cyclotricity error code issue

[VINTAGEBASS]

Looking for some assistance as I am at my wits end! I have a cyclotricity 500 watt rear wheel kit with LCD at 36v. It has developed a fault where the battery power displayed on the LCD goes from full to empty in a blip if I start going uphill, the pedal assist works in short surges and it is throwing up error code 06. If I turn the battery on/off then it will work again temporarily but cuts out again. I have tested the battery across all cells and it is still showing 4.02 volts per cell and a total of 40.2 volts at the output and charge sockets, hence I think I can rule the battery out. I am not getting excessive resistance when turning the wheel so all wiring seems okay there. HELP!!

 

[amberwolf]

What does the battery show for cell voltages *during* acceleration, or with an equivalent load on it? Since the problem happens only with a load, you must test with a similar load.

If it doesn't sag a bunch, causing LVC cutout, then it's probably a power connection between the cells and the controller having too high a resistance. (partly unplugged?)

 

[VINTAGEBASS]

I will try to wire my multi meter in to get an accurate reading, I have been advised that the error code is for motor load issues and like you said this could be down to a bad connection. Time to reconnect all cables and check for pushed in pins thanks for your help

 

[VINTAGEBASS]

I have tried all cables and continuity tested wherever possible and found no issues. I ran the bike with a voltmeter on the battery and under load it didn't drop below39v so think I can rule that out too. My next target is the controller, when using PAS it cuts in/out in 1 second bursts making me think something has gone out of whack. Hoping this fixes it and will update once it arrives.

 

[VINTAGEBASS]

Problem sorted, turned out to be a faulty controller. I removed it and adapted a cheap Chinese controller and now it runs brilliantly. unfortunately the controller I bought does not support the LCD screen so I have no way of limiting the power, any suggestions would be greatly appreciated as it currently goes over the UK 25 km/h legal speed.

 

[amberwolf]

A "simple" way, if using a throttle (don't know a way to do it for PAS):

Measure the speed (cycle computer, speedometer, etc) at maximum, loaded while riding. If not possible just do wheel-off-ground test at full throttle.

Then use that speed and the limit to make a ratio.

Use that ratio to create a voltage divider of two resistors, or use a potentiometer. 5-10kohm total should be fine.

Connect hte bottom of the divider (or one outer leg of pot) to throttle ground.

Connect middle of divider (or middle leg of pot) to controller throttle signal input.

Connect top of divider (or other outer leg of pot) to throttle signal output.


Now the voltage the controller receives will only ever be enough to reach the legal speed.

Unfortuantley it will also limit max power for hills and whatnot, as it prevents ever using full throttle, unless you put an override button somewhere that shorts across the top resistor of the divider (or the center to "top" leg of pot).

 

[VINTAGEBASS]

Thanks Amberwolf, I actually thought about trying a potentiometer in but didn't know how. This should be all I need to get up running again.
This is a great forum and its down to people like you.