Newbie needs help please

[Neil H]

Hi All

I have just aquired a Diamondback bike with a 48volt rear wheel conversion fitted, this was previously working fine but dont have any more info than that.
I have checked the battery and it charges and holds charge, all the wiring connectors from the controller and motor etc seem ok.
There is a large twin plug which connects to the battery which I assume is the main power, at the side of this is a small 3 pin round socket were the charger connects.
There is also a 6 cable round flex that is taped with the main battery connector which looks like it should connect to the 3 pin round socket but the plug is missing.
I do not get any life from the controller even with a fully charged battery and suspect it has something to do with the 6 core cable and missing connector that is not allowing the controller to fire up.
Does anyone have any ideas or info please, it would be much appreciated.

 

[Nealh]

Looks like I've a doppelganger now (if only by name) .

You will need to show us some pics of what you have to get an idea also of the kit you have. The 6 wire cable/flex sounds like a hall sensor wires for the motor and usually has a moulded 6 pin square plug to mate with it's other half , 6 in to 3 doesn't usually work !!
We needs some clear pics of wiring, motor & controller.
Also what is the actual battery charged voltage ?

 

[Deleted member 4366]

Hi All

I have just aquired a Diamondback bike with a 48volt rear wheel conversion fitted, this was previously working fine but dont have any more info than that.
I have checked the battery and it charges and holds charge, all the wiring connectors from the controller and motor etc seem ok.
There is a large twin plug which connects to the battery which I assume is the main power, at the side of this is a small 3 pin round socket were the charger connects.
There is also a 6 cable round flex that is taped with the main battery connector which looks like it should connect to the 3 pin round socket but the plug is missing.
I do not get any life from the controller even with a fully charged battery and suspect it has something to do with the 6 core cable and missing connector that is not allowing the controller to fire up.
Does anyone have any ideas or info please, it would be much appreciated.

We can sort you out, but I can't make sense of anything you said. All ebike wiring is pretty much standard. Don't forget that all wires have two ends. 6 cores is very unusual unless it's a separate motor sensor cable. Motor numbers and controller labels don't mean anything, so don't bother with them. Just show us pictures of the bike, the wires and the connectors.

 

[Neil H]

We can sort you out, but I can't make sense of anything you said. All ebike wiring is pretty much standard. Don't forget that all wires have two ends. 6 cores is very unusual unless it's a separate motor sensor cable. Motor numbers and controller labels don't mean anything, so don't bother with them. Just show us pictures of the bike, the wires and the connectors.

Hi All

I have just aquired a Diamondback bike with a 48volt rear wheel conversion fitted, this was previously working fine but dont have any more info than that.
I have checked the battery and it charges and holds charge, all the wiring connectors from the controller and motor etc seem ok.
There is a large twin plug which connects to the battery which I assume is the main power, at the side of this is a small 3 pin round socket were the charger connects.
There is also a 6 cable round flex that is taped with the main battery connector which looks like it should connect to the 3 pin round socket but the plug is missing.
I do not get any life from the controller even with a fully charged battery and suspect it has something to do with the 6 core cable and missing connector that is not allowing the controller to fire up.
Does anyone have any ideas or info please, it would be much appreciated.

 

[Neil H]

Hi,
As requested I have attached several pictures of the bike and various parts, I have confirmed it is 48 volt 250w motor as it is stamped on the side of the hub, the battery is at 42volts as I am awaiting a new charger as the original one is dead.
The wiring in question is the 6 core which is taped up with the main +ve and -ve which goes to the battery pack which may suggest it somehow connects to the 3 pin charging socket or I may be completely off the mark here.
Any help is greatly appreciated.

 

[Neil H]

Just received the new charger today and charged the battery, got a green light on completion and now have 52 volts at the main battery connections.
Still no life from the motor, suspect it may be due to the 6 core cable near the battery which isnt connected to anything (see pic)
Only name I can see on the conversion kit is ZANNX which is on the throttle control on the bars.
Now a little stumped were to go from here

 

[Nealh]

I can't cypher much at all from the pics.
Where does the other end of that multicore cable go to ?
I count 7 wires and not 6 !!
The pics are to close up and don't show any of the cable runs.

One thing you need to confirm is a voltage reading out of the controller box which appears to be the black box above the rear wheel.

