Wiring info for Crystalyte controller

[NeilP]

having just fried the MOSFETS on my Lyen controller within 5 days of using my first e-bike, I am very wary of just plugging the wires straight in to my new controller, so want to make sure I get ti riht before I do any random plugging.

I have a controller from maxwell65, a Crystalyte 72volt 48 amp (think it said 48...certainly not 40 amp). It is black in colour with a on/off switch and a little keyed switch ...which turns out to be forward reverse.......it was a shock when I found that...and shot backwards into the workbench when I wa expecting to go out the door of the workshop

Anyway, I have mailed Max,and waiting a reply, Also tried the Crystalyte Europe web site...but no similar controller...and the main crystalyte web site seem to be down. Have seen a bit of info on the Power In Motion site, but it does not cover all the plugs on this particular Crystalite controller I have

So any one have a comprehensive list of Crystalyte controllers and wiring.

I have ID'd the CA-DP plug, the throttle, Halls, Phase and power...So i am not totally brain dead...yes I can id big fat red, black, yellow, green and blue wires but the rest are beyond me.

things I need to connect.
Brake levers...
pedelec sensor
Cruise control
LMH switch...possible the wire with yellow heat shrink according to max

Apart from the CA lug, none of the other match the plugs on the accessories I have...and bearing in mind my record ( Lyen controller dead with 5 days) I do not want to just plug things in and see what..happens. Don't want to risk loosing more of this expensive magic smoke

Am off down workshop again soon so will post some pics of the controller when I get back if what I have said so far is not enough info for ID

Thanks

Neil

 

[biohazardman]

Lots of info here not sure if it's usefull to you or not. http://endless-sphere.com/forums/viewtopic.php?f=2&t=19446

 

[MadRhino]

This controller has no pedelec connector, all the rest that you need is there.
I used to set the reverse switch as an anti-thief safety when parked.
You can upgrade this controller easily, it's a 18 4115 mosfet

Here's the connector map
http://endless-sphere.com/forums/download/file.php?id=39557&mode=view

 

[NeilP]

Thaks Guys,

I think the controller is already 4110's at least according to the internal pictures of it I have seen., But I have no need to upgrade this one..Just bought it till my 18 FET 65 amp one comes back from Lyen

Unfortunately the picture
http://endless-sphere.com/forums/download/file.php?id=39557&mode=view

Only shows the ones I already know..the obvious ones. The ones I do not know are just bundled together in the pic with the words "throttle, CA, Cruise, LMH etc...without identifying which one is which.

I have taken pics of the ones I need, but left the camera in workshop...will post them up tomorrow after work

 

[itselectric]

having just fried the MOSFETS on my Lyen controller within 5 days of using my first e-bike, I am very wary of just plugging the wires straight in to my new controller, so want to make sure I get ti riht before I do any random plugging.

I have a controller from maxwell65, a Crystalyte 72volt 48 amp (think it said 48...certainly not 40 amp). It is black in colour with a on/off switch and a little keyed switch ...which turns out to be forward reverse.......it was a shock when I found that...and shot backwards into the workbench when I wa expecting to go out the door of the workshop

Anyway, I have mailed Max,and waiting a reply, Also tried the Crystalyte Europe web site...but no similar controller...and the main crystalyte web site seem to be down. Have seen a bit of info on the Power In Motion site, but it does not cover all the plugs on this particular Crystalite controller I have

So any one have a comprehensive list of Crystalyte controllers and wiring.

I have ID'd the CA-DP plug, the throttle, Halls, Phase and power...So i am not totally brain dead...yes I can id big fat red, black, yellow, green and blue wires but the rest are beyond me.

things I need to connect.
Brake levers...
pedelec sensor
Cruise control
LMH switch...possible the wire with yellow heat shrink according to max

Apart from the CA lug, none of the other match the plugs on the accessories I have...and bearing in mind my record ( Lyen controller dead with 5 days) I do not want to just plug things in and see what..happens. Don't want to risk loosing more of this expensive magic smoke

Am off down workshop again soon so will post some pics of the controller when I get back if what I have said so far is not enough info for ID

Thanks

Neil

Neil:

There is extra jumper wire in the controller, i think it is white, i don't have controller in front of me, I am just going by memory. This jumper wire with automatic adjust controller to match with the hub motor to run it correct phase sequence. It actually is very interesting feature. I don't remember the exact steps at the moment, i will have look it up tomorrow.

Please find the attached crystalyte wire-diagram, this old doc back 2009, i just didn't have time to update it yet. Just let me know which wire you know, I can tell you what they are.

Also, i hate to bring this up, your controller are most likely no compatible with CycleAnayst, which mean when you plug it in, you will be get reverse amp, if this the case, for sure you have a imcomptable controller that will work with C.A.

Ken

 

[NeilP]

Hi Ken

No, the CA seems to work fine...so lucky there. It is only a temporary controller for this build so am not going to be opening it up to mod it...at least not tlll my 18 fet ones gets back.


View attachment 3




Thanks for the d/load but I alreaady have that one,,,and it is not helping much...
It may show me which is the cruised control 5 pin with only 4 pins attached.....but where to connect it..this is the wires from my cruise control...Both plugs...Lyen tells me to use one or the other


I have 4 connectors that I do not know where to connect them

One with Yellow heat shrink
It is a female plastic black socket with the male pins sticking out
three pin:4.85 volts
Earth
4.85 volt

Another similar 3 pin black heat shrink
4.86 volt
Earth
4.35 volt

3 pin plastic male with female connectors
4.36
earth
4.85

The 5 pin housing...Cruise control ?
N/C
4.46
0.81
Earth
4.32

 

[PowerPedro]

Hello Neil

I have the same controller like you just trying to find out what connector is used for what?! Did you allready solve the misery? Thanks for sharing...

Peter

 

[NeilP]

Hope this helps

 

[PowerPedro]

Thanks for the picture.... I still have 2 more plugs with unknown funtion (see picture) Do you know what they are for?

 

[NeilP]

the 6 pin will be a cycle analyst plug and the other is probably the throttle

 

[wojtek]

hi,

im considering getting the controller from Peter as my back up controller

but before:
1. regen braking - does it have one? does regen braking switch on each time i press ebike level? can i use it without ebrake level , but as a switch?
2. my pack is 88v, 100V fully charged. I know i cant use this controller with this v but i can easily change the pack to 44v [50v max] - but will it work or cut off below 56V [low V limit]

thanks!
Wojtek

 

[NeilP]

hi,

im considering getting the controller from Peter as my back up controller

but before:
1. regen braking - does it have one? does regen braking switch on each time i press ebike level? can i use it without ebrake level , but as a switch?
2. my pack is 88v, 100V fully charged. I know i cant use this controller with this v but i can easily change the pack to 44v [50v max] - but will it work or cut off below 56V [low V limit]

thanks!
Wojtek

You should be OK using that controller. if it is the same as the one I have pictured above, at 24 series..100 volt full charge. I have the same controller..I pictured it..and regularly run it at 100volts on a 24 series pack..The FETS are 4110 and the caps are 100volt caps.

OK, you are running a bit close to the limits. but it has worked OK so far. My lyen 4110 controller has also been run at those voltages too.

Cant remember about braking, if it will give regen or not..it won't at those voltages, without a resistor MOD, but yes, you can use a switch for the e-brake and not use a special brake lever.

The brake wire coming out will have three wires.

I will send yo a private e-mail with al the pictures of it I have inside
. I will sned them small, and if you wnat bigger versions of any of them let me know which ones and I'll post the full size images to you