throttle types, and wiring questions

[Rober]

I am trying to uncover some basic information about twist throttles. I have a ORO twist throttle from a E-4 kit (I think this is basically a Cyclone motor kit adapted for a recumbent). The throttle has 5 wires, some LEDs which I think indicate battery voltage. I can't really find anything on the basics on the web and even my electric bike book fails to explain the most basic elements of the controller/throttle function. I really want to understand at a basic level what goes in and comes out of this black box, and I want to figure out if it can be adopted for my next ebike project.

I understand that there are potentiometer-type throttles, which are just basically a (5 K ohm?) resistor with a variable resistance. And I have heard of Hall-effect throttles. Are there any other types?

What are the input and outputs on a Hall-effect throttle? I speculate that there must be a ground, an input power wire (which supplies power at ? volts), and an output signal that goes to the controller (and that must put out a signal between 0 and ? volts, depending on the throttle position). Am I on the right track here?

I think 2 wires connecting my throttle must go to the battery and go to the LED voltage indicator on the throttle.

I would love to find a book or article that explains the inputs and outputs of controllers and throttles. This would help immensely in getting the whole system wired together correctly.

Robert

 

[Ypedal]

Welcome to ES !

Most ebike throttles are indeed Hall types, 0 to 5v , 3 wire.. the other 2 are for the battery voltage and can be left un-used.

There is plenty of info on this forum discussing in detail how it all works in various levels of complexity !! will try to dig a few up for you.

 

[John in CR]

The 3 wires for the actual throttle are +5V, ground, and signal as you expected. They connect to a hall sensor that is stationary in the throttle. There is a magnet in the part that twists. The twisting moves the magnet relative to the hall sensor which senses the change in magnetic field and sends a voltage that varies based on position up the signal wire, 0V for 0 throttle varying continuously up to approximately 4.7-4.9V for full throttle. 5V is avoided as the max because many controllers will interpret 5V on the signal wire as a short in the throttle or its wiring and shut down, which can happen when water gets in the throttle and later works fine when it dries out.

Note that the pot throttles can also be modified with resistor(s) to replicate the 0-4.9V signal of the hall throttle. A lot of guys do that so they can use a higher quality 5kohm throttle like a Magura.

The 2 wires for the fuel gauge LEDs connect to the pack + and - after your switch. If your pack voltage is different than the throttle expects, you can tune it to match your pack with a resistor. I use a 5kohm pot and adjust it until the LEDs function properly, mostly by verifying that only the last red light is lit at the lowest voltage I want my pack to bet at. Then I measure that resistance and install a resistor of that value in line with the positive wire.

John