SHENZHEN Controller Installation Stories

[Knuckles]

Fechter's awesomely detailed description of the SHENZHEN 72V Controller (I LOVE the oscilloscope) can be found here ...
http://endless-sphere.com/forums/viewtopic.php?f=2&t=4282&p=64570

I have found that the following wire color combinations work for my Grubee Motors …

Motor Hall Sensor Connection
Controller ... Grubee Motor
Yellow ........Yellow
Green ........Green
Blue ...........Blue
Black .........Black
Red ...........Red

Phase Wires Connection
Controller ... Grubee Motor
Yellow ........Green
Green ........Yellow
Blue ...........Blue

Throttle Hall Sensor Connection
Controller ... Shenzhen Throttle
Green ........Green
Black .........Black
Red ...........Red

Throttle Hall Sensor Connection
Controller ... Grubee Throttle
Green ........White
Black .........Black
Red ...........Red
(Purple not used)

I hope other members will post their wiring setups as well. I am curious how different motors wire up to this controller.
Toa Chie

 

[Jonathan]

Have anyone tried these with the BMC motors?

 

[Knuckles]

Have anyone tried these with the BMC motors?

The PUMA BMC solution is being worked out as we type. Fechter and Keywin are on the JOB!
Mark from TeamHybrid too!

 

[tostino]

Have anyone tried these with the BMC motors?

The PUMA BMC solution is being worked out as we type. Fechter and Keywin are on the JOB!
Mark from TeamHybrid too!

Very important to me =)

I have a BMC (non-hub) motor that isn't working with my controller.
http://www.endless-sphere.com/forums/viewtopic.php?f=3&t=4007

 

[Larry]

Excellent idea for a thread, Knuckles.

Anyone hooked up a crysytalyte yet?

 

[Knuckles]

X-Lyte motors kick ass. Serious copper. Man I would LOVE to see a top-of-the-line Crystalyte motor at 80-amps and 140V. I bet 8 HP delivered to road. Yow!

Only motors I have now are ... Yee-Haw! ... Don Grubee!


I hear that Don's PMGR motor's are strong like Bull.

Toa Chie

PMGR = Permanent Magnet Gear Reduction

 

[Knuckles]

Success!

Here is the color-coding to connect the Shenzhen controller to a 400 series C-lyte motor:

Knuckle-troller C-lyte

Hall sensors-

Blk Blk
Red Red
Yel Yel
Grn Blu
Blu Grn

Phase-

Blu Yel
Grn Grn
Yel Blu

Note: connecting color color will drive the motor backwards quite nicely.

 

[Knuckles]

I had a discussion on phase/hall wiring with a forum member. He said there are 36 possible combinations.
I disagreed. I say there are only six possible combinations. I was close but not exact.

THERE ARE ONLY 6 POSSIBLE combinations (and only one will work) BUT only for a single direction.

When you find the right combination (1 out of 6) AND the direction is FORWARD then you are lucky.
If the direction is BACKWARD then switch 2 of the Hall wires and try the six (3-phase wire) combinations again.

This time when you find the right combination (1 out of 6) the direction WILL BE FORWARD.
See my xls spreadsheet here ... http://98.131.176.65/endless-sphere/Phase-Hall-Wire-Combinations.xls

cheers

 

[MyPC8MyBrain]

Used your wire color combo to install the 48v Shenzhen on my 500w Grubee [Skyhawk] motor.. thanks !
Saved me a whole lot of screwing around and head scratching!

Seems to have more low end torque and slightly more top end than the original 20amp controller.
Still...need more speed

In the endless quest to become satisfied with power and speed, next step will be a Crystalyte 5304 and
ebikes.ca controller.

If that doesn't do it, im buying a motorcycle :lol:

 

[Larry]

Does anyone know where we can order matching connectors for the Shenzhen controller. Couldn't find anything local for the first controller and I got a bit tired of switching to Andersons. It would be nice if we could order the mating connectors somewhere. Anybody know where?

 

[Knuckles]

Does anyone know where we can order matching connectors for the Shenzhen controller. Couldn't find anything local for the first controller and I got a bit tired of switching to Andersons. It would be nice if we could order the mating connectors somewhere. Anybody know where?

I generally cut those connectors.
But good point. It would be a nice courtesy to provide the client with mating connectors. I agree.

Meanwhile just cut them. Say WTF and cut them. That is what I eventually do. WTF! I like electrical tape anyway (unless I have to unwrap it ... then I cus and curse).

cheers

 

[fitek]

Hi folks, having a bit of a problem. My controller "stutters" at low speed, in fact it's hard to get started at all from a dead stop. I suspect there must be something up with the hall sensor wiring, unless this is normal. The stock controller was super smooth. Jonathan loaned me a 36v Makita pack and I reconfigured my 48v Shenzhen controller for 36v operation. I placed a 3.9k resistor in parallel with R3 and jumpered R1. I then hooked it up to my Kollmorgen as follows:

Motor->Controller
Power
Green -> Blue
Blue -> Green
Hall
Brown->Black
Blue->Green
Yellow->Yellow
Green->Blue

However I believe I rewired the Kollmorgen hall wires in the past so the color coding may not be too useful for others out there with Kollmorgens. When I get this sorted out I'll post a picture of the configuration that "works." FYI swapping green and blue reversed the direction of the motor.

I took the bike for a ride this morning; with the wheel unloaded it spins up nicely, but with any weight on the bike it sounds like a fan with a bad bearing. The bike is also pretty slow, though it does run.

I also have not had any luck finding connectors for this controller, so I used a small screw driver and removed the blades from their housing and used spade connectors and duct tape to hold it together. I could not remove the blades from the hall sensor connector so I just stuck bare wires in and taped the hell out of it. Sounds like I may be better off chopping the connector and soldering the wires together.

Any thoughts?

 

[fechter]

It sounds like you don't really have the right hall and phase wire matching. Try more combinations. The correct combination will start from any position and run smooth.

 

[jorge75]

Hello Can a member publish the phase and hall signal combination for a golden motor? I've seen several threads talking about golden/infineon but none give details about the wiring.

Is there a way of bench testing a controller (without connecting it to a motor), presumably one would need to feed some kind of periodic input to the hall signals...it would be nice if someone could write a mini tutorial about this scilloscope ,mini gadgets etc

 

[philf]

Timing, or what?

I was looking for something else, and saw this - only half a day later than the question was posted to this otherwise stagnant thread. Just goes to show the value of this forum, wot?

Anyways, getting a Golden to work with the Infineon, I actually found a combination that both *works* and is easy to visualize (if you're into patterns like I am ). Just swap the yellow and blue wires on BOTH the phase lines and the sensors (so the blue wire from the controller goes to the yellow wire on the motor cable, and vice versa - green stays with green). That's it!

[Edit - a few hours later]. I'm probably the only one who found it funny that I'd verbally explain how easy this combination was, immediately after having claimed to be a "visual" kinda guy. So, for the record ...

Phase wires...

Yellow Blue
Green Green
Blue Yellow

Halls...

Phase wires...

Yellow Blue
Green Green
Blue Yellow

(the same!).

Hope that's more useful...

 

[jorge75]

Thanks for the answer;easy to remember; so i insist with question 2
I would like to experiment with the endless possibilities of the infineon: programming, unpopulated connections etc without immobilizing my byke
So , to bench test the controller one would need to provide I imagine some periodic signals to the hall wires in order to get juice in the phase wires; so a little gadget need to be made for this.
How one connect a scope ( I've got a bitscope) to wiew the phase outputs; do I need to put a load, a resistor in each wire and can i join them afterward or I test the phase separately :?