The example below shows how to wire up a current throttle such that the regular throttle signal is intercepted by the Cycle Analyst which takes this as the command current The Cycle Analyst then sends it s own throttle output signal along to the controller COE Input Signal from Throttle Throt Output 0 Tho 5VG POT Signal from CA Optional Sv rottle Power Throttle CAPCB Motor Gnd Controller 5V Throttle Power from Controller In this manner if full throttle is set to be 20 amps then by riding half throttle you could ensure exactly 10 amps are drawn from the battery regardless of the vehicle speed giving the user more direct control over their power usage Similar setups can be used to implement accurate speed control systems Note that it is essential to set the AuxVoltage input see 8 17 to either the current or speed limit first otherwise the system will take off at full power when turned on 20 9 4 Firmware Programming The Cycle Analyst V2 3 and later devices have an onboard bootloader that enables firmware updates via the communications cable with no need to flash the device using a dedicated microchip programmer Instructions and downloadable software for updating
16. output Vbatt 500mA Max N Protective Cap This cable comes with a rubber cap to protect against corrosion or inadvertent short circuits It is important to leave the rubber cap on the plug when you don t have it connected to a device especially if you are running more than 48V 3 Installation The Cycle Analyst display box comes with a mounting bracket for installation on the handlebar of your bicycle This bracket can rotate in two axis to adjust the display position and fits bars from 22 to 36mm in diameter Rotate to Adjust re Handlebar Clearance Cable Ties Spoke Magnet In the case of the CA SA CA DPS and CA HC models there is also a speedometer pickup cable and spoke magnet The pickup attaches to the fork with two cable ties and must be mounted to pass within 6mm of the magnet for the speed readings to register The magnet should pass by the middle section of the sensor pickup at the small band For systems like scooters or motorcycles that don t have spoked rims a standard magnet can be attached with epoxy to a suitable location on the wheel The remaining installation details depend on the model 3 1 Wiring of the CA DP S With the Direct Plug models simply plug the 6 pin connector of the CA into the matching 6 pin connector on the motor controller Because there are large voltages present through this connector it is a good idea to protect the pins with dielectric grease particularly if it
17. ovides the lifetime information of the battery pack These figures are especially useful in computing the lifecycle costs of the vehicle and comparing the economics of different battery chemistries This display is not shown when the vehicle is in motion Cycl The cycles value increments when the meter is reset Provided that the meter is reset each time the battery is charged then this will indicate the number of charge and discharge cycles on the pack In order to prevent false cycle counts from cases where frequent resetting is performed the value is only incremented if more than 1 6 amp hours was drawn at the time of the reset TotAh The total battery amp hours is a running sum of battery use over its life to the nearest 1Ah TotMi or TotKm This is the odometer function showing the total distance that has been travelled on the battery pack 5 Additional Resetting Options In addition to a regular reset to clear the trip distance time and amp hour data see Section 1 2 there are two other reset possibilities 5 1 Peak Reset In some instances for diagnostic and performance testing it is desirable to clear only the peak statistics Amax Amin Vmin and Smax without resetting anything else This can be accomplished by holding the right reset button when the display is showing Amin Amax and Vmin The message PEAK STATS RESET will appear on the screen and only the previously mentioned values will be cleared 5 2 Full Rese
18. r button will toggle between mi or km and holding the right button again will save your selection and move to the nextitem 6 2 Setting the wheel size After units are input you will be presented with Set Wheel to input the circumference of the tire To change this to your actual wheel size hold the right button until OK appears in the bottom right hand corner Then the first digit will flash and you can cycle it through 0 9 with the left and right buttons When the correct value appears hold down the right button to save it and move on to the next digit Button Hold Button Increments for OK to E Save and go igi to Next Digit 11 The following table is a convenient reference on the circumference of several popular bicycle tire sizes For greatest accuracy measure the actual circumference directly with a tape measure or compare the trip distance from the CAwith map or GPS data to get it exact Tire Size Circumference Tire Size Circumference 16 x 1 50 1185 26 x 1 1 2 2100 16 x 1 3 8 1282 26 x 1 5 1995 20 x 1 75 1515 26 x 1 75 2035 20 x 1 3 8 1615 26 x 2 0 2075 24 x 1 1 8 1795 26 x 2 25 2115 24 x 1 1 4 1905 26 x 2 35 2131 24 x 1 75 1890 700c x 23 2097 24 x 2 00 1925 700c x 28 2136 24 x 2 125 1965 700c x 32 2155 26 x 1 1 8 1970 700c x 38 2180 26 x 1 3 8 2068 700c x 2 0 2273 The next three setup items only matter to Cycle Analysts that have been wired with the throttle over ride signal connected to the
