Bafang M300/G360 Mid Motor Controller User Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your Bafang M300 or G360 series mid motor torque controller. Please read this manual carefully before installation and use to ensure proper function and safety. This controller is designed for Bafang mid-drive e-bike systems, supporting both 36V and 48V 250W configurations.

2. Specifications

Note: Specifications are subject to change without prior notice.

3. Package Contents

Upon opening the package, please verify that all components are present and undamaged:

• Bafang M300/G360 Mid Motor Torque Controller with integrated wiring harness
• (Optional, depending on kit) Mounting hardware
• (Optional, depending on kit) User Manual (this document)

Figure 3.1: Overview of the Bafang M300/G360 Mid Motor Controller with its wiring harness.

4. Safety Information

Always observe the following safety precautions to prevent injury or damage to the product:

• Ensure the e-bike battery is disconnected before performing any installation, maintenance, or wiring work on the controller.
• Only use the controller with compatible Bafang mid-drive motors and components (e.g., display, battery).
• Avoid exposing the controller to extreme temperatures, direct sunlight for prolonged periods, or excessive moisture.
• Do not attempt to open or modify the controller casing. This will void the warranty and may cause damage or injury.
• If you are unsure about any installation steps, consult a qualified e-bike technician.
• Keep out of reach of children.

5. Setup and Installation

The Bafang M300/G360 controller is an integral part of the mid-drive motor system. Installation typically involves integrating it within the motor housing or a designated compartment on the e-bike frame. The following steps provide a general guide:

1. **Disconnect Power:** Before starting, ensure the e-bike battery is completely disconnected from the system.
2. **Access Motor Area:** Depending on your e-bike model, you may need to remove covers or components to access the mid-drive motor and controller area.
3. **Identify Connections:** The controller features a multi-wire harness with various connectors for different components of the e-bike system. Refer to the images below to identify the main connectors.
   

   Figure 5.1: Side view of the controller showing various connectors for system integration.
   

   Figure 5.2: Top view of the controller, illustrating the main wiring harness.

4. **Connect Components:** Carefully connect the controller to the following components:
   • **Motor Phase Wires:** Typically three thicker wires (often green, blue, yellow) connecting to the motor.
   • **Hall Sensor Wires:** A smaller connector with multiple wires (usually 5 or 6) for motor position sensing.
   • **Battery Power Input:** Two thick wires (red for positive, black for negative) with a robust connector (e.g., XT60 or similar) for battery connection.
   • **Display/Control Panel:** Connector for the e-bike display unit.
   • **Speed Sensor:** Connector for the speed sensor, usually mounted on the chainstay.
   • **Brake Levers:** Connectors for brake cut-off sensors (if applicable).
   • **Throttle (Optional):** Connector for a thumb or half-twist throttle.
   • **Lights (Optional):** Connectors for integrated e-bike lights.

   Ensure all connections are secure and correctly oriented. Mismatched connections can damage the controller or other components.
5. **Secure Controller:** Mount the controller securely within its designated location, ensuring it is protected from physical impact and moisture.
6. **Cable Management:** Route all cables neatly and secure them with zip ties or cable clamps to prevent snagging or damage during riding.
7. **Reconnect Battery:** Once all connections are verified, carefully reconnect the e-bike battery.
8. **Initial Test:** Power on the e-bike system and perform a basic function test. Check the display, motor assistance, throttle (if installed), and brake cut-off functions.

**Important:** The specific wiring configuration may vary slightly. Always refer to the wiring diagram provided with your complete Bafang mid-drive kit or consult a professional if you are unsure.

6. Operating Instructions

The controller manages the power delivery from the battery to the motor based on your input (pedaling, throttle, assist level). Once installed, its operation is largely automatic, working in conjunction with your e-bike's display and sensors.

• **Power On/Off:** Use the power button on your e-bike's display to turn the system on or off.
• **Assist Levels:** Adjust the pedal assist level via your e-bike display to control the amount of motor assistance.
• **Throttle (if installed):** Apply the throttle for immediate power, independent of pedaling.
• **Brake Cut-off:** The controller will cut power to the motor when the brake levers are engaged, enhancing safety.

For detailed instructions on using your e-bike's display and specific functions, please refer to the manual provided with your display unit.

7. Maintenance

Proper maintenance ensures the longevity and reliable performance of your Bafang controller:

• **Regular Inspection:** Periodically check all wiring connections for signs of wear, corrosion, or looseness. Ensure connectors are fully seated.
• **Cleanliness:** Keep the controller and its surrounding area clean and free from dirt, dust, and debris. Use a soft, dry cloth for cleaning. Avoid using high-pressure water jets directly on the controller.
• **Moisture Protection:** While the controller is designed to be water-resistant, avoid submerging it or exposing it to heavy rain for extended periods. If it gets wet, allow it to dry completely before use.
• **Temperature:** Operate and store the e-bike within recommended temperature ranges to prevent damage to electronic components.
• **Firmware Updates:** If available, Bafang may release firmware updates for their controllers. Consult your e-bike dealer or Bafang's official resources for information on updates and how to apply them.

8. Troubleshooting

If you encounter issues with your e-bike system, the problem may sometimes originate from the controller. Here are some general troubleshooting steps:

• **No Power:**
  • Check if the battery is fully charged and properly connected.
  • Ensure all power cables to the controller are securely connected.
  • Verify the e-bike's display is functioning.
• **Motor Not Assisting:**
  • Check the pedal assist level on your display.
  • Ensure the speed sensor is correctly installed and functioning (magnet aligned).
  • Verify brake cut-off sensors are not stuck in the "engaged" position.
  • Inspect motor and Hall sensor connections to the controller.
• **Erratic Behavior/Error Codes:**
  • Note any error codes displayed on your e-bike screen and consult your display manual for their meaning.
  • Perform a system reset by turning the e-bike off and on again.
  • Check for loose or damaged wiring.

If the problem persists after basic troubleshooting, it is recommended to contact a qualified e-bike technician or Bafang support.

9. User Tips

• **Cable Management:** Proper cable routing is crucial. Use cable ties to secure all wires, preventing them from rubbing against moving parts or getting caught.
• **Water Protection:** While the controller is robust, adding extra protection (e.g., a small fender or splash guard) in very wet conditions can extend its lifespan.
• **Regular Checks:** Make it a habit to quickly check visible connections before each ride, especially after riding in rough terrain or wet conditions.
• **Compatibility:** Always ensure any new components (e.g., display, throttle) are compatible with your Bafang M300/G360 system to avoid damage.

10. Warranty and Support

For warranty information, please refer to the terms and conditions provided by your original retailer or Bafang directly. Keep your proof of purchase for any warranty claims.

For technical support, troubleshooting assistance, or spare parts, please contact your authorized Bafang dealer or the official Bafang support channels. When contacting support, be prepared to provide your controller's model number (e.g., CR S10L 350 FC 1.2, visible on the unit as shown in Figure 5.3) and serial number.

Figure 5.3: Bottom view of the controller, showing the model number (CR S10L 350 FC 1.2) and serial number for identification.