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Complete useless idiotic dummy ( that is me)

Joined
Feb 28, 2012
Messages
86
Location
Los Angeles
Please help

I purchased a cellman, rear mac kit and a battery from sunthing.

I have no idea of how to install the cables, I have everything in the bike, brakes, motor, throttle and battery and controller. I just cant figure out what goes where. I was expecting that this was going to be color coded or something but I just cant understand the thing. I need a clear diagram of what to connect with.

I will be making pictures and numbering each connection as soon as I get another day off ( rare for me) but if some one can orient me first I will be eternally indebted.


Thank you

silent
 
Regarding the different connectors on the controller, I agree Cellman should be supplying a wiring diagram.

However, as someone who just put his first Mac kit together in the last few weeks, I would say the idiots guide goes like this.

Attach your ebrakes to the controller first. There is only one connector on the controller that fits.

Then connect all the other cables, they will now also only have one available option that fits.

Note the on/off switch will have two connectors but one is not used, so don't worry about having it not plugged in.

Your controller probably came with bare wires for the main power leads, so you will need to attach some connectors here yourself.
I used anderson PP30 connectors ( which I think should be put on at the factory).

Kudos
 
If you know nothing about ebikes, I would say some really important basic info to be aware of is as follows (and for the learned members of this forum, I totally understand the hilarity of me talking technical or seeking to teach in relation to ebikes, it is like listening to a Creationist explain Darwin's theory of evolution - it makes everyone uncomfortable how dangerously close to being accurate the information is, but tends to leave out really core important parts):

The "hall wires" are the five thin wires. Of these, the red and black are the positive and negative of the halls, and the the other three colours relate to the three hall sensors inside the motor which relate to each of the three phases of the motor (these wires tell the controller where the motor is positioned).

The phase wires are the thicker three wires (usually green, yellow, blue). Each of these deliver the power to each phase, don't ever let them touch each other (as in the naked wire or connections), or your will create a short and blow your controller. Be aware that the colour of the hall and phase wires on the motor may or may not match up to the colours of the hall and phase wires on the controller (this can change depending on whether each were sourced from different places - I have no idea about cell_man's stuff, but check the forum for colour combos or send him an email/message and ask him) My advice to remember how important this issue is, is to think of the likelihood that the colours of the phase and halls on the controller and motor matching like for like, is as likely as the colours of the actors in internet porn matching. They will almost always be different. Ok that is a bad example, because in internet porn it will always be male black on female white, but almost never the other way around. In this case there are colours other than black and white, so it is a really bad example. Forget everything I said about internet porn.

The red and black thick wires on the controller are the positive and negative wires, and these are the wires that take the power into the controller. There is also usually a thin red wire, which is like an "ignition" wire. A switch can be put on this, and when turned on it will power up the controller, and can be turned off (search the forum on this, because Cell_man has some kind of pre-charge resistor thingy magig, which needs to be considered - that would be in a footnote if I had that facility). Be aware even when off, whilst this means the controller is not "live", power will still be flowing into the caps in the controller, and can mean if left for weeks in this state unused/charged, can flatten the battery.

Finally, treat an ebike like a dangerous powertool. Don't use it if you are drunk, or alternatively, if you are going to use it when drunk, make sure a friend is videotaping you, so that hilarity can be recorded for the enjoyment of others, and to remind you that you are basically just a shaved monkey who started wearing clothes.

That last point also applies to women, drugs, cars, motorbikes..... come to think of it..... anything that makes living worthwhile....
 
"you are basically just a shaved monkey who started wearing clothes" That is too good. I cannot stop laughing! But helpful information.
 
I just copied and pasted that exact line to my mates......hilarious.....
 
Theres always the small chance that something was wired wrong, but even if that's true, the kit you have may still be salvageble. Either put the driven wheel propped in the air, or set the bike upside down. You will eventually need an inexpensive digital volt meter, might as well get one now. Verify the two fat wires from the battery are labeled properly (red positive/black negative).

If you could take some pics and post them, it would help us and also others like you.
 
He may not have a camera, but somebody who bought the same kit here must.

It's quite a nest of wires indeed. But mostly, which plug goes where is pretty hard to mess up. 5 wires red black blue yellow green, is not going to plug into three big wires, yellow green blue.

Find those on the controller, and you are pretty much 3/4 there. Next find your throttle. I don't know if it's 3 wire or 4, but likely it won't plug into anything else on the controller but the throttle plug. A CA plug is 5 wire for example. Brake plugs are usually two wire. There may be two of them. So your throttle won't go on those.

