With the V3 CA devices, the functionality of the CA now includes not just throttle limiting, but actually driving the controller's throttle signal directly, and this is NOT possible if there is a diode inline with the throttle signal. So, if you have a CA-DP compatible controller and want to use the CA-V3 device as your new throttle, you will need to do a bit of modification. Here are 3 approaches:
#1) Swap pins around
so that the green wire from the CA-DP goes into the controller's regular throttle input. You can either do this at the CA-DP plug end as shown below, or you could do it on the controller end:
#2) Insert a short between 5V and your throttle signal.
This way the throttle signal is being pulled high by the short circuit, and so the CA only needs to pull the signal down from there which it can do via the diode. This method is easiest for sure, however, it is crucial that you only do it if your controller has a proper over-throttle voltage fault. Otherwise, if you unplug the CA then the controller will take off full tilt as the throttle input is at 5V. You want to be sure that the controller treats this situation as a fault and shuts down.
#3) Open up the controller
and replace the diode with a ~500-1000 ohm resistor. Depending on where your controller is from, the diode may be a surface mount device on the PCB or a clearly obvious inline diode to the green CA wiring. While you could in principle completely short out or bypass the diode, this isn't recommended as then the CA will usually be directly connected to the microchip which can be an issue if your ground connection fails. A 500 to 1000 ohm resistor will provide some protection.
For all controllers going forward, we are working on a formal spec document for a CA V3 compatible plug standard, which is similar to the #3 modification above. Basically, both the CA plug and the Throttle are connected to the controller's throttle input, but via resistors so that the CA has a closer connection to the signal going to the microcontroller. For instance, with our current 12 mosfet infineon boards the original CA wiring used to be as follows:
We have now spec'd it like this, where the regular throttle signal needs to go through a 10K resistor to reach the microchip, while the CA's throttle signal only has 1K in it's path.
So the resulting pinout is simply
This scheme has the following benefits:
- Controller still works with no CA attached, just plug a throttle and away you go
- Controller is compatible with a throttle + V2 CA for limiting, provided that it is a CA2 with Rev11 or later PCB.
- Controller is plug-in compatible with a V3 CA device acting as the throttle.
The only drawback is that if someone attaches a pre-2011 Cycle Analyst device that doesn't have the diode built in (Rev10 PCB or earlier), then it could potentially cause the ebike to take off when the CA is plugged in.
Previously competed in the Suntrip race on a back to back tandem solar powered row/cycle trike
. 550 watt solar roof, dual Grin All Axle hub motors, dual Phaserunner controllers, 12 LiGo batteries, and a whole wack of gear.
Now back in Vancouver learning to be a dad with my Big Dummy Frame (yes This One
, thanks ES!) with GMAC 10T rear hub motor, Phaserunner controller, and 52V 19Ah EM3EV pack
My website: http://www.ebikes.ca
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