CYCLE ANALYST V3
2400 Firestone blvd, South Gate, CA 90280
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The V3 Cycle Analyst is the next step for the CA product line to not only monitor what is going on in an ebike, but also control it. In the V2 CA we included basic throttle over-ride capabilities for speed, current, and low voltage limiting that proved quite popular, but fundamentally it was mostly a passive display. With the V3 Cycle Analyst, all the ebike signals, from your brake cutoffs to your throttle to your pedal sensor, are first intercepted at the Cycle Analyst. The CA then processes all of these inputs to determine how to control your bike, which it then does via one standard throttle output signal to the controller.
There are many advantages to this arrangement. In the traditional setup, any features that you wanted on the ebike, be it cruise control, torque sensing pedalec modes, temperature rollback etc. had to be supported by your particular motor controller. An OEM ebike company can design a custom controller that works with a specific set of input sensors, but DIY projects don’t have this luxury. With the V3 Cycle Analyst, you have access to all these advanced sensor and control schemes no matter what model motor controller powers your system.
Here are some of the more popular features you can include by using the V3 CA as your central ebike/EV console:
- Thermal Rollback: A temperatures sensor input allows the V3 Cycle Analyst to scale back power as a motor heats up and prevent overheating damage.
- PAS Sensor: The V3 Cycle Analyst can take the pedal pulse inputs of almost any ebike pedal rotation sensor to display your pedal cadence. It can use this to provide automatic power whenever you pedal (PAS mode) .
- Torque Sensor: There is an analog input to sense a pedal torque sensor (such as the THUN bottom bracket), display your human power input, and give proportional no-throttle pedalec control.
- Ebrakes: A digital input for ebrake sensors to plug in directly to the CA3, without needing to run another set of cables all the way down the bike to the controller.
- Throttle Input Mapping: The CA3 can map your input throttle range to an output range suitable for the controller in order to eliminate dead-band zones at the beginning and end of the throttle motion.
- Throttle Modes: Setup your throttle in Pass-Thru mode for conventional voltage control, or have your throttle directly regulate the battery current or motor power instead.
- Throttle Ramps : Reduce the sensitivity and off-the-line kick of high power systems by setting ramp limits on the CA’s output throttle signal.
- On the fly Limit Adjustments: Use a potentiometer or multi-position switch to instantly adjust any of your current/power/speed or pedal assist limits.
- Mode Presets: Configure up to three distinct power mode presets each with their own limit settings and PAS/Throttle behaviors, and then easily switch between them with a double button press.
- Battery SOC and LVC: Accurate State Of Charge (SOC) estimator based on your cell chemistry and voltage. Configure up to two batteries each with their own details and Low Voltage Cutoffs.
Plus many advanced capabilities to discover, and of course all the functionality that you have in the V2 CA like volts, speed, amps, amp-hours, %regen, watt-hours/km etc. An official user manual has not yet been prepared, but almost all of the information is exceedingly well documented in the unofficial users guide written by Endless-Sphere forum member Teklektik.
The V3 Cycle Analyst has a total of 11 display screens to scroll through, and as a user you can mask screens that you don’t want to show up from the preferences section of the setup menu.
Display #1 – Main Screen
The primary display screen shows at a glance all of the key info you would want to see from the bike. There is a battery fuel gauge in the top left, plus a readout of your pack voltage, speed, and battery power draw. The button right corner toggles between showing your accumulated trip distance and accumulated battery amp-hours, and if a temperature sensor is enabled it will show the temperature too.
Meanwhile, on the bottom left there are two additional graphic blocks. A throttle slider icon shows visually where your input throttle is at, switching to a flashing mode if throttle auto-cruise is latched, and then to a brake lever if ebrakes are engaged. Adjacent to this is a human power indicator that works if you have a PAS sensor enabled, indicating either your human power or your pedal cadence.
Also note that if you exceed the speed limit, then the speed units will flash, and if you hit the battery low voltage cutoff then the voltage sign will flash. If you are below the minimum start speed, then the speed number itself will flash.
