Wiring for Greentime controller?

[ammodave]

I bought this Greentime controller http://www.aliexpress.com/item/High-quality-36V-350W-BLDC-motor-controller-E-bike-brushless-speed-controller/429352116.html to replace an apparently malfunctioning KU65 controller on my 36v Q100 build. The wiring is different and I have a few extra unidentified wires. Specifically:

-The battery connector has a lg red and black wire and a smaller purple wire. What do I connect to the purple wire?

-There are 2 blue wires with small black male and female connectors. Is this a speed limiter or cruise control?

-There are black and white wires going to a white female connector. Is this for the brakes? It was black and yellow on the KU65.

-There is a single small gauge yellow wire going to a white female connector. What's this for?

-There is a purple wire with a small black female connector. What's this for?

-There is a small gauge green wire going to a female bullet connector. What's this for?

The bike has a BMS Battery "meter " (battery meter and 3 speed switch) on it now but I'm guessing I'll have to discard that with this controller. I'll then have no on/off switch except on the bottle battery. Am I right in assuming the purple wires are meant to go to a separate on/off switch? If I choose to have no separate switch, what do I short together to make the bike run? I see lots of traffic here about Greentime products but I couldn't find anything on wire colors. Any help would be appreciated.

 

[ammodave]

Greentime sent me a wiring diagram but it doesn't quite match the wiring on the controller they provided. I still don't know what to short together so my bike will work without a separate on/off switch. Anybody have any ideas? I'd hate to fry this controller by doing something stupid.

 

[wesnewell]

I'd bet money the purple wire with the power connector is the ignition wire. Connect to + direct or through a switch.

 

[dogman dan]

I would say the purple wire on the battery plug goes to a keyswitch or other controller switch. Connect that to battery + or the controller will not turn on. You can run it through a switch or not, your choice, but it has to be hot to run the bike.

The big plug with two wires, black and white should be brake cutoffs. Use them or not, your choice.

The orange wire connecting to itself would likely be regen enable, reverse enable, and most likely, a watt limiter. Plug it in, and see what happens.

The other wires, who cares? If you have your throttle, ebrakes, phase power, and halls connected, you are up and running. Likely the green wire grounds the thing to the frame, which you don't need. The others were likely to be tail lights or horn power, something like that. Whatever they are, you don't need them to run the controller.

They aren't Cycleanalyst or programming plugs.

 

[ammodave]

I connected the purple wire to the positive terminal on the battery and now I have power. Two of the throttle wires on the connector on the new controller were also reversed from the KU65 configuration. I'll have to make a run tomorrow in the daylight to see if this controller solves my problem with the motor turning off and on at 12mph (almost like a speed limiter) that I was having with the old KU65. Does anyone know if I can get the Greentime controller to operate the BMS Battery "meter"?

 

[dogman dan]

Not familiar enough with the wiring on them to know exactly what to do.

Mainly, a battery meter just needs a + wire connected to full battery pack voltage to work. So I'd connect that to the purple wire so the meter switches off when you switch off the controller power.

Then someplace on that meter box, one wire will be the ground you need to connect. Other stuff on the box I don't know about, it might be the location of your controller on off switch, or a horn button, or a three speed switch that might be connected to one of those other unknown plugs.

You just need to really dig for a wiring diagram for that controller. Did you try asking the vendor for it?

 

[ammodave]

I requested and got a wiring diagram from Greentime but it's a little generic, probably the same diagram for all their controllers. The wire colors don't quite match what I have but it was good enough to get the bike running. I'm getting a smooth unassisted 20+mph on level ground which was all I was really hoping for with a 36v battery and a 350w hub motor. I'm not sure the BMS Battery "meter" ( with its on/off switch and 3 speed control) is really worth the trouble but it would be nice to know how much charge I have left.

 

[dogman dan]

Get a wattmeter from Ebay, Less than 20 bucks these days.