How to install a Brushless DC Controller on Ebike: The missing manual

[@BakedAndAwakePodcast]

This Man is a National Treasure and must be protected at all costs

[@SurfStr33t]

Man you are not lying.

[@LachiTRM]

Agree

[@stevenmonkman2027]

Great way to explain things, slowly and easy to understand, this was the tutorial id been looking for. Many thanks.

[@2tbalon]

Many thanks! It is good to know someone has taken the time to share this information with the masses.

[@Andy-cq3iu]

Hallo zusammen, FRAGE, Ich würde gerne so ein Controller mit RCfernbedienung verbinden. Stehe etwas auf m Schlauch. Was brauche ich dafür? Oder ist das überhaupt möglich?

[@km4hr]

I don't understand why this info is so hard to find. It's seems like the manufacturers don't want anybody to know. Thanks for taking the time to explain. Very helpful! The controllers I've seen don't even have the wires labeled in Chinese.

[@MistahMatzah]

The sellers have the manual but won't disclose it - they treat documentation like an official Chinese state secret.

[@00708046]

I think that this video can teach us how to figure out almost any controller wiring just by using your methods of voltage testing along with your explanations . It is amazing that you can figure it out blind folded (without information) and the Chinese quite often either have the wrong information or none at all. Great video ! (Best) I will be watching it a few more times and taking notes so that I can really understand it like you do . Thank you !

[@Decibe1child]

Yeah this guy is good, its a basics into electronics sneakily hidden within a 3phase motor controller lesson

[@warrenbosch3581]

This is the clearest, most intelligent, and inspiring tutorial I have ever seen. Thank you very much!!!

[@mickyb.8014]

Just did my first build a few days ago (voilamart 1500w 48v rear hub, 52v 20ah battery) and I wish I had watched this video before I started my build... Got it all nicely done (was a bad birds nest, but now wrapped and all tucked away/tie-clipped ever so neatly to the frame) but I learnt the hard way as the voilamart instructions diagram was pathetic, you needed a magnifying glass (not joking I had to use one) just to see the wiring information... So clearly and precisely explained in terms even a simpleton like me can understand😂. Brilliant video.

[@00708046]

This is the best , most informative video ever made for understanding how brushless dc systems work . Basically applies to anything with a brushless motor and a . controller . Thank you for your sharing !

[@fuizipra]

Spent hours trying other tutorials, you were the one that finally showed me how to do it. Thank you!

[@slicaltimistic1]

This is important. Man does he explain these functions all the way down to the wire. Excellent job.👏👏👏👏👏

[@alltheboost5363]

There's something about how you explain it that is so calming. Thank you for explaining it.

[@ashroffzahir6196]

7h

[@ucheucheuche]

You have instilled more confidence in me to repair my Dualtron scooter, than talking to official electric scooter distributors and scooter repair shops.

[@supernova046]

theres a lotta people who are going to be happy you uploaded this video,those wires have been driving me n my mate round the bend for days.with no manual,wiring diagram and ilegible manufacturers name etc on the controler,its basicaly a nitemare when you have to get a replacement,nothing quite matches.many thanks,more videos like this needed.

[@shanehogarth6373]

Your video saved me hours and hours. Couldn't believe it came without any paperwork and without this I would have never discovered the learn feature probably. I now have mine controlling an old converted vehicle alternator without a hall sensor. Well done mate, and thank you.

[@mjyanimations1062]

wait, it can work without hall sensors connected?

[@shanehogarth6373]

@@mjyanimations1062 yes, works fine. You need to use the learn function as mentioned in the video

[@Magma_Boy]

@@shanehogarth6373 Did he say anything about it? I have a motor without hall but cant get it to run without using the "learning cable".

