Internal controller installation

Bikes with hub motors using internal controllers (mounted below the battery in 
frame box)

Introduction:

The LCD screen and button pad is the rider/user interface for operating your E-bike, while the controller box is like the CPU (central processing unit) or the brain of your E-bike. The controller sends and receives electrical signals that control many functions including the motor, lights, pedal assist, and other sensors.

Controller problems can be complex to diagnose. Symptoms may be varied, and the LCD screen will not always show an error code to inform you of a problem .Typically controller problems will allow you to turn your bike’s screen on but the motor or other components may not function correctly or consistently.

Troubleshooting controller and electrical cable problems may involve multiple variables at play. In order to determine if your controller or some other component needs replacing or repairing, it may require examining electrical components, connectors, and assessing what your E-bike is “doing” and “not doing”.

Isolating variables and swapping in test components one at a time can sometimes be the best method to get your bike rolling again. Having a second VoltBike for testing the motor, LCD screen or throttle can help eliminate particular components as a source of the a problem. When problems arise affecting two or more electrical components this may be an indication the controller or wire harness could be the source of the failure.

Error codes will vary on the type of failure and model of bike or model of LCD screen on your E-bike. Typical causes of controller failure may include:

-controller plug to motor plug has disconnected

-communication error from a bad cable / wire connection

-melted controller / motor plug-over heating from improper Amp setting

-over heating from constant “throttle only” usage

-water and corrosion damage.

Tools Required:

- Flush cutter

- #2 Phillips screwdriver

- Spare zip ties

- Sealant / silicone

To replace the internal controller follow the below instructions:

- Steps 1-5 removal s

- Steps 6-12 install

Removal:

1. Turn the key to the unlock position and remove the battery. Hold the bike’s power button ‘on’ to discharge the controller. The screen may flash for one second and go out. The bike is now fully discharged.

Tip: This is a good time to double check the battery-rail screw is tight.

2. Use a #2 Phillips screwdriver to remove the four small bolts that secure the side plate to the frame box.

3. Carefully remove the controller from the frame box and disconnect the plugs (cable harness, PAS sensor, front light, rear light, and red/black power wire connectors).

4. Remove the Velcro chainstay pad (on some models) and disconnect the large plug from the hub motor to the controller. Cut zip ties as needed.

Carefully remove any old sealant from the frame’s rear cable hole. Pull the light cable plug through the hole to make clearance for the controller’s motor plug end to pass through the hole.

5. Gently pull the controller’s motor plug through the frame box hole and remove the old controller.

This is a good time to double check your new controller has the correct plugs, connectors, and specifications as the old controller.

Installation:

6. Route the new controller’s motor connector plug through the frame hole. Next route the rear light plug and cable into the frame box hole.

Note: the alignment arrows and connect the motor and rear light plugs.

7. Carefully reconnect the plugs and connectors. Note the alignment arrows on plugs to ensure the pins are not bent or damaged. Ensure all the connections are secure and will not disconnect! Check the power wires connections (red & black) are tight and properly insulated.

8. Position the new controller and excess cable in the frame box, so the side plate can be easily reinstalled.

9. Reinstall the aluminum side plate and four bolts. Ensure the plate is flush with the frame box and the four bolts tight.

10. Reinstall the battery and test the bike to ensure any controller related electrical problem have been resolved and no error codes are shown. Check the upper wire harness plugs are also connected.

Turn the key to the ‘ON’ position and test the new controller: power the LCD screen on, twist throttle, PAS sensor, lights, and brake sensor motor inhibitors. (Warning! Lift the rear wheel off the ground prior to testing the motor)

11. Once the bike and new controller have been tested successfully the frame box hole should be sealed to prevent contamination of water and dirt. Use a flexible silicone type sealant.

12. Secure the rear light and motor cable with a zip tie and re-install the velcro chainstay pad.

Note for TRIO:

Installation for an internal controller in a Trio generally follows the same procedure. A long separate motor cable extension is used that will be routed forward to the front wheel motor and connected at the front fork.

Error codes for 860C colour deluxe screen:           

Error codes for 850C colour screen:               

 01 Communication Error Check the cable connection
 02 Controller protection Check three-phase power line.
 03 Three-phase power line connection /Check  motor cable plug to controller plug
 04 Battery low Charge the battery
 05 Brake error Check the brake connection/ motor inhibitor sensor error
 06 Throttle error / malfunction
 07 Hall error/ internal motor Hall sensor connection