Display #2 – Electrical Only
The 2nd screen only shows electrical stats; Volts, Watts, Amps, and Amp-Hours. It is useful when using the CA on non-vehicle systems where all the additional details on the first screen are not relevant.
Display #3 – Human Power
The 3rd screen is interesting for people who have a torque sensor in their system. The top line shows key vehicle stats: your voltage, amps, and speed, while the 2nd line displays your human power input and pedal cadence.
Display #4 – Energy Mileage
The next display is the same popular readout from the V2 CA devices which shows the net watt-hours taken from the battery pack, as well as your energy ‘mileage’ in units of Wh/km or Wh/mi. This is the EV equivalent to gas mileage in L/100km, and the smaller the number the better energy economy and longer range you’ll get from a battery pack.
Display #5 – Human Stats
Screen number 5 is a summary of the human power statistics for the trip, showing the total human watt-hours, along with the average watts and average pedal cadence. Note that the human watts are only averaged while the rider is pedaling, so if you coast or ride throttle only for a while this won’t reduce your average.
Display #6 – Regenerative Braking
The relative benefits of regen are debated at length in the ebike community, and the point of this screen is to at least help provide analytic numbers to the discussion. On the left you will see the % by which your range has increased as a result of regen, and on the right it toggles between the total forwards and reverse amp-hours that were accumulated. (The Ah display on the 1st and 3rd screen is the net difference).
Display #7 – Max and Mins
The next stat shows the electrical max and mins on the system. Usually the max amps isn’t all that interesting since it will be the same as your controller current limit, but the Amin will show the max regen current, and the multiplication of Amax and Vmin will typically coincide with the maximum power draw as well.
Display #8 – Speed Stats
This one is self explanatory. Max speed, average speed, and trip time. In some cases you may see a somewhat wild value for MaxS, this can be the result of a double bounce in the speedometer pickup switch and adjusting the relative magnet and sensor positions can solve it.
Display #9 – Odometer
Here you can see the same total trip distance as the first screen but with much greater precision, along with the lifetime odometer for the vehicle.
Display #10 – Battery Stats
The battery statistics includes the lifetime cycles and amp-hours of the battery pack, along with a current estimate on the battery’s internal resistance in Ohms. The Cycles count increments every time you reset the CA by holding the right button, and both the Cycles and Total Amp-Hours are unique to each battery. So if you have both an ‘A’ and ‘B’ battery enabled, you can keep separate stats on each pack.
The battery resistance is computed on the fly by seeing how much voltage sag accompanies changes in current draw. This stat is useful, not only to quantify the performance of a pack but also to assess its aging and cold weather behavior. The internal resistance of most batteries will start to increase well before there is much noticeable decrease in the amp-hour capacity.
Display #11 – Diagnostics
The final display screen is most useful when initially setting up the CA for various feedback and control modes. On the top line you can see both the input throttle voltage from the user, as well as the output voltage that the CA is sending to the motor controller.
The bottom line has a row of limit flags showing which throttle limiting feedback loops are currently engaged. So if you are exceeding the speed limit, the ‘s’ becomes a large ‘S’, and similar flags for the current limit (a/A), power limit (w/W), low voltage rollback (v/V), and thermal rollback (t/T). If for instance you have the bike setup for proportional pedalec assist, then the commanded power limit of the CA is being set by your pedal effort, and so the power limit flag ‘W’ will be set showing that the CA is in a power limit control loop.
CA3 Setup Menu
The setup menu is accessed by pressing and holding the left button for several seconds, or by holding the right button down while the CA is powered up. It is a 2-level deep menu list organized into 13 high level groups to let you adjust over 60 different settings. Remember the left and buttons toggle left and right (or up and down), while pressing and holding the right button selects something.
There are also a few visual cues to help with the navigation. Arrows on the left and right show when there are more items in the current menu level, while a straight bar indicates you are at the end of the list, and pressing the next button will take you up a level.