 

[Deleted member 4366]

Your pictures still don't show where the wires go, but my guess is that tha 7 way bundle is what should go forward to the throttle, switch and cruise control(?). For them, you need 6 wires. Are there any LEDs on the throttle.

be very careful with those wires. One will have battery voltage on and if it touches any of the others, you'll wipe out the controller. I fear that that advice might be too late. You need to check that the black is a ground by checking continuity yo the negative side of the battery connector. With the battery connected and switched on, check which wires have 5v on them and which one has battery voltage. The only way to determine which is the ignition wire is to open the controller.

You only need to identify the battery wire, the ignition wire, the 5v and the ground to make the bike work. You can experiment to see which is the throttle wire, but sometimes the markings on the controller's pcb give you some idea. The ignition wire will be connected to the big resistor/s in the controller.

 

[Neil H]

Hi Dave & Neal
The wire in question is a 7 core (apologies) need to learn to count.
This comes from the controller in sleeving with the main positive and negative from the battery pack.
The switch and throttle wiring comes from the handle bars and goes right down to the controller, this is in place and connected.
There is a key switch on the side of the battery pack which mechanically locks the battery in place but also switches 2 of the pins on the 3 way connector on the battery (see photo) there is nothing connected to this socket once the charger is disconnected.
When I collected the bike there was a 3 way plug connected to this with the 7 core fex pushed in but the pins were missing on the inside, suggesting it had possibly been ripped out previously, hence me thinking it came from there as there is nowhere else for it to go??
If I need to upload further pictures I am happy to do this

 

[Neil H]

Throttle has no indictor lights or LED's fitted

 

[Nealh]

A nice general pic of the complete bike from both sides might be better, esp one with the hub motor cable and its route.
The 2nd to last pic shows to me what looks like the botched three phase wires and five hall sensors, looking at this diy repair makes me think the previous owner has added the 7 core as an extra may be to try and run a second motor or an attempt to repair the original motor wire.
It is possible that the controller is toast but you will need to put a meter on the hall sensor output connectors + & -- to see if you have any reading or cypher the 7 core to get a reading. Temporarily you are best fitting a wire connector to each wire end to prevent any shorting which will fry the controller if it already isn't fried.

 

[Deleted member 4366]

In that case it's probably for a Cycle Analyst. If it is:
red = battery voltage
Black = ground
Green = throttle signal
Another = shunt voltage (similar to battery voltage
Another = speed sensor signal
Another = brake signal

 

[Neil H]

Please see clearer pics

 

[Nealh]

Can't see what the seller is doing with that extra 7 core.
Obviously the battery connects to the controller so do you know if power is actually going in and coming out ?
If the 7 core is wired to the pcb you would at least expect to see a voltage reading on the red and black.
What you need to do is see how many of those 7 wires are actually soldered to the controllers pcb.

 

[Neil H]

Hi Guys,
Now took the controller completely off the bike, looking inside at the pcb there doesnt appear to be any damage.
The 7 core cable heat shrinked with the main power (battery connections) is in fact only using 1 wire the small black one in the picture which goes in the controller along side the heavy power cables.
To recap, my connections are
3 Motor cables + hall wiring
Main +ve and -ve from battery
7 core from battery area only using 1 black wire
2 x 6 core connectors (1 x 6 core not used) which goes to handlebars for switch and grip throttle

I have checked across 3 motor wires now controller is disconnected and get 0.1 ohms across each pair..............this sounds suspicious! maybe motor is u/s

 

[Deleted member 4366]

I told you that it's most likely for a Cycle analyst. You should measure voltage, not resistance!

 

[Neil H]

Hi Dave
Still not sure were the single black wire should go from the 7 core flex??
Unsure were to go from here, do I need to connect the controller back up before I can check the motor, resistance readings on the 3 motor wires show short circuit or virtuall short?

 

[Deleted member 4366]

The phot is blurred. I can see the black wire going into the controller. Where do the other six go?

 

[Neil H]

The other 6 wires are not used, just one small black wire from the 7 core goes into the controller.
Does it make sense that this may require a negative from the battery to fire up the controller as it is still dead and no motor operation?
Connected the motor wires together in pairs and I get a lot of resistance on the back wheel so maybe the motor windings are OK.
Not sure were to go next?

 

[Deleted member 4366]

You have two switches on the handlebar, One is likely to be the ignition. Do you know what they do? Did you switch any of them on? I would guess that the other is cruise, but it could be anything.