An advise & proper English translation to help Replacing Control Gears of Chinese Electric Bike

   

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.