I have troubled to replace a malfunctioning the Chinese made bike controller and successfully finished after several times of try
outs.
Here are some hints for your successful project.
First of all, I prefer to fix the poor
Chinese English from the above LED Display Manual.
1.
Applicable Bike Voltages: 24,
36, 48V
2.
Functions
-
Electronic Power Switch
-
Battery Level Meter(4 Levels, Indicating LEDs)
-
Speed Setting, Low/Mid/Max
Modes
-
Fixed Speed(6km/h) Cruise
Control – Press “Power” and “Mode” Buttons simultaneously, the Speed Set
Output(Green Wire) shall be 4V
-
Headlight Switch with LED
Indicator
-
Sleep Mode in 10 Minutes of no-operation.
3.
Dimensions and Material(Skip)
4.
Wire Color and Functions
1)
Red: B+, drains 200mA
2)
Black: B-
3)
Blue: B+, when pressed “Power
Switch” and shall be kept on(see below)
4)
Green: Speed Set Output:
Low(1V), Mid(2V), Max(3V)
5)
Yellow: Headlight Output(B+)
6)
White: B-, for Headlight/Horn
** I have found the “Power Switch” couldn’t keep the “On” state and since of it; I have made a jump the Red and Blue wires together. It made the
power turn on as soon as the Battery Switch “On” and it could just “Turn-Off”
the Power during "On" time.
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The above photo illustrates the wires of the Controller and it shows the
functions of every connector.
I will show you the functions step by step as below with correct
English expressions.
1. Two Green wires in 1P Male & Female Connectors: It shall be required to connect each other for initial
power-up what it makes a “Self-Study” of the connected Bike side wires
configurations. After it, It shall be disconnected after the initial set-up.
2. Black and Green wires with 2P Female Connector: Black wire is B- and
Green wires carry a Speed Set signal (1~4V) from the LED Indicator.
3. Blue and Black wires in 2P Female Connector and a jumper wire in 2P
Male Connector: It looks like hardware Cruise Control, just remove the jump
Connector.
4. Red, White and Black wires in 3P Female Connector: Connected to
Throttle while Red & Black wires supply 4.3V power and receive Throttle signal
through the White wire.
5. Black & White wires in 2 Male 2P Connectors: Brake Signal,
Making contact when applying the hand-operated brakes.
6. Red & Blue wires in 2P Female Connector: Red is B+ supply to LED
Indicator and the Blue wire go B+ when pressing the “Power Button” of LED Indicator - I jumped it.
7. Black, Red & Blue wires in 3P Male Connector: to be connected
with PAS(Personal Assistance System).
8. Red, Black, Yellow, Green, Blue & White(Sometimes omitted) wires in 6P
White Male Connector: Shall be connected with Motor Hall Sensor.
9. Heavy gauge of Green, Yellow & Blue wires with individual Female
Bullet Terminals: Connected with Motor Phase Lines. - I had experienced having a big noise on the Motor when I applied the Throttle and it was cleared after switching Green and Blue Motor wires. Maybe it would be wrong sequential connections.
10. Heavy gauge of Red & Black wires with individual Male Bullet
Terminals: Battery Terminal shall be connected, Red(B+) and Black(B-),
sometimes after Key Switch. - Some Controllers are Red wire with a Male Bullet connector and Black wire with a Female Bullet connector.
** I had to buy 3 Controllers to fix the trouble and this lesson was made through it.
** I do not recommend purchasing a Controller with an LCD Display but an LED Display and it will be easier to apply/match.