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    A strange battery problem

    I start by saying that I build batteries from scratch and can repair most non fatal issues. This one has me scratching my head. I it is a 36V 375w battery. The bike was not coming on at all so I put a power supply to it and it is fine. So I check the voltage of the battery and the voltage is...
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    S866 Display and Control Unit Issue

    Hi All, We have installed loads of these kits. I received a new batch a couple of months ago and just put the first set on. We cannot get it to work right. We have tried all of the setting changes that we can imagine but the bike still works on full throttle all of the time. Even when the power...
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    Battery voltage dropping far too low under test

    Yes, I can create whatever profiles I want with the LVC determined. I've always run my 36V at 30V LVC. Once the battery is down to 30V the tester does not draw anymore amps from it. When it dropped to 14V at the end of the load test that was a static reading with no load or at the most a few...
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    Battery voltage dropping far too low under test

    Yes, everything you are saying makes sense but for that I've tested hundreds of batteries with this tester and this is not the usual reading for a healthy battery. When I used the word Dumps I just meant that it drops significantly, quickly and unexpectedly. I've been using this tester for a...
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    Battery voltage dropping far too low under test

    Thanks, The tester I have doesn't register the leakage as it stop within seconds of hitting the expected low voltage. It will sometimes show a volt or two below 30 but this time it dumped to 14V before the tester could register that the expected voltage had been achieved. when the test is...
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    Battery voltage dropping far too low under test

    Thanks for your reply, Yes, the tester stops loading the battery as soon as it hits the expected 30V. However, when the drain on the battery took it to about 32v it nose dived to 14v. This of course caused the tester to stop loading the battery. Before this happened it had measured a loaded...
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    Battery voltage dropping far too low under test

    Hi, I test a large number of batteries with a computerized load tester and usually when a battery is bad the capacity is very low. In this case the capacity is fine but the voltage dumps. I'm testing a 36V 15Ah battery. it fully charges to 42 volts and it fully discharges measuring a capacity of...
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    Need to find a replacement for a 5 Pin Giant charger. Do I need the other 3 pins to be active?

    Most charges I have used only have 2 active wires, the positive and negative that goes into the battery. This old charger actually has the + & - but also has a blue/white/yellow combo going into the charger. Does someone know the purpose of these 3 wires? What are they communicating to the...
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    Figuring out the wiring for a hall sensor

    Hi all, We got this hooked up and it is running but it is very low power. We tried a different motor on it and got the same result. It is running at far less than half the speed we expect and that is on the rack so not under load. Do you think this could this still be the result of the phase...
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    Figuring out the wiring for a hall sensor

    Ah, I see, your colours are going from right to left in the photo is that correct? You are referring to the far right pin as pin 1, is that correct?
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    Figuring out the wiring for a hall sensor

    Sorry about the photo. I couldn't get the wires pulled any further out. Going from left to right it is: Pin 1=Green, Pin 2 = Black, Pin 3= Orange, Pin 4 = Grey, Pin 5 = White and Pin 6 = Brown.
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    Figuring out the wiring for a hall sensor

    Ah, the phase wires are brown/white and grey but not sure how to interpret that.
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    Figuring out the wiring for a hall sensor

    The old controller isn't working. I've disassembled the motor to see if we can identify the wiring plan I've attached a couple of photos of the hall sensor board. Remembering that the Green wire is not connected to anything on the bike and that it also is connected to a terminal on the board...
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    Figuring out the wiring for a hall sensor

    There are a few numbers on the PCB such as C37 but I imagine they are not informative.
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    Figuring out the wiring for a hall sensor

    They all have independent locations on the PCB with no traceable common path.
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    Figuring out the wiring for a hall sensor

    I've opened the old unit and there is no helpful markings on the PCB where the 5 wires are attached. They are all grouped into 4mm space.
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    Figuring out the wiring for a hall sensor

    If we assume that black and brown are positive and negative is there a way to determine for the other 3 wires?
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    Figuring out the wiring for a hall sensor

    Is there a resistance or continuity measurement that can be done on the 3 wires to determine their wiring series?
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    Figuring out the wiring for a hall sensor

    Hi Pete, The wires on the old controller are the same colours as the ones coming from the motor. The speed sensor is an old style magnet job on the rear wheel. Good point about the white wire from the motor however. It made me look at the loom going from the motor to the control unit. So the...
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    Figuring out the wiring for a hall sensor

    Hi, We have a Giant Twist on which we are replacing the control unit. We have a problem with wiring the hall sensor. The hall sensor wires from the bike are Black/Brown/White/Grey/Orange/Green. The wires on the control unit are the standard stuff Black/Red/Blue/Green/Yellow. I'm trying to...