Are you not confident with power limitation at low battery SOC %?
Would you like to set lower discharge cut off voltage to get more range from your battery?
Would u like to use 52V battery with 48V motor and have accurate SOC % reading? Or just to be able to switch between 4 Speed limits by pressing magic button combination?
Then you are on a good address… check the functions of brand new K1 product: BlackBox Racing
BB Racing is permanently connected to middle connector of M500, M510, M600, M560 Bafang motor or to 8 pin speed sensor connector M820, M625 (2 cables version) and hidden inside the frame or under the cover. For M620 CAN motors will be BBR available later.
Device is estimating SOC % of your battery and override motor estimation. K1 SOC® estimation is based on coulomb energy counting and not pure on voltage mapping as Bafang controller does – you should not get SOC % raising when you rest battery after higher load.
– Set battery Low Voltage Cut-off (down to 2.8V per cell) – see Battery functions
– 4 Battery modes: Normal mode , Battery Voltage indication (instead of battery percentage on main screen, without decimals) , Battery SOC Freeze mode , K1 Estimation Off
– Use One-Up Cell battery to motor firmware voltage (48V battery and 43V firmware or 52V battery and 48V firmware) and get accurate SOC % estimation! You can get extra power from motor by this trick – up to 100W!
– Total Energy Used in Ah , Energy used since full charge in mAh, Battery cycles, Motor temperature – can be checked on LCD display under Battery Info
– Speed limit can be set and switched anytime over magic combination. Go with 4 default speeds : 25, 32.2, 45, 65kmh or choose any speed limits you want. Also wheel diameter and circumference can be set.
– ASLS function – Auto Set Low Speed – choose any speed limit you want to start motor after power on. (Not supported with M510 FC2.0 and M560 motors – here is needed restart to take effect).
– Rotor Calibration – calibration can be run over command over USB port. Is needed after controller replacement or rotor swap.
The following product description is also a BB Racing User Manual with step by step. We are going green and thinking before printing…
Device is cabled to your motor over middle 6-pin violet connector (sometimes can be taken by brake sensors – please check!) and hidden inside bike frame or under the plastic motor cover. There is avaailable also 2 cable version for 8 pin speed sensor connector – BBR will sit between motor and speed sensor.
BBR Instalation Instructions
1. Turn off motor. You can also physically remove battery from your ebike.
2. Remove bottom and left plastic cover from your ebike (sometimes needed also to take off left pedal).
3. Locate middle 6 pin connector according the picture above. There could be a rubber cover cap on this connector – just remove it.
4. Cable K1 BBR to motor – sometimes it is not easy and you would need to use players to push in the connector to get a steady connection. Use some force, but be careful.
5. Hide device in front of motor, above motor or under the plastic covers.
6. Put back main battery and turn on motor.
7. Go to Info screen on your LCD. If you see Battery Info screen active – BBR device did start and successfully installed. Turn off motor.
8. Put back plastic covers and pedal if was removed.
Notes
– If you already have original Bafang battery with CAN communication it is not allowed to have also K1 SOC Estimation running simultaneously! Unplug battery CAN connector (we saw already many CAN connectors running from battery – 3 pin triangle orange, round 5 pin green, also square connectors)
– Default length of cable is 20 cm. If you want different length, please let us know in order form.
This device is estimating SOC (State Of Charge) of battery according K1 SOC® algorithm and allows to discharge your battery deeper to get more usable energy. To get accurate estimation is important to set correct battery capacity (in Ah, can be calculated from Wh) and Nominal battery Voltage. We will pre-set these parameters for you before shipping – these are the mandatory information in the order form below. Setup of device can be changed anytime over USB Terminal (app for free) and USB-C cable (not included in a package) – check Configuration tab.
There are 4 Battery modes, which can be switched over magic button combination.
Mode 1 – Device starting in this mode after motor turn on. K1 SOC is estimated and shown. Low SOC Motor Power limitation is in place according Bafang defaults. Can vary according motor type and firmware (saw already power limitation starting at 30% with M600, 25% and 10% with M510, 20% with M500 ).
Mode 2 – Device is showing battery Voltage instead of SOC percentage. Voltage number is without decimals. As battery voltage wont drop under 30V you wont get any Motor Power limitations. You can discharge battery down to Racing Low Voltage Cut-Off (LVC) which can be pre-set (even down to 2.8V per cell). When reaching LVC, battery number would jump to 1% and then 0% and motor will stop assistance.