19. raw during acceleration and hill climbing C Safely cycle atlow currenta NiMH or NiCad pack that has been sitting unused for along period D Keep the motor s power within a legally stipulated power limit A speed limit can help make any electric bicycle abide by the legal speed caps that exist in most jurisdictions while not affecting performance below that speed It can also be useful for extending the range or for taming a setup that is otherwise too fast for comfort without sacrificing hill climbing torque The voltage limit is used primarily to prevent the battery pack from being over discharged which can be damaging to the cells Typically you would set it between 29 to 31V for a 36V pack and between 39 to 41V fora 48V pack 7 1 How the feedback works To understand how the limiting features work just imagine how you would operate the throttle manually If you are going over a desired speed limit you would back off the throttle If the vehicle then reached a hill and started to slow down from your target speed you would further engage the throttle thus continuously adjusting the throttle position to maintain your desired velocity 13 The Cycle Analyst behaves similarly When it senses that any one of the limiting quantities has been exceeded then the throttle output signal starts to decrease from its resting value of ITermMax until the limit is no longer exceeded A simple circuit is required so that the controller only sees
20. re are just under 2 Ah remaining in the battery This will become quite intuitive after a few rides and you will be able to accurately gauge when the pack will run flat 1 2 Resetting After you have recharged the battery pack you should reset the trip statistics Ah Distance and Time to clear them all to zero This is done by pressing and holding the right button for 1 second until the message Reset shows up across the display Hold Right Button for 1 Second to Reset 1 3 Saving The Cycle Analyst will automatically save all the statistics when power from the battery pack is cut out This allows you to turn off the vehicle at any time and turn it on later without losing data 2 Device Summary Like most electric power monitoring devices the Cycle Analyst measures the battery current in amps by amplifying the small voltage produced when current is made to flow across a shunt resistor Battery HUL Ls Motor Controller Hi Shunt Resistor V Signals for Shunt Cycle Analyst Shunt This shunt resistor must be wired in series with the negative lead of the battery pack The power to run the Cycle Analyst then comes from the connection to the positive lead of the battery There are several wiring variations to accommodate different hookup strategies The Stand Alone Cycle Analyst CA SA includes a molded shunt capable of 45 amps of continuous current 100 amps peak w
21. t When it is time to switch battery packs then the battery cycle count lifetime amp hours and total distance can be zeroed by performing a full reset on the system This is accomplished by continuing to hold the button for 6 seconds after RESET is displayed The message FULL RESET will appear to indicate that all stored data has been cleared from memory Notice that a Full Reset does not restore any of the gain or calibration values that may have been changed in the setup menu The default values for these are shown in Section 8 10 6 Setup Menu There are many setup options that can be accessed at any time by pressing and holding down the left button Alternately if only a single button interface is desired then holding the right button while power is applied to the device will also enter the setup menu Hold Left Button for SETUP oF 2 Seconds Once entered navigate through the setup options in the following manner Hold Right Button while Turning On Press either button briefly to toggle the information at hand like up and down arrow keys Hold the right button down for one second to save thatinformation or to enter a submenu like an enter key 6 1 Selectyour units The first setup option is to choose between displaying in miles or kilometers If you want to change the setting hold the right button until _OK appears on the screen Then pressing eithe
22. t has cooled off 21 11 Circuitboard Connections Optional Connections sai sae BP Xx Cycle Analyst 2 Rev13 gt Potentiometer Ebrake Divides bikes RIN 45 600 00 wa 00 n O Eek ej Lex 6 a Oo 5U POT G K ex 5 5 d CE rit B DO ri Ro R11 A 3 8 y x f A gt i ca mi Taa po sd 1b g n18 12110 2 6 diy g 1D n12 E tij g o c3 R22 Le lubu 5 egede Bo Teg 5 u20 b o o tol R5 a fs 58 8 o Og ji a 5 e Fa R192305 O o 3 K o c O us olo d i On 3m a d o d 5 ma ro o J Eere a2 R14 oe C IG Q 1M UDD G De ck n v DOO Lemp sev Bing ev EE OO 00O NG a o LA HEN D4 05 D6 D7 Ors O 0000000000000 O A Standard Connections Solder Jumper for using Vex B1 Primary button input Voltage Sensing G Ground B2 Secondary back button input S Negative side of current sense Shunt Resistor Must be within 400 mV of Gnd blue wire S Positive side of Shunt Resistor white wire G Ground black wire ThD Throttle Over ride output green wire same as ThO signal but already connected via a diode to pull down user s throttle ThO Throttle Output use this pad for output with Current Throttle mode described in Section 9 2 Sp Speedometer pulse input yellow wire Can be either magnetic reed switch to Gnd or a 0 5V 0 12V hall signal V Positive lead to battery pack red wire can be shared with other devices requir
