User Manual: 36V Brushless Motor Controller

1. Introduction

This manual provides essential information for the safe and effective installation, operation, and maintenance of your new 36V Brushless Motor