Cycle Analyst V3.0 Programming Instructions
Cycle Analyst V3.0 Setup Menu
The CA 'Setup Mode' 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 pressing the left/right buttons toggle the menus left/right (or up/down), while pressing & holding the right button opens that menu or selects an item for modification.
There are also a few visual cues to help with 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.
Once you enter the 'Setup Mode', you can toggle through a series of 13 category menus you can select from and/or modify. Each category menu provides a small preview line showing some of the key settings and real-time input signals for that category.
1 - Setup Speedometer
Preview line shows current units (mi/km), current wheel size (in inches, #Poles, and the state of the speed sensor input (up arrow = 5V, down arrow = 0V)
Units: Select between using units of kilometers or miles. Notice that changing this will not rescale the odometer, speed limits, etc.
Circuf: Exact wheel circumference in mm.
#Poles: This is the number of magnetic pulses received to equal one full wheel revolution. The Fat Woody CA utilizes an external speed sensor mounted on the left front fork. A small magnet, mounted to the left side of the front wheel rim, passes this sensor and the CA counts these as pulses. For greater resolution of exact speed, you can place more magnets around the wheel and increase the # of poles to match # of magnets.
TotDist: Let's you pre-load the vehicle odometer.
2 - Setup Battery
Preview line shows nominal voltage and chemistry of the selected battery pack.
A or B: Lets you choose the current battery preset provided that you've already enabled 2 batteries. Otherwise, this screen does not show up. All values following will be linked accordingly to either battery 'A' or 'B', including the cycles and total Ah statistics.
Chemistry: Select the cell chemistry of your battery pack (Fat Woody utilizes LiMn)
LiMn: Lithium Manganese
LiPo: Lithium Polymer
RCLiP: Lithium Polymer used in R/C vehicles (High 'C' Discharge Rate)
LiFe: Lithium Iron Phosphate
SLA: Sealed Lead Acid
NiMH: Nickel Metal Hydride or NiCad
String#: Number of cells strung together in series to make the battery pack. For LiMN and LiPo, 36V is 10S, 48V is 13S.
Capacity: This is the capacity of the battery pack in amp-hours, which is used to improve the accuracy of the battery fuel gauge display while you are drawing current.
Vlt Cutoff: This is the low voltage rollback. When the CA detects the battery voltage falling below Vlt Cutoff, it will gradually scale back the power draw to keep the voltage from dropping any lower.
LoVGain: This is the feedback gain setting for the low voltage rollback. A higher number will result in the power scaling back more abruptly when voltage falls below the cutoff.
TotCyc: This is the total number of charge cycles on the battery pack, assuming that the CA was reset after each full recharge.
TotAhrs: This is the total life cycle amp-hours that have been pulled from the battery to date.
3 - Setup Throttle In
Preview line shows measured voltage of throttle input, the equivalent % throttle that this voltage corresponds to, and the throttle mode (amps, speed, pass-thru, etc.)
Cntrl Mode: Allows you to select the function of the user's input throttle. Your Fat Woody has been configured for Pass-Thru throttle mode operation.
Pass-Thru: User throttle is linearly remapped from the input throttle range to the output throttle range, and then passed on to the output.
Current (A): User throttle controls the battery current, from 0A up to the value in the Max Current. If using this mode, it makes sense to have your CA's Max Current equal to or lower than the controller's current limit, otherwise only part of the range will be mapped.
Speed (kph): User throttle directly controls the speed of the bike, from 0 up to the value in Max Speed. This is not a recommended throttle mode for most scenarios as small twitches in the throttle can result in large pulses of power as the bike attempts to track this.
Power (W): User throttle controls the power to the motor controller, from 0 up to the value in Max Power. In this mode, you should not have your Max Power set much higher than your battery voltage times the controller current limit.
Off ( 0V ): This mode ignores the input throttle, and sets the output throttle signal low. The output can then only go high if you have one of the PAS modes enabled and are pedaling. You can achieve the same thing by simply unplugging the throttle, but this option can be useful if you want to swap between different presets with and without throttle modes.
Off (WOT): User throttle is ignored as well, the the CA's output will default to Max Throttle until one of the limits is exceeded. This is included for legacy support for people using a V3 CA on a controller designed for V2 CA-DP connector, which have a separate throttle feeding the controller and the CA is diode connected to only pull that signal down. If this mode is selected with the CA's output going directly to a CA3 compatible controller, then it will cause the bike to take off on power up. So be careful.