[@crazybird9588]

Thanks for a great tutorial. I just bought a speed controller that came with a Chinese manual lol. It had some English instructions on each wire/plug. However, it was hard knowing what wire did what. You have saved me so much time and stress on how to connect each wire and what it does. I am so grateful for your time. You are the man. 👍

[@nealshue6791]

This video gave me the confidence to buy two brushless controllers and power an old hoverboard. I built a little motorized trailer for a pedal car. I just took it for a test ride. Thank you Vuaeco.

[@mendivilmarisa]

!! This was by far the Most helpful Video on You Tube I have watched, when trying to figure out the wires on a newly bought 36-48v Brushless Ebike Controller. !! I know nothing, and I mean nothing about these bikes, I picked one up for cheap at a yard sale, was told it needed a new throttle and controller. Bought them both on Ebay and jumped in. Having Zero knowledge about Ebikes, Controllers, wiring, and motors, I was shocked to find all videos on you tube, people assumed basic knowledge and therefore it was useless and I gave up. After a few months, I took out my new controller and tried again. Your Video was a Success!! Easy to understand follow and So Helpful! Thanks for making videos like this... you genuinely are helping people.. :-)

[@jerseyguy-hq8wv]

Thank You very much for explaining how to connect a brushless dc controller the way you did. You made something that could be a bit intimidating to the beginner actually seem doable. Hats off to you my friend.

[@DanielLopes-jt8yl]

You always explain things exceptionally well. There is a simplicity in your talking about what is (to me) something complicated. Glad your on my feed since I am determined to get my RadMini to where it works best for “my needs”. I can’t rely on Rad Power Bikes as they have their own needs/reasons concerning how the RadMini performs. The information you are presenting here is important to me and I will store it in my library. I will refer to it to watch repeatedly and study. Thank you and I will look for more videos from you on my feed by searching for them if I have to. The internet is an amazing thing, I’m in California (USA.) and glad to connect to you. Thank you.

[@brannenthompson9662]

The best controller video out there and believe me I've watched a lot in 6 yrs of E biking.

[@brannenthompson9662]

Loved the 5v its ok join up the battery 40v, gonna have a big bang. lol.

[@jaaasgoed]

"Or google is wrong" And that was the last we ever heard of him. Thank you for the in depth review. This helped me out configuring my controller.

[@vuaeco]

Was that the last? :D

[@MarcQuinton]

@@vuaeco yes where is the second video ; excellent tutorial en ebike controllers ; many thanks.

[@MarcQuinton]

I've found it : kzbin.info/www/bejne/h5PWga2gfJKEpqM (may be). Thanks.

[@guygarciavargas]

You are Great!!!! After two weeks trying to connect my Chinese controller you gave me all the hints!

[@Andrews_vids]

This is the best and most helpful video i have ever seen this man deserves a nomination to the grammy awards

[@rokitman5753]

My 48 volt charger smoked up so i put two laptop chargers at the thrift store together with 53volts combined 👊 two years and still working!!!

[@johndoe-si9ch]

I would love to know more about this and how to do that. did you follow a guide or was this your own project? :)

[@philewuppallthwagh226]

@@johndoe-si9ch Hi, John. I think he just ran the 2 chargers in series. There is a + and - on each laptop charger. Take a positive(red) from one charger and connect it to a Negative (black) wire on the other charger. Now take the remaining positive (red) of one charger and make sure you connect it to the positive lead of the charging port and then the Negative (black) remaining wire from the other charger and run it to the negative on the charge port. Try to get two chargers of the same voltage and amperage when selecting the computer charger. You will want to have 3 to 5 volts more than the battery you will be charging 24v battery youll want 26 to 29 volts total of both chargers. 48v battery you'll want 51 to 53 volts total. Hope this a makes sense. If if you don't understand this or don't feel comfortable attempting it please find someone who is knowledgeable do it for you. 👍 good luck !

[@dannyrusso8279]

You are great. My new controller is arriving in 2 days and was in the dark as to how to make the proper connections. Your clear and concise instructions will be a major help when I make my controller upgrade. Thank you!

