Help! Help urgently needed with Freego Hawk controller

[Macster58]

Hi again everybody & happy new Year.
I’ve had an absolute disaster whilst trying to find the problem with my FreeGo Hawk bike as the stuttering
problem has re-occurred after a few days. Now this is where it gets bad I stupidly connected the battery + & - the wrong way around (I know.., I’m an idiot) anyway you know what came next it made a pop sound in the controller box. I opened it to find the 68v 470uf cap had blown and the negative rail exploded under the 1st mosfet. I’ve patched it with a 2 mm thick copper wire to join the rail together again and I think it has done it as none of the other traces look damaged & I have replaced the cap with one from another controller that is perfectly good as I have tested it. however I can’t get the hub to power up. The lights come on. The break light works. The handle bar speed selection for pas all lights up but no power to the hub. So I’ve tried to locate a schematic online without much luck for the 36v freego hawk. I have even tried to locate suitable cheap replacement that can control everything on my bike as I am currently out of work due to health problems & an original one is about £70 on eBay & I just don’t have that spare due to being on a Benifits claim. So If anyone can help with a schematic or a link to a replacement controller you would have my thanks and my appreciation. Thank you

 

[Deleted member 33385]

Hi again everybody & happy new Year.
I’ve had an absolute disaster whilst trying to find the problem with my FreeGo Hawk bike as the stuttering
problem has re-occurred after a few days. Now this is where it gets bad I stupidly connected the battery + & - the wrong way around (I know.., I’m an idiot) anyway you know what came next it made a pop sound in the controller box. I opened it to find the 68v 470uf cap had blown and the negative rail exploded under the 1st mosfet. I’ve patched it with a 2 mm thick copper wire to join the rail together again and I think it has done it as none of the other traces look damaged & I have replaced the cap with one from another controller that is perfectly good as I have tested it. however I can’t get the hub to power up. The lights come on. The break light works. The handle bar speed selection for pas all lights up but no power to the hub. So I’ve tried to locate a schematic online without much luck for the 36v freego hawk. I have even tried to locate suitable cheap replacement that can control everything on my bike as I am currently out of work due to health problems & an original one is about £70 on eBay & I just don’t have that spare due to being on a Benifits claim. So If anyone can help with a schematic or a link to a replacement controller you would have my thanks and my appreciation. Thank you

I really don't know if this helps, but after Googling "Yuan Lang Intelligent Motor Controller", I got to this page:

https://visforvoltage.org/forum/11134-yuanlang-controller-wiring-scheme-questions

...which contains two images, which might or might not be what you're looking for.

https://visforvoltage.org/sites/default/files/Clipboard02.jpg

https://visforvoltage.org/sites/default/files/Clipboard01.jpg

The same page links to this website, which used to contain a controller schematic, which may or may not be yours in all exactitude, but this link now goes absolutely nowhere:

http://en.njyuanlang.com/products_detail/&productId=da289ebe-f63a-4763-aee7-3faedd5d7723&comp_stats=comp-FrontProducts_list01-1278837448483.html

...then I tried to load up njyuanlang.com, but it doesn't seem to deliver a website to my PC, but it does deliver a mobile website in Chinese, here's a translation where you can look for contact information, to request a schematic:

https://translate.google.com/translate?hl=en&sl=zh-CN&u=http://m.njyuanlang.com/&prev=search&pto=aue

...and here is a link to the original mobile site in Chinese:

http://m.njyuanlang.com/

 

[vfr400]

Hi again everybody & happy new Year.
I’ve had an absolute disaster whilst trying to find the problem with my FreeGo Hawk bike as the stuttering
problem has re-occurred after a few days. Now this is where it gets bad I stupidly connected the battery + & - the wrong way around (I know.., I’m an idiot) anyway you know what came next it made a pop sound in the controller box. I opened it to find the 68v 470uf cap had blown and the negative rail exploded under the 1st mosfet. I’ve patched it with a 2 mm thick copper wire to join the rail together again and I think it has done it as none of the other traces look damaged & I have replaced the cap with one from another controller that is perfectly good as I have tested it. however I can’t get the hub to power up. The lights come on. The break light works. The handle bar speed selection for pas all lights up but no power to the hub. So I’ve tried to locate a schematic online without much luck for the 36v freego hawk. I have even tried to locate suitable cheap replacement that can control everything on my bike as I am currently out of work due to health problems & an original one is about £70 on eBay & I just don’t have that spare due to being on a Benifits claim. So If anyone can help with a schematic or a link to a replacement controller you would have my thanks and my appreciation. Thank you

Connecting with wrong polaity is normally terminal for the controller. A few people have tried repairing, but I don't know anybody that was successful.

