Powacycle Windsor controller wiring

[liammcl]

Hi, I have just got a Powacycle Windsor ebike,
and it looks like the wiring has been tinkered with...

Atm, when connecting the 24v battery there is a spark and 4amp current whilst the wheel isn't moving.
The throttle works ok, regardless if the brake levers are on or off, or if the pedals are moving.

Something is amiss...so I'm going back to basics...
I just want the throttle to work, regardless of the brakes, or pedalling.
just as simple as possible to start with...

Could you please tell me what the wires are..


Many Thanks
Liam

 

[Nealh]

If your bike has throttle, pas, exterior wheel speed sensor and brake sensors then likely the following is correct.
Not all throttles and brake sensors use 3 wire hall sensing and will use 2 wire only.
Trace your throttle wire to check it is two wire first as this will mate with the correct opposite connector.

5 wires lcd or led.
The others from what I can figure are;
Grey/Black = Brake wire.
Blk/Blu/R = Speed sensor.
Gr/Y/R = PAS.
Br/Blk = throttle

 

[liammcl]

Many thanks Nealh

What is the real concern for me, is that there is nearly 4 amps flowing from the 24v battery, even when the throttle is off, and the wheel isn't spinning.
Any ideas what could be causing that ?
As expected , there is quite a spark when connecting the battery up.

 

[Nealh]

No idea why amps are flowing must be the controller being asking for it for some reason, by what though ?
My Swizzbee sees 1.25a flowing when battery is connected but slowly diminishes after a few minutes.
The spark connection is normal esp with no battery on/off switch, it is the flow/rush as the discharged controller in rush capacitor charges up. Fitting a switch to the v+ battery side may help or adopt an anti spark wiring set up.
http://scriptasylum.com/rc_speed/nospark.html

Alternately XT90AS connectors are available shame they aren't yet in XT60 form.

 

[liammcl]

Many, many thanks Nealh,
I shall investigate more.
It seems fine when it is running, so maybe I am worrying about nothing
Thanks again !
clear skies and clear roads

 

[liammcl]

... I am half tempted to connect up 36v volts ...
My other 2 electric bikes deffo have a lot more oomph..
the 24v meerkat , i upped to 36v without any probs (so far)
*update*
Nah, the controller stopped the 36v dead