I've completed a new front controller upgrade to the bike this week. I ordered this simulated sine-wave controller a couple of months ago:
The goal was to (finally) replace my Magic Pie 4 internal controller. Although the controller still worked; it wasn't able to be programmed anymore and it had some glitches that I wanted to eliminate. The glitches were:
abrupt accelleration from start. Even with acceleration turned down it felt jerky.
regen wouldn't work unless I was below 56.5V; not ideal since I pretty much always top up my pack right before riding. I rely heavily on regen braking force on the front and rear.
when I exceeded the Magic Pie's max rpm, it was if regen braking would suddenly engage unless I disabled it's throttle signal to the controller
When the new controller arrived, I was uncertain if it was in fact, a programmable Infineon 4 clone/xie chang controller like I was hoping for. I opened it up and had a look. It seems promising as the board looked similar to other Infineon 4 style controllers I've seen online. The board says "606-THP-5" which is a good indicator that is actually a KH6XX type controller. I added some leads to the +5, GND, SDA, RXD and TXD spots on the board.
Once I figured out the correct wiring to the USB-to-Serial adapter as seen here
I was able to successfully program it using the XPD controller software! After soldering the matching motor and throttle/brake connectors (re-used the magic pie waterproof connector) I gave the motor a test spin. The motor phase cable and hall sensor wires matched colour for colour with the controller (a nice bonus
After a few trial runs; I figured out that I needed to jump the BK to GND on the board to enable regen even though I had enabled it in the firmware. I was also able to get the motor rpms to "130%" which is right around what I was hoping for. This is probably like a phase advance, basically the poor man's flux weakening. This allows the front motor to help the rear motor out as it nears max rpm. Not a bad feature set for a $60 USD controller in my opinion. I would have went with a Greentime or KT controller but they do not seem to have this ability.
removing the original controller and running a new controller wire harness to outside the hub motor
BK jumped to GND to enable regen:
After having the bike out for a couple shakedown tests; I'm very happy with the new controller. The acceleration is much smoother and all my glitches are gone. I'm keeping the controller at 25A battery 75A phase which is pretty much the same setting as the original magic pie 4 controller although it feels like it has a bit more punch. The bike is working like a dream now.