Connecting the motor and controller should be pretty much self-explanatory, but here are the important points:

Your controller is rated for no more than 40 amps, so it is VERY important that you use a 40 amp (or lower) fuse in line in the power line feeding the controller.

IMPORTANT! The red push on/push off switch acts as a motor reversing switch when the unit is operating a neutrally timed motor. (such as Kollmorgen motors) It will not properly reverse a motor such as the BMC that is manufactured with advanced timing. Attempting to reverse the rotation of a motor with advanced timing by using this switch while the throttle is applied could destroy the controller.  (gentle throttling without load will not immediately destroy the controller).

MORE IMPORTANT! Because this motor reversing switch is exposed, there is a significant risk that the switch position could be changed without the operator's knowledge. I know of a case where a loose bundle of wires bumped the button and reversed the controller while the bicycle was in motion. 

I consider this to be a design flaw which will be corrected on later versions of the controller, but in the meantime I have disconnected the switch from the circuit and set the controller correctly for your particular application. If for any reason you should want to return this controller to it’s original condition simply open the lid and re-attach the wires to the legs of the reversing push button. Or you can just ignore the switch. The two wires involved are easy to spot and you can open or close the circuit manually.

Phase Wiring

Just follow the color-coding. Black to Black, Green to Green, Yellow to Yellow. You will note that both the motor and  controller phase connectors are female quick-connects. Use the 50 amp maxi- fuses that came with your motor/controller to complete the phase connections. Then use the quick ties (also included) to tightly bundle the 6 wire ends together. This is important to keep the phase connections secure.

The fusing of the phase connections is an important safety feature. It protects the controller.

It's a good idea to pinch all the phase connectors tight before inserting the fuses in order to assure the best connection possible. A loose fuse or fuses can significantly reduce performance.

IMPORTANT -A failure of a phase fuse is an indicator of a system failure. Examine the hall effect wiring for a loose or broken connection. If a failure occurs immediately after making your phase connections, double check to make sure your phase connections are correct. If you replace a failed phase fuse and it immediately fails again contact us using the  information at the end of the page.

Hall Sensor Connection

The 8 position connector accommodates the standard 5 Hall sensor wires and two positions devoted to an optional thermal cutoff switch for the motor. As installed, there is a short loop of black wire closing a circuit between the 6th and 7th pins. If desired this loop can be cut and a cutoff switch installed in the circuit. Installation of a thermal cutoff is recommended for 48v operation. Below 48v the cutoff shouldn't be so important. Eventually all these motors will ship with thermal cutoffs installed.

This is the enable switch for the controller. When it is in the off position the light goes off and the controller won't operate, but don't mistake this for a true power switch. Even when in the off (disabled) position the controller is "on" and will produce a slow steady drain on your batteries. As with all controllers, you must have a main power switch in your system or the controller will run the batteries down to the point of destruction.

Standard connector for the 5k thumb throttle. (Currie or equiv) The controller can also be throttled with a Hall type throttle.

Some units will ship with a 2 position Molex connector compatible with the older style Currie brake inhibit connector (used with the brushless motors). Many units will ship with the stock 3 position brake inhibit connector provided by the manufacturer. (due to the fact that it is impossible for me to predict which connector will be appropriate for a given customer’s system) I have plenty of the two position Molex connectors that were used with Currie brushless motor scooters. For a few bucks (including shipping) I can provide you with either or both connectors.

NOTE- If you choose to rig your own inhibit switch you only need to close the circuit between the two light colored wires (of the three) in order to inhibit the controller. You may ignore the red wire.