Universal 3-Speed Switch (no programming,works w/any cntrlr)

[Sacman]

I'm gonna put the potted adjustment blob near the controller. There is normally a cluster of connector plugs about 5 inches away from the controller that I normally just wrap up in electrical tape to protect from dirt and moisture. I figure just putting that potted blob right there as well.

Is there any ideal placement location thought of to put the potted adjustment part on the bike somewhere hidden or out of sight?

[Trackman417]

I plan on placing the potted mass in my battery box, if it will fit. If that doesn't work, sacmans approach seems to be the way to go. Camouflage the wirey mess with another wirey mess

[methods]

Just ordered one.
How are they setup "right out of the factory"?
Any ballparks on the percent throttle in each position of the switch?

I dont know about that... you will have to ask Matthew.
Best bet is to jack up the ass end of your bike so that you can do some testing. I like to flip my bike upside down... but this can be dangerous

I would raise up the rear tire, secure the potted module with a piece of tape, take a screwdriver in my left hand, twist the throttle in my right hand, and turn the pots while watching the speed readout on your ca.

Matthew has some rough numbers he can share... but the problem is that the circuit is dependent on your controller input resistance so any absolute percentage mappings he gives you will be skewed a bit. Just look at your freewheel speed, calculate your desired percentage, and tune to that speed. (if you want to get all scientific )

Is there any ideal placement location thought of to put the potted adjustment part on the bike somewhere hidden or out of sight?

Thanks.

They are set up with a long whip so that you can put the control on the handlebar and mount the epoxy block right at your controller (with the other stuff that you dont want to get all that wet)

Anyway -
I suppose you guys have figured out that I put them up on the website. I have been working 13 hour days trying to dial in this new LVC_Breaker. There is one nasty mode where I can blow it by stalling out the bike. It is really kicking my ass I will get it tho - I always do

It is looking like I may possibly be able to have it act as both the HVC_Breaker and LVC_Breaker in one box - but that will take some tricky wiring and a lot more testing.

-methods

[Stochastic]

Just ordered one.
How are they setup "right out of the factory"?
Any ballparks on the percent throttle in each position of the switch?

I dont know about that... you will have to ask Matthew.
Best bet is to jack up the ass end of your bike so that you can do some testing. I like to flip my bike upside down... but this can be dangerous

I would raise up the rear tire, secure the potted module with a piece of tape, take a screwdriver in my left hand, twist the throttle in my right hand, and turn the pots while watching the speed readout on your ca.

Matthew has some rough numbers he can share... but the problem is that the circuit is dependent on your controller input resistance so any absolute percentage mappings he gives you will be skewed a bit. Just look at your freewheel speed, calculate your desired percentage, and tune to that speed. (if you want to get all scientific )

They are not set at any particular setting right out of the factory right now. I did hook them all up to a bike and test them so they may be sitting at the maximum or minimum resistances for each trimmer pot.
I will have to look at my notes later to see what the exact percentages I found when hooked up to my bike.

-Matthew

[cal3thousand]

...
It is looking like I may possibly be able to have it act as both the HVC_Breaker and LVC_Breaker in one box - but that will take some tricky wiring and a lot more testing.

-methods

This sounds awesome.

[Trackman417]

Got the three speed switch today!
The pots that are potted in epoxy are much smaller than I thought they would be. I can't wait to put these things to the test tomorrow morning and tune it up.
Thanks for the great innovation Methods and Stochastic

[Stochastic]

Got the three speed switch today!
The pots that are potted in epoxy are much smaller than I thought they would be. I can't wait to put these things to the test tomorrow morning and tune it up.
Thanks for the great innovation Methods and Stochastic

Glad to hear that you like it!
Let us know how it performs on your bike .

-Matthew

[methods]

We toyed with the idea of installing larger 1-turn pots that you could adjust on the fly. In the end we figured folks would test and tune then pretty much leave it alone so Matthew went with the much smaller 10-turn pots that have more resolution and are less likely to get bumped.

We have 20pcs of 24fet kits on the way from China now. We also have 5pcs of 24fet sample about to go into production. These will have 7AWG wires, genuine IRFB4110 fets, retarded overkill on capacitors, TVS Diode protection on the fets, cleaned, conformal coated, power switches, etc. Folks are going to love these things... for guys currently pushing the limits of 18 fet controllers these will be ROCK SOLID reliable performers. After all the testing we have been doing we have a much better idea of how to protect and manage the mosfets. These controllers are going to be killer.

-methods

[gensem]

expected price on the 24fet controller methods?
variable regen (soft start regen)?

[methods]

expected price on the 24fet controller methods?
variable regen (soft start regen)?

The batch of 20 are programmable - Not familiar with soft start regen - link?
The batch of 5 will not be programmable and regen will be maxed out (perhaps unusable?).

Our final product will sell for $420 and will be rated for 420A (burst rating) and come with a programming cable. This first batch of 20 may sell for less if we start selling them before we get enough testing in to assure they will do what we want them to. Really wont know until we do some testing. The idea is to put out a controller that can either be super reliable for guys running 100V 100A or at least *capable* for guys who want to punch harder currents into CroMotors.

The other non-programmable units will be significantly less - but that price will end up being a percentage of our cost. Wont know until we test them and determine how much modding they need.

I am building prototypes today - in fact I am off to the electronics store in a few here to see what they have in the way of caps in stock. Screw Digikey - I am so sick of having to choose from 56,000 parts... I just want to pick from 3

-methods

[gensem]

The batch of 20 are programmable - Not familiar with soft start regen - link?
The batch of 5 will not be programmable and regen will be maxed out (perhaps unusable?).

-methods

I dont have a link either, its just something thats really needed when you have big power numbers, much like a progressive throttle (ie CA current throttle).
I think you ll lock the wheel quite often with max regen even without modding the shunt. Im using a bone stock 18fet 4110 controller and it does hit my moped tire very hard.

400 is a nice price... 40kw bursts looks nice also!

[methods]

A year or two back there were a bunch of Infineon type controllers that had variable regen. Ebikes.ca had a batch. Pressing the regen button would get you some small amount (like 20%) then twisting the throttle would increase the regen.

This is totally unsafe though on a powerful bike - if you keep that throttle pinned and let go of the regen button you get instant full throttle.

-methods

[Trackman417]

Jut got around to using the three speed switch today.... Well it's a two speed switch right now. It was too dark for me to adjust the tiny screws on the pots, so all I have is the medium and the high power modes to work with. But so far it is a great way to just tune down the power for other people to ride your high powered bike . Definitely takes care of that initial kick you feel when you just want to feather the throttle. Will try to work out the low positions tomorrow when I get some more sunlight.
Great job GUYS