Bravo EVT 4000e Throttle Conversion

[ProtonPozer]

Hey guys! I feel like I am retelling my story each time, but in case you didn't scan my others, here is my abbreviated story: I have a 2008 Bravo EVT 4000e Scooter.
I recently started a project to replace the controller without first fully understanding how the original arrangement operated. The new controller seems to work in the "Learn mode" (short circuiting the two white wires), but there is no throttle response. (I ordered a cheap Hall Effects throttle and will try that as a fix.

I am not certain that the original throttle Unit on my scooter is a Hall Sensor type. To me it resembles a 3-wire rheostat.
I am pretty sure that the new (after-market) controller is looking for a Hall Effects Sensor from the throttle.
And maybe I am wrong and would not mind being corrected by others with vastly more experience.

I tested the existing throttle assembly. Between the BLACK and the GREY wires (throttle side) there is a range in resistance from 1.25KOhms to 9.17KOhms, from zero to full throttle and no reading from the ORANGE wire.
For the sake of conversation, if I tried to connect the old throttle with the 3-wires on the new controller, please make an educated guess as to which color should attach to which. (See my rough sketch).

Thanks!

 

[TommyCat]

no reading from the ORANGE wire.

To me this would seem problematic.

I would encourage you to read this section on potentiometer verses hall sensor throttles.

Guide to Hall Sensor Throttle operation, testing, and modification. - Electricbike.com Ebike Forum


Regards,
T.C.

 

[ProtonPozer]

Hey guys! I feel like I am retelling my story each time, but in case you didn't scan my others, here is my abbreviated story: I have a 2008 Bravo EVT 4000e Scooter.
I recently started a project to replace the controller without first fully understanding how the original arrangement operated. The new controller seems to work in the "Learn mode" (short circuiting the two white wires), but there is no throttle response. (I ordered a cheap Hall Effects throttle and will try that as a fix.

I am not certain that the original throttle Unit on my scooter is a Hall Sensor type. To me it resembles a 3-wire rheostat.
I am pretty sure that the new (after-market) controller is looking for a Hall Effects Sensor from the throttle.
And maybe I am wrong and would not mind being corrected by others with vastly more experience.

I tested the existing throttle assembly. Between the BLACK and the GREY wires (throttle side) there is a range in resistance from 1.25KOhms to 9.17KOhms, from zero to full throttle and no reading from the ORANGE wire.
For the sake of conversation, if I tried to connect the old throttle with the 3-wires on the new controller, please make an educated guess as to which color should attach to which. (See my rough sketch).

Thanks!View attachment 359534

Tommy Cat,
Thank you for the information on POT vs. Hall. (I suppose I should have more correctly used the term "potentiometer" rather than "rheostat.") But for full transparency, I am a "wrench turner" and not adequately versed in electronics, so I am out of my league with most of you guys that know this stuff profoundly.

It sounds like the fact that the ORANGE conductor had no resistance response (in any configuration) is a powerful symptom. Perhaps an indication that it has failed? Since your article suggests that the POT is more expensive, I tend to think that this inexpensive after-market controller probably wants a Hall input. At this point, it can't hurt to try.

 

[TommyCat]

It sounds like the fact that the ORANGE conductor had no resistance response (in any configuration) is a powerful symptom. Perhaps an indication that it has failed?

I agree with your assessment.

I tend to think that this inexpensive after-market controller probably wants a Hall input.

Looking for the “speed set” values would eliminate any doubt, if shown.

Best of luck with the hall throttle.

 

[ProtonPozer]

Thanks Tommy Cat.
I wish the controller that I purchased had the "Speed Set" information that yours does.

 

[ProtonPozer]

Tommy Cat,
Success! I plugged in the new aftermarket Hall Effects Throttle into the new aftermarket controller and it works fine. I used the existing wires in harness and re-pinned new multi-pin connectors to make the transition. In case others are curious, here is a Sketch of the final wiring adaptation. Hope it helps someone else.

 

[TommyCat]

Looks like your intuition was right all along.
Job well done!

Cheers,
T.C.

 

[ProtonPozer]

Thanks Tommy Cat, I appreciate the encouragement. Now I just have to figure out the wiring polarity of my 48VDC to 12VDC Converter. But I'm in no hurry. Cheers! P/P