controller wiring

[bagsater]

Hi Folks
i have 2 electric bikes with the kits purchsed some time ago from conismotors , alls been well for over a year but one of the controllers has gone kaput , i bought another one off Ebay but it has come with many more wires and also different colours and am not sure how to connect . the motor , power , and halls are fine , its just the throttle and brakes that have got me .
I shouldnt have bought this one , (cos it was cheaper ) but if all fails i will have to purchase another exact copy.

Sorry to bother you with this

Best Regards Pete

 

[Jeremy Harris]

Throttle wires will almost always be red green and black or red blue and black, for a three wire throttle (you may have a four or five wire throttle, in which case things get a bit more complex). The brake wires will usually be pairs from the controller, often either black and white or black and yellow. The brake wires may just be single wires, rather than pairs, it depends a bit on the particular controller.

If you can take a better photo of the controller wires we can probably take a stab at giving you a better answer.

 

[bagsater]

Thanks for the reply , very kind , i have a 3 wire throttle , better pic attached thanks

 

[Jeremy Harris]

Going from left to right it looks as if the wires are:

Big red and black - main battery power
Big green, blue and yellow - motor phase wires
Single red wire - controller "ignition" (turn on) wire (connect to battery +ve to turn on the controller)
Five way connector with red, black, green, blue and yellow wires - Hall sensor connector to motor
Two white wires - most probably ebrake connection
Two blue wires - most probably ebrake connection ground wires (check with a meter, they should be connected to the controller -ve if this is what they are)
Two grey wires - not known, may be a speed restrictor link
Yellow and black wires - These might also be ebrake wires, check to see if the black wire is connected to controller ground
Red green, and black wires - probably the throttle connection (red is +5V, black is 0V, green is throttle signal) but may be the pedelec sensor connection
Single yellow wire - as above, maybe an ebrake wire
Green, black red wires - probably a pedelec sensor connection, but might be the throttle
Blue, black, grey - no idea, maybe a 3 speed switch?
Red and black - possibly an alarm output - you can probably ignore this.

I suggest connecting just the power, motor phase, motor Hall, controller ignition and the throttle wires up and testing it. If the throttle doesn't work when connected to the first connection suggested above, try connecting it to the other connector. Leave the ebrakes disconnected for now (the controller should run without them connected). Once that works, then check the voltage at the blue and white wires and also that at the yellow and black wires and report back and we can try and guess which of them is the right ebrake connection (there are sometimes two ebrake options, a normally closed switch in the brake levers and a normally open switch, plus some controllers have the option of being switched from an existing brake light).

 

[dogman dan]

Agree with the major identified wires above, Power, phase, halls, throttle, and the red wire to switch it on.

Others could be anything, but might not be needed to run the bike. Those pairs of wires that have the same color and black plugs look like jumpers to me. Connect one might enable a speed/watt limiting circuit, connecting another might enable regen, stuff like that.

The rest will be all that junk they put on scooters I bet. Very likely this is a scooter controller, not a bike controller per se. So there will be lights wires, horn wires, turn signal wires, ebrake wires yadd yadda.

Beats me sometimes why the decision is made to run every thing on the scoot through the controller. To me, the controller should be as kiss as possible.

For others about to buy that might read this. I bought a generic 48v 40 amp controller recently. One of the criteria I used to choose which vendor was a picture on the ebay page that labeled all the wires.
It's almost ciminally stupid they can't just put a page with the info in the box, or even better a label stuck on the controller itself.

Sure, the factory doesn't need this on every controller to assemble scooters, but when you buy from a guy selling individual controllers identifying the wires should not be too much to ask. Don't send money to those who don't give you this info!

 

[bagsater]

Thanks very much folks , i will have a go with the info i have now , and let you know how i get on .

 

[gwhy!1]

just for the record I have come across the 2 white wires on some controllers to reverse the direction of the motor just by momentary connecting them then this programs the controller to always run the motor in the opposite direction .

 

[Kingfish]

Battery, Phase, HE Sensor wires, and Ignition - very obvious, no question about it.

• White Wire pair with M/F connector is to enable Ebrake/Regen (BK->GND) or to set Cruise.*
• Gray Wires I suspect is Reverse.
• Yellow & Black is Ebrake (-EBS-> GND) and requires a switch in-between.
• There is also a single Yellow or is it a Yellow & White? If the latter, then I suspect that’s Cruise and requires a momentary switch in-between.*

There are three that confuse me:

• Red-Blue-Black
• Green-Blue-Red
• Blue-Black-Gray

These will be HE Throttle, possibly Resistor Throttle, and 3-Way.

And then there’s small Red & Black. Maybe an Power-on light or Pedelic or accessory power. I don’t know; I’ve never had a controller with that set of wires.

The only way to know for certain is to open up the controller and trace each wire to the associated pad on the PCB and read the designations. From that – we can positively identify each set.

It's too bad the supplier didn't tell you. Post the seller's name so we all know whom to avoid :wink:
~KF

 

[Jeremy Harris]

Red blue black is usually the pedelec sensor connection, I believe.

 

[dnmun]

sometimes the pcb is labeled so you can guess the function of the wires that connect to that spot on the pcb from the labels.

 

[dogman dan]

The controller I just bought has two jumper pairs. One is for speed limiter (for a 2 speed switch), the other is reverse. Sometimes they can be regen.

Once it's up and running, try em and see what they do. Others you could look at and get some clues. 5v won't be turn signals or headlights power, but 48v might be. As said above, opening it up will tell those that can decipher that stuff more.

Don't just avoid that seller, avoid all that provide no clue what the wiring does.