In principle any 36v brushless controller will work. It's not possible to advise further without knowing what you have. As always, you guys show loads of photos that, as far as helping you are concerned, are completely useless. What we need to see are the wires, connectors and control panel - and not so dark that you can't see anything.

 

[Nealh]

It won't be just the main inrush cap or fet that has been damaged likely some other components like resistors or diodes are toast as well or even the main memory chip.

We have seen the Yuan lang's mentioned a few times and they are like most simply OEM only, you won't find one on any web site except if very lucky on an auction site.

 

[Andy-Mat]

It won't be just the main inrush cap or fet that has been damaged likely some other components like resistors or diodes are toast as well or even the main memory chip.

We have seen the Yuan lang's mentioned a few times and they are like most simply OEM only, you won't find one on any web site except if very lucky on an auction site.

You are absolutely right, particularly if any PICs, MPUs or Controller chips were incorporated, which are often then finally programmed by the final assembler company, to have the features they want to sell, so even if the chip was available, the cost of the programming tools and necessary knowledge would be prohibitive.....
My own bike has a good set of features, that can ONLY be bought from the bike company itself it appears, as I have yet to find any company selling a controller with ALL the features I have.... It costs around €100 I believe from the bike company....
As when the throttle got soaked and misbehaved, at the time I investigated the possibility that a new controller might be needed....luckily it was not!
Andy

 

[Macster58]

Connecting with wrong polaity is normally terminal for the controller. A few people have tried repairing, but I don't know anybody that was successful.

In principle any 36v brushless controller will work. It's not possible to advise further without knowing what you have. As always, you guys show loads of photos that, as far as helping you are concerned, are completely useless. What we need to see are the wires, connectors and control panel - and not so dark that you can't see anything.

Hi thanks for your reply I kind of thought that the controller was going to be dead I know it was a long shot but I was touching wood and hoping & preying. The funny thing is everything e-learning seem to work ie pas contraindications my handle bar and the lights front and back turn on and even the break light works. The only thing that doesn’t work is the throttle and motor. so what I will have to do is find a replacement but you’re right about the photos and obviously what I will do is I will take photos of all the connectors and wires and give all the relevant information on the connections and if you could possibly help me on a suitable controller as I’ve tried looking online without much success As most controllers I’ve seen seem to be the missing one or another connector I actually need one that does all the functions of my bike. I will upload all the details shortly. Thank you so much for your input

 

[Macster58]

I really don't know if this helps, but after Googling "Yuan Lang Intelligent Motor Controller", I got to this page:

https://visforvoltage.org/forum/11134-yuanlang-controller-wiring-scheme-questions

...which contains two images, which might or might not be what you're looking for.

https://visforvoltage.org/sites/default/files/Clipboard02.jpg

https://visforvoltage.org/sites/default/files/Clipboard01.jpg

The same page links to this website, which used to contain a controller schematic, which may or may not be yours in all exactitude, but this link now goes absolutely nowhere:

http://en.njyuanlang.com/products_detail/&productId=da289ebe-f63a-4763-aee7-3faedd5d7723&comp_stats=comp-FrontProducts_list01-1278837448483.html

...then I tried to load up njyuanlang.com, but it doesn't seem to deliver a website to my PC, but it does deliver a mobile website in Chinese, here's a translation where you can look for contact information, to request a schematic:

https://translate.google.com/translate?hl=en&sl=zh-CN&u=http://m.njyuanlang.com/&prev=search&pto=aue

...and here is a link to the original mobile site in Chinese:

http://m.njyuanlang.com/

Thank you for you help. I did try the first few links but I couldn’t get them to work but I did manage to send an email to yuan Lang so thank you for that.

 

[Nealh]

Swap the controller and lcd out for KT with LCD3 or 4. One may well have to play with some wiring but we can help you out with that.

 

[Macster58]

I really don't know if this helps, but after Googling "Yuan Lang Intelligent Motor Controller", I got to this page:

https://visforvoltage.org/forum/11134-yuanlang-controller-wiring-scheme-questions

...which contains two images, which might or might not be what you're looking for.

https://visforvoltage.org/sites/default/files/Clipboard02.jpg

https://visforvoltage.org/sites/default/files/Clipboard01.jpg

The same page links to this website, which used to contain a controller schematic, which may or may not be yours in all exactitude, but this link now goes absolutely nowhere:

http://en.njyuanlang.com/products_detail/&productId=da289ebe-f63a-4763-aee7-3faedd5d7723&comp_stats=comp-FrontProducts_list01-1278837448483.html

...then I tried to load up njyuanlang.com, but it doesn't seem to deliver a website to my PC, but it does deliver a mobile website in Chinese, here's a translation where you can look for contact information, to request a schematic:

https://translate.google.com/translate?hl=en&sl=zh-CN&u=http://m.njyuanlang.com/&prev=search&pto=aue

...and here is a link to the original mobile site in Chinese:

http://m.njyuanlang.com/

Thank you for you help. I did try the first few links but I couldn’t get them to work but I did manage to send an email to yuan Lang so thank you for that

Connecting with wrong polaity is normally terminal for the controller. A few people have tried repairing, but I don't know anybody that was successful.