[@digitgig336]

your simplicity of explanation is top notch, really enjoyed watching your videos. please can you do a video on conversion of car alternator to brushless motor for use on ebikes and show a video of the practical connection. Thanks one more time

[@sbjones313]

This was the best explanation of the controller on an ebike and the explanation of the wiring I have yet to read. Very good video, thank you!

[@offgrid2010]

My conversion kit came with no instructions either and the ebay seller wants me to give him great feedback. Anyway, i was lucky the controller is marked in my native language (+ Chinese) and your great presentation makes the building of my bike possible. Wonderful presentation. Thank you.

[@DanielPlatt-d6u]

Just wanted to take a moment and say thank you, your walkthrough of this DC controller allowed me to replace the drive controller on my electric riding mower :)

[@lukmannet]

You are such a great teacher, I have been upset dealing with my Chinese controller, thankyou

[@picwick57]

your tutorial videos are @ Grand Master's level! I just began my first ebike project and feel so much more confident tackling after watching this video you have shared.

[@mastergspot7699]

One of the best done full walkthrough tutorial I have seen yet Bless you and all that you do sir! ❤

[@satyamostwanted]

Best explanation among the million videos on this topic. And this guy is really hilarious

[@46B3x2you]

I subscribed to your channel a while back but I forgot about it. I really appreciate that you've taken the time to explain all the things that I also had to figure out myself. We're brothers in this controller configuration experiment with regard to not having directions and not being able to read Chinese. Thank you for the Google Translate idea. I never thought about that. I just figured it all out on my own. It's been fun watching and listening to you as you go through the same problems I did years ago. I've built some really nice dual drive fat tire bikes with dual controllers and I would love to talk shop and share photos. I can't believe that I was able to figure out how to connect controllers when I first started..Not to mention Dual Controllers. The biggest problem I had was with the Displays. The Displays were always the weakest link in the chain. The display, no matter which one I tried, would always eventually give an error message and kill the whole system. This was with single motor systems, not just dual motor systems. It took me some time to find an answer to the problem. Some people made a lot of money while a lot of people lost out on being able to enjoy their bikes, scooters, trikes because the Displays Failed Them.

[@46B3x2you]

@@k31thd4885 I used an analog display by e-bikeling from Amazon. It's a 5 pin connected display that has three pedal assist setting. I always leave it on pedal assist one because I use a thumb throttle. I use a phone app for my speedometer. Urban Biker is a good app that will actually track your ride on google maps, another one is Speedometer. It's a simple app that doesn't track your location. it just gives you the speed of your ride. I hope this was helpful.

[@tonymunn]

Excellent video. I learned a lot and I am no longer afraid to connect my own brushless motor controller.

[@pedieasuncion6875]

Bro I need help, I connected all the wires and the motor sounds like it runs but the wheel is not spinning please tell me what to do to make my wheel turn

[@abomoataz6094]

thank you for your efforts the orange socket with red , blue,yellow wires is for anti theft system and lonely yellow for speed meter

[@DeviceOverDose]

Dude, this is a powerful tutorial... they shipped my new dual motor ebike out with the wrong controller. To avoid an exchange, 🤔 they offered to send a new controller 🤷🏻‍♂️... your video might get me might get me through this ...

[@martinhirsch94]

I believe the black and orange wires are cruise control for throttles that have an extra switch on them to provide for that function. I imagine a separate switch can be wired on the black/orange wires to enable cruise on bikes that don't have that switch built in to the throttle, it just makes the controller remember the speed you're running at, so you can let go of the throttle.

[@chrisapal1]

you did a nice job on this... thanks for taking the time to put this together.

[@AidanMacnamara777]

Thank you for this video. Been trying to find one that explains not only what the connectors are but where they should go. Brilliant!

[@markdemell3717]

I see that I am not the only one ,great video !