Mode 3 – SOC Freeze mode – Device is estimating and showing K1 SOC %. When SOC will fall to predefined limit value it will freeze here to avoid Motor Power limitations. When reaching LVC, battery number would jump to 1% and then 0% and motor will stop assistance.
Mode 0 – K1 SOC estimation is turned off. When this mode is selected you must turn off and turn on motor to take into effect. Battery Info Screen wont be available after motor resatrt. This mode will stay selected unless you switch to Mode 1 over magic button combination.
How to switch between battery Modes - Magic combination
1. Power On motor
2. Go to PAS level 0 on your Bafang display
3. Press 2 times “+” button and 2 times “–” ( so on older bafang displays you running over PAS 1 2 1 0)
4. Repeat previous 2 steps to cycle between Battery Mode 0 to Mode 3 (this mode can have 3 different settings of SOC Freeze %)
After magic combination button detection you would see new battery Mode Number (0, 1 or 2) on a display for a second. SOC Freeze modes are identified as limiting number (usually 2 digit, eg. 31% or 26%) for a second.
Video will be available soon…
Low Voltage Cut-Off settings
You can set Low Voltage Cut-off per cell (average cell voltage). This parameter correspond to DOD (depth of discharge) – basically how much usable energy you can get from the battery which corelates with range. K1 BBR is coming with logic of 2 low voltage tresholds, which can be set:
- 1% Voltage Treshold – once average battery cell reach this treshold for few seconds, battery SOC is jumping automatically to 1%. Your motor will have very limited power. Can be set to one of these 4 values: 3.0V 3.1V 3.2V 3.3V per cell.
- Low Voltage Cut-off – battery cell voltage reached hard stop – battery SOC will jump to 0% and motor assistance is disabled. Can be set as low as 2.8V per cell.
There is option to set different tresholds for Battery Mode 1 and for Battery Modes 2 and 3 – internally called “Racing tresholds”. These are the defaults:
Mode 1 tresholds:
1% Voltage treshold: 3.1V
Low Voltage treshold: 3.0V
Mode 2 and 3 “Racing” tresholds:
1% Voltage treshold: 3.0V
Low Voltage treshold: 2.85V
If you would like to set different values, let us know and we will pre-set treshold values before shipping. Setup of device can be changed anytime over USB-C – check Configuration tab.
When BBR is connected (and is not operating in Battery Mode 0 – K1 SOC estimation Off) you would see some useful info under Battery Info screen: Remaining battery capacity, two Energy counters: Total and since last Full battery charge, current Battery voltage, Motor temperature.
How to check Battery Info Screen
Example will be shown at DPC245 display. All Bafang displays have almost same Battery Info screen.
1. Turn on motor with BBR attached
2. Press and hold + and – button simultaneously till Setting Screen show up (some displays also by double-click on “i” button)
3. Go to “Information” and then “Battery Info”
Battery Info screen - Parameters description
First Battery Info screen
Totalvolt – current battery voltage in mV
Res Cap – remaining battery capacity in Ah
Current – this parameter is actually Motor temperature. It is NOT current draw from your battery! Take upper two digits as a temperature in degree Celzius. So in this example motor temperature is 24 degree.
Temp – this is system diagnostic variable. Can be replaced in the future by Controller temperature.
Second Battery Info screen
Full Cap – Nominal battery capacity in Ah. Bafang is not showing decimal values and can be also rounded.
Battery capacity is pre-set inside BBR over configuration command “capX” – see Configuration tab.
RelChargeState – Estimated SOC %
AbsChargeState – Estimated SOC %, same as previous
Third Battery Info screen
Cycle Times – number of full charge cycles of battery (counted over usable energy of battery).
M.N.T – Total energy consumed in Ah
L.N.T – Energy counter in mAh. Is automatically re-set to 0 after full charge of battery and power on motor.
Cell – Number of series cell of your battery. Can be configured over configuration command “cellX”, See Configuration tab.
Remark: Bafang display is reading these variables on page 3 only after the power on. So to get actual data about used Energy you need to power off and on motor..
Once device is installed you can simply switch between pre-set Speed limits* over magic button combination – pressing PLUS and MINUS button on your Bafang display/buttons.
New controllers (M510 FC2.0 and M560 so far) are taking settings into effect just after restart of motor – please allow to power motor Off and On. All other Bafang CAN motors accepting speed limit change imediatelly.
* Some new Bafang controllers have hardcoded throttle speed limit. With older controllers you set also throttle speed limit with pedalling Speed limit.
