8fun vandalised controller Help Please

[Shady_Brady]

Hi I'm new to pedelecs but some good information so far thanks.
Right my problem is I have an electric 8fun mountain bike which my wife bought me secondhand after some nagging. Used it to go to friends near me parked up removed battery, locked it up and went in a few hours later came out to find that some a***ehole had gone at the controller with what I would belive are side cuts as the cable are clean cut.
Now I'm not worried about repairing but my problem is the majority of the cable are easy to identify but there are a larger group of smaller cables consisting of greens, reds and black with no real way to identify them. The motor is a SWXK36V250W185R if that helps the identity sticker is rubbed off where the serial number of the controller is so any help would be great ie can I use another controller and if so what do I need to look for thanks.

 

[Spinalot]

That sucks, I hope our resident ebike gurus come by and help you out
I suggest you take some pictures and post them so they can help more.

 

[RobF]

Are you anywhere near Telford...?

 

[Shady_Brady]

Thanks I was just getting into the ebike scene only used it a few time I'm gutted. Ill try and get some pictures to post up if that helps. Not near Telford thanks close to Sheffield I have tried to speak to 8fun without any success.

 

[Deleted member 4366]

In principle, it should be easy to identify which wire is which, but you're not giving us much to go on. You haven't told us which bike it is or where the wires have been cut,

8 fun made a lot of different bikes and used different controllers at different times. A photo of the bike, the controller and the damage would help.

 

[KirstinS]

I have a kit from 8fun - post some photos and I'll compare with mine

 

[Shady_Brady]

I understand that but its hard to explain, the cable where cut as they leave the controller. I've soldered the battery cable back together, and the power supply plug for the handle bar battery and mode unit. I can identify the blue, yellow and green for the motor but now I'm not totally sure there are 4 black, 3 green, 2 red and 1 blue of which will be the 3 to the proximity switch on the pedals, two more cables to the handlebar unit, 2 to the brake switch and 3 to the throttle. Other thing I've only just noticed only one brake lever has the switch in.

 

[Spinalot]

In principle, it should be easy to identify which wire is which, but you're not giving us much to go on. You haven't told us which bike it is or where the wires have been cut,

8 fun made a lot of different bikes and used different controllers at different times. A photo of the bike, the controller and the damage would help.

Yay, you are saved, D8veh is here!

 

[JuicyBike]

That's rotten luck Shady.
If we can be of assistance to you from our workshop in New Mills, 300 mtrs from New Town Rail Station, let me know.
Take some time to snap some photos and it will be much easier for all of us to help.

 

[Spinalot]

close to Sheffield

Me too

 

[Deleted member 4366]

While I wait for photos, you must be very careful. There's 4 wires to the control panel. One is a thin red with 36v on it. There's also a thin red to the pedal sensor and another one to the throttle that both have 5v on them. You must be sure which is which because the 36v one will wipe out the pedal sensor or throttle if you connect it to the wrong one. Best to check with a meter to be sure. All the blacks are 0v.
The rest are from memory:
The control panel has blue, red, black and green wires, The throttle and PAS are red, green and black, but you have to get the greens to the right device otherwise it won't work. The PAS pulses 4v, the throttle is variable between 1 and 4v and the green from the control panel does something else. Each goes to a particular pad in the controller that processes the signal, so if you can't figure out which is which, you have to open the controller to see where they go.

 

[Shady_Brady]

I'll sort pictures tonight for tomorrow as I'm on nights, another concern I've got now is that it looks as if water has entered the controller as the pcb board is showing signs of corrosion. But I have just received an e-mail from 8fun for picture of the controller so they can identify a spare. Fingers crossed I can get it sorted.

 

[Deleted member 4366]

I thought the bike was working before the wires were cut. Why are you worrying about marks in the controller, which are most likely dried flux from the soldering process? The only thing that might need attention is the battery fuse because the wires would have shorted when cut unless the battery was switched off (not by the panel).

 

[Shady_Brady]

The controller was working before, but as you can see the controller casing was damaged when attacked which I can’t understand why they targeted the controller. My concern about the controller is the longevity as the seal around the entrance wasn’t the best to say where the unit was placed.

 

[Old_Dave]

May want to tighten the screws that hold the FETs to the heat sink before you power it up.


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[Shady_Brady]

Ye thats me, was going to remove board to check rear side for corrosion.

 

[Old_Dave]

Ye thats me, was going to remove board to check rear side for corrosion.

Lol.... I thought they had tried to steal them.


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[Deleted member 4366]

Unfortunately, I don't know that controller. I don't know whether this picture is any help. The only other thing is to post the colours of the wires and the markings on the pcb where they're soldered. They might be the same as another controller, so we can decode them.
http://www.8funbike.com/images/products/8F20F36R Details1_big4.jpg

 

[103Alex1]

Lol.... I thought they had tried to steal them.

Someone with a mosfetish ?

 

[Deleted member 4366]

I've just been studying you photos and something's not clear. Can you confirm that you've got an LED display/control panel that switches on the controller and has 3 levels of PAS? If so, does it have two two-wire connectors or a single 4 wire one? It looks to me like the thin red and blue wires alongside the main battery wires are the "on" switch at 36v, then the other two red wires are the +5v for throttle and PAS. There should be a green PAS level return from the control panel and a black 0v for it as well. That leaves two green wires for the throttle and PAS signals. The blue wire must therefore be the brake 5v, which will be paired with a black 0v, so the only thing to figure out is which green is which, maybe from the pcb markings. All the blacks are 0v, so you can take your pick. You can check the 2 reds have 5v. If one's a bit lower, it's probably the PAS one, otherwise it doesn't matter which is which.

To summarise:
meter power - red and blue 36v
meter pas level - green and black
Brake - blue and black
PAS - red black green
Throttle - red black green

That makes 4 black 3 green 2 red 1 blue not counting the red and blue for the panel switch.