No label on the controller showing which plug is for what? Shame on you Cellman!!!!! Spend 5 min hand drawing a guide and zap it though a copier. Then put it in the kit. Sheeesh!
 
I just want to be clear about what I said about internet porn, because I think I made things unecessarily confusing. Forget what I said about internet porn. Stop looking at it. Don't look at efukt.com whatever you do.

I am just worried that you are going to take the big part of the black plug, theatrically spit into the small white hole, and then push it in. Don't do that!

Or if you do, video it, and post it up.
 
From my build thread: http://endless-sphere.com/forums/viewtopic.php?f=6&t=41127
02+contents+connected.jpg


The unplugged wires exiting the controller are:
red/white/black bundled >> battery
red two wire with white connector >>on/off switch (not pictured, and as mentioned will have an extra plug for whatever the green button does. Regen for DD I think.)
multi-color exiting toward the charger >> Cycle Analyst
 
Does anyone know if that on - off switch is really needed or if I can just splice the wires together and do away with the whole thing? I never use it and it just ends up in the controller bag taking up space..
 
Thanks guys, I will be making pic tomorrow, yesterday it was too dark for my phone and my camera was nowhere to be found. There are a few connectors that connect to at least two different opposite female...the color of the cables do not match.
I totally feel like a shaved monkey
thanks again

later
 
silentfoster said:
There are a few connectors that connect to at least two different opposite female...the color of the cables do not match.

I think you're talking about the white, 6-pin connectors. If you look inside, one connector will only have 5 pins, missing one in a corner. Match that with the female in the same config.


RyanTo said:
Does anyone know if that on - off switch is really needed or if I can just splice the wires together and do away with the whole thing? I never use it and it just ends up in the controller bag taking up space..

I don't know if it's really needed, but I seem to remember reading that without turning the controller off, if your bike sits for a long time without disconnecting the battery, you will lose charge. I've been considering swapping out the switch for a keyed switch, which will be less obtrusive and more useful, IMO.
 
silentfoster said:
... There are a few connectors that connect to at least two different opposite female...the color of the cables do not match.

The wire colors on each side may not match so you instead try to match on the presence of pin/no pin on one plug and socket/no socket on the other plug. For example, there may be a plug that has only 5 of 6 pins installed and the empty pin in the top left corner like this:
X..
...

So you look for the plug on the other side that matches it with an empty corner socket. Another 6-pin plug might be the Hall sensors:
.X.
...
So you plug it into the one that matches with the empty center socket--but not the previous one with the corner pin missing.

Since you got your battery separately you probably got a controller to battery adapter cable from Cellman. A picture of one follows below. The plug on the left side goes to the controller. The plug in the middle with the looped back red wire turns the controller on when plugged in. The wires on the right side connect to your battery.

Batt2ctlr.jpg
 







here are some pictures of the bike and the cables. I tried again today and nothing is happening. no light on the indicator no motor movement, nothing.
 
Philistine said:
it is like listening to a Creationist explain Darwin's theory of evolution - it makes everyone uncomfortable how dangerously close to being accurate the information is, but tends to leave out really core important parts):

Well, that doesn't go unchallenged... --> http://jus-sumguy.blogspot.com/ Skip the intro and go right to chapter 1

If you would like to start a different thread, I would love to debate you. 8)

-
 
Hey mate,

Sorry to be a pain but is there any way you could disconnect everything from the controller and lay it out like this, so I can see all the wires going to the connectors?

Controllerspaghetti.jpg

From your pics...

Second pic down, the silver pinned socket with the missing central left hand side pin is your wheel hall wire connector, and from controller connects to equivalent 6 pin connector in wheel cable... (which also has those three thick wires with anderson connectors that you have connected up correctly...)


I would suspect that your other 6 pin connector left over after plugging in the wheel cable hall sensor wires is from your throttle and carries the throttle hall sensor (three wires )and the on off switch (two wires)) Connect this up.

If you could take a pic of the connectors/wires from the controls (brakes, on off switch, battery indicator (if you have one) that would be great..

Joe
 
Philistine wrote:
it is like listening to a Creationist explain Darwin's theory of evolution - it makes everyone uncomfortable how dangerously close to being accurate the information is, but tends to leave out really core important parts):


Well, that doesn't go unchallenged... --> http://jus-sumguy.blogspot.com/ Skip the intro and go right to chapter 1

If you would like to start a different thread, I would love to debate you.

I read your website, but when I hit these words:

Personally, I know The Lord exists.

I quickly closed the whole browser. Thanks for the invitation for us to take our fight to the death to our very own thread, but I politely decline (I plead hangover).

