I'm installing a new BAC-028x controller and throttle in my scooter. The old throttle was shorting and needed to be replaced, is I just decided to install a new controller.
Which function of the throttle was
"shorting" and how was this diagnosed? Was it the Battery Gauge, the Switch or the Throttle Hall Sensor?I removed the wiring connectors provided from the factory for the S1 through C terminals but still using the twelve terminal connector. I left S1 jumped to G per the factory setting.
Are you sure this is how it was originally connected? The original Magic Pie internal controllers were based on the same circuit board layout as the external controllers, and S1 was directly connected internally to the Yellow Phase wire, and if your controller is the same, it should
not be connected to the G terminal, as the G terminal should be fed with battery voltage when the controller is powered up and enabled.
You can clearly see on the following picture that external connection to S1 is not being used:
I suggest that you carefully check the wiring on the old controller to see exactly how it was wired.
When I check the voltage on G it registers 8.4 volts. Is this correct?
According to the schematic it looks to me that the G terminal is an "ignition" circuit used to power up the controller. And as such I would expect full battery positive power to it to make it active. As shown going thru an "On/Off lock" or key switch.
As Tommycat has already stated, the voltage on the G terminal should be full battery voltage for the controller to work.
There is also a possibility that the wires on the new throttle could be connected differently inside the throttle. Did the throttle supplier explain the correct function of each of the wires, or were they connected to separate connectors for the Throttle, Switch and Battery Gauge?
My bike has a on/off switch directly connected to the battery so I'm not using the provided Power Switch. Does this need to be connected to Z/0V?
On early Magic Pies, the switch was sometimes used to control the reverse function, and on later Magic Pies it was used for turning battery voltage LED lights On or Off:
But if your throttle has a separate 2 pin connector with Brown and Yellow wires, it should not need to be connected to anything for the controller to operate. I sometimes have this switch connected to the brake switch wires so that it prevents the motor from being accidentally operated when it is pressed in.
Alan