In principle any 36v brushless controller will work. It's not possible to advise further without knowing what you have. As always, you guys show loads of photos that, as far as helping you are concerned, are completely useless. What we need to see are the wires, connectors and control panel - and not so dark that you can't see anything.

hi again, I have taken some photos of the controllers connectors and there are some other pictures. I don’t know if you can advise on a suitable replacement but any information will be much appreciated.

 

[Macster58]

So as you can see from the white page there are quite a few things that need to be powered. Again thank you for any help you can provide.

 

[Macster58]

Thank you for you help. I did try the first few links but I couldn’t get them to work but I did manage to send an email to yuan Lang so thank you for that

hi again, I have taken some photos of the controllers connectors and there are some other pictures. I don’t know if you can advise on a suitable replacement but any information will be much appreciated.

The first white page was actually missing the PAS wires so I have updated it .

 

[vfr400]

I nearly have the picture. I was hoping to see just a photo of the wires and connectors on the controller. That's all I need to help you. It's still quite difficult to figure out where wires are coming from and going to, but after lots of study, I think I have most of it. The remaining question is about the PAS because some Freegos do weird things with the PAS connection, and that's the only thing you haven't shown. An answer to this question should sort it: Is it a simple case of a three-wire cable from the PAS connected to another one, where all three wires go straight in to the controller? If not, how is it?

 

[Macster58]

I nearly have the picture. I was hoping to see just a photo of the wires and connectors on the controller. That's all I need to help you. It's still quite difficult to figure out where wires are coming from and going to, but after lots of study, I think I have most of it. The remaining question is about the PAS because some Freegos do weird things with the PAS connection, and that's the only thing you haven't shown. An answer to this question should sort it: Is it a simple case of a three-wire cable from the PAS connected to another one, where all three wires go straight in to the controller? If not, how is it?

hi sorry for the late reply. I think i have everything you need now. these are the conections. For some reason the pictures are up side down. Sorry about that but i cant get the the right wat around. I will also put up some other pics just in case. Thanks again for any help you can give.

 

[vfr400]

It's still not possible to see what happens to the PAS. There are three wires connected to it: red 5v, yellow ground and blue signal. The 5v and ground are connected directly to the controller, but the signal wire (blue) joins to a blue with a red stripe, which then goes to a connector, but it's not clear which of the two wires it's connected to. Whatever, it seems to go up to the handlebars. This is what I was worried about in the beginning when I said there might be a weird PAS connection. If it's like the one I looked at before, it goes into the control panel, which then processes it into a throttle signal. Controllers and control panels that work like that are extremely rare.

All is not lost though. It just means that you have to do a bit of wiring and get a controller and a control panel. Your PAS and throttle willl work with any controller. Cost would be about £40.

Can you confirm that the 5-way connector is for the motor hall sensors?

 

[Macster58]

Hi the block connector with 5 pins is the hall connector. Red black yellow green blue. Where the pas sensor connects to the controller’ the wires are as follows. From the handle bar controller (black thing with light switch and low medium & high I.e. M790) there are 5 wires in 2 connectors.
They are:
red & black in one 2 pin connector.
Green blue & yellow in one 3 pin connector.
Then by the crank arm the sensor has:
Red yellow blue in one 3 pin connector.
The second of these pictures is the connectors by the handle bar. The other picture is the main controller end.
Ps I hope I have it right for you this time.

 

[Deleted member 33385]

Hi the block connector with 5 pins is the hall connector. Red black yellow green blue. Where the pas sensor connects to the controller’ the wires are as follows. From the handle bar controller (black thing with light switch and low medium & high I.e. M790) there are 5 wires in 2 connectors.
They are:
red & black in one 2 pin connector.
Green blue & yellow in one 3 pin connector.
Then by the crank arm the sensor has:
Red yellow blue in one 3 pin connector.
The second of these pictures is the connectors by the handle bar. The other picture is the main controller end.
Ps I hope I have it right for you this time.

£11 to £20-ish? I've filtered for UK results only, but that's no guarantee that they won't be shipped from China:

https://www.ebay.co.uk/sch/i.html?_from=R40&_nkw=36v+brushless+controller&_sacat=0&LH_BIN=1&_sop=15&rt=nc&LH_PrefLoc=1

I always go by the rating of the seller, reviews from people who have recently bought the same or similar (they can be shills), and whether they offer tracked delivery (that's no guarantee either - sometimes they ship from China and track by Royal Mail for the last leg). Sellers who ship from China (quite often dropshippers, who don't give a damn, know nothing about the product and offer zero support) while pretending not to... rarely have a high rating count, or high rating in general.

