Bafang E-bike Hub Motor Controller Instruction Manual

1. Safety Information

Please read and understand all safety instructions before installing or operating the controller. Failure to follow these instructions may result in electric shock, fire, serious injury, or property damage.

• Electrical Safety: Always disconnect the battery before performing any installation, maintenance, or troubleshooting. Ensure all connections are secure and properly insulated to prevent short circuits.
• Voltage Compatibility: Verify that the controller's voltage (36V or 48V) matches your e-bike battery and motor. Using an incompatible voltage can damage components.
• Fire Risk: Exercise caution with electrical components. Improper wiring or damaged parts can pose a fire risk. Store and charge batteries according to their specific instructions.
• Professional Installation: If you are unsure about any installation steps, seek assistance from a qualified e-bike technician.

2. Product Overview

This manual provides instructions for the Broercok Bafang E-bike Hub Motor Controller, designed for use with Bafang hub motors (front or rear) and compatible BF-UART protocol displays. The controller manages power delivery to the motor, enabling electric assistance for your bicycle.

Key Features:

• Supports 36V and 48V systems.
• Compatible with 250W, 350W, 500W, and 750W Bafang hub motors.
• Utilizes BF-UART communication protocol for display compatibility.
• Available in different connector types (Type A, Type B) for specific motor configurations.

3. Specifications

Controller Label Details (Example for 48V 500W Type A):

• Voltage: DC48V
• Undervoltage: 39±1V
• Brake Type: P-
• Current-limiting: 18±1A
• Motor Phase Angle: 120°
• Type: YCSV233-001-48T
• Number: 20191204000171
• Data: 2019-12

Controller Label Details (Example for 48V 750W Type B):

• Voltage: DC48V
• Undervoltage: 39±1V
• Brake Type: P-
• Current-limiting: 22±1A
• Motor Phase Angle: 120°
• Type: YCSV233-002-48T
• Number: 20191204000170
• Data: 2019-12

Controller Label Details (Example for 36V 250W Type A):

• Voltage: DC36V
• Undervoltage: 29±1V
• Brake Type: P-
• Current-limiting: 18±1A
• Motor Phase Angle: 120°
• Type: YCSE233-006-36TC6
• Number: 2024100600005
• Data: 2024-12

4. Package Contents

The package typically includes the selected Bafang Hub Motor Controller. Depending on the specific kit purchased, it may also include:

• Controller (36V 250W/350W, 48V 500W/750W)
• Protective Controller Box (optional, for certain models)
• Mounting hardware for the controller box

Note: Motor, battery, display, and other accessories are typically sold separately unless explicitly stated as part of a complete kit.

5. Setup and Installation

Proper installation is crucial for the safe and efficient operation of your e-bike. Ensure the battery is disconnected before starting.

5.1. Component Identification

Familiarize yourself with the controller and its connectors:

The controller features multiple cables for connection to the motor, battery, display, and other sensors (e.g., brake levers, throttle).

5.2. Controller Types and Specifications

Ensure you have the correct controller type for your motor and desired power output.

5.3. Wiring Connections

1. Motor Connection: Connect the main motor cable from your Bafang hub motor to the corresponding connector on the controller. Ensure the 9-pin connector type (Type A or Type B) matches your motor.
2. Battery Connection: Connect the battery power cable to the controller's power input (typically a yellow XT60 connector). Double-check polarity.
3. Display Connection: Connect your BF-UART compatible display to the designated display port on the controller.
4. Sensor Connections: Connect any additional sensors such as throttle, brake levers, and pedal-assist sensor (PAS) to their respective ports on the controller.

Note: The controller is specifically designed for Bafang hub motors (front or rear) and is not compatible with mid-drive motors.

5.4. Controller Box Installation (if applicable)

If your controller comes with a protective box, install the controller inside it and mount the box securely to your bicycle frame using the provided hardware.

6. Operating Instructions

Once the controller is correctly installed and all connections are secure, the e-bike system is ready for operation. The controller works in conjunction with your Bafang BF-UART display to provide electric assistance.

1. Power On: Turn on your e-bike battery and then power on the display unit. The display should illuminate and show system information.
2. Assist Levels: Use the controls on your BF-UART display to select the desired level of pedal assistance.
3. Throttle (if installed): If a throttle is connected, it will provide power to the motor independently of pedaling, up to the set speed limit.
4. Brake Cut-off (if installed): Brake levers with cut-off sensors will momentarily cut power to the motor when activated, ensuring safe stopping.

For detailed operation of specific features and settings (e.g., speed limits, wheel size, battery parameters), please refer to the instruction manual of your Bafang BF-UART display unit.

7. Maintenance

Regular maintenance helps ensure the longevity and reliable performance of your e-bike controller.

• Keep Dry: Protect the controller from water and excessive moisture. While some controllers are water-resistant, prolonged exposure can cause damage.
• Clean Connections: Periodically inspect all electrical connections for corrosion or loose fittings. Clean with a dry cloth if necessary.
• Inspect Wiring: Check all wires for signs of wear, fraying, or damage. Repair or replace damaged wiring immediately to prevent short circuits.
• Avoid Impact: Protect the controller and its housing from physical impact, which can damage internal components.

8. Troubleshooting

If you encounter issues with your e-bike system, refer to the following common troubleshooting steps:

Common Issues:

• No Power to Display/Motor:
  • Check if the battery is charged and properly connected.
  • Ensure all power cables to the controller are securely connected.
  • Verify the display is correctly plugged into the controller.
• Motor Not Responding:
  • Check the motor cable connection to the controller.
  • Ensure the correct pedal-assist level is selected on the display.
  • If using a throttle, check its connection and functionality.
  • Verify that brake cut-off sensors are not stuck in the 'on' position.
• Incompatible Display:
  • This controller only works with BF-UART protocol displays. Ensure your display is compatible.
• Incorrect Voltage/Wattage:
  • Ensure the controller's voltage (36V or 48V) and wattage (250W, 350W, 500W, 750W) match your motor and battery specifications. Using mismatched components can lead to malfunction or damage.

If the issue persists after checking these points, contact customer support or a professional e-bike technician.

9. User Tips

• Connector Verification: Before purchasing or installing, always carefully check that the motor connector type (e.g., 9-pin Type A or Type B) on the controller matches your motor's connector.
• Display Protocol: Confirm that your e-bike display uses the BF-UART protocol for guaranteed compatibility with this controller.
• Voltage Matching: Ensure the controller's voltage (36V or 48V) is identical to your battery and motor's voltage to prevent damage.
• Programming: Controller settings are typically configured via the connected BF-UART display, not directly via a laptop. Refer to your display's manual for programming options.

10. Warranty and Support

Warranty Agreement:

• Controller: One (1) year warranty, except for physical damage and incorrect operation.
• Motor Kits: One (1) year warranty, except for physical damage and incorrect operation.
• Battery: One (1) year warranty, except for physical damage and incorrect operation.
• Accessories: One (1) year warranty, except for physical damage and incorrect operation.

For any warranty claims or technical support, please contact the seller or manufacturer directly with your purchase details.