EHC replacement

[Th3InfamousI]

Hi Erik,

The failure rate of my D-Box is about 10 percent while the installation and about 1 percent when ready installed. However, 90 % of the failures are customer problems while the installation and could solve by phone or mail. That´s why I prefer to sell my boxes to a few distributors with technical background knowledge and a good telephone support. However, the 1 % sounds good at the first view but here are many custom bike owners around in Europe who drive a few hundred miles per year. So, even the worst electronic design might work for a couple of years in this case. I still have sometimes returns from my old C-Box what I made between 2008 and early 2009. This box was my first "experiment" in this area. I still change these old devices against the H-Box for free, even after 7 years, cause I can not let my costomer hang in the rain. The warranty time is 2 years normaly. Just feel free to search "Elektronikbox" in several European custom bike internet foren. I believe, my customer support is not so bad. The comments in the foren speak for themself and it´s better than any stupid advertisement.

Erik, you know my opinion about the connectors. It was good intending from BD to give the customer the opportunity to change the EHC in a couple of minutes in case of problems but you see the result. if you would like to do a good job on your bike then better buy a D-Box or something else with better connectors, rip parts of the old harness and invest 1 day work with the installation together with an experienced bike technican and you might have fun for many years without any problems if you do the wiring in a professional way. A bike control is absolute not rocket science.

By the way, I wonder that BD had changed the connectors in the late 2008. The frame from the cable connectors covers the EHC connectors what will prevent the EHC connectors better against water compare to the older con´s. The rest of the schematic is almost the same with only a few minor differences. Why not earlier? What is your opinion about?

All the best!
Axel

Cool I agree install failure is common. I'm sure you have seen a Wire Plus unit that has two separate modules there failure rate was quite high due to the installation process. Cutting and soldering 50 wires one by one. I've had mine trouble free for 5 years but it was a pain and see where people mess up.

I was wondering if any of the components you used would be considered of better quality or sturdier than the original EHC ? But seems like for the most part they are the same?

Anyways thanks for it. I wish I could try it but both my dogs have different units so I no longer have the harness. Got a Wire Plus in one and a PDM in the other.

Enjoy your time off over the next few weeks you deserve it!

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[francoblay1]

Well....... I think its awesome that Axel came out with this piece of kit.

@Axel , if you need another "guinea pig", I will be more than happy to try your EHC in my 06 K9. (I am still running the original EHC, and I am worried about it letting me stranded any day) I do ride long trips all over Spain.

 

[Th3InfamousI]

Well....... I think its awesome that Axel came out with this piece of kit.

@Axel , if you need another "guinea pig", I will be more than happy to try your EHC in my 06 K9. (I am still running the original EHC, and I am worried about it letting me stranded any day) I do ride long trips all over Spain.

If I were you I would claim the first batch which he is selling cheap, I know I would if I had a use for it. If nothing else a spare for you.

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[BWG56]

good idea

Your from New York, its Idear

 

[francoblay1]

I used his email he posted and he got back to me already I'm getting one for a back up to my original ehc he said after April 11th

Same here.

 

[Rottweiler]

I used his email he posted and he got back to me already I'm getting one for a back up to my original ehc he said after April 11th

Same here also. I will put it on and keep the EHC as a backup. Hopefully put some more miles on this year and test it.

 

[Axel]

Hi,

...just a small update: I got the 2004 boards today and found the time to fix 4 boards. The boards look not very professional at this time. My solder paste was almost dry what followed that I need to replace and solder some parts by hand :-/ Anyway, I hope to test it tomorrow on a bike. I´ll keep you inform tomorrow or after April 11...

All the best!
Axel

 

[Axel]

Hi,

i just be back from the local BD dealer. The EHC 2005-8 works fine with the changes. Also the small plastic window for the led´s is not perfect yet, but the led´s are much better to recognize. Unfortunaly he had no model available for a 2004 EHC test but he will check it together with a customer within the next week. I´ll keep you inform.

All the best!
Axel

 

[BWG56]

Great job , Axel

 

[timy1360]

great!!! How can i buy one for my ridgeback 2005? thanx.

 

[Axel]

Hi Timy1360,

just contact me at info@elektronikbox.de and i´ll send a proforma invoice when everything is fine.

However "my" local BD dealer had installed the 2004 EHC today and everything works fine )) This board was my first 2004 "shot" and everything is nice. This is not very often happen...