Min Input: This is the voltage threshold for the lower bounds of the input throttle. When the throttle signal is less than this, then it is assumed the throttle is off. It should be set at least 0.2V higher than the voltage present on the throttle when the throttle is disengaged. If it is set very close to your actual minimum voltage signal and you have one of the PAS modes enabled, then electrical noise can cause the CA to briefly assume that you are using the throttle which will disable the PAS output, resulting in a momentary drop in power.
Max Input: This sets the upper bound that is considered the 'full throttle' voltage. It is possible to play with this voltage to adjust your throttle range and sensitivity, but normally it would be set about 0.2V lower than your actual full throttle voltage.
Fault Volt: This sets a fault detection threshold. If the throttle signal is higher than the Fault Volt, the CA will assume there is a fault and not treat it as full throttle. This situation can happen for instance if the throttle's ground wire gets disconnected while the 5V and Signal lines are still connected. You would usually want this about 0.1V higher than you actual full throttle voltage.
Auto Cruis: This feature enables you to have a cruise mode if you hold the throttle steady in the same position for a length of time. At that point, the throttle slide on the first (Main) screen will start to flash. You can release the throttle but the CA will still maintain that throttle setting. The cruise mode is released anytime you hit the e-brakes or operate the throttle again.
Off: Auto Cruise Mode is Disabled.
2 Sec - 8 Sec: Auto Cruise will latch after holding throttle for (x) seconds.
Important Note: Your Fat Woody has been designed with a 'push button' cruise control connected to the controller (not the CA). Auto Cruise is disabled (turned OFF) on the CA. DO NOT enable this feature without discussing with Fat Woody, or there could be a conflict in e-bike operation that could be potentially dangerous.
Cruise Hld: This setting lets you adjust adjust the voltage sensitivity for the auto cruise throttle latch. If you have twitchy thumb throttle, then you may need to have a large voltage band. Too large of a band can cause the auto cruise feature to latch inadvertently even when you didn't want it.
4 - Setup Throttle Out
Preview line shows the current output throttle range, whether it is in Volts or mS pulse width, and has a crude graphical indicator of the throttle ramp rate.
Outpt Mode: Lets you select between a steady analog voltage output from the CA's Throttle Output line, or a 1-2mS RC servo style pulse output.
Min Out: This is the lower output throttle range. You can use the pass-thru throttle mode to see exactly what voltage your controller starts to respond to a throttle signal, and then set the Min Output about 0.2V less than this.
Max Out: This is the maximum voltage the CA will send to the controller. Many controllers have an over-voltage throttle fault, so you want to make sure the CA's throttle output does not exceed this. For most e-bike controllers, the throttle that results in full power is somewhere between 3.5 to 3.9V.
Brake Out: This is the voltage output of the CA when you squeeze the e-brakes. In some setups, you can use a lower value than the Min Out setting to have your controller recognize that the brakes are activated and engage regen.
Up Rate: This sets a firm maximum ramp-up rate for the throttle output signal, and can be used to smooth out harsh kick on powerful systems. A lower value in V/sec will result in a longer time for the throttle to ramp up, resulting in a more gentle application of power. Values of 0.5 to 2 V/sec are recommended.
Down Rate: This can be used to clamp how fast the throttle output will ramp downwards. For safety reasons, you would generally leave this at a high value so that the system can shut off promptly, but there can be times where a slower disengagement of motor power is preferred. Values of 4 to 8 V/sec are recommended.
Fast Rate: This is an additional fast ramp-up rate for the throttle output that applies only if the CA has not detected any current flow from the battery. It allows the CA's output to quickly reach a level that's starts having an effect on the controller before then dropping to the normal 'up rate' limit. This eliminates the lag time for ramped throttle output to catch up with the bike when you apply the throttle and are already moving. Values of 4-8 V/sec are recommended.
Fast Thrsh: This sets the threshold current that must be seen by the CA for it to switch from the 'Fast Rate' to the standard ramp-up rate. For direct drive hub motors, it should be quite low, like 0.5 to 1 A. But for geared motors and mid-drive systems, it should be higher than the no-load current required to accelerate the motor from still. Usually a threshold of 2 to 4 Amps works well.
Builder's Note: The next few 'setup menus' make specific changes to the Preset you've selected. Your Fat Woody has three (3) different 'presets' that correspond to the 3-position switch (power settings) on the left side of your handlebar.
For example, if you want to make changes to Preset #1 - Legal power setting (switch position 1), put the switch to position 1 before entering the Setup menu. Any changes made, like lowering the speed limit or lowering the power will only be made to Preset #1 - Legal. If you want to change limits in Preset #2, exit setup first, then put the switch to position 2, and then enter setup again.
This is key: Once you make changes to a preset, exit setup for the changes to take effect. Do not change the 3-position switch while in the setup mode. If you're changing multiple presets, always exit setup, then change the switch, and re-enter setup.
