Mismatched Controller wire colors

[JaysDIY]

New here, hope its not a complete rehash.
Upgrading my controller from 48v/18amp to 52v/45a controller from Amazon.

Controller came with a display and connector plugs that everything easily swapped into EXCEPT the Throttle and PAS. Wire colors are mismatched from the Contoller to the bike wires. The connector ends were also misgendered. I figured the connector gender issue was factory error and NOT mislabeling, because with I swapped the throttle and PAS connectors into the "fitting plugs"-ERROR 30. I cut off the connectors so I could try some combinations of these mismatched colors. So far no combos work

See photos for wire colors/labels.

I tried the obvious combinations and get ERROR 30. When I leave PAS and throttle detached ( and learning wire connected) I get THROTTLE ERROR- but the motor does spin as soon as the controller is powered on with the thumb touch button. I can make the wheel stop by unplugging the learning wire.

Throttle wire bench tests OK with a 4.5V power supply separate from the controller. Across black and white wire- .1v to 4.97v with the twist throttle.

Controller throttle wire bundle (Green with white stripe/Red with white stripe/Black) tests 4.97v across red-white stripe wire and black. Tests .1v across black and green-white stripe. Normal, I think.

Controller PAS bundle tests 4.97v across red/black and 4.25v across black/blue. I don't know what normal should be.

Any help is appreciated.

 

[E-HP]

Since you've bench tested the throttle and know which wire is 5V, ground, and signal; and you've tested the controller side and know which conductors are 5V and ground, I'd skip the PAS for now and get the system running first on throttle (since PAS can be finicky and there are more things that can go wrong or need troubleshooting). Connect the red to red, black to black, and the remaining conductors are the signal wires. Hopefully during your earlier testing and wire swapping, nothing was damaged. Run the self learn routine, and check the throttle response.

 

[TommyCat]

Throttle wire bench tests OK with a 4.5V power supply separate from the controller. Across black and white wire- .1v to 4.97v with the twist throttle.

The low voltage output is too low, and the high voltage output couldn’t possibly be that high with a hall sensor throttle.
Recommend you re-check.

More in depth information on throttles can be found here…
Guide to Hall Sensor Throttle operation, testing, and modification. - Electricbike.com Ebike Forum

And welcome to the forum!



Regards,
T.C.

 

[E-HP]

The low voltage is too low, and the high voltage output couldn’t possibly be that high with a hall sensor throttle.
Recommend you re-check.

And welcome to the forum!



Regards,
T.C.

I should have looked closer at the voltages. I guess the 4.5V supply, with a 4.97V output signal should have stood out if I were paying attention.

 

[d8veh]

New here, hope its not a complete rehash.
Upgrading my controller from 48v/18amp to 52v/45a controller from Amazon.

Controller came with a display and connector plugs that everything easily swapped into EXCEPT the Throttle and PAS. Wire colors are mismatched from the Contoller to the bike wires. The connector ends were also misgendered. I figured the connector gender issue was factory error and NOT mislabeling, because with I swapped the throttle and PAS connectors into the "fitting plugs"-ERROR 30. I cut off the connectors so I could try some combinations of these mismatched colors. So far no combos work

See photos for wire colors/labels.

I tried the obvious combinations and get ERROR 30. When I leave PAS and throttle detached ( and learning wire connected) I get THROTTLE ERROR- but the motor does spin as soon as the controller is powered on with the thumb touch button. I can make the wheel stop by unplugging the learning wire.

Throttle wire bench tests OK with a 4.5V power supply separate from the controller. Across black and white wire- .1v to 4.97v with the twist throttle.

Controller throttle wire bundle (Green with white stripe/Red with white stripe/Black) tests 4.97v across red-white stripe wire and black. Tests .1v across black and green-white stripe. Normal, I think.

Controller PAS bundle tests 4.97v across red/black and 4.25v across black/blue. I don't know what normal should be.

Any help is appreciated.

Maybe you have them mixed up. PAS is normally green and throttle is normally blue!

 

[JaysDIY]

I'm too ashamed to say that the throttle problem was me..using the wrong connector that was shorting out the circuit.


Still can't make the PAS run the motor. I put a voltage meter across ground and signal while I cranked the pedals and the average was 1.39volts. I don't know if that's normal.

On an aside the Headlight connection does not test for voltage when the + button is held and display shows lilght. HOWEVER there is an unlabeled RED/BLACK wire from the controller that is HOT wired to battery voltage even when the display is off! Seems dangerous. ANYhow, I suppose I could use this hot 52v wire to power this installed light/horn/switch combo, but I can figure how. The light/horn had a wire from buttons-to-controller and another wire from controller to light/horn unit. Each Red/Green with a common black together in a connector. Happy to cut off connectors and hard-wire this.