Unlabeled controller plugs

Liam.great98

100 mW
Joined
Sep 20, 2013
Messages
42
Location
Burlington, Ontario
I have a 24v 250w brushed motor controller that just arrived but the motor and battery plugs aren't labeled. I guess the assumption is that I'm putting into an actual electric bike, rather than using it to make my own. There are two pairs of wires, black and red, and blue and red. The blue and red are slightly thicker which leads me to believe they connect the battery. All the other plugs are labelled. I attached a picture, you can see what the connectors look like. Does anybody know which plugs are for the battery and which are for the motor? My plan was to just remove the connectors and attach spade connectors to attach my motor.
 

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The picture on the website isn't the same colour as mine, it has red/black and the other is brown/blue, whereas on mine they are red/black and the other is blue/red. Judging by other controllers, I am guessing the red and black is for the battery and the other one (which seems to have a variety of available colours) is for the motor. The black/red connector is male and the red/blue connector is female. Other controllers see, to have a male on for batteries and female for motor, which confirms my suspicion. I'll get a few replies and I emailed the seller.
 
I found this online:
http://www.electricscooterparts.com/hookup/SPD-24250.htm
it isn't exactly the same controller as mine, but it looks pretty close. It says that the female connector is the motor, which is what I suspected. The other thing I'm unsure of is about my throttle. The throttle on my bike has a female connector, but my controller also has a female connector for the throttle. Is there supposed to be a male-to-male extension in between or something? The other major thing is on the controller the throttle wires are the same colour as the wires from my throttle, but in a different order. I was planning to solder the connection or use spade connectors anyway. Should I leave the wires in the same way they would line up, and have not matching colours, or should I rearrange them so the red connects to red, blue to blue, and black to black?
 
I've never struck a brushed controller that wasn't red+black for the battery supply, and blue+something else for the motor wires.
I'd go with your hunch, should be fine.

http://tncscooters.com/index.php?route=product/category&path=41_73
 
Liam.great98 said:
I am guessing the red and black is for the battery and the other one (which seems to have a variety of available colours) is for the motor.

Yep sounds right to me.
As you've found there are no hard and fast rules on wiring from all the different controller manufacturers but there is some comonalities. I have brushed controllers blue/brown or blue/yellow motor.

As to the throttle - definitely use colours not position in the existing plug. Better yet measure them with a multimeter, but colour matching red,black and the third (green, white or blue?) is probably going to be it.
 
Alright, I'll definitely use black/red for the battery and blue/red for the motor. Thanks.
For the throttle, I know the throttle I have is a hall effect one, is there a chance that the controller uses a different type of throttle? And where can I find instructions on measuring it with a multimeter? How would I go about doing that?
 
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