electric scooter controller wiring

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myzter
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Last seen: 6 years 8 months ago
Joined: Thursday, July 24, 2008 - 07:35
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electric scooter controller wiring

Hello

I need some help here,

controller is similair to this model:
scootrcontrlr.jpg

the wiring is causing some issue..

the wires from left side to right
blue, red, red, black

which ones connect to motor ? (red/black)
which ones connect to battery ? (red/black)

also connecting charge plug wires with 40 amp fuse

any ideas or help would be great !!

nasukaren
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Joined: Sunday, July 6, 2008 - 04:05
Points: 188
Re: electric scooter controller wiring

Yikes! What a mess! You didn't get it with any of the connectors? These are often a huge help in decoding the inputs / outputs.....

I think the red/blue is the motor (brushed) and the red/black next to it is main DC battery power, but the rest is a mess. Worst comes to worst, you might need to open the controller up and have the Gurus (Fechter, etc.) peer inside.

Karen

Working on a Piaggio Boxer (mo-ped) EV conversion: http://gpsy.com/ev

myzter
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Last seen: 6 years 8 months ago
Joined: Thursday, July 24, 2008 - 07:35
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Re: electric scooter controller wiring

hi thanx nasukaren

I could have added this to my original post.
The mess of wires except for the four wires on the left are connected with connectors, they are not any issue.

The basic of the problem is the first four wires, they are (previously) working, they must connect to four other wires which are from the battery/motor.

So far I have tried the comment you've made, with the following the result:
- red/blue is the motor (brushed) and the red/black next to it is main DC battery power

This will result in the motor engaged full output. My ignition switch is being totally bypassed/missed, also the throttle is not engaged/working. Even though the throttle and ignition are wired up properly.

goodnslo
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Last seen: 11 years 5 months ago
Joined: Monday, January 8, 2007 - 19:31
Points: 67
Re: electric scooter controller wiring

- red/blue is the motor (brushed) and the red/black next to it is main DC battery power

This will result in the motor engaged full output. My ignition switch is being totally bypassed/missed, also the throttle is not engaged/working. Even though the throttle and ignition are wired up properly.

I think you see the problem and dont realize it.

Assuming that you wired it up correctly (which it sounds like you did), the motor goes to full "ON" meaning that the controller is shot and stuck in short. To confirm this get a multimeter and disconnect the batts and motor from the controller (ENSURE THAT THERE IS NO POWER AT ALL ON THE CONTROLLER). Do a continuity check on the positive sides and then on the negative side. If BOTH show a path (usually it is just the negative that does), then your controller is trashed and get a new one.

If it doesnt show a path on the positive side, then you need to confirm if both the ignition switch and throttle are shot (or wired incorrectly which we will need more info), OR the control sensing function inside the controller is shot (which still means that you need to get a new controller).

I have not been following your previous thread, so if you can post it, I might get some further details.

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