How to Remove and Replace an Electric Bike Controller?
Are you looking for a complete guide on removing or replacing an electric bike battery?
We are going to guide you now on removing and replacing the controller. The controller is the inside part of the brain of the e-bike. The controller housing is the battery slides into to connect with the controller. It gets power from the battery, but then what it does is it gets information from your LCD, and then it tells the motor how much pedal-assist or how much power to give you.
How to Replace the E-bike Controller?
We will take that outright controller now and then replace it. It’s a pretty basic job, and it’s not difficult. All we need are two tools of Phillips and some snips. All right.
- We will go ahead and snip the wires free. They are held by zip ties in three or four places and snip those. There is one down here that goes to the motor. Of course, you want to be careful that you don’t snip the wire itself.
- Now, we can go ahead, and there are two screws here in the front called Phillips. They are very easy to remove. One and two numbers hold the front panel of the controller housing, and in this black part, you will see a little plastic tab on either side. We can use the screwdriver to push those and pull that front panel out.
- The front panel comes out, and the controller will come along it. We can pull that right out of the front, and there it is connected to everything.
- To change the controller,we need to disconnect it from all the wires holding it still onto the bike to replace it with a new one. What we will first start with is we have two leads going to the battery tip. They are black and red like you may have seen in a car.
- Now We will take the electrical tape off it. And then, the next step would be to pull the leads apart at the clips, which happens when you can pull on the tape just then. The red and the red go together, and then we will unbind the black one. We will remove those apart as well with the black leads.
- And now, the controller housing is free of the controller. So, we just unplugged the rest part. We have this connection in the yellow one, which goes to the pedal-assist, and the next one is for the throttle. It has a little clip, you push down that little clip, and they will drop apart. And now, the last part is the longest than the others. There is one that goes down to the motor. We want to pull that part, and then there is one more zip tie right there, which is a little slippery.
- The controller is free now. And then feed the wire that goes to the motor. We have to feed it through the bike’s frame. There is a little bit of cable management plastic right there, and you need to push that connector part through the frame, and there is one more zip tie. Some extra zip ties ones in; no harm it, and now, we need to move the other wires out of the way. And then, pull it right through the frame’s part it will come out. You will have the controller free of the controller housing and the bike, and then you can replace the controller.
- Now, you can put the controller back in or the new controller, and now, first, you can connect the red and black lead. It’s going into the controller housing. They are very easy. They snap together like red and red, and then black and black are connected. Then next, there is yellow on that one, and you can match that up with the yellow one for the pedal assist. Put those wires between the rack arms.
- There is also a little direction and directionality to the clips. You’ll see a little tab that will fit in there and little arrows. You can line up the arrows and then slide those back together.
- The motor connection will have to be feedback through the frame. So, it will put it through between the seat stays and then down into the bike’s shell on the backside of the seat tube and push it. It is the trickiest part, just getting this part fed back through there. And then, this connection will go up to the LCD monitor and the brakes for the three-way part. Where is my connection?
- Again find out the way that lineup. You can see a little tab, and there are also arrows, and it’s best to line up the arrows but do it very gently. You don’t want to hurt these parts. They are fairly delicate, and the connections are too.
- And then, the throttle one’s very easy to see because it looks different than the other ones, snaps together with a nice positive snap. So then, now that we have the motor wire fed through the bike‘s shell, line those two arrows up again, gently find the fitting, and then firmly push them together.
- We have to put the controller back into the controller housing, tuck the wires away, and then the black wires coming out will be centered. And then, you’ll notice on the front plate of the controller housing that there is an opening area. Put where all the central wires are, click the front plate into place, the little snaps, and then we’ll secure it with those two little screws. Put in screw number one and number two, and that’s all there is. We are done.
Many well-known brand-name electric scooters and electric bikes have easy-to-install plug-and-play replacement speed controllers available in the market.
What if a Replacement Speed Controller is Not Available?
Most electric scooters and bikes have speed controllers made or wired specifically for that model. These speed controllers may only have connectors and wiring patterns unique to that model. Suppose a plug-and-play replacement speed controller is not available. In that case, a speed controller with the same Voltage rating and an equal or slightly higher Watts rating may be replaced for the original speed controller as long as it is wired to the other parts of the bike.
How To Install E-bike Controller?
If a speed controller is available, that will plug and play directly into an electric scooter or bike. However, when installing it, be careful because the connectors may be the same. However, the wiring patterns going to the connectors may differ from that of the original controller.
- Double-check the wiring to ensure it is correct before installing the new controller. The pins can be removed and installed in different locations on the connector if the connectors are correct but the wiring going to the connectors is incorrect.
- To rearrange the pins inside a connector, use a narrow metal rod to push on and bend the pins locking tab inside the connector, and then gently pull the wire and pin out of the back of the connector.
- Now, turn the locking tab back to its original position and insert the pin back into the connector in the preferred location.
When the pin is fully inserted into the connector and the locking tab has been correctly bent back into position, it will make a small “snap” or “pop” sound to let you know that it has been perfectly installed.
Final Thoughts
We have tried our best to explain how to replace ad install the e-bike controller. If you still have any questions, comment below. We’ll contact you as soon as possible.
