I'm posting this in the hopes of getting responses from ES users who have experienced similar issues as I have. Based on the reading I've done of many previous posts dealing with the new CA, my hardware is most likely fine, and the "fix" will probably be to reflash the firmware on the CA. At any rate, this a copy of the email I recently sent to ebikes.ca and Ed Lyen:
Justin, et al.
Thanks for all of the excellent hardware and service supplied to our project. We've been impressed with the quality of all items from you and Ed Lyen, and the wealth of information available via the folks on endlessphere.com I probably missed something in following directions that were out there, but I'm now stuck at this point and don't want to break anything while trying to "fix" it. Hence, my cry for help from you. I'm cc'ing Ed Lyen on this in the event that he might have an insight to what I did wrong.
CA v3 Prelm6 Cal->RShunt value always resets to 0.000mOhm after being hand edited and saved
CycleAnalyst Ver3 DP, firmware Prlm6 (purchased from ebikes.ca, Sep 2013)
LiMn 13s 48V battery pack (purchased from ebikes.ca, Sep 2013)
12 FET 3077 MOSFET Extreme Modder Controller LYEN Edition (purchased from Lyen, Sep 2013)
Crystalyte HT3525 rear hub motor (purch. from Lyen, Sep 2013) in 20" spoked wheel (laced by us)
eBrakes (2) input to CA only, via factory connector (modified connectors on brake side wires)
throttle (1/2 twist, hall effect) input to CA only, via factory connector
CA to controller via standard JST-SM 6 conductor wire
no jumpers or crossover wires installed
Bike was tested with controller, battery and motor (w/o CA) yielding expected results. Brake and throttle inputs went directly to controller, and worked as expected (smooth response from throttle, high torque, expected RPM's, quiet running, no heat). Battery was fully charged, and resting voltage of the pack was at 52.56VDC, as received from ebikes.ca When CA was first plugged into system, the CA booted to display "Low V", and the throttle, when connected via the CA, would not activate the motor. I (mistakenly?) assumed that the CA would display the "live" voltage from the battery, and would default to a reasonable low voltage cutoff value.
Using the two buttons on the CA, I began programming the CA. I entered the battery chemistry (LiMn) and cell count (13s), and the CA correctly calculated it to be a nominal 48V battery pack. However, the "Low V" still displayed. Thinking it might affect this, I tried to reprogram the Cal->RShunt value from 0.000 to 1.333mOhm, which is what Lyen recommends for this particular controller. Unfortunately, each time (tried this more than a dozen times) I changed the value, it would return to 0.000.
To get past the "Low V" display, which prevented the motor from being turned on, I changed the Cal->V Scale setting from the default of "00.00 V/V" to to "52.55 V/V" (actual battery voltage). This indeed eliminated the "Low V" display, but resulted in battery voltage reading on CA now being 89V, and even 91.6 after the battery's first full charge after doing an 8 mile test run. I left the Cal->Zero Amps setting unchanged at "2.50V 2.50V".
While the system "works" in that the throttle and brakes now make the bike go and stop, the voltage display is obviously incorrect, and the current/amps display shows all zero ("0.00") values, probably due to the incorrect RShunt setting. My speedometer settings also work perfectly, although they don't appear to be "remembered" by the CA at the end of a trip.
From my studies of the posts on endlessphere.com, which have been extremely helpful, it would appear that I should reflash the CA's firmware. To prepare for that, we got the CA programming cable from ebikes.ca, and I have downloaded the correct software, including the latest? (Prelim 6) hex file. I have *not* yet changed the firmware on the CA, as delivered from ebikes.ca in Sept 2013. I do not want to run the risk of "bricking" the CA, if that is possible -- as it is with some other devices whose firmware can be reflashed.
Please advise what I should do, given the above circumstances. Thanks in advance!
The Tringa Group
St Paul, MN USA