BMC600/CLite 40A/CA build - CA settings?

[www.recumbents.com]

I finally got my ebike #2 put together (or it's first incarnation in any case). It works well except for one problem which I'm hoping you guys can help me diagnose.

Full susp MTB
600watt BMC rear motor
Crystalite 40A 24-72V controller
Ping 2.0 20Ah 48 V batt
Direct plug in Psycho-Analyst

http://www.recumbents.com/wisil/e-bent/zcommuter.htm

Without the CA, it pulls hard to a scary fast speed, but I don't know how fast. With the CA on and at over half throttle it cuts in and out, then hovers around 25 MPH cutting in and out. Max amps were around 1600, and low voltage was 40V or something. After my first run with the CA default settings, I set the CA to a 40A limit, 35 MPH limit, and 35V lower limit. Same problem. The readout said I was not getting close to those limits, but obviously it's trying to limit. I still need to go back and test with all the limits set to uselessly high or low numbers to see if that helps. Has anyone else seen this issue? Also there are a huge number of things to set up, like shunt resistance, hall sensor, etc. Does anyone have values for those? Are the default values ok for this controller? The manual is pretty vague and I can't find this info online anywhere. Is the CA Psycho or does it just need some setup?

Thanks,

-Warren.

 

[www.recumbents.com]

Sound of crickets....

OK, I cranked all the settings to the max and it worked fine, then adjusted the amps back down to 40 and got the same problem. Up to 50 and all is good. Any idea if the default shunt value is really correct for that controller, or do I need to take it apart and figure out how to measure it?

BTW, cruising speed is 30MPH on a flat road with this configuration.

-Warren.

 

[hejo]

Hi,

please read carefully the manual.http://www.ebikes.ca/drainbrain/Cycle_Analyst_Manual.pdf
The default values should work nicely with your setup / controller.
Check the wiring of the throttle override (diode!)

Hard reset should set all values to default

This is accomplished by continuing to hold the
button for 6 seconds after "RESET" is displayed. The message "FULL
RESET"

 

[www.recumbents.com]

Thanks for the reply hejo.

I did read the manual (RTFM). The reseller the I purchased the controller / motor / CA from now says that 1.2 mOhm should be right for Crystalite controllers. The default value is 1.0 mOhm. The controller came pre-wired for the CA, it sounds like Crystalite pre-wired them, but that doesn't mean they did it right. Does anybody have a digram showing where the control wires from the CA are supposed to be attached inside the 40Ah 24-72V controller? Justin from ebikes.ca says he thinks the control wire is connected to the the digital ebrake signal rather
than the analog throttle signal.

-Warren.