Integrated Lishui Controller in Hailong Battery holder with 5 Gold-plated Round Plug
1.Technical Data:Fit for: Yose Power 36V350W rear motor kitCompatible with: 36V 13Ah Hailong battery Rated voltage: DC36VRated current: 9ALow voltage protection: DC31VMax. current: 18A Throttle adjustment voltage: 1.2V-4.4VWeight: 0.3kg
2.Packing List controller x 1
3.Warm tips Shipping from China takes 20-30 working days. Please read the instruction manual carefully after received the package, this will help you to use the product effectively.If you want to return the product, please return the complete product as soon as possible and ensure the product has not been used and doesn’t affect secondary sales.
Copyright StatementAll the contents including words, pictures, and videos are originally made by YOSE POWER.It is not allowed to plagiarize without permission or we keep the right to pursue legal responsibility.
Customer Reviews
Sehr schön, dass die Steuerung jetzt im Akkuhalter integriert ist. Wäre die externe Steuerung nicht durch Wassereintritt beschädigt gewesen, hätte ich mir keine neue kaufen müssen. Bin mal gespannt wie lange das jetzt mit der integrierten Steuerung gut geht.
Integrated Lishui Controller in Hailong Battery holder with 5 Gold-plated Round Plug
Je suis très satisfait du produit : l’assistance est relativement progressive pour un moteur-roue. Dans le commentaire précédent j’ai écrit que la connectique n’est pas adaptée : il s’agit du controller par défaut mais Yose Power vous envoie dans un colis séparé la bonne référence. Je suggère à Yose Power de ne pas envoyer le controller par défaut (celui avec le fil rouge et le fil noir pour limiter ses coûts et être encore plus vertueux. Merci Yose Power vous êtes les moins chers du monde et très fiables !
Integrated Lishui Controller in Hailong Battery holder with 5 Gold-plated Round Plug
Integrated Lishui Controller in Hailong Battery holder with 5 Gold-plated Round Plug
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Introduction to E-Bike System Communication Types
When choosing the type of communication protocol for your electric bike battery, it is important to take into account not only how well it communicates with the system but also what are its limitations.
In this blog post, we will take a look at a different type of communication in lev e-drive systems and why CAN communication is usually found in high-end systems.
CAN has many segments but shares the same characteristics. In recent years, CAN has been a more and more popular protocol for high-end electric bicycles. Uart may be a good choice if you have an open-source drive system or want to use more simple software on another platform. Smart BMS is often used on high-end e-drive systems because they offer enhanced safety and security features.
What are the different types of communication for electric bicycle battery packs?
There are a few different types of communication for the e-drive system.
The first one is Uart which uses a serial connection to communicate between the battery pack and the display or controller and display. It was also used computer data transfer device in early times. In an electric bicycle system, Uart only sends out basic information such as voltage, SOC, etc.
Bluetooth and other wireless technologies use radio signals to communicate. This allows for system-wide communication but is more susceptible to interference.
What is the process by which the data is transmitted in electric bicycles?
The data that is transmitted between the battery pack and the e-bike drive system can vary depending on the protocol used.
CAN bus, for example, sends messages in a series of packets. These packets are small pieces of data that are sent one at a time. This allows devices to send and receive messages even when they are not actively communicating with each other.
Uart, on the other hand, sends data in a continuous stream. This means that data is sent as soon as it is available and there is no waiting for packets to be assembled.
These high-performance hub motor systems can use CAN bus or Uart while older models might only have one of these options available. For example hub motor kit or front hub motors.
Which Brand is using the CAN bus?
CAN bus is a common communication protocol in the electric bike industry. Many different brands use it to communicate with their drive systems.
Some of the more well-known brands that use CAN bus include Bosch, Shimano, Bafang, and Yamaha. If you are looking for a battery pack that uses CAN bus, these are some of the top brands to check for. CAN bus is a common communication method in the electric bikes industry so it is not necessary to specifically look for CAN, but this term does narrow down your search results.
Which Brand is using Uart?
Uart is a common solution in e-drive systems. It is simple to use but has limited performance. CAN and BMS have many segments but share the same characteristics.
UART stands for Universal Asynchronous Receiver Tx/Rx which means it can be used on most of all types of battery types (not only CAN bus). It looks like CAN, but it is simpler and slower. CAN has many segments but shares the same characteristics while UART only has one segment which allows devices to send and receive messages even when they are not actively communicating with each other.
Uart is a common solution in e-drive systems that communicate over CAN bus. Some of the more well-known brands that use Uart include Curtiss, Vintage Electric, Faraday, and Bafang. If you are looking for a battery pack that uses Uart, these are some of the top brands to check for.
What are some advantages and disadvantages of each type of communication for an electric bike battery?
The first one is Uart, which is a common solution in e-drive systems. it is simple to use but has limited performance.
CAN and BMS have many segments but share the same characteristics.
CAN bus improves safety by limiting communication between functions that are not needed at any given time while BMS ensures there are no conflicts between the battery cells.
RS-485 is common on the elder e-motorcycle. It is a common communication method in the industry.
