Before you get a standard Cycle Analyst V3, you need to decide which model CA3 you need:

  1. the CA3-DP with the speed signal entering the CA3 via the main cable only
  2. or the CA3-DPS with an external speed sensor hardwired to the CA3 board. Here the wire from the main cable is disconnected from the board and tucked back.

On both standard models all cables enter the housing through the rear housing half. The holes are larger than the cable diameter, and the cables are secured with a piece of hotmelt lined shrinking tube from inside the rear housing.

The cables except the programming cable and the power jack are terminated with JST-SM connectors, in one case a single cable is terminated with 4 JST-SM connectors, leaving its inner wires exposed. The programming socket lies open.

The housing halfs are joined with silicone paste, and the front cover glass is glued to the inside of the housing.

The naked housing screwheads allow for moisture to seep into the housing, even though there are O-rings between the CA's rear housing and its board.

 

What do we need to do in order to reach a dust- and waterproof rating of IP66?

Firstly, get rid of the JST-SM connectors. They are neither water- nor dustproof.

Unscrew the 4 screws holding the 2 housing halves together. Prise the 2 housing halves apart. Pull the connector coming from the front housing half from off the board pins and remove the front housing.

Unsolder the wires from the CA board, and remove them from the rear housing.

You now have to decide if you want to:

  1. retain the rear housing with its cable type connectors or
  2. whether you replace the rear housing with a 3D-printed rear housing that lets use 10 HIGO Mini-B panelmount connectors instead of 6 HIGO Mini-B cable connectors.

In the first case, we call the model CA3-HIGO. In the second case, the model is the CA3-CX, with the C standing for Custom and the X (X standing for the Roman number 10) for the up to 10 HIGO panelmount connectors you can fit. This allows you to use the Cycle Analyst as a cable hub centrally mounted on your e-bike's handlebar.

If you decide on retaining the rear housing and build a CA3-HIGO, you need to drill a hole for fitting the GORE© pressure equalising valve and drill an extra hole for the main cable if needed.

Once you have fitted all cables and secured them with a piece of hotmelt lined shrinking tube from inside the housing, and fitted your GORE© pressure equalising valve, you need to pot the areas around the cables and the valve with epoxy.

If you go with the panelmount version CA3-CX, pre-wire the HIGO Mini-B panelmount connectors and fit them in place. If you don't use all 10 holes, seal the remaining holes with a silicone plug. Fit the main cable, secure it and pot it with epoxy.

Now you need to solder the wires to the board, or terminate them in groups. Follow the wiring layout on this drawing: CA3-CX and CA3-HIGO standard internal wiring diagram

Notice how I said standard diagram?

That is because if there is an established standard for wiring JST-connectors to a CA3, there must also be a Standard for wiring HIGO connectors to a CA3  in order to make things work as a plug and play system:

 

 converting the Cycle Analyst V3 to HIGO connectors wiring diagram

CA3-CX and CA3-HIGO standard internal wiring diagram as PDF to download

 

Continue to: The HIGO Connector Standard on the Cycle Analyst V3