[@miketayse]

I've fixed and worked on cars, motorcycles and various electrical devices, but am new to electric vehicles. It would be nice if the electric vehicle manufacturers had a shop manual and a schematic, like motorcycles and cars. Thanks for the tear downs and explanations!

[@69Judge]

I am purchasing the controller you are discussing. Please advise the absolute simplest way ( fewest steps) to reverse the motor then returning to forward. YOU ARE THE BEST.

[@leafypath7290]

I've been looking for a video like this for ages! Great detail and explanations!

[@terryhuston9011]

Thank you for teaching us how to understand the wiring! Huge help!

[@fransschutte3859]

thanks for clear and easy help. i have watched this a few times now and am getting more confident to tackle the connections

[@lennartwiklund8840]

Thanks, it fixed my problems

[@roubenp6]

Very interesting and easy to understand video. Now I know the wire functions I can go ahead and rewire a new controller to an old bike. Thank you Vuaeco.

[@j-anaya3624]

Thank you for the video. I had an issue with the rear hub locking up. Don't know why but I was just able to free it up. However the wheel was traveling in reverse. After swapping wires and not getting anywhere I saw your " relearning " white wire trick. I followed your direction but it wouldn't change direction until I connected the wires. Changed direction and with power still on, disconnected the white wires. It was then that the forward direction was saved. All good now.

[@capone3167]

Where can I purchase the man speaking in this video?!! I’ve spent two days trying to find the diagram to my sons e-bike so that I can wire the new controller to his bike without frying the damn thing and then I came across this video while driving home from Home Cheap-Oh. I would like to be this man’s pen pal (if pen pals still exist). Thank you and always remember, you’ve brightened my day and have prolonged my life by putting an end to my frustration! God Bless You

[@martinhirsch94]

From what I gather, the low brake line enables power regeneration from the motor and high brake simple disconnects power to the motor altogether. You can connect one or the other to the switches on your brake levers. From what others have said, using power regeneration typically extends the range of your ride by 3-10%, depending on how much you stop and go, and how many hills you go down - as when going down a hill you can hit the brakes lightly to enable the generator function which will recharge your battery a bit. I think using the low brake line makes the most sense, and only hit the brakes hard, only when you really need to. In other words, only hit the brake levers lightly and let the regen function slow you to a stop.

[@ScottTheis]

The best walkthrough of the learning wires anywhere. Thank you.

[@derdrolftesinn]

Hey Vuaeco, thanks for your Videos about controllers! Helped a lot! 😊 Thank you very much for your work to help us

[@SilverShadow2LWB]

Nice video. The high and low brake wires will apply a high or low brake force (or slowing) to the controller when connected to ground. I think that most of use connect to high brake to basically disconnect power when activated. Thanks

[@martinhirsch94]

From what I gather, the low brake line enables power regeneration from the motor and high brake simple disconnects power to the motor altogether. You can connect one or the other to the switches on your brake levers. From what others have said, using power regeneration typically extends the range of your ride by 3-10%, depending on how much you stop and go, and how many hills you go down - as when going down a hill you can hit the brakes lightly to enable the generator function which will recharge your battery a bit. I think using the low brake line makes the most sense, and only hit the brakes hard, only when you really need to. In other words, only hit the brake levers lightly and let the regen function slow you to a stop.

[@SilverShadow2LWB]

@@martinhirsch94 Thanks. That is a pretty good description. Nice to have the option to try out both modes depending upon riding habits and terrain.

[@simongray7620]

Thank you for making and sharing your video you explain it all so very well, this as given me the confidence now so i can finish building my ebike.

[@AOTechWorx]

Thanks for the video. Now I understand a lot more of these controllers. Thank you very mutch for sharing.

[@jeremycatches9766]

Probably there is a power out for headlight and tail light, And some wire that need to be hooked to a switch to turn them on and off. Great Video ! Thanks for all the info !

