Help with e bike electrical connections
03-01-18 | 05:19 PM
#1
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Senior Member
Joined: Nov 2014
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From: Saratoga calif.
Bikes: 2 ezip electric bikes, trek 800 antelope, nishiki international, 1948 schwin new world, phillippe french boutique bike
Help with e bike electrical connections
This e motor was recently donated to the Bike Exchange. I am trying to determine how to connect the charger to the controller.
Pictured are 3 wire/ connector units, large red/black, small red/ black , small green/red/black, and a black plug connected to the charger with a red(with fuse) and a yellow/green stripe wire plus one prong on what looks like a plug end that has no wire connected to it.
Can anyone tell me what the proper connections should be.
The long wires in the battery bokx connect to the wiring harness . I assume one goes to the red connector on one battery and the other goes to the black connector on the third battery with 2 jumpers(not shown) that connect bat1 to 2 and 2 to 3.
Pictured are 3 wire/ connector units, large red/black, small red/ black , small green/red/black, and a black plug connected to the charger with a red(with fuse) and a yellow/green stripe wire plus one prong on what looks like a plug end that has no wire connected to it.
Can anyone tell me what the proper connections should be.
The long wires in the battery bokx connect to the wiring harness . I assume one goes to the red connector on one battery and the other goes to the black connector on the third battery with 2 jumpers(not shown) that connect bat1 to 2 and 2 to 3.
03-01-18 | 06:33 PM
#2
Cycleway town
Joined: Jul 2014
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From: Milton Keynes, England
Bikes: 2.6kw GT LTS e-tandem, 250w Voodoo, 250w solar recumbent trike, 3-speed shopper, Merlin ol/skl mtb, 80cc Ellswick
The one on the left looks like PAS.
The one in the middle, i don't know. Plug looks like display (5 segments in line) but only two wires..? Maybe battery level indicator.
The one on the right is obviously power.
A charger connects to the batteries, not via the controller. It's okay to charge the batteries whilst the controller is still connected though (obviously it's advisable to switch it off). Really you want this loop... Controller-switch-chargerplug-batteries. So you can switch the supply to the controller off, but the charger plug will be on the battery side of the switch, so the charger will still charge the batteries.
The one in the middle, i don't know. Plug looks like display (5 segments in line) but only two wires..? Maybe battery level indicator.
The one on the right is obviously power.
A charger connects to the batteries, not via the controller. It's okay to charge the batteries whilst the controller is still connected though (obviously it's advisable to switch it off). Really you want this loop... Controller-switch-chargerplug-batteries. So you can switch the supply to the controller off, but the charger plug will be on the battery side of the switch, so the charger will still charge the batteries.
03-02-18 | 11:51 AM
#3
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From: Chicago Suburbs
Bikes: GT Transeo & a half dozen ebike conversions.
What else is in the puzzle? I see brake levers. Are they connected to the brown/yellow wires? There should be a throttle with a on/off start button and maybe a LED display top show battery level? Knowing how that looks will tell a lot about the remaining connectors.
The power to the controller is the two heavy red/black wires in the bladed connector, but attaching power will not start it until you find the power on wires.
Looks to me like three 12 V lead acid batteries, connected in series for 36 volts. You should verify they are lead acid. If they're lithium, a lithium battery charger is absolutely required. Otherwise, you can charge them in series with a 36V lead acid charger, or one at a time with an automotive 12V charger.
The power to the controller is the two heavy red/black wires in the bladed connector, but attaching power will not start it until you find the power on wires.
Looks to me like three 12 V lead acid batteries, connected in series for 36 volts. You should verify they are lead acid. If they're lithium, a lithium battery charger is absolutely required. Otherwise, you can charge them in series with a 36V lead acid charger, or one at a time with an automotive 12V charger.
03-03-18 | 12:15 PM
#4
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Any markings on the motor?
Any additional components, display, switch, anything with a wire, do the brake levers have wires?
Good news and bad news. You have all the major, most expensive, and essential elements for an e-bike. That's the good news.
The bad news is, that almost always the controller is connected to some sort of display, panel, or switch, that for the most part is really not all that necessary, BUT includes the on/off switch.
Now, you also have to have either a throttle, or PAS, so of the two unidentified connectors you have, one has to be throttle or PAS, and the other has to be display or switch. They are fairly standard connectors, and throttles are cheap. SFAIK the switch can be activated by a jumper wire or clip, however I am not sure if that needs to be momentary or constant.
Any additional components, display, switch, anything with a wire, do the brake levers have wires?
Good news and bad news. You have all the major, most expensive, and essential elements for an e-bike. That's the good news.
The bad news is, that almost always the controller is connected to some sort of display, panel, or switch, that for the most part is really not all that necessary, BUT includes the on/off switch.
Now, you also have to have either a throttle, or PAS, so of the two unidentified connectors you have, one has to be throttle or PAS, and the other has to be display or switch. They are fairly standard connectors, and throttles are cheap. SFAIK the switch can be activated by a jumper wire or clip, however I am not sure if that needs to be momentary or constant.
