Superharness

Introduction

The Superharness is a smart cable that hooks up to the 9 pin Mains plug of Phaserunner and Baserunner motor controllers to support the use of industry standard ebike displays that operate on the KM5s display protocol, without loosing the proportional regen control normally provided by the Cycle Analyst.

Features

Supports 3 modes of proportional regen (Bidirection throttles, analog brake levers, digital brake + throttle)
Control Front Light from Display, Up to 1.5 amps at battery voltage
Rear Brake Light Option changes mode when brakes are active
All Waterproof Higo Connectors most widely available molded plug standard for ebike accessories
LED Feedback, three LED lights provide status output for troubleshooting
Compact Design Overmolded circuitry is not much larger than a typical cable junction

Connections

Here is the plug standard for the device

	Main9 This hookup matches the 9 pin plug present on the V4 and later Phaserunner and Baserunner motor controllers. However, the firmware to properly support 3rd party displays is only present on the V6 motor controllers.
	Display The diplay plug is a 5 pin female Higo, using one of the 3 common pinout standards. Connection to a display with the same pin style but a different pinout will almost always damage the display, harness, and motor controller as the full battery voltage pins are swapped around.
	Throttle The throttle plug is a 3 pin female Higo in the most popular industry format. This supports regular throttles with a 1-4V signal ranges, as well as bidirectional throttles with a 1V center point that go down to 0V for regen control.
	Ebrake The ebrake connector is a 4 pin female Higo and includes both a digital input and an analog input pin to support both ebrake styles. All of Grin's Higo ebrake plugs use this standard. There is also a 4 pin to 3 pin adapter cable to use a 2nd throttle as the regen brake control, plus 4 pin to 2 pin adapters for compatibility with ebrakes sourced elsewhere.
	Front DC Power The front DC power port is a 5.5x2.1mm jack designed primarily for front lights, and can be configured to be always on or turned on and off with the display. It outputs full battery voltage at up to 1.5 amps. Devices with high inrush current may trip the overcurrent protection circuit.
	Rear DC Power The rear light control also uses a 5.5x2.1mm jack and has the same current capability as the front light, and this can be further configured to act as a brake light, going from flashing to steady mode or visa versa when the ebrake is engaged.
	Programming There is also a TRRS port on the superharness that is used for programming the firmware and debugging. If this is connected to one of Grin's USB->TTL cables and hooked up to a terminal program set to 9600 baud, a steady stream of data will be seen showing the state of all the signals in and out of the superharness.

Additional Cables

There are other accessory cables that may be useful for Superharness systems

	4 to 3 Pin Higo Adapter - This adapter hooks up to the 4 pin ebrake plug of the Superharness and allows the use of any of our 3 pin throttles as a proportional regen control input. The superharness remaps the 1-4V output of the throttle into a 1-0V regen control to the controller.
	4 to 2 pin Higo Adapter (Future Product) - Allows hooking up 1 or 2 digital ebrakes using a more conventional 2 pin Higo plug
	Dual Controller Cable (Future Product) - 9 pin Mains Splitter cable that connects one superharness to 2 motor controllers. Option to run 2WD ebike systems with a Superharness based setup. Note that only one motor controller will communicate to the display and respond to PAS or torque control, while the 2nd motor controller will respond whenever a throttle or regen brake signal is active. This works well for 2WD setups that use the 2nd motor primarily as a boost hub for climbing hills, it is not very ideal for 2WD setups (like trikes) where you want both motors responding equally at all times.
	9 Pin Extension Cable - For those needing extra length to the motor controller, we have a 1m long Main9 extension cable to provide greater reach. We do not recommend more than 1 extension if front lights are used due to biasing of the ground offset.

Compatibility

Full functionality of the Superharness and display requires a V6 Phaserunner or Baserunner motor controller with at least the 6.025 firmware installed. Controllers sold before 2023 typically had 6.023 firmware, which has a bug preventing the assist levels from properly toggling up and down. The V4 and V5 baserunner controllers also have a 9 pin mains plug, but these run an older 5.9XX ASI firmware that can't be updated to 6.XX because they use a more limited microchip.