[@kmaltman]

Thanks...A truly excellent video, always sufficient info, without unnecessary waffle. Brilliant

[@endysantoso4936]

Thanks a lot. This video is very useful. My controller cables have no labels at all. After viewing this video and of others, I get more understanding on how to test the cable ports voltage and to make correct connection.

[@d1o2n4]

Just like all the comments, thank you very much! I was given a dual 1200w motor, 48v off-road scooter that was running slower than its buddy, that was imported from Alibaba. I can change the 3 speeds but overall doesn’t match the power of the other one. Now it has developed an intermittent knocking sound which stops the rear motor for a split second. Thinking it was a gear inside (I’m used to electric transaxles) I opened it up to discover there are no gears and everything seems ok.. At least one of the bearings spins freely with no noticeable play. All the magnets seem good and no burns coils or smells. Got me thinking now it could be one of the Hall effect sensors so will be testing them next. I’m used to programmable PMDC Curtis controllers, so opening the scooter with all those wires! Jeez. Overwhelming to say the least, so your video showing not only what the wires do, but how to test them is invaluable. Thanks again. Don

[@kensharpe9949]

" Go Figure" Awesome response to the three wires with no labels :)

[@francoisguyot9770]

Excellent explanation of ESC functions and connectivities.

[@andingjia8099]

Really great! This operation video can help a lot of people! !

[@mattjohnston5807]

Awesome videos and thank you for simply explaining it. Too many people over-explain how electric motor systems work to sound smart and most of the time they have no clue what they are talking about and just waste your time. Not you though brudda!😉🇱🇷👍

[@sofyan3]

Thank you brother.. so i was just forgot to make a short between the yellow cable from throttle to the positive.. took me 3 hours till i found this video. Hail from Indonesia..

[@mhmdsaleh3502]

You are clever and good teacher .. thanks alot

[@kevinnee1990]

Good job vuaeco. Really in details and easy to understanding . Love your Vietnamese accent. :)

[@1bigsyd]

This video explained everything so easily..thanks

[@tomdorman2486]

Very good, sir. On the brake cutoff, you could use the anti theft for the second one. Thanks for all the info it will really help.

[@SteeLSxns]

this guy is insane at what he does precaite the vids keep up the good work

[@frankhodges6734]

Thanks so much for doing this video, it was a real help.

[@maruthupandian3728]

thank you, i bought a controller from ali express and it did not come with a manual. you video helped me sort it out.

[@Lowegy]

Excellent video. I got mine finally working after watching your video. The learning switch is useful to know.

[@certifiedshopifydeveloper]

You saved me brother!This is very helpful way how to test your motor hub before replacing a new one. Thank you so much! You deserved to have more subscribers and thumbs up!!! You muck it pretty well :)

[@derrickjguidry]

Just what I needed. THANKS.

[@joehanke8547]

Thank you for this video. Very informative. I expect it will prevent me from making my own smoke.

[@biduttamachintyabagchi9806]

The best explanation 💗

[@ch2o2]

very nice and intuitive instructions, thanks, you do it perfectly. However, just to mention, if you measure full voltage at a (unknown) pin it must not necessarily mean, that there is full connection to the voltage plus. It might be a signal-input with a pull-up resistor (which pulls the voltage up to VCC). It might be a signal-input (for whatever purpose) which is waiting to be set to ground (in order start "something") ..it doesn't necessarily make a "bang" ,) In such moments of doubt just take a resistor with which you connect the doubtful pins safely (start with higher values like 5kohm and slowly step down with it, till you see that something changes in the system) ...well, just sayin' - sometimes you might succeed. My controller, a no-name cheap one, has also outputs for the braking light in the rear (which is flashing, when braking), for front light and it is also managing the charging input for the battery etc. it's so bad, that there is no manual - guess, the manufacturer just doesn't want that people know too much about their product ...just why?

[@hai-hotranphotography1169]

Thanks for the video. Very helpful. Bought a system but haven't started to put it together yet.

