hidden wire brake sensor... ?

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dirtbiketoebike   1 W

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E-bike motor cut off sensor-universal fit for cable brakes

Post by dirtbiketoebike » Jun 14 2014 11:42pm

Looked but didn't see one here. Purchased this sensor for my back brake not the front as I feather them more. The great thing is I can now use my gear shifter brake combo now that came on my original bike. Couldn't figure out how to paste the ad on here.. Item #281294629865 on ebay. Easy to install, tie red wire into my 5v throttle and other 2 wires to the brake controller. Sorry picture file was too big, I'll have to use my other camera if I get a moment.
Last edited by dirtbiketoebike on Jun 14 2014 11:48pm, edited 1 time in total.

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Re: E-bike motor cut off sesor-universal fit for cable brake

Post by dirtbiketoebike » Jun 14 2014 11:48pm

Brake cable goes through the sensor housing which goes into the brake cable adjuster into the caliper.

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Re: E-bike motor cut off sensor-universal fit for cable brak

Post by Gregory » Jun 15 2014 12:04am

BMSBattery and other vendors sell them under HWBS or Hidden Wire Brake Sensor.


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1) x5305 Hub Motor in a 24" Sun rim with 10G spokes, Kelly 72601 controller, 74V 10Ah Turnigy LiPo 20C Battery and CycleAnalyst
2) Mac 10T rear hub in a 700C "comfort bike" 15S 5Ah LiPo, stock 28A Xie Cheng controller
3) 38" Longboard, Turnigy 6374, CC Mamba XL2 ESC

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Re: E-bike motor cut off sensor-universal fit for cable brak

Post by dirtbiketoebike » Jun 15 2014 12:06am

These been out for awhile?

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Re: hidden wire brake sensor... ?

Post by pythonz » Jun 29 2014 11:31am

I just got my eBike parts including two HWBS. I have the same problem as Knightly posted earlier in this thread, i.e. the brakes are always on and the red led is constantly litting.

I have one of the sensors mounted over the brake wire and it does not matter if I pull my brakes or not. The brake signals always on.

As a test I connected my other brake sensor to my controller but did not pass the brake wire through it. The brake was off and no led was litting. Later i put a wire inside this brake sensor and the brake was trigged (led was litting) and now it will never go off no matter if I remove the wire or if restart the system (disconnect -> connect the battery)

Has anyone else had these problems? How does the sensor know when the break is on or off? Does it need some calibration?

I have a S09P controller from BMSBattery with three wire brake connectors. I have checked that the correct colors are connected.

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Re: hidden wire brake sensor... ?

Post by jateureka » Jun 29 2014 5:33pm

The sensor is directional, so make sure the brake cable comes from the brake lever feeds down through the sensor and then connects to the brake caliper. The LED on the sensor should be facing the brake caliper.

The sensor works with active low brake so your controller needs to have that, not active high.
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Re: hidden wire brake sensor... ?

Post by nukezero » Jun 29 2014 11:56pm

I'm using one with Lyen 12 fet controller. works great, very sensitive.

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Re: E-bike motor cut off sensor-universal fit for cable brak

Post by kampua » Aug 27 2014 7:26am

Anything that comes with bullet head suitable for Bafang BBS02 mid drive?

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Re: E-bike motor cut off sensor-universal fit for cable brak

Post by wesnewell » Aug 27 2014 8:31am

Need Advice? https://endless-sphere.com/forums/viewt ... =3&t=66302
Mongoose 26" Ledge 2.1 mtb bike $99, yescomusa.com 48V 1000W rear hub kit $200, Hua Tong 72V 40A controller $35, 10ah 24s lipo $217=~43mph, range=45 miles @ 20mph. 25K miles and still going strong.
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Re: hidden wire brake sensor... ?

Post by brianLEV » Nov 17 2014 9:18pm

Does it improve the performance of the braking force???

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Re: hidden wire brake sensor... ?

Post by amberwolf » Nov 17 2014 9:56pm

It's just a switch to engage whatever form of ebrake your controller has, or to disable the motor during braking.

It does nto change anythign at all about the braking performance of your existing controller.

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Re: hidden wire brake sensor... ?

Post by brianLEV » Dec 12 2014 12:26pm

oh thanks.

then if it does not improve the braking, then there's seems to be no added value of having it...

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Re: hidden wire brake sensor... ?

Post by d8veh » Dec 12 2014 5:07pm

They enable you to use your existing brake levers, which are probably the correct leverage for your brakes, unlike the Chinese ebrakes. They're also necessary if you have your gear changers integrated into your brake levers, so you can't use ebrakes.

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Re: hidden wire brake sensor... ?

Post by BoomerChomsi » Dec 12 2014 6:13pm

Will it works if my controller only has two wires (5V and ground).
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Re: hidden wire brake sensor... ?

Post by jateureka » Dec 12 2014 7:52pm

If it is 2 wire and one is +5V then it is active high, so no, not without additional circuitry.
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Re: hidden wire brake sensor... ?

Post by BoomerChomsi » Dec 13 2014 5:08am

Regarding to the Ebay seller, it works wit two wires controller?

My controller output is 5V and when it is 0V, E-brake is active.

Thank you!
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Re: hidden wire brake sensor... ?

