Connector Compatibility Issue for Replacing a Generic Controller

[Jay-Cee]

Hello everyone!

I would like to replace my controller (48V, 25A) and the original display with a JN model (48V, 25A, 750W) and the S866 display (Julet connector). I would like to keep my current wiring, which consists of, on the controller box side, 2 connectors (5-pin JST SM) and, on the handlebar side, 5 Julet connectors (2x green for the display and the front light and horn control, 2x red for the brake levers, and 1x yellow for the throttle).

Upon examining how the JN controller is wired, I noticed that the connectors for the brakes, front light, and display do not match the 2 connectors that are present on my bike.

Does anyone have a solution to my problem, please? Many thanks in advance!

I have identified the data sent by my controller through these 2 connectors. This will help to better understand how to connect the JN controller.

 

[neptronix]

On ebay and amazon there exist JST 2.0 PH connector kits that could be used for everything except the battery and phase connectors.

Example: ( female connections only )
PH 2.0 Connector Pre-Crimped Cable Kit Compatible with JST-PH 2.0mm for Battery | eBay

I recommend a XT90 with an antispark connector as your standardized battery connector.

I use hobbyking 4mm billets for my phase connectors. Many RC controllers use them as the standard connectors and they can transmit a large amount of energy in a small space.

 

[Jay-Cee]

On ebay and amazon there exist JST 2.0 PH connector kits that could be used for everything except the battery and phase connectors.

Example: ( female connections only )
PH 2.0 Connector Pre-Crimped Cable Kit Compatible with JST-PH 2.0mm for Battery | eBay

I recommend a XT90 with an antispark connector as your standardized battery connector.

I use hobbyking 4mm billets for my phase connectors. Many RC controllers use them as the standard connectors and they can transmit a large amount of energy in a small space.

Thank you for the information! I was already planning to buy JST SM connectors with 2, 3, 4, and 5 pins to make a clean wiring job. But the help I need is mainly about the connections: how to connect the wires for the brakes, front light, and display to my two connectors.

 

[neptronix]

But the help I need is mainly about the connections: how to connect the wires for the brakes, front light, and display to my two connectors.

Are you good with a soldering iron? if not, time to pick it up!

What would be ideal is if you went to a well supported, common programmable controller so you don't have to do this wiring job again!

 

[Jay-Cee]

Are you good with a soldering iron? if not, time to pick it up!

What would be ideal is if you went to a well supported, common programmable controller so you don't have to do this wiring job again!

No problem! I know how to solder

I'm open to all proposals, but I have some constraints:
- The controller's dimension: 118 cm maximum length so it can fit in my box.
- It needs to be a 48V 25A, given that I have a 750W motor.
- I want to keep my current wiring.

But even with a programmable controller, we'll come back to the same question: how to wire it

 

[neptronix]

Take your pick:

Current evaluation going on here:
Successor to the infineon clone controllers in the 1000-2000w power range?

Phaserunner or Spintend VESC are the winners of my comparison so far.

 

[Jay-Cee]

Take your pick:

Current evaluation going on here:
Successor to the infineon clone controllers in the 1000-2000w power range?

Phaserunner or Spintend VESC are the winners of my comparison so far.

That sounds good! But it doesn't meet my requirements for dimensions, power, or wiring. Anyway, let's get back to the point : are you able to help me wire this controller?

 

[neptronix]

I'm pretty sure 3 of those controllers could fit your box.

I don't know how to wire up a controller given no wiring diagram for it. I always suggest when you buy a new controller you get a matching throttle, ebrake, lever, screen, etc as often, the colors will not match and without a diagram for both controllers you could easily find yourself shooting in the dark and potentially damaging the new controller as a result if a mis-wire.

 

[E-HP]

I have identified the data sent by my controller through these 2 connectors. This will help to better understand how to connect the JN controller.

View attachment 356201

View attachment 356200

Why are you trying to retain the two connectors? I thought you were swapping out the display.

 

[Jay-Cee]

Why are you trying to retain the two connectors? I thought you were swapping out the display.

This is confusing, I don't keep the 2 male JST connectors in the photo on my diagram, they belong to the original controller. I simply used the electronic board to identify which signals it sends through each wire. In order to know how I should build my 2 male connectors for the JN controller, which will connect to the 2 female connectors on my general cable already in place on my bike.

 

[n00b]

Hello everyone!

I would like to replace my controller (48V, 25A) and the original display with a JN model (48V, 25A, 750W) and the S866 display (Julet connector). I would like to keep my current wiring, which consists of, on the controller box side, 2 connectors (5-pin JST SM) and, on the handlebar side, 5 Julet connectors (2x green for the display and the front light and horn control, 2x red for the brake levers, and 1x yellow for the throttle).