23. the firmware will be provided on the www ebikes ca website as new firmware becomes available Firmware programming requires a USB gt TTL cable or for those who are old school a TTL gt RS 232 level shifter and a vintage computer equipped with a serial port 10 Operation in Wet and Cold Conditions The Cycle Analyst enclosure contains a clear sealed window to protect the circuitboard and LCD from water exposure There is generally no problem using the meter in light rain or heavy rain so long as the meter is upright if the with the cables exiting downwards The open holes in the bottom allow the device to breath to prevent condensation issues That said there have been occasional instances of water ingress into the button keypad circuitry that has caused the buttons to misbehave If this happens please contact your dealer for a replacement front enclosure casing Also if the enclosure is ever opened up it is important to re apply a bead of silicone sealant around the seam so that itis properly waterproofed again on reassembly The LCD screen is specified to operate between 10 C to 50 C At the colder end of the temperature range the response time of the LCD segments is slow and so rapidly changing digits and screen changes will appear as a blur The underlying operation of the internal circuitry is unaffected At high temperatures in direct sunlight the display characters may become quite dark but will return to normal once the uni
24. the lower value of the throttle signal or the Cycle Analyst signal This is generally achieved with a diode as follows which is included in the ThD output pad 5V Diode Throttle Output of Throttle t Resistor Cycle Analyst G 2140k Throttle Signal Throt Signal inside Controller There are various setup options which control the speed at which the Cycle Analyst responds to these signals If the settings are too fast then the control can be twitchy or oscillate around the desired value while gain settings that are too low will cause a lag time before the limiting kicks in 7 2 PIController Each of the three limiting features is implemented as a digital Intergral or Proportional Integral PI controller The actual output for speed regulation is computed as follows ITerm Previous ITerm IntSGain Set Speed Actual Speed Clamp ITermMin lt ITerm lt ITermMax Throttle Ouput ITerm PSGain Set Speed Actual Speed Similar values are calculated with the current limit and low voltage limit and the smallest of the three over ride terms is the throttle output voltage If this output is less than the user s throttle voltage then it is the Cycle Analyst which is ultimately controlling the vehicle 7 3 Tuning the feedback The ability of the Cycle Analyst to limit the speed current or low voltage in a fast yet smooth manner depends on setting the appropriate Gain terms for the feedback loop The default values wor
25. uld be equal to the voltage of the pack multiplied by its amp hours but it will typically be less than this because of voltage droop caused by large current draw Notice that only the positive watt hours pulled from the pack are recorded During regenerative braking when the watts are negative the watt hours value does not decrease Wh km or Wh mi The watt hours used per unit of distance travelled is a measure of the average energy efficiency of your vehicle With this figure you can readily quantify how different riding styles impact your range and predict with high accuracy the expected travel distance with any particular battery pack The Wh km or Wh mi figure is calculated taking into account current that may have flowed back into the battery pack from regenerative braking The actual formula used is Wh FwdAh RegenAh _1_ Dist Wh FwdAh Dist In order to reduce computational round off errors the figure only displays after a total distance of 0 5 km or mi has been travelled 4 2 Display Screen 4 Regenerative Braking The next screen shows information that pertains to negative current that is current flowing into the battery pack Regen The percent regen indicates by how much your range was extended as a result of energy returned to the battery from regenerative current Most direct drive vehicles that do not have 8 explicit regen braking can still produce negative current when they are driven at high speeds
26. will be exposed to wet conditions To Cycle Analyst i Motor Controller NODDO 3 2 Wiring ofthe CA SA With the Stand Alone version wire the molded shunt in between your battery and the motor controller This is most conveniently done by attaching connectors on the shunt leads which match your battery connectors If you have a switch in the system it is best to wire the shunt after the switch so that the Cycle Analyst powers down mS onor Switch Fuse e To Motor iii Controller Connectors To Cycle Analyst 3 3 Wiring of the CA HC The High Current model attaches to a 3 party shunt resistor and the positive battery lead The shunt must be connected to the ground side of the battery connection of the shunt to V can panata the circuitry On Off Switch Black Gnd can go to either side of shunt To Cycle Analyst Blue to Shunt 4 Display Information In addition to the screens discussed in section 1 there are 5 others that show a range of statistical information relating to the energy use of your vehicle 4 1 Display Screen 3 Power Information Watt hrs This is a measure of the total energy that has been pulled out of the battery pack One watt hour is 1 1000th of a kWh and slightly less than one food calorie To a first approximation the watt hours available from a battery sho
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