Post by d8veh » Dec 13 2014 5:49am

These three wire sensors work with almost any controller. If you have two-wire brake connectors, you connect the ground wire of the sensor to the ground in the brake connector and the sensor signal wire to the brake connector signal. That leaves the sensor 5v wire, which you splice into either the throttle or PAS 5v (red) wire.

If you want to be neat, there's normally a spare 5v pad on the controller's PCB next to the throttle one, so you can solder on a wire, which will give you the three wires onto which you can add the correct connector. You can buy the connectors from EBay ( JST SM 2.5 3 pin)

Note that the colours on the sensors are unusual: red is 5v as normal, but blue is signal and yellow ground.

The sensors only work in one direction. If you put them the wrong way round, they work in reverse, so on all the time and off when you apply the brake, which should be OK if your controller has only a high-level brake connector, otherwise you have to mount them the correct way round, which is normally off and on when you apply the brake.

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Re: hidden wire brake sensor... ?

Post by BoomerChomsi » Dec 13 2014 6:06am

Yeah you are right I didn't think about that way :oops:

Thank you very much!!!!
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Re: hidden wire brake sensor... ?

Post by jonathan75 » Apr 30 2015 7:25pm

I successfully just wired up my three-wire HWBS onto a controller with a two-wire brake connector.

As you can see, the red wire from the HWBS gets 'spliced' (here shoehorned) in with the red wire for the controller's throttle connector; the black wire from the controller gets connected to the yellow wire from the HWBS; and the yellow wire from the controller, goes to the blue wire on the HWBS. Very chuffed to finally get it to work.

Actually now I have no idea how to find compatible plastic/metal connectors as these don't fit but that's another challenge. If anyone knows please let me know. Thanks.

https://drive.google.com/file/d/0B7ym9W ... sp=sharing

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Re: hidden wire brake sensor... ?

Post by d8veh » May 01 2015 5:06am


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Re: hidden wire brake sensor... ?

Post by nutnspecial » May 01 2015 6:19am

Jonathon, could you do me a favor?

Before you final wire, could you test continuity on signal/ground of hwbs with brake applied and not? 5v doesn't need to be powered.

Mine tested closed no matter what I did?

+1 the jst connectors, makes me feel like a watchmater or something to succesfully do them with needle nose pliers. They must have a tool. Don't forget some heatshrink tube to sure up the fragile 22/24ga wires leaving the connector.

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Re: hidden wire brake sensor... ?

Post by jonathan75 » May 01 2015 12:29pm

nutspecial wrote:Mine tested closed no matter what I did?
Yes exactly the same happened to me I think - the HWBS had its red light permanently on, and the motor wouldn't run. So (keeping with the red HWBS wire stuck in the throttle red bit like in my photo) I just swapped the other two wires around, it wasn't the intuitive setup but it worked. Then the red light would be off, motor could run, unless I pulled the brake lever, and then the red light went on and cut the motor power.

Oh - there's another thing to try. Make sure that the brake cable is pulling through and returning properly, sometimes when I've cut the cable housing it sticks, so you need to clench and unclench the brake lever a few times, give the cable a wiggle back and forth, as I gather the sensor in the HWBS can misread if things aren't pulling quite right. Apparently it can be sensitive and temperamental.
nutspecial wrote: could you do me a favor?
I would happily do that but I'm afraid I literally don't know what
nutspecial wrote:Before you final wire, could you test continuity on signal/ground of hwbs with brake applied and not? 5v doesn't need to be powered.
means, my electronics knowledge is that poor. If you can explain in very simple terms I can try it but I don't think I even know how to operate my electrical testing box thing. Sorry.

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Re: hidden wire brake sensor... ?

Post by nutnspecial » May 01 2015 1:45pm

I appreciate the effort to help!
I'm pretty sure to have ruled out my wiring (was same as your successful combo).

Testing would tell when the sensor is opening and closing circuit. Mine tested closed no matter what I did- wire in or out, moving magnet to top or bottom of travel with wire, 5v hooked up or not.

yellow and blue tested closed, which tells me it's faulty. I would think it should only test closed(continuity) when magnet in the barrel is pulled 1/4" from resting, and possibly then only if the 5v is hooked up.
The best way I can troubleshoot is to understand the circuit's proper operation.

A cheap multimeter will test, but google or the instructions can do a much better job explaining than me. It's handy to know, but don't worry about it on account of me! I'll either try another or just scrap the idea.

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Re: hidden wire brake sensor... ?

Post by d8veh » May 02 2015 1:38am

A couple of reminders. The colours of the wires are unusual. Red is 5v, blue is signal and yellow is ground, so red to red, yellow sensor to black, and sensor blue to controller low voltage brake signal wire.

Secondly, the HWBS is directional. You have to put it on the correct end of the brake cable. One way, it's off and comes on when you operate the brake, the other way, it's on and goes off when you operate the brake. The red LED gives a clue to whether it's on off. The controller will not give power when the LED is stuck.

Occasionally, they get stuck on. This can happen if there's a problem with the brake cable. To reset it, switch off the controller, pull the brake on, switch on the controller, let go of the brake.

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Re: hidden wire brake sensor... ?

Post by docnjoj » May 02 2015 9:22am

Sorry to ask a dumb question but how do you know which way is correct for mounting those sensors? I would guess that you should have the red light side facing the rider?
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