Controller for electric bicycle 48V 350W

Controller is designed for 3 phase 120 degree mostly  bicycle and similar motors. This controller is designed for operation in 48 volt system. It can function with lead-acid and lithium-ion batteries. This controller cannot be used for   single phase ( 2 wire ) motor systems.

Wire connection:

1. Red and black (larger diameter with connector block) - to battery.

2. Yellow, blue, green (larger diameter without connector block) - phase wires to motor. Connect by the color.

3. Thin yellow, blue, green, red +5V, black (5 wire connector block) - to hall sensors inside the motor. Some controller modifications can work without them but without them it will be difficult for the system to determine the rotor position at the starting moment and riding at low speeds therefore the system will operate in the economy mode (low power).

4. Thin black, green, red - to throttle handle. If the controller is operating normally, there should be a constant 4.2 V voltage between black and red color wires, green wire voltage level should differ from 0,8 to 4,2 volts in proportion to the throttle handle turning position. If there's a constant +4,2 volt voltage between the red and the black wire but if the green wire voltage is not changing when turning the throttle it means the throttle handle is broken. Please note -sometimes the manufacturers change the wire arrangement inside the connector blocks. Check if the wire colors match before connecting.

5. Red orange (sometimes it is red blue) - to the key switch.

The aforementioned wires are sufficient for the system to function. Other wires do not have to be connected - they are designed for supporting functions. Their count may differ depending on the controller model.

6. Two white wires with black connector at the back - these are for the controller training. The controller needs to identify the motor because it is designed to be used with various motors. Before connecting, remove motor load, disconnect hall sensor wires - raise the wheel and take off the chain. Connect the ends of the white wires and turn on the power supply. (Important - first connect the ends of the white wires and only then turn on the power supply) - after 2 or 3 seconds the motor will start turning. If it is turning in the correct direction, disconnect the white wires and turn off the power supply. If the wheel is turning in the opposite direction, disconnect the white wires for 2-3 seconds and connect them back - the motor will start turning in the opposite direction. (In some controller modifications two white wires are used for speed limiting).

7. Black purple - break lever (sometimes it is yellow black). The controller will cut the motor power supply if they are short-circuited.

8 Purple (it may be thin yellow in some models) –  also breaks. When connected to negative terminal the controller will help stop the motor more intensely using electric energy. That means it will go to recuperation mode when the battery is charged using the breaking energy. 7 and 8 points - are two brake use options. You can either use one or both of them. The controller will also not work if these connections are not used.

9 Black and yellow – reverse drive.This function is designed for non-reducer (direct speed) motors, which can be mounted in e.g. trike bicycles.

10 Black red and brown - gearbox switch.

11 Grey - horn.

12 Black red - alarm power supply.

13.Orange, grey , brown - alarm.

Controller connection.

Connect the power supply, motor, throttle, safety wire and key switch connector. Do not connect the hall sensor wires. Connect white training wires. Turn on the key switch, turn the throttle. If the motor is turning in the correct direction, disconnect the training wires, turn off the power supply and connect the hall sensor wires. If the motor is turning in the wrong direction disconnect training wires for 2-3 seconds and connect them back again. The motor will start turning in the opposite direction. Finish the procedure as described earlier. Connect the hall sensor wires.