 

[vfr400]

£11 to £20-ish? I've filtered for UK results only, but that's no guarantee that they won't be shipped from China:

https://www.ebay.co.uk/sch/i.html?_from=R40&_nkw=36v+brushless+controller&_sacat=0&LH_BIN=1&_sop=15&rt=nc&LH_PrefLoc=1

I always go by the rating of the seller, reviews from people who have recently bought the same or similar (they can be shills), and whether they offer tracked delivery (that's no guarantee either - sometimes they ship from China and track by Royal Mail for the last leg). Sellers who ship from China (quite often dropshippers, who don't give a damn, know nothing about the product and offer zero support) while pretending not to... rarely have a high rating count, or high rating in general.

You can't just get any random controller. Some of them are terrible. He needs one with proper PAS control.

 

[vfr400]

All things considered, I'd go for this one:

16.38￡ 32% OFF|Brushless Controller 24v/36v/48v/60v | Electric Scooter Controllers - Electric Bike - Aliexpress

Smarter Shopping, Better Living! Aliexpress.com

www.aliexpress.com

UK supplier here will be a bit quicker but costs more. Normally you don't have to pay duty on a controller that ships from China.

250w/350w Brushless Motor Controller Set LCD Display for Electric Bike Scooter for sale online | eBay

Find many great new & used options and get the best deals for 250w/350w Brushless Motor Controller Set LCD Display for Electric Bike Scooter at the best online prices at eBay! Free delivery for many products!

www.ebay.co.uk

 

[Deleted member 33385]

All things considered, I'd go for this one:

16.38￡ 32% OFF|Brushless Controller 24v/36v/48v/60v | Electric Scooter Controllers - Electric Bike - Aliexpress

Smarter Shopping, Better Living! Aliexpress.com

www.aliexpress.com

UK supplier here will be a bit quicker but costs more. Normaaly you don't have to pay duty on a controller that ships from China.

250w/350w Brushless Motor Controller Set LCD Display for Electric Bike Scooter for sale online | eBay

Find many great new & used options and get the best deals for 250w/350w Brushless Motor Controller Set LCD Display for Electric Bike Scooter at the best online prices at eBay! Free delivery for many products!

www.ebay.co.uk

As usual, there are sellers who claim to ship from the UK without extra charges - if these are the same product:

https://www.ebay.co.uk/itm/24V-36V-250W-350W-Brushless-Motor-Controller-W-LCD-Panel-for-E-bike-Scooter-UK/313308073690?epid=4041358363&hash=item48f29dceda:g:L0YAAOSw6X9eu-Qy&LH_BIN=1

https://www.ebay.co.uk/itm/36V-48V-Electric-Bike-Ebike-Scooter-Brushless-Motor-Speed-Controller-LCD-Panel/164324211810?hash=item26427c7c62:g:H-4AAOSwP8pfK8Ch&LH_BIN=1

https://www.ebay.co.uk/itm/24V-36V-250W-Brushless-Motor-Controller-LCD-Panel-Rainproof-for-E-bike-Scooter/143896589443?epid=4032705089&hash=item2180e7b483:g:HFcAAOSwXQpctUxP&LH_BIN=1

https://www.ebay.co.uk/itm/36V-48V-350W-E-bike-Scooter-Brushless-Speed-Motor-Controller-with-LCD-Panel-UK/373217364121?hash=item56e57d0899:g:k0sAAOSwroxfY4gi&LH_BIN=1

More results to pick through here:

https://www.ebay.co.uk/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313&_nkw=Electric+Bike+Controller+24V/36V/48V+250W/350W+Brushless+Controller+with+LCD+Display+Panel+for+Electric+Bicycle+e-bike+scooter&_sacat=0

Ebay have always refunded me, I don't know anyone else's experience is.

Macster58: I'm all for fixing things, but that thing seems f****ed! Even if you manage to get it working, it'll never be reliable. But of course, I could be completely wrong.

 

[Nealh]

There are so many crap PAS control systems on ebay it is best to ignore most as they all tend to be speed control and not very controllable at all. A lot are for scooters and have no PAS or display input at all and are purely twist and go only.
For generic after market systems there are mainly two on ebay to opt for.

I. Cheap prices Brainwave with 5 pas Levels, not had one so can;t comment much except quite a few have issues in understanding all the settings and parameter values. vfr though seems to have sussed them out regarding programming.

2. Probably the most user friendly though at about twice the cost is a KT system, 5 PAS levels with wide varying current % levels (non settable) PAS1 13%, PAS2 20%, PAS3 33%, PAS4% 50% & PAS5 100% same as a throttle.