For a man who has a degree and deep interest in philosophy, when I read those words, coupled with your invitation, is like if someone walked up to me, with an empty jar and offered to remove the lid, with the words "Do you want to smell my Ebola in here?"

Smart men walk away from those invites. No-one can win in that transaction. Either you are bat-shit crazy, or you are some magical wizard, like that Voldermort guy who my son keeps asking me to assure him isn't real, either way, let's not have a thread together. Ever. Please. Don't cast a spell on me. Please.
 
I like the shaved monkey story much better. And I second the emotion of this is not the forum or thread for religious preaching please!!! Personally, I know that I am much happier without the BS. "you are basically just a shaved monkey who started wearing clothes". Stick with that!
 
Come on guys, shut up so this guy can get help.

Looking at what I see in the pics, you do seem to have your motor to the controller plugs correct. Look very closely at those plugs, and the others to be sure no plug contact pins have backed out of the housings. Make sure the big connectors, called andersons have the contact clicked securely into the housing. they grab a spring at the very end of the connector.

Next, I would suspect the other plugs. Any that go to the brakes, unplug them, it should run without them, but a short on that brake switch would stop the motor.

It could be the on off switch at the handlebars if you have that. Have you even tried to email cellman? We know he is no always fast to respond, actually takes a day or two off at times. Imagine that!

You haven't mentioned battery at all. Controllers have a low voltage cutoff. Got enough voltage?

No light on the indicator seem to me to indicate your controller has not turned on. The second red wire needs to be connected for it to do so. That second wire often leads to a switch, or a jumper as shown in the pic earlier.

Your pictures don't really show connection to the battery well. I doubt you have a major problem, other than CELLMAN DOESN'T SEND A WIRING DIAGRAM. Likely you aren't reading this, but you are about to go off the dogman recomended list buddy.
 
silentfoster said:
here are some pictures of the bike and the cables. I tried again today and nothing is happening. no light on the indicator no motor movement, nothing.

silentfoster, if it's still not working you'll have to provide more info so that you can be helped. All we have so far are some pictures and that you tried it again but nothing's happening. That's not enough. All posts so far should have been enough to get you going assuming you read them and the kit parts are ok.

How is the controller connected to the battery? Anderson connectors? Bare wires? I do see a red wire with a bare end in the first picture but that's all. Is that the controller sitting on the battery in the third picture down?

Aside from the main power wire is there any red wire coming out of the controller that is still unconnected?

What kind of throttle do you have? If you have a combination half-twist throttle, 3-speed switch, and green button cruise control it has a 6-pin connector minus a corner pin and another 2- or 3-pin connector I can't remember right now. Regardless what throttle it should be connected to matching connectors at the controller.
 
'kay I have resumed looking at the puzzle...

I didn't notice the first picture originally (with complete bike).

I have added some labels to your pictures:

View attachment 1

ControlsPlugs.jpg

So as said by Dogman... You don't need to connect the brakes for this test

It appears you have the right connections for:
phase wires (single anderson Blue Green yellow)
Hall wires (6 pin connector to same "cable" as phase wires
Throttle, switch, Battery indicator (other 6 pin connector)

Make sure the switch on the throttle is out...

Now.. Umm... Err... :oops: again as Dogman mentioned... Have you connected the battery? looking at the pics it appears to me there are no connectors on the main power wires, thick Red and Black wires...

Ya gotta have a battery for anything to work....

Joe
 
Oh, That must be it! I should have connected the battery!!! Hahahahahaha!

I guess with the tittle of the post it's a thing to consider that I am so stupid that I did not connect the battery...

Of course, I did the test with the battery on, and fully charged...

This is my controller, out and organized, I haven't had a chance to play with it the last two days, probably I won't have it tomorrow neither. But I will examine my your posts and all the info on Monday or Tuesday and I will see if I can make it move...



Uploaded with ImageShack.us
 
silentfoster said:
Oh, That must be it! I should have connected the battery!!! Hahahahahaha!

Ha ha ha.

Those two red wires with the plug at 11 o'clock in the picture connect to an on-off switch. SkyknightJohn in a previous post confirms that's what they are. Those red wires connect to a circular on-off switch and green button (but not the throttle) that wraps around the handlebar. Pictures of the switch here:

SkyknightJohn 3rd picture down, the switch next to handlebar stem
http://endless-sphere.com/forums/viewtopic.php?f=6&t=41127#p601561
HombreNeuvoElectro 4th picture down, the LHS switch
http://endless-sphere.com/forums/viewtopic.php?f=6&t=42313#p618678

Can't tell whether you have such a switch from your pictures but your whole bike picture has those red wires hanging off the rack unconnected. So can't assume that you even have the on-off switch connected until you confirm it.
 
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