Use Xtyle Controller for Schwinn AL1020

[The7]

Finally, The bike controller arrived.
It is almost the same as 1000 watts bike controller
read this tread for controller
http://endless-sphere.com/forums/viewtopic.php?f=2&t=4282

I connected all wires, and test it with 48 volts
It runs, but there are something wrong with this, Controller run hot and all 3 wires to motor also very hot without load, Run test it and running poorly, almost same as original controller running as 24 volts..

How did you match the colour wires of the new controller to the ebike?

 

[fechter]

Yes, the colors on the motor do not match the controller. You need to re-arrange them to make it work. P75NF75 FETs are OK for up to 60v.

See this thread:
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484

 

[computerpc101]

Thanks for your input, I haven't play with Electronic project for long time, I need more time with better setup to test them especial that I need to see the current rating, I just fix my multimeter so I can test current.

For now, I may be wrong but I feel that something wrong with this brand new controller, Brake control is not working, Not sure that this brake line connect to PIC chip or not, I will have to open up this new controller and hoping that it is a broken wires problem.

 

[fechter]

If you measure across the two brake wires with the brake off, you should have 5v.

 

[computerpc101]

Thanks fechter and The7 for your great help.
Sorry for The7 for high-jack your forums

Both of them are right,
Shenzhen BL4828 controlor use different connection as my Motor
Shenzhen Hall sensor plug = 100% match

Motor wiring
Controller ---> Al1020 Motor
Yellow ----> Blue
Blue ------> Green
Green -----> Yellow

After I connected, My bike run very well, much more power on hilly area, However, This controller is bigger, I need to refit everything before I do further testing for 48 volts and 60 volts test on real world.

I opened up My Shenzhen BL4828 (48 volts 28 amp)
It is 99.9% the same as BL7228 ( 72 volts 28 Amp)
(Please see picture)

Different I find
Input filter capactor Is 2 63 volts 470Uf comapre 100 volts 470uF (BL7228)
Regualars resistors are 2x150 Ohms compare to Ap 1000 ohms for (BL7228)
Of course LVC is change as well.

 

[computerpc101]

*** Old AL1020 controllor


I opened up this controllor and the current limited resistor is located here, you can increase current by adding resistor

I guess that adding current should be like this

15 AMP + 0.5 volts / Resistor = Total cut off current

So if we want to increase current to 20 Amp

15A + 0.5 volts / 0.1 Ohm = 20 AMP

I might be wrong, I haven't test it
Please see current limited resistor location

 

[The7]

Shenzhen BL4828 controlor use different connection as my Motor
Shenzhen Hall sensor plug = 100% match

Motor wiring
Controller ---> Al1020 Motor
Yellow ----> Blue
Blue ------> Green
Green -----> Yellow

After I connected, My bike run very well, much more power on hilly area,
I

Glad to see that you found the correct connections.

 

[The7]

*** Old AL1020 controllor

I opened up this controllor and the current limited resistor is located here, you can increase current by adding resistor

I guess that adding current should be like this

15 AMP + 0.5 volts / Resistor = Total cut off current

No sure if this is correct formula.

If you could trace this part of the circuit, then it may be possible to calculate the value of resistor used.