5 - Setup Speed Limits
Preview line shows the speed limit of the selected preset.
Max Speed: Upper speed limit. The CA will roll-back its throttle output voltage if you start to exceed this limit setting.
Strt Speed: This is a minimum starting speed that must be reached before the CA will allow an output. The rider must pedal the bike up to the Strt Speed before power will be applied to the hub motor.
IntSGain: Integral feedback gain for speed PID control loop. Lower values give smoother control and less likelihood of hunting, but it can increase the time it takes for the speed limit to stabilize.
PSGain: Proportional feedback term for speed control loop. Displayed in terms of Volts / (mph or kph). So if you set it to 0.5V/kph, then for each km/hr you go above the speed limit, the throttle output will immediately drop by 0.5V.
DSGain: Differential feedback term for speed control loop. This is used to dampen oscillations from speed limiting as it allows the CA to anticipate that you are accelerating towards the speed limit and scale back power before you reach it. Values in the 100-300 range seem to work well.
6 - Setup Power Limits
Preview line shows the amps limit and watts limit of the selected preset.
Max Current: This sets a current limit in Amps for the selected preset. This value may be further scaled down by the throttle, and/or the Aux Voltage, and/or the temperature limit.
A Gain: Feedback gain for the current control loop. Generally it should be increased until you start to feel the current limiting being rough or oscillating, and then scaled back about 30%.
Max Power: This sets a power limit in Watts for the selected preset. It has a very similar effect as a current limit, except that it is independent of the battery voltage.
W Gain: Same as the A Gain above, only now applied to the power limiting feedback loop. This is also used by any control modes that are based on power limit, such as AutoPAS mode or Torque Assist. Gain values between 10-20 seem to work well with most e-bikes operating in the pedal assist mode.
7 - Setup PAS Sensor (Pedal Assist is not a feature on your Fat Woody e-cruiser)
Preview line shows # of PAS poles, the state of both the PAS and DIR digital inputs (up arrow is 5V, down arrow is 0V), and the current PAS assist mode. While there are many settings in this menu, your Fat Woody e-cruiser is not equipped with pedal assist sensors. Keep the PAS mode disabled.
8 - Setup Torque Sensor (Torque Sensing is not a feature on your Fat Woody e-cruiser)
Preview line shows the measure voltage from the torque sensor signal. If the torque sensor is enabled, then it shows the corresponding calculated N-m of torque on the cranks. While there are many settings in this menu, your Fat Woody e-cruiser is not equipped with torque sensors. Keep the TRQ mode disabled.
9 - Setup Temp Sensor
Preview line shows the measured voltage from the temperature sensor pad as well as the corresponding temperature in degrees if temperature scaling is enabled.
Sensor: Select which type (if any) of temperature sensor is connected.
Disabled: Temp Sensor not used.
10K Thrmstr: Voltage is scaled into degrees Celsius assuming a 10K NTC thermistor with a beta constant of ~3900.
Linear Type: Voltage is scaled linearly into a temperature reading based on a custom scale and offset. This is the type your Fat Woody uses.
0 Deg: (bug in Prim6 shows 'Units' text instead) Only present if Linear Type is selected. This represents the sensor voltage that is treated zero degrees.
Fat Woody Setting - 0v = 0 degrees
T Scale: Also only present if Linear Type is selected. This sets the scaling factor for converting the sensor voltage into degrees, Deg/V.
Fat Woody Setting - 100 deg / 1 v
Thrsh Temp: This is the temperature at which thermal rollback of the CA's current limit begins to kick in.
Fat Woody Setting - 100 degrees C
Max Temp: This is the temperature at which the thermal rollback will have brought the CA's current limit down to 0 amps. The current limit is scaled linearly down from the Max Amps to zero amps as the temperature increases from Thrsh Temp to Max Temp.
Fat Woody Setting - 130 degrees C
10 - Setup Aux Pot
Preview line shows measured voltage of the auxiliary potentiometer input, the equivalent % full scale limit that this voltage corresponds to, and the limit value that is being scaled (amps, speed, watts, etc.)
Function: This determines the function of the auxiliary potentiometer input.
Off: Voltage on the POT input pin is ignored.
Limits: Voltage on the POT input pin is used to scale one of the CA's limit parameters.
Presets: Voltage on the POT input pin is used to switch between different mode presets, if mode presets are enabled. Mode presets have been enabled / pre-programmed on your Fat Woody e-cruiser.
Scale Lim: This option only shows up if 'Limits' are selected as a function for the Aux Pot input.
Amps Lim: Voltage on the POT input pin linearly scales the current limit, from 0 to Max Amps.
