Giant Suede Controller Replacement

The original controller and/or handlebar switch had stopped working on the bike, so I thought it was time to install a new controller (I also wanted to add a thumb throttle). 

I bought a cheap controller and thumb throttle off of a well known on-line auction site for less than £25 for the pair.

Then the fun starts, trying to determine how to wire it in, a basic list of connections was provided with the controller but the wiring colours didn't match the existing bike wiring. 

The key discovery was that the new controller motor power wiring relates to the original wiring as follows:

Old colour         New Colour

Brown               Yellow

White                Green

Grey                  Blue

The Giant manufacturers try and trick us by using different coloured wires between the haul sensors in the front wheel and the controller, you can see the same colours behind the grey plastic cover on the side of the front forks. I just ignored the intermediate colours and connected up in the same order as above and it worked fine.

I fitted a thumb controller which also had a power switch and volt meter. Throttle wires seem to be standard with red for +ve and black for -ve and green for signal, the other two wires created a loop from the battery supply to the controller power on (on the controller I have the controller power on is called the "electric lock" line) depending on which way round these wires are connected the volt meter is on all the time or just when the switch is turned on.

I used the white learning wires on the new controller to calibrate the controller to the wheel and change the direction of rotation (I just connected them for a while - the wheel spins up when the white wires are connected, so I had to make sure it is free to do so), and then I disconnect the white wires and tried the controls.

The thumb throttle works well as you can decide when to add power. I disconnected the pedal switch.

I did not use the following connections on the new controller:

- Brake lines, these cut the power, a switch could be added to the brakes somewhere if so desired, but releasing the thumb control cuts the power anyway.

- 3 speed line, but that can be used to slow down top speed or increase it a little.

- Anti theft/alarm lines

- Instrumentation line

I hope this is helpful to anyone wanting to upgrade their Giant Suede to use a modern controller and thumb throttle.

Giant Suede E electric bicycle replacement battery

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Giant Suede E electric bicycle replacement battery

A while ago we bought a Giant Suede E electric bicycle, it was in fairly good condition but had been used to commute 15 miles a day, so the 36v 9Ah NiMH  battery was at the end of its life.

 Giant Suede Battery

We tried to rejuvenate the existing NiMH battery, but although it would hold a charge, it would not supply a high enough discharge rate to propel the bike without a warning sound and power cut out.

We decided to take the battery pack apart and test cells individually and found that there were no dud cells, they were all about the same, so there was no quick fix of replacing the odd dud cell.

 

NiMH Cells Found Inside Battery Housing

After quite a lengthy search on the web we could find a number of generic replacement battery packs for electric bikes but none of these could be fitted in the same location as the existing battery pack which is customised to the bike and is quite stylish.

We decided to explore replacing the cells in the battery pack and contacted a well known battery manufacturer in China about making a custom battery pack.
After a lengthy and detailed exchange of information we agreed on a specification and paid in advance for the battery pack to be assembled and sent along with a new dedicated battery charger.

The part number is LNW-INR10S-5P29-Y15-SL (from Shenzhen DROWSEN Technology Co).

The specification is as follows:

1. Nominal voltage: 36V
2. Rated capacity: 14.5Ah.
3. Cell: Panasonic 18650PF 3.7V 2900mah
4. Dimension: 21.5x 11 x 6cms
5. Weight: 2.5KG
6. Operating temperature: -20 °C to 60 °C
7. Charge temperature: 0 °C to 45 °C
8. Storage temperature: -20 °C to 45 °C
9. Operating humidity: 5% to 90%

BMS Specification:
1. Operating current: 15A (max constant)
2. Peak current: 18A  (10mins max)
3. Charge current: 2A
4. Over-voltage protection: 42.5V
5. Under-voltage protection: 28.0 V
6. Over-temperature protection: 70°C

Charger Specification:
1.Output: 42V DC 2A
2.Input: 100- 240V AC (As your country's standard)

 

Battery Pack and Charger Prior to Shipping

Soon after ordering the battery arrived and we were able to integrate it into the existing housing and modify the existing power connector port to suit the new charger plug and added a 40A discharge protection fuse.

Installation pictures are below:

 

Packaged in Existing Casing Padding Provided by Battery Supplier

 

Internal 40A Fuse and Power Outlet

Rear of charging connector retained with metal clip to resist push back (under fuse)

Charging point integrated into existing connection port

We have been using the battery for a number of weeks now and it is excellent, the bike has good range and recharge times, and has transformed the performance of the bike.

Hopefully this Blog will help others who would like a new battery for a Giant Suede E electric bike.

If you need any help, leave a message with your contact details.