Dualtron Storm 5-Switch Mod Upgrade for Nami Burn E3 Scooter - Page 1
Forum section: electronics / projects

author: Gerhan
author_rank: Contributor
timestamp: June 25, 2025, 12:33:53 am
content: 🛴 Dualtron Storm 5-Switch Upgrade for Nami Burn E3 ScooterProject by: Switch ChangeStatus: ✅ Successfully CompletedDifficulty: Intermediate to AdvancedFocus: Signal logic handling, voltage regulation, safe switch integration🔧 Project SummaryThis project aimed to upgrade the stock 4-button switch module on the Nami Burn E3 scooter to a 5-button switch from the Dualtron Storm. The original switch lacked both ergonomics and flexibility, while the Dualtron unit offered a better layout, tactile feel, and expanded control. However, the upgrade involved several electrical challenges due to the scooter’s mixed-voltage system.⚠️ Key ChallengesVoltage MismatchThe Dualtron switch was designed for 12V operation, while the Nami Burn E3 uses both 80V (e.g., for headlights) and 12V (e.g., for horn and signals). Interestingly, the factory switch had its LED indicators powered from 80V using SMD 333 resistors to drop the voltage, which is not ideal and introduces long-term risk.👉 Instead of reusing this resistor-based voltage reduction, I took a safer approach by bypassing the 80V line completely and connecting the Dualtron switch’s internal LEDs directly to a 12V regulated line — preserving their lifespan and eliminating heat or overstress issues.Signal ComplexityThe switch logic required support for independent left/right indicators and a hazard mode that activates both simultaneously. Achieving this without introducing cross-signal interference required thoughtful diode logic design.Button MappingThe new switch has five buttons, compared to the original four. This allowed a more logical and user-friendly function mapping, but demanded custom rewiring and signal routing.⚙️ Technical SolutionsVoltage RegulationI had already purchased a DC-DC buck converter to step down 80V to 12V before starting the project. However, I later discovered the scooter already had a small onboard converter supplying 12V to some components. I decided to utilize this existing 12V supply, simplifying integration and reducing component count.⚠️ Wrong resistor choice during bench testing damaged some of the switch's LEDs — a reminder to always double-check connections when integrating new hardware into an unknown electrical environment.Signal Logic & DiodesTo implement hazard lighting functionality, I used diodes to merge the left and right signal lines into a unified hazard output. This allowed all signals to work independently or together, without back-feeding or voltage leakage.Physical IntegrationMounting and wiring were handled with care for weather resistance and reliability. I used heat-shrink tubing, silicone sealant, and proper routing techniques to ensure a professional, durable installation.✅ Final OutcomeDespite an early testing mishap, the system now operates flawlessly. Each of the five buttons on the Dualtron switch is assigned as follows:Left Turn SignalRight Turn SignalHornHeadlightHazard (Both Blinkers)The result is a cleaner, safer, and more intuitive control setup — especially beneficial for night riding and high-traffic navigation.🧠 Lessons Learned- Always check component values REGARDLESS and measure voltage outputs before connecting sensitive components.-Avoid relying on resistor-based high-voltage drops — use proper 12V rails for LEDs and logic whenever possible.-Be Creative - Diode logic is an effective way to safely merge signal lines in DC environments.-Before adding hardware like a buck converter, inspect the system — it might already have what you need.🔧 What’s NextI’m currently working on reviving my Ducati electric scooter, whose controller was completely damaged due to overheating — specifically caused by factory solder joints melting under very high temperature. It’s turning into a full diagnostics and board-level repair project, which I’ll share once I installed completely new controller with different brand. It is an exciting project. I recommend utilizing drills to clean up left overs on high temperature solders, it less damaging on circuit connections.Happy to share diagrams or pictures if anyone's interested. Comments and ideas welcome!