I had potted a few test plastic boxes yesterday and today. I had closed the threaded holes with normal acryl glue and it works perfect to close the holes against the potting compound. So, there is still only one challenge with the potting compound what I need to solve: The potting compound will not give a good connection to the plastic box, even when I put very low quantities of hardener in the compound what result in a long reaction time. I attach a photo. You can see that the connection to the Polycarbonat spacers is good but not to the walls of the box. This will be a risk for water on the pcb and is not usuable yet, even when the pcb board inside is covered with potting compound.



I never had the same problems with my other electronic boxes right now. My old electronic box cases are made in Polycarbonat but the new case is made from ABS material, what have a different performance. I´ll contact my distributor for the potting compound when I´ll be on the road tomorrow and think that he can help me, cause ABC is a common material for potting boxes as well.

By the way, does somebody knows the current from A-1 of the 2005-2008 EHC to the starter solenoid? Is it about 10 Ampere like in a Harley D.? I wonder a bit, that the internal highside switch for the starter solenoid is not getting warm when in use. There is just a temperature difference of about 20 degree what is pretty low. I have designed it for 30 Ampere and I just looked again to the manual and have seen that the high side switch will switch off somewhere between 30 and 45 Ampere. Maybe this highside switch is still too big and will not switch off in case of a short circuit will happen at the bike. I´ll keep the suggestion from Curtis "CaptainAmerica" in mind and put a 30 Ampere fuse in the main line between battery and EHC...

I hope I don´t disturb you with my small problems. I´ll keep you inform.

All the best!
Axel

 

[BWG56]

Very interesting reading, if I might add

 

[Th3InfamousI]

Yep..that potting looks not good.

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[Rottweiler]

Thanks for all the info. and testing.

 

[Axel]

Hi,

...just a small update: I have changed the D-Box software to the EHC software yesterday. I felt, that the D-Box software had to many options what are not be used in the EHC and what made it a bit complicated to the end user. I attach the temporary manual with the software describtion what is still with some "funny" english mistakes...

Last week I had some calls to employers of 3 potting compound companies, I had try to deal with material data sheets, potting compound profiles and other shit. I have only understand a bit of the theorie stuff what the guys told to me, but I´ll get a potting compound for the EHC tomorrow morning and I´ll looking foreward for the test of it

I´ll change the layout of the EHC devices one more time within the next weeks in order that there is no need to put an additional fuse in the main line. Right now, every output is good short circuit protected, except of the pins A14, A15, B31, B32, B16, B17, what are protected only via the 30 Ampere ignition High Side switch what is too high. I´ll use one of the double output pins of the Hightside switch for the rear light, what still can handle 12 Ampere. This will reduce the maximum output current to the rear light down to 6 Ampere what is more than enough and I can put the other output to the pins A14, A15, B31, B32, B16, B17 and the corresponding input to the ignition input of the controller. I don´t know, why I haven´t did it earlier... However, I hope you understand my confusing describtion ;-)

All the best!
Axel

 

[Rottweiler]

Thanks Axel

 

[timy1360]

Great!!! Thank you .


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[Axel]

...Just a short update: I got 2 potting compounds today and already potted 2 boxes. It looks much better compare to the other compound . I´ll destroy it tomorrow when it´s complete hard and see what compound is better connected to the ABS material.



All the best!
Axel

 

[Axel]

Just a small update:

I tried 3 different potting materials and 4 different primer what should connect the ABS wall material with the potting compound. One combination is not bad in my opinion. Also the treatment inside of the box with sand paper before potting helps to improve the connection. However, all combinations can be removed from the ABS with force. I think, I´ll use a compound combination what is not complete hard. The connection of the potting compound to the pcb board is perfect in my opinion. There are no visible gaps and I was not be able to remove the compound from the pcb. The resin is very liquid what reduces bubbles in the material while the drying process. The board is an epoxyd material, what is a bit similar to the potting material. This might be the reason for the good connection. I think, the chance to flood the circuit is not pretty high, even if there comes water between the box walls and the board. The only weak parts are the connectors in my opinion. Let´s see...

I have assembled and tested 4 pcs. of 2005-8 Cabureted EHC and 3 2004 EHC today and will pot it tomorrow and bring it to the local dealer this Friday or Saturday. The devices of the first serie what I promised to you will be available after April 22, when I have got the sch... mixed signal connectors (...after 4 weeks delay :-/ )

However, I have not expected so many challenges with the case material. The electronic job was more like a kids birthday compare to the challenges with the case.



All the best!
Axel

 

[Axel]

Ready




I think, it´s sexy. On the next version I try it without my fingerprints in the potting compound. I´ll bring it to the local BD dealer tomorrow. The other devices will be ready at the end of next week. I´ll come back to you when the next devices are ready and tested.

All the best!
Axel