Control box advice please

[Mercian70]

Hi
, I have a Falcon spark which I’m trying to find a controller box for , the original DC moto jn067-a05006 doesn’t work so I tried one from another bike and all was good , I’m now struggling to find a replacement ( the falcon factory are useless ) , I got one off fleabay same voltage and wattage , all but one cable were the same , it lights up the control panel but when the crank is turned it just makes a buzzing sound and the wheel doesn’t turn , I resolderd the crank sensor wires in the right colour order but still no joy , I also tried a throttle control instead , excuse my ignorance on this as im new to electric bikes but I am learning and hoping to start converting vintage bikes to electric , any help would be appreciated, thanks .

 

[vfr400]

It looks like your new controller has self-learning wires, but not easy to determine from your photo of jumbled wires. Did you do the self-learning procedure?

Can you give us a link to the listing from where you bought the controller so that we can confirm the wiring?

 

[Mercian70]

Hi , thanks for the reply, ok so what is the self learning procedure ? And what would the wires be connected to ? The control box came with a control panel which is identical to the one on the bike so I hoped I’d be on to a winner , the connector to the wheel is identical and the power cables all match , it all seemed a bit too easy and then it wasn’t , as I said it’s a learning curve for me I’m used to dealing with vintage bikes where the biggest problem is a stick seat post , cheers , I’ll try and find the wiring diagram .

 

[Mercian70]

Hi , thanks for the reply, ok so what is the self learning procedure ? And what would the wires be connected to ? The control box came with a control panel which is identical to the one on the bike so I hoped I’d be on to a winner , the connector to the wheel is identical and the power cables all match , it all seemed a bit too easy and then it wasn’t , as I said it’s a learning curve for me I’m used to dealing with vintage bikes where the biggest problem is a stick seat post , cheers , I’ll try and find the wiring diagram .

Is this what you need ?

 

[Nealh]

Relying on matching phase & the 3 main Halls is also not a given that a new controller will work, sometimes you have to play with phase & Hall wire combo's to find the few that work well. The new Brainpower phase & halls may not match the old controllers on the pcb.
There are 6 combos of 3 Halls to configure and each set of Halls has 6 combo's of phase to configure.
Here is a diagram for testing all sequences, only a few will work well.
When testing use low PAS power and no throttle until you get the motor running nicely.
Test as per the attached doc, start at the top and configure the Halls and then test the six phase combos, repeat the same for all six Hall combos along the top.

 

[vfr400]

The two green wires marked intelligent identification are the self-learning wires. They allow the controller to configure itself depending on the arrangement of hall and phase wires, so that you don't need to do the procedure in the above post.

You switch everything off, connect those two green wires together, then switch on with the motor wheel in the air. The controller will go through some configuration routine, so you might see the wheel jog a couple of times, then start rotating slowly. When it rotates slowly forward, you can switch off, disconnect the green wires, then everything should work properly when you switch on again. If during the procedure you can hear the motor make a slight whirring noise but not moving, it means it's rotating backwards. Switch off and repeat the procedure until it runs forward. Sometimes, you need to initiate the procedure by opening the throttle slightly for a moment.

 

[Mercian70]

Hi , thanks that does sound like what was happening a whirring noise but no movement , I’ll give that a go first and see what happens , really appreciate the advise , I’m quite enjoying learning how they work and can’t wait to build something weird and wonderful the falcons are ok but a bit blah , cheers .