External Controller Installation

For Voltbike models:

Bikes with rear hub motors using external controllers (mounted behind seat tube)

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.

Trouble shooting 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 a problem. When problems arise affecting two on 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
- #1 Phillips screwdriver
- 3mm hex tool
- spare zip ties

To replace the external controller follow the below instructions:

Steps 1-7: Removal
Steps 8-12: Installation

1. Remove the battery, and 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.

2. Carefully remove the rubber grommet that fits in the downtube and unwrap the plastic cable coil or cut upper zip ties to provide more cable harness slack at the handlebars. This will allow you to easily connect or disconnect the lower plugs.

3. Cut the zip ties under the crankset, and carefully remove cables and connector plugs from inside the downtube. Start with the pedal assist sensor cable. Other cables include the main cable harness plug, front light plug, rear light plug, motor plug, and main power wires going to the battery.

4. Examine all cable plugs and power wire connections for any issues that could be the cause of the problem prior to disconnecting plugs and removing the controller from the frame. Check for damaged, cut, or melted cables and plugs.

5. Firmly pull to disconnect all plugs and connectors. Check if any pins are damaged or bent.

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

7. Use a #1 Phillips screwdriver (or 3mm hex tool) to loosen and remove the small bolts that secure the external controller to the frame bracket. Most controllers can be recycled at municipal waste or recycle depot that accept small electrical appliances.

8. Install the new compatible external controller to the seat tube bracket and install the small bolts.

9. Carefully reconnect the plugs and connectors. Note the alignment arrows on plugs to ensure the pins are not bent or damaged. Check the power wires connections (red & black) are tight and properly insulated.

-main cable/wire harness      -pedal assist sensor

-rear light                                   -motor plug cable

-front light                                  -black and red power wires

 Ensure all the connections are secure and will not disconnect!

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.

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).

Once the bike has been tested successfully, remove the battery again, and turn the bike on to discharge the controller and continue with the installation/repair.

12. Carefully insert cables and plugs back up inside the downtube. Use zip ties the ensure the cables are secure and will not be snagged or fully exposed to dirt and water. Re-install the velcro pad over motor plug.

Error codes for deluxe color screen 860C