1. Introduction
This manual provides essential information for the safe and effective use of your Brainpower Motor Controller Model 930-6. This intelligent controller is designed for electric bicycles (e-bikes) and is compatible with 24V, 36V, and 48V power systems. Please read this manual thoroughly before installation and operation to ensure proper function and longevity of your product.
Figure 1: Brainpower Motor Controller 930-6 with its wire harness.
2. Safety Warnings
⚠ Disclaimer: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of your e-bike battery and related components. Improper installation or use of this controller can lead to serious injury or damage. Always disconnect the battery before performing any installation or maintenance.
- Ensure all connections are secure and correctly matched to avoid short circuits or damage.
- Do not attempt to open or modify the controller casing.
- Keep the controller away from water, excessive heat, and direct sunlight.
- Consult a qualified technician if you are unsure about any installation steps.
3. Specifications
The following table details the technical specifications of the Brainpower Motor Controller 930-6:
| Feature | Specification |
|---|---|
| Model | Controller 930-6 |
| Type | E-bike Intelligent Motor Controller |
| Voltage Compatibility | DC 24V / 36V / 48V |
| Power | 350W |
| Lower Voltage Limit | DC 19V / 30V / 42V (depending on system voltage) |
| Current Limiting | 13A |
| Rated Working Current | 6~25A |
| Maximum Working Current | 30mA |
| Off-state Leakage Current | <1μA |
| Degree Brake | Low |
| Angle | 120/60 |
| Working Temperature | -20℃ to 60℃ |
| Storage Temperature | -30℃ to 70℃ |
| Dimensions (L x W x H) | Approx. 13 cm x 7 cm x 5 cm |
| Weight | Approx. 0.215 kg |
| Origin | Mainland China |
Figure 2: Controller label with detailed specifications.
4. Package Contents
Your package should contain the following item:
- 1 x Brainpower Motor Controller 930-6
5. Installation and Setup
Important Note: This is a customized product. For specific wiring diagrams and detailed installation instructions tailored to your e-bike model, please contact the seller directly. Incorrect wiring can damage the controller, motor, or battery.
General steps for connecting an e-bike motor controller typically involve:
- Disconnect Power: Always ensure the e-bike battery is disconnected before starting any installation work.
- Identify Connectors: The controller features various connectors for different e-bike components. These typically include:
- Motor Phase Wires (usually thicker, 3 wires)
- Motor Hall Sensor Wires (usually thinner, 5-6 wires)
- Battery Power Input (red/black, thicker)
- Throttle Connector
- Brake Lever Connectors (often two, for front and rear brakes)
- Display/Panel Connector
- Pedal Assist Sensor (PAS) Connector
- Self-Learning Wires (if applicable, for initial motor pairing)
Figure 3: Close-up of controller wire connections.
- Connect Components: Carefully match and connect each wire from your e-bike to the corresponding connector on the controller. Ensure all connections are firm and secure.
Figure 4: Another view of the controller's wire connections.
- Secure Controller: Mount the controller securely in a protected area on your e-bike, away from direct impact, water, and excessive vibration.
- Initial Power-Up: After all connections are made and secured, reconnect the e-bike battery. Power on your e-bike system and test all functions (throttle, brakes, display, pedal assist) at a low speed in a safe environment.
6. Operating Instructions
The Brainpower Motor Controller 930-6 manages the power delivery to your e-bike motor based on inputs from the throttle, pedal assist sensor, and brake levers. Its operation is largely integrated with your e-bike's display unit.
- Power On/Off: Turn on your e-bike's main power switch or display unit. The controller will initialize.
- Throttle Control: Use the throttle to manually control the motor's speed.
- Pedal Assist System (PAS): Engage the PAS by pedaling. The controller will provide motor assistance based on the selected assist level on your display.
- Brake Cut-off: The controller is designed to cut off motor power when the brake levers are engaged, ensuring safe stopping.
- Display Integration: The controller communicates with your e-bike display to show speed, battery level, assist level, and other relevant information. Refer to your e-bike display's manual for specific operating instructions.
7. Maintenance
Proper maintenance ensures the longevity and reliable performance of your motor controller:
- Keep Clean: Regularly clean the exterior of the controller with a dry, soft cloth. Avoid using water or harsh chemicals.
- Check Connections: Periodically inspect all wire connections to ensure they are secure and free from corrosion or damage.
- Avoid Overheating: Ensure the controller is mounted in a location with adequate airflow to prevent overheating, especially during prolonged use or in hot weather.
- Protect from Moisture: While the controller may have some water resistance, it is not fully waterproof. Avoid exposing it to heavy rain or submerging it in water.
- Storage: When not in use for extended periods, store the e-bike and controller in a cool, dry place within the specified storage temperature range (-30℃ to 70℃).
8. Troubleshooting
If you encounter issues with your Brainpower Motor Controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not responding / No power |
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| Erratic motor behavior / Intermittent power |
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| Display not working or showing errors |
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|
If troubleshooting steps do not resolve the issue, please contact the seller for further assistance.
9. User Tips
- Always ensure your e-bike's battery voltage matches the controller's compatibility (24V, 36V, or 48V) to prevent damage.
- When replacing a controller, it is often beneficial to take photos of the original wiring before disconnecting anything to serve as a reference.
- For optimal performance and safety, ensure all electrical connections are insulated and protected from environmental elements.
10. Warranty and Support
Warranty Information
The seller strives to provide high-quality products. If you receive a defective or damaged product, please follow the guidelines below:
- Defective Products: If the product arrives defective, do not sign the shipping bill. Take photos of the defective product immediately and contact the seller for a refund or replacement.
- Returns: You may return goods within 15 days of receipt if the issue is due to a product defect, damage, or any fault of the seller. Returned items must be in their original condition. Returns due to personal preference or inability to use the product (not due to defect) may not be eligible for a full refund.
- Refunds for Issues: The seller offers refunds for issues such as lost packages or damaged items during transit.
Figure 5: General return process overview.
Customer Support
For any questions, concerns, or support needs regarding your Brainpower Motor Controller 930-6, please contact the seller directly. When contacting support, please provide your order number and, if applicable, images or videos of the issue.
11. Frequently Asked Questions (FAQ)
- Q: What should I do if the product is customized?
- A: This product is customized. Please contact the seller immediately after placing your order to provide necessary information and receive specific guidance for your setup.
- Q: What if I have problems with the item or service?
- A: Your satisfaction is important. If you encounter any problems, please contact the seller before leaving feedback. They are committed to resolving issues.
- Q: Why might the product color appear different from the images?
- A: Product images are based on true products, but due to variations in monitors and brightness settings, there may be slight color differences. This is considered normal.
- Q: What should I do if the product arrives defective?
- A: If the product is defective upon arrival, do not sign the shipping bill. It is the shipping company's responsibility. Please take photos and contact the seller for a refund or replacement.
- Q: What is the return policy?
- A: You can return goods within 15 days of receipt if the issue is due to a product defect, damage, or seller fault. Returned items must be in the same condition as received. Returns based on personal preference or inability to use the product (not due to defect) may not be covered.