Speed Lim: Voltage on the POT input pin linearly scales the speed limit, from 0 to Max Speed.
Power Lim: Voltage on the POT input pin linearly scales the power limit, from 0 to Max Watts.
PAS Level: Voltage on the POT input pin linearly scales the proportional PAS assist, either your PAS Watts in AutoPAS mode, or your Assist Factor in TrqPAS Mode.
Min Aux In: This sets the lower range of the auxiliary potentiometer input. Any voltages less than this will be treated as zero.
Max Aux In: This sets the upper range of the auxiliary potentiometer input. Any voltages higher than this will be treated as 100%.
11- Setup Calibration
Preview line shows the programmed value for RShunt in mOhms.
Range: The CA can be configured in a Low Range mode appropriate for e-bikes, as well as a High Range mode intended for elevtric cars, motorcycles, and other large EV's.
Lo (W): This mode is intended for system with shunt sense resistors that are in the 1-9mOhm range. Current resolution is to 0.01A and power is shown in watts. This is the range your Fat Woody e-cruiser uses.
Hi (kW): The high range mode is intended for high current systems. This range is NOT used on the Fat Woody e-cruiser.
RShunt: The CA is only as accurate as the calibration value for the current sense shunt resistor. The calibration value for your Fat Woody e-cruiser has been pre-programmed with a value of 1.1 mOhms.
Zero-Amps: Pressing the button here will take the present amperage readings as the 'zero amps' reference. After holding the button, you will see two voltages on the screen which are the outputs of the two current amplifiers. They should be around 2.5V.
VScale: This is used to calibrate the voltage display. The factory calibration is about 31V/V. If you use an external voltage divider, you would set this to match the voltage scaling ratio.
12 - Setup Presets
Preview line shows the number of mode presets (1, 2, or 3), and number of batteries (1 or 2) which are enabled. In use, you can change between the presets by pressing both buttons, right first to change the battery, and left first to change the preset mode.
Preset Cnt: Select how many preset modes you will use.
Only 1: Effectively disables mode presets.
1&2 En: Allows you to easily toggle between two distinct sets of CA limit, PAS, and throttle settings.
1,2&3: Allows you to setup and toggle between 3 distinct CA limits, PAS, and throttle settings. Your Fat Woody e-cruiser has been configured with this option selected.
Preset #1 Name: Lets you select a name for the first CA preset. There are currently 14 possible names to choose from (Blank, Low, Medium, High, Economy, OffRoad, Unlmted, Legal, Pdl Ast, Trq Ast, Power, Current, and Speed). Assigning a name does NOT preload any particular set of limit values, so you will still need to manually input the various current, speed, and power limits, throttle, and PAS mappings that you want for each preset.
Preset #2 Name: Lets you select a name for the 2nd CA preset. This option only shows up if you have at least (2) two mode presets enabled.
Preset #2 Name: Lets you select a name for the 3rd CA preset. This option only shows up if you have at least all (3) three mode presets enabled.
Crnt Prset: Select which of the 3 possible presets is currently active. This screen only shows up if you have at least 2 mode presets enabled.
Power On: Here you can select the behavior of the CA when it is turned off and on.
Last Preset: The CA will boot up in the same preset it was in when powered down.
Preset #1: The CA will always default to the first preset whenever it boots up.
Batteries?: Here you select whether battery presets are enabled as well.
Batt A only: Only one battery pack setup.
Batts A&B: Allows you to easily toggle between two different battery packs.
13 - Setup Preferences
There is no preview line info in the final 'Setup Preferences' setup group.
Main Disp: Here you can choose if the primary display screen shows amps or watts on the lower left corner.
Averaging: This controls the time period for the display averaging of the voltage and power readings. A short value like 0.15 Sec will result in a screen shows nearly instant readings but can fluctuate too fast to process, while a long value like 1.2 seconds will be very steady but will lag in reacting to changes in power draw.
Data Rate: Allows you to select between a 1Hz or 5Hz data output rate for data logging. The 5Hz rate can show more interesting vehicle dynamics, but the file size on long trips can become quite large.
Vshutdown: This is the threshold voltage at which the display shuts down and the CA powers off to save data. It should not be set lower than 10V or else data may not save correctly. If you set it to higher value, then the message 'Low V' will appear on the screen whenever voltages are low. Do not confuse this with the Low Volt Cutoff for low voltage pack protection.
Stop Scrns: This allows you to customize which of the 11 'User' display screens show up on the CA when the e-bike is stopped. Each screen is listed in sequence, with a '1' indicating that it shows up, while a '0' means that it will be skipped.
Movn Scrns: This allows for an even smaller subset of screens to show up when you scroll through the CA's display when the e-bike is in motion.