Can damaged BBSXX programming cables kill controllers?

[guerney]

Rather like headphone jacks, I think one or more of the wires has broken at the julet connector end. It was a glitchy connection - usually when I connect the cable and turn on the battery, the gear sensor pulses continuously with a little green light. When it didn't connect to the Windows PC, I flexed the connector plastic sheathing above the julet connector, and the green light would flash and stop. Would glitchy signals from the damaged connection, terminally confuse the controller? My bike is working fine, but the plan to increase amps from 15 to 20, has been thwarted. Now that I can solder ( ), I can simply order a new connector from China. When it arrives, I'll reinforce the flexing part of the julet connector with self-adhesive marine heat shrink, to reduce extreme flex and prevent that happening again.

 

[Fordulike]

The connector on the harness side does carry battery voltage (orange and brown wires on a Higo connector, not sure of julet connector colours). This in theory could blow a controller, if the wires were to short out anywhere along its length up to the USB adapter.

You've not made it totally clear which connector you think is damaged, the programming cable connector or the harness cable connector?

There are better quality programming cables on eBay. The ones with the clear heatshrink can give problems, as they use inferior connectors (non Higo) and cheap USB adapters, which can cause issues with Windows recognising the adapter. Plus, the wiring to the USB adapter doesn't appear to have any form of cable strain relief, which could cause a short if the cable is tugged too hard.

 

[guerney]

You've not made it totally clear which connector you think is damaged, the programming cable connector or the harness cable connector?

It's definitely at this end - glitches on and off when I bend the flexible part of this connector. I thought about excavating the wires out of the non-flexing part to splice... but I think I'll order a new connector or cable. Considering how many thin wires are going through, a bit more strain relief would have been wise to add to these cables.

 

[Fordulike]

Wow, is that your actual connector, or a generic photo off Google?

 

[guerney]

Wow, is that your actual connector, or a generic photo off Google?

That is indeed a photo of my own very naughty glitchy connector.

 

[guerney]

There are better quality programming cables on eBay. The ones with the clear heatshrink can give problems, as they use inferior connectors (non Higo) and cheap USB adapters, which can cause issues with Windows recognising the adapter. Plus, the wiring to the USB adapter doesn't appear to have any form of cable strain relief, which could cause a short if the cable is tugged too hard.

Mine's a good quality black one - but the connector was very tight at the julet end, and it was always a struggle removing it. I'll add some non-conductive silicone lubricant at the connector edges to make removal easier probably, in future.

 

[guerney]

There's usually some sort of error-correcting feature in communication systems using cables, and it might be built into whatever protocol Bafang uses. Maybe truncated commands are discarded by the controller.

 

[Fordulike]

Mine's a good quality black one - but the connector was very tight at the julet end, and it was always a struggle removing it. I'll add some non-conductive silicone lubricant at the connector edges to make removal easier probably, in future.

I must admit, original connectors are quite tough to pull apart. I suppose it's inherent in the design to ensure a waterproof connection.

I grip the two connectors firmly and use a gentle wiggle motion whilst pulling, to disconnect mine. I never pull apart by the cables, as the cable relief was never designed for that amount of force. Never had a problem with Higos to date, touch wood

 

[Fordulike]

There's usually some sort of error-correcting feature in communication systems using cables, and it might be built into whatever protocol Bafang uses. Maybe truncated commands are discarded by the controller.

That went well above my head, but never had a problem programming my BBS02 either

 

[guerney]

That went well above my head, but never had a problem programming my BBS02 either

I just hope garbled commands, received by the controller through a damaged programming cable, doesn't cause problems later - or indeed immediately cause it to cease functioning; locked in a terminal state through confusion.