[@israelkingsley8290]

Your tutorial was very helpful to me today, I really appreciate... Gods speed

[@timothytacner4865]

I bought the same throttle kit. Thank you so much for making this.

[@johnsherry6021]

You deserve a sun for this for sure! Thank you much!

[@andrewpipitone1572]

Ohh Thankyou I believe you gave me incite to why my motor would not go fast. I have to get a new controler but you explaine so very well what these wires are for.☺️🙏

[@wilsonmoreau4947]

Nice video well explained make me understand how it works and how to connect all the wires thank you nice work

[@ninjapancakes9435]

This was actually exactly what I needed. Thank you very much.(Trying to change rotation without changing the orientation of the motor but holifex sensor made it difficult.)

[@sovereignentity4924]

Thank you brother...🙏 Excellent detailed explanation 🛵🛵🛵🛵🛵🛵🛵🛵🛵🛵

[@bluhuptie]

Great job ! You are a godsend for us DIYers

[@ojc147]

Thanks so much for this very informative walk-through video. You are the best!

[@robwalmsley8235]

Just found you... im building a disabled off road vehicle for myself... decided to go hubb motor in wheel... any way you just saved my pain... thankyou for that video... its everything I would ask for...... unless you have a video on controlling four esc's with one twist throttle....??

[@thelaserhive3368]

This is the most helpful video! Well done, thank you.

[@kovidivi]

orange: pwm signal, rpm for display. your display has settings, you can change the magnets and tire rim size, then you have the actual km/h or miles/h reading. you can test it with frequency measure. low rpm gives you low freq, high rpm gives you high freq. this cable is similar with your phase signal, but not for motor, only for display.

[@chatracuk310]

Hi, Great video and explanation. I have recently bought two of the 250w 24v/36v controller to use on some repurposed hover board bloc motors and this has helped tremendously so thank you very much. Something that is more challenging is the plug types used on the controllers. I have searched high and low and cannot find anything definitive. If you do know the names\types that would be appreciated. The bullet connectors I believe are 3.5mm type but it is molex (???) and\or Dupont types I am struggling with to find. I have seen the automotive\motorcycle sets on eBay (380pcs) that look similar well the translucent white ones in any case but I cannot be sure of these. Thank you sir and once again great video and once my project is complete I will post on KZbin.

[@Oli420X]

I'm doing the same thing!!

[@frankzander7151]

Great video, this will help me figure out the wiring of my E-Scooter controller. Thanks for your effort. 8-)

[@M13x13M]

Thanks this helped so much. I could not figure out why my motor was running backward.,

[@sunnybeaches1331]

My wheel ran backward too! I did the SIMPLEST THING a simple mind could do. I turned the wheel around. It still works. Lol!!! I sure wished I had this video then!

[@daboyjames]

You didn't even need to do that. All you need to do is reverse the Polarity of the motor Yello-Blue. Green-Green. Blue-Yello.

[@kevinwise5583]

Very thorough video! Thank you very much!

[@AlejandroFelix-he9ib]

Excellent! Explanation, so easy you make this to understand, thank you so much ! I really appreciate u guy's work, you put into this🙏

[@Jhpc399]

Thank you for sharing your knowledge!! Super video and much needed. I appreciate that you did not include any Looney tunes for your background music.

[@jaridleighty4088]

Thank you you have helped me understand these controllers greatly Top Notch instruction

[@jellisellis8558]

Great vid , I also own a swagtron ebike my question to you will be if upgrading to a new controller for more speed does that means you’ll need a bigger battery and motor?

[@gasparcunha]

Thanks,very useful my regards from Brazil.

[@nicolasjurion7931]

Muinto obregado

[@aruns349]

Thanks a lot for such a detailed video.

[@Kamomil05]

thank you bro. finally, i test my controller

[@digicabtech]

The last green and orange cables may be for cruise control and speedo meter cables. Some speed controllers use the purple color for the cruiser