As well, for each of the 13 categories there is a small preview line showing some of the key settings and real-time input signals for that category.
All of the Cycle Analyst setup parameters can also be configured from your computer using the Setup Utility program. The latest release (V1.31) also has the firmware update utility and latest firmware available from the file menu so no need to download this separately, and is available for Windows, Linux, and MacOS
Older versions are here for the record. Note that they all have a minor bug in that the display of PAS -> Dir Prlrty is reversed, so if it says 5V = Fwd in the setup software, it will write 5V = Rev in the CA's setup menu and visa versa.
CA Setup Utility V1.3 for Windows
CA Setup Utility V1.3 for MacOS
CA Setup Utility V1.3 for Linux
CA Setup Utility V1.20 for Windows
CA Setup Utility V1.10 for Windows
CA Setup Utility V1.05 for Windows
CA Setup Utility V1.05 for Linux
CA Setup Utility for Mac OS
Additional information on using this setup utility can be found here on the CA3 Endless-Sphere Thread
Firmware and Programming
The CA firmware is updated via the communications port. The V1.3 and later CA Setup Utility has the firmware upload function built in, but if you want to use a stand alone program for this then you can download and uncompress the following and launch the file "CAFirmareUpdateTool.exe"
As well, you will need the programming cable to be recognized as a COM port on your computer. Windows XP and Windows 7 will both find the correct driver automatically if you enable it to search windows update, otherwise you can download and install the VCP (virtual com port) drivers from FTDI:
In order for the bootloader to work the Cycle Analyst must be externally powered up, it won't get power just from the programming cable alone. So either bring a laptop nearby to your ebike, or have a battery or other source at hand to turn on the CA.
To update the firmware, select the .hex file you want to load, select the serial COM port on your machine that is connected to the CA, and then hit the button "Update Firmware".
At that point, the program will detect the CA automatically and start programming, or it will say "Please cycle power to the device" and it is waiting for the Cycle Analyst to be turned on. You have 30 seconds in which to turn on the device, and once that happens the Cycle Analyst will be detected and you will see a message showing the firmware upload progress, followed by a verify process, and finally an "Upload Complete!".
Note that certain systems have had trouble detecting the CA connection with the V1.1 and V1.2 firmware update tools which were simplified to a single button operation. In those cases, you can try using the original firmware tool from 2012 which required first pressing "detect device" and then afterwords "Flash Device!"
Download Old 2012 CA Update Tool, (only if the V1.2 utility fails to detect device even after power cycling the CA)
The current firmware release is the stable V3.0 code.. This will work fine for any devices currently programmed with Beta16 or later firmware. If you have a way old unit with Beta15, then you will first need to use the “CalOverwrite” firmware option.
CA V3.0 Official Firmware Package Jan 2016 Current Release, use this.
CA V3.0 Prelim13 Firmware Package Nov 2015, (Has Proportional Regen) - Note it is a .zip file, so uncompress it first.
CA V3.0 Prelim12 Firmware Package Nov 2015
CA V3.0 Prelim10 Firmware Package July 2015
CA V3.0 Prelim9 Hex File Feb 2015
CA V3.0 Prelim6 Hex File May 2013
Cables and Connector Pinouts
The V3 CA has a bundle of additional wires coming out of it in addition to the normal 6-pin CA-DP plug. These are input plugs for different sensors and accessories, mostly terminated with female JST-SM connectors, and their pinout and description is in the diagram below:
Circuitboard Pad Descriptions
If anyone wants to do their own custom wiring harness directly into the Cycle Analyst, then the following diagram shows the solder pad location for each of the sensor inputs along with a description of each pad.
Features Requests and Bug Reports
Please feel free to use the following form to submit any bug reports and/or feature requests, as the CA3 is an ongoing development project.
Here is the current list of known bugs in the V3 Prelim6 code, as well as the features we are working on for the next release