- CAN bus improves safety by limiting communication between functions that are not needed at any given time while BMS ensures there are no conflicts between the battery cells.
- Uart is a common solution in e-drive systems that communicate over CAN bus. CAN and BMS have many segments but share the same characteristics while UART only has one segment which allows devices to send and receive messages even when they are not actively communicating with each other.
Disadvantages:
The CAN bus can be complex to set up and requires a higher level of expertise, whereas BMS ensures there are no conflicts between other devices.
Uart on the other hand is limited by its performance. Which is when the number of the device in the network increase. Uart can not handle that large amount of data sharing. Especially in the high-end electric bike, which offers support even APP on mobile phones for riding data, and other relevant data.
The future of e-bike batteries
The future of electric bicycle batteries looks bright with the continued development of CAN bus communication. CAN has many advantages over other types of communication, such as UART. It is faster, more reliable, and can handle a higher volume of data. This makes it the perfect choice for high-end e-drive systems.
Also, wireless communication has huge potential in the electric bicycle market. It can provide a more user-friendly experience by allowing riders to control their electric bike without having to touch any buttons. This could include features such as starting and stopping the electric motor, changing gears, and adjusting the settings on the display.
What we can do
Tritek has rich experience with CAN 3.0, CAN open, Uart project experience, etc. Our Smart batteries with our server software in BMS have been used on many well-known brands such as Specialized, Cannondale, Giant, and more. Our ability of RD and quality has also been approved by the world’s top E-drive system company. For more information on our electric bike batteries with CAN bus or CAN open communication types, please contact us.
The eBike Controller and Its Purpose
The invention and wide use of the controller has helped the eBike industry explode in recent years. The controller is the CPU (central processing unit) of the eBike that receives power from the battery and transfers it to all the various components of the bike along with signals giving specific instructions for which functions to perform.
The Delfast | My eBike Ride app, for example, communicates over Wi-Fi, Bluetooth and 4G connections signaling the Hyper-intelligent controller to perform a host of functions. E-bikes have different types and levels of sophistication when it comes to controllers based on the functions they are expected to perform.
Understanding Controllers
Most eBikes being sold today use brushless motor controllers, though some do still use brushed motor controllers. In simplest terms, a controller is the brain of the eBike. It receives information from the parts and translates that information in real-time to relay signals to the different components of an eBike. Some controllers may only be responsible for the acceleration of the eBike, or when using the pedal assist system. Other more advanced controllers, such as the one inside the Delfast Top 3.0i, that have more processing power, can control a wide array of features using inputs and outputs and complex algorithms.
Twist the throttle and the signal travels to the controller and is relayed almost instantly down to the in-hub motor to accelerate or decelerate. Set the level of pedal assistance and it will communicate to the motor how much assistance to give a rider based on the resistance detected or the algorithm programmed into the controller. The controller can communicate between all the connected components and the platforms that are at your fingertips, such as: the throttle, pedal assist levels, regenerative braking, speed modes, and the connected displays and apps. The more advanced the controller, the more functions it can handle.
The Most Commonly Used Motors and Their Controllers
To understand controllers, it’s also helpful to understand the motors that they are used to control. The two main types of motors in use for electric bicycles are brushed motors and brushless motors. Both are DC motors. Both motors use a set of positively and negatively charged magnets, though they do so in different ways.
The brushed motor uses electromagnetically charged coils of wire on a rotor. When current is applied it is alternately attracted and repelled by the opposing fixed magnets (the stator) to make the rotor turn as brushes keep contact and conduct the current that keeps the rotor spinning. This was the DC motor in use for many years and is still in use for numerous applications, including power tools like impact drills and electric screwdrivers, as well as various smaller motors inside appliances. It was among the first types of motor used in electric bikes. The main drawback of the brushed motor can be seen in its name. The brushes must have a contact point which creates friction that over time causes the brushes and surfaces to wear out and need maintenance. Brushed motors also tend to be heavier than newer brushless motors.
Brushless motors are not only much lighter, but because they don’t have brushes creating constant friction, which causes slowing and heat buildup, they tend to last much longer and require much less maintenance. Since brushless motors don’t have brushes to conduct electricity through contact, they require more advanced controllers to precisely control the amount of energy sent to negatively or positively charge the coils that then attract a moving set of oppositely polarized magnets. This ability to precisely control current through algorithms and sensors set to detect minute changes means the controller can detect when a motor slows or speeds up and can add or reduce the exact amount of power needed. This not only makes a more accurate motor but reduces wastes of energy leading to longer battery life and overall motor life.
Why is this Important?
Why is this information important? Knowing the evolution of technology from brushed motor to brushless motor, and then the continuing evolution and advancement of the technology inside controllers allows us to predict the ways in which technology will change how we live. We are huge geeks for technology here at Delfast. The controller inside the brushless motor has wide applicability in other technologies of interest.
An exciting example is the use of controllers and brushless motors inside of the hubs of wheelchairs. Having a controller that can gauge the amount of force needed versus the amount of force being used to push a wheelchair up a hill means the controller can communicate to the hub motors the need for assistance without having to push a button. These exciting leaps forward in technology can make our lives not only easier but more accessible and enjoyable as well.