Upon examining how the JN controller is wired, I noticed that the connectors for the brakes, front light, and display do not match the 2 connectors that are present on my bike.

Does anyone have a solution to my problem, please? Many thanks in advance!

I have identified the data sent by my controller through these 2 connectors. This will help to better understand how to connect the JN controller.

View attachment 356201

View attachment 356200

What all do you absolutely have to have?

 

[Jay-Cee]

What all do you absolutely have to have?

I don't understand? Sorry, my english is not very good

 

[n00b]

I don't understand? Sorry, my english is not very good

What functions have to absolutely work for you?

 

[Jay-Cee]

What functions have to absolutely work for you?

All of them (display, brakes, throttle, ...) but it's mainly on the side of the front light and the horn because there is a relay but I can't understand what its purpose is. Are you knowledgeable about electronics?

 

[E-HP]

This is confusing, I don't keep the 2 male JST connectors in the photo on my diagram, they belong to the original controller. I simply used the electronic board to identify which signals it sends through each wire. In order to know how I should build my 2 male connectors for the JN controller, which will connect to the 2 female connectors on my general cable already in place on my bike.

Great. So the corresponding male connectors on the bike side, in the the small photo with your fingers, are going to be replaced. That makes more sense.
You should have gotten the exact same controller as a replacement. You'll probably need some additional relays and probabluy a buck converter to get what you're trying to achieve.

I think you need to start with the basics. It appears to be a factory/store bought ebike. What is the model and if you have a link, that would help. Without the controller in place, but with the battery in place, does the horn work? Is the horn electronic with a speaker, or a regular scooter type of horn? Post a picture of the relay(s) and the location on the bike. It would be unusual for a controller to be able to supply the low voltage current to drive an actual horn, so the bike may have a 12V converter, converting the battery level voltage down to use with lights and accessories, if you're lucky.

What is the "..." ??

(display, brakes, throttle, ...)

 

[Jay-Cee]

Great. So the corresponding male connectors on the bike side, in the the small photo with your fingers, are going to be replaced. That makes more sense.
You should have gotten the exact same controller as a replacement. You'll probably need some additional relays and probabluy a buck converter to get what you're trying to achieve.

I think you need to start with the basics. It appears to be a factory/store bought ebike. What is the model and if you have a link, that would help. Without the controller in place, but with the battery in place, does the horn work? Is the horn electronic with a speaker, or a regular scooter type of horn? Post a picture of the relay(s) and the location on the bike. It would be unusual for a controller to be able to supply the low voltage current to drive an actual horn, so the bike may have a 12V converter, converting the battery level voltage down to use with lights and accessories, if you're lucky.

What is the "..." ??

(display, brakes, throttle, ...)

Yes, that's right!

The original controller has limitations, including limiting the PAS to 23 km/h. Replacing it with the JN controller and S866 display is cheaper for me than buying an original controller. However, I'm still open to keeping the original controller, as the purpose of this post is also to explore the feasibility of the change.

I've read and seen on a Facebook group that someone with the same bike as mine managed to change their controller and display to a Kunteng model, but was having difficulties getting their front headlight to work.

What is the purpose of the relay currently present? And why should I add more?

Here's the link to the bike: Fiido T1 Pro - Vélo électrique Fatbike Cargo

The two female JST connectors (circled in red) are located on the side of the box where the controller is placed. The cable runs through the bike frame and comes out at the handlebar to connect the brakes, throttle, display, light control, and horn.


There is only one relay, and it's located in the controller, which is why I was able to photograph it. Would it help if I removed the insulation to see the model?



I've made progress in understanding the signals, but there are still two wires whose function I couldn't confirm. I think the white connector is intended for the display

White connector
RED : VB+ (+48V)
YELLOW : VK+ (??)
ORANGE : VB- (ground)
BLUE : TX
GREEN : RX

Relay and black connector (2 pins)
BLACK : VB- (ground)
RED : VB+ (+48V)
BLUE : CAN-TX (??)

Black connector
WHITE : SP5V (+5V)
BROWN : SP (throttle signal)
BLACK : VB- (ground)
GREY : BKL (brake signal)
PURPLE : in MOSFET (+48V light)

 

[E-HP]

However, I'm still open to keeping the original controller, as the purpose of this post is also to explore the feasibility of the change.

Thanks for the clarification. Knowing that would have saved a lot of typing. For some reason I thought you already had the parts ready to install. Yes, get the original controller.

 

[Jay-Cee]

Thanks for the clarification. Knowing that would have saved a lot of typing. For some reason I thought you already had the parts ready to install. Yes, get the original controller.

I'm rather close to buying the controller, but to avoid wasting money, I wanted to review the process beforehand. In any case, whether I already have the new controller or not, I have all the necessary information to visualize the connections. Right? You can still offer me your help.

 

[E-HP]

You should worry about the main ebike connections first, rather than focusing on accessories. How are you going to connect the controller to the motor??

I'm guessing "..." includes PAS
(display, brakes, throttle, ...)

 

[Jay-Cee]

You should worry about the main ebike connections first, rather than focusing on accessories. How are you going to connect the controller to the motor??

I'm guessing "..." includes PAS
(display, brakes, throttle, ...)

The connectors of the phase, power, PAS and the rear light are compatible with the connectors present on my bike. That's why I didn't mention it.

 

[E-HP]

You will need to cut the brown black and white conductors from the connector in the box and add a 3 pin JST to match with the new controller's throttle connector. You will need to cut the display cable at the existing display so you can graft the new display to the existing cable, since you want to retain the display connector in the box. You will need to trace the conductors from the relay to find where the source of power is for the lights. You may be able to re-use the relay if you're lucky.

Having the same connectors on the things you listed doesn't mean it's plug and play/compatible, and it's likely you will need to troubleshoot and reorder the conductors in the connectors to match the new controller.

You'll need help from others on lighting. That's an area that is very simple electrically, and easy to implement, but requires a disproportionate amount of typing to explain. It's not really ebike related, but a separate category, since it s a similar discussion whether it's lighting for your ebike, a regular bike, a scooter or boat, etc.

 

[Jay-Cee]

You will need to cut the brown black and white conductors from the connector in the box and add a 3 pin JST to match with the new controller's throttle connector. You will need to cut the display cable at the existing display so you can graft the new display to the existing cable, since you want to retain the display connector in the box. You will need to trace the conductors from the relay to find where the source of power is for the lights. You may be able to re-use the relay if you're lucky.

Having the same connectors on the things you listed doesn't mean it's plug and play/compatible, and it's likely you will need to troubleshoot and reorder the conductors in the connectors to match the new controller.

You'll need help from others on lighting. That's an area that is very simple electrically, and easy to implement, but requires a disproportionate amount of typing to explain. It's not really ebike related, but a separate category, since it s a similar discussion whether it's lighting for your ebike, a regular bike, a scooter or boat, etc.

I have also thought about the process and we agree on certain points :

Connector 1: I should create a cable with 2 male-male connectors to be able to connect the female connector of the controller display to the female connector of the bike, as the new display is equipped with a Julet connector which is already present on the handlebar side.

Connector 2 (male 5 pins): the 3 wires of the throttle (SP5V (red), SP (white) and VB- (black)) plus BKL (yellow) from the brake and the +48V light which will need to connect to one of the relay terminals.

I relied on an installation designed for the same bike as mine and with a Kunteng controller. The person mentions that they haven't tested the lighting. The problem is that I have no knowledge about relays, I'm going to start learning about them! By analyzing their installation, there is: 1 terminal for +48V light, 1 terminal for VB- (brake connector), and then I can't determine the other connections.




Would you know where I could go to solve this lighting-related installation?

 

[Jay-Cee]

You'll need help from others on lighting. That's an area that is very simple electrically, and easy to implement, but requires a disproportionate amount of typing to explain. It's not really ebike related, but a separate category, since it s a similar discussion whether it's lighting for your ebike, a regular bike, a scooter or boat, etc.

I think the lighting is going to be very complicated because I just removed the insulation and what I thought was a relay is actually a printed circuit board.

 

[E-HP]

I think the lighting is going to be very complicated because I just removed the insulation and what I thought was a relay is actually a printed circuit board.
View attachment 356248

Looks like maybe a MOSFET relay. If blue is a signal wire, it may get the signal from the controller to turn the lighting system on for the rear lights (red and black) and headlight (purple). Do the lights come on when you power up the bike?

 

[Jay-Cee]

Looks like maybe a MOSFET relay. If blue is a signal wire, it may get the signal from the controller to turn the lighting system on for the rear lights (red and black) and headlight (purple). Do the lights come on when you power up the bike?

That's right! The blue wire is CAN-TX. I don't know what CAN stands for, but TX means transmission signal.

The lights turn on when I press the dedicated headlight button on the screen.

I thought that relay and MOSFET meant the same thing. Will the MOSFET need to be kept to be put back on the new controller?