DYU DQHB2.6 CD3F-6 Electric Bicycle Controller User Manual

Introduction

This manual provides essential information for the installation, operation, and maintenance of your DYU DQHB2.6 CD3F-6 Electric Bicycle Controller. This controller is designed for DC brushless motors in DYU electric bicycles, operating at DC36V. Please read this manual thoroughly before attempting any installation or operation.

Figure 1: DYU DQHB2.6 CD3F-6 Electric Bicycle Controller

Specifications

The DYU DQHB2.6 CD3F-6 controller features the following technical specifications:

Figure 2: Controller Specification Label

Setup and Installation

Installing an electric bicycle controller requires technical knowledge and should ideally be performed by a qualified technician. Incorrect installation can lead to damage to the controller, motor, battery, or personal injury. Always ensure the e-bike's power is completely disconnected before beginning installation.

Safety Precautions:

• Disconnect the battery before installation.
• Wear appropriate safety gear, including insulated gloves.
• Ensure all connections are secure and properly insulated.
• Refer to your specific e-bike's wiring diagram for precise connection points.

Installation Steps (General Guidance):

1. Identify Components: Familiarize yourself with the controller's various connectors. These typically include connections for the motor, battery, throttle, brake levers, display, and pedal assist sensor (PAS).
2. Mount the Controller: Securely mount the new controller in the designated location on your e-bike. Ensure it is protected from moisture and physical damage.
3. Connect the Motor: Connect the motor phase wires (usually three thicker wires, often green, blue, yellow) and Hall sensor wires (a smaller connector with five wires) to the corresponding ports on the controller.
4. Connect the Battery: Connect the main power wires from the battery (red for positive, black for negative) to the controller's battery input. Ensure correct polarity.
5. Connect Peripherals: Connect the throttle, brake levers, display, and PAS sensor to their respective ports. Pay close attention to the labeling on the controller and your e-bike's existing wiring.
6. Initial Check: Before fully powering on, double-check all connections for tightness and correct pairing.
7. Power On and Test: Carefully reconnect the battery. Perform a low-speed test of the motor, throttle, and brakes in a safe environment.

Figure 3: Controller Wiring Harness

Operating the Controller

The DQHB2.6 CD3F-6 controller functions as the brain of your electric bicycle's propulsion system. Once correctly installed, its operation is integrated with your e-bike's existing controls (throttle, pedal assist, brake levers).

• Power On: Turn on your e-bike's main power switch. The controller will initialize the system.
• Throttle Control: Use the throttle to manually control the motor's speed. The speed set range is 1-4.2V.
• Pedal Assist: If your e-bike has a PAS sensor, the controller will provide motor assistance based on your pedaling input.
• Brake Cut-off: The controller is equipped with a brake input (High-level) that cuts off motor power when the brakes are applied, ensuring safety.

Always operate your e-bike responsibly and in accordance with local regulations.

Maintenance

Proper maintenance can extend the lifespan of your controller and ensure reliable performance.

• Keep Dry: Protect the controller from water and excessive moisture. While designed for outdoor use, direct exposure to heavy rain or submersion should be avoided.
• Cleanliness: Periodically clean the exterior of the controller to prevent dust and dirt buildup, which can affect heat dissipation. Use a soft, dry cloth.
• Inspect Connections: Regularly check all electrical connections to ensure they are tight and free from corrosion. Loose connections can lead to intermittent power or system failure.
• Avoid Physical Damage: Protect the controller from impacts or vibrations that could damage its internal components.
• Temperature: Ensure the controller has adequate ventilation to prevent overheating, especially during prolonged use or in hot weather.

Troubleshooting

If you experience issues with your e-bike's electrical system, consider the following basic troubleshooting steps:

• No Power:
  • Check the battery charge level.
  • Ensure the battery is properly connected to the controller.
  • Verify the e-bike's main power switch is on.
• Motor Not Responding:
  • Check all motor phase and Hall sensor connections.
  • Inspect throttle and brake lever connections.
  • Ensure brake levers are not stuck in the 'on' position, which would cut motor power.
• Intermittent Operation:
  • Examine all wiring for loose connections or damaged insulation.
  • Check for signs of overheating on the controller.

For complex issues or if you are unsure about any step, it is highly recommended to consult a professional e-bike technician or the manufacturer's support.

User Tips

• Model Verification: Before replacing a controller, always double-check that the new controller's model (DQHB2.6 CD3F-6) and specifications (e.g., DC36V) precisely match your e-bike's requirements. Using an incompatible controller can lead to system malfunction or damage.
• Professional Installation: Due to the complexity of e-bike electrical systems, professional installation is strongly recommended to ensure correct wiring and safe operation.

Warranty and Support

For specific warranty terms and conditions, please refer to the documentation provided at the time of purchase or contact the seller directly. Keep your proof of purchase for any warranty claims.

For technical support or further assistance, please contact the PowerTown Store or the manufacturer, Shenzhen DYU Intelligent Mobility Technology Co., Ltd.