How to switch Speed Limits
1. Power On motor
2. Go to PAS level 0 on your Bafang display
3. Press 3 times “+” button and twice “–” ( so on old displays you runing over PAS 1 2 3 2 1, on old displays also works holding “+” for few seconds)
4. Repeat previous 2 steps to cycle between pre-set speed limits (default: 25, 32.2, 45, 65 km/h)
5. If you own M510 FC2.0 or M560 you need to re-start motor to take effect
New Speed Limit will be shown on a display for a second.
Video comming soon…
Wheel Size and Circumference
You can specify Wheel size in inches and Circumference in mm. This will be set with first switch of Speed Limit. We can pre-set these parameters for you before shipping – fill in desire values in Order form. Is good to set 2230mm for 29 inch wheel and 2130mm for 27.5″ to have accurate speed to GPS speed.
ASLS Function
When this function is activated, Speed limit is set to predefined value every Motor power on. You can choose any speed limit value. We can activate this function for you before shipping. Does not work with M510 FC2.0 and M560.
Device parameters can be set over USB port – using USB-C cable (not included) and free USB Terminal software. For Android phones we recommend Serial USB Terminal, for Windows computer use TeraTerm. Step by step instructions can be found here. Document is written for BB3, but procedure is the same also for BBR.
BBR must be cabled to your motor and just then connect over USB-C port for setup.
BBR setup screen (android phone):
You can change device parameter over a command – example of a command is in the square brackets.
Parameter description
Speed Limit setup
You can set up to 4 speed limits. If you wanna disable speed item just set to 0. Is good practice to set speed limit up to 72kmh (45mph) for motor and display compatibility.
Example command: “1S32.5” – set first speed limit to 32.5 kmh
Wheel size and Circumference
Set wheel size in inches. Circumference of rear wheel in mm. Set to 0 if you do not wanna change these parameters. These parameters will be set just after the first speed limit switch – go to PAS 0 and then press + + + – –
Example command: “circ2100” and “w27.5”
ASLS function – Auto Set Low Speed
When this function is activated, Speed limit is set to predefined value every Motor power on. You can then any time switch to predefined Speed limits over magic button combination.
This function does not work with new controllers (M510 FC2.0 and M560) though. Supported with all other CAN Bafang motors including HUB motors. We assume new models of motors also wont be supporting this function.
You can choose any speed limit value. Or turn off this function by setting to 0.
Example command:
“asls25” – activate ASLS function. Speed will be set to 25km/h after motor power on.
“asls0” – turn off ASLS function
Battery parameters – Nominal Capacity and Voltage
Set nominal battery capacity in Ah. Set battery voltage in number of series cell:
10S = 36V
12S = 43V
13S = 48V
14S = 52V
0S = Auto
When set to 0 – Voltage auto-detection according firmware in a motor.
Example command: “cap17.5” and “cell13”
Battery parameters – Low Voltage Cut-off tresholds
As explained sooner there are 2 set of low voltage tresholds: Normal and Racing. For each one is defined 1% Treshold Voltage and Low Voltage Cut-off.
1% Treshold is accepting only values: 3.0 3.1 3.2 or 3.3V per cell
LVC: can be set between 2.85V and previous value
Example command: “tre3.1” and “lvc2.9” ; Racing: “rtre3.0” and “rlvc2.85”
Battery SOC Freeze tresholds and Temperature safety
SOC Freezing is a function to trick motor and avoid power limitation at low SOC levels. You can choose up to 3 SOC freeze values. SOC wont go down under this value to avoid motor power limitation. Then jump to 1% SOC at 1% Racing Treshold Voltage.
Example command: “1fr26” and “2fr11”
You can choose motor temperature safety in degree Celsius – SOC will jump to 3% and will limit motor power. SOC will be restored to actual value once motor temperature will cool down under value decreased by 3 degree. (3 degree hysteresis)
Set to 0 – turn off this function.
Example command: “html110” – when motor temperature reach 110C -> SOC will be set to 3%, at 107C will return back
Order Form, Pricing, Shipping and Payment
Cost and Shipping:
K1 BB Racing cost 160 Eur including shipping in EU.
Shipping over National Post with tracking – so far 100% shipping success rate. Shipping outside of EU – add 5 Eur (higher shipping cost and also PayPal currency conversion fee).
Finland, Norway, Swiss – no additional fees.
Payment options:
– PayPal transfer – we will send you a PayPal request.
– Bank SEPA transfer
– Bitcoin transfer – 1BBRa8L9iyx8haoYQsWNN6Mhgy8LysnoGb