Controller and motor - how to connect wires?

[davidsvoboda]

Hi, is there a way to connect the motor and controller if the colours for controlling the motor do not match?

I don't know if they match, I guess not, cause if I connect them right, it does not work.. Controller is not supposed to be with this motor, so I am just trying to make it work..

Could anyone tell the function of each cable with its colour by looking where it is connected on the controller???

This seems stupid to me, because all you need is to have some chinese connector that has different colours and it won't work - and you can't try like 120 options.. (

Coming from motor I have 3 cables to connect to controller - green, blue and yellow - here they match with controller. But than I have 5 smaller wires - black, red, green, blue. yellow. and from the controller the 5 smaller cables with colours - black, yellow, yellow/green, blue and green.

 

[amberwolf]

https://endless-sphere.com/w/index.php/Determining_the_Wiring_for_a_Brushless_Motor

 

[davidsvoboda]

I dont understand the site. I would have to try all the 120 options anyway right?

I am kind of giving up. Should I even try? I am just gonna waste another 50 pounds on new controller than be trying 120 options.. ((((

 

[docw009]

Coming from motor I have 3 cables to connect to controller - green, blue and yellow - here they match with controller. But than I have 5 smaller wires - black, red, green, blue. yellow. and from the controller the 5 smaller cables with colours - black, yellow, yellow/green, blue and green.

Why is the controller board not in an enclosure? What does the actual cable ends look like? Is there not a wiring diagram for the controller? Is there not a wiring chart for the motor?

Those 5 smaller wires from the motor are probably the Hall sensor wires. Red and Black would be +5 power and ground. The other three are outputs from the three Hall sensors in the motor. Some manufacturers are nice and group them in a 5 pin connector.

You need to look at your controller diagram and find out which of those five smaller wires are power and ground wires. Then the other three are the phase wires. You don't want to guess. 5 factorial is 120 combinations. Some of these may fry the Hall sensors in your motor. Others might blow the 5 volt regulator in your controller.

I'm just a newbie to ebikes too, but you could post the make of your motor and controller, and any wiring diagrams even if they're in chinese.

.

 

[flangefrog]

Black and red on the controller are probably 5V and gnd. Red on the motor will probably be 5V and plain yellow is often gnd. Now you've only got three wires to figure out by trial and error (four if yellow isn't ground). If the motor goes reverse you'll have to swap any two phase wires and find the right two hall wires to swap. As long as 5V goes to the correct wire it's unlikely you'd fry the hall sensors.

 

[davidsvoboda]

Black and red on the controller are probably 5V and gnd. Red on the motor will probably be 5V and plain yellow is often gnd. Now you've only got three wires to figure out by trial and error (four if yellow isn't ground). If the motor goes reverse you'll have to swap any two phase wires and find the right two hall wires to swap. As long as 5V goes to the correct wire it's unlikely you'd fry the hall sensors.

I know that red on the motor needs to be basically put into circuit otherwise it won't even start. So I don't have any red coming from the cable.

Just to be clear - do I need to set up right the 5 cables first before I set up phase wires?
If I need to be both right at the same time, it is like 36 plus 120 combinations and if I need to have it right at the same time, than it is even impossibly more combinations.. I think I am giving up on this.

 

[davidsvoboda]

Will I fry it even if I don't apply much throttle? it seems like too much risk for me and I can even manage to connect fuse, it is too complicated for me, I'm a complete noob in this.

 

[docw009]

Well, you know your probability and statistics. You should be able to wire up your motor if you stay logical.

Heres's another question. Do you own a multimeter?

 

[flangefrog]

Will I fry it even if I don't apply much throttle? it seems like too much risk for me and I can even manage to connect fuse, it is too complicated for me, I'm a complete noob in this.

As long as you don't use much throttle or add a small fuse while testing you won't fry your motor. It is possible to fry halls but if you get the positive wire correct it's unlikely. Are you able to open up the motor? That would make it easy to tell which are the 5V and Gnd hall wires.

 

[davidsvoboda]

Can we just make this clear - I don't know how to connect the 5 hall sensor cables. If I connect them somehow, can I test the 3 phase wires combination?
Or do I need to have those 5 hall sensor cables connected right first? If yes, how I even try if one of the 120 combinations for hall sensors is right, if I don't have phase wires right yet??

 

[davidsvoboda]

Will I fry it even if I don't apply much throttle? it seems like too much risk for me and I can even manage to connect fuse, it is too complicated for me, I'm a complete noob in this.

As long as you don't use much throttle or add a small fuse while testing you won't fry your motor. It is possible to fry halls but if you get the positive wire correct it's unlikely. Are you able to open up the motor? That would make it easy to tell which are the 5V and Gnd hall wires.

I could open the motor, but don't think that would help me as I have no idea which are which on the controller either. (controller I did open already)

 

[flangefrog]

It's very easy to tell which are the 5V and Gnd hall wires on the controller. As docw009 mentioned a multimeter would be helpful. But not a problem if you don't have one. Post high res pictures of front and back of your controller board and mark where the hall wires go. If you post pictures of your motor halls people can help let you know which wire is which.

Edit: I just reread your first post. Your motor has red and black hall wires so it would be fairly safe to assume these are 5V and Gnd. So it's just the controller hall wires you'll need to figure out. If one of the controller hall wires goes to where lots of red wires are connected then it will be 5V. And if one wire goes where all the black wires are connected then it will be Gnd. If you have a multimeter you should measure 5V between the 5V and Gnd wires from the controller.

From what I can see on your photo the wires at B-HA, B-HB and B-HC are probably your hall signals. The black wire at top right is Gnd. I can't see a yellow wire, only another yellow/green. That is most likely going to be your 5V wire.

There are multiple correct combinations for the hall and phase wires so it doesn't matter which ones you connect up first. You do need to have both connected to test it.

Once you have 5V and Gnd hall wires connected correctly there is no chance of frying the halls, just be easy on the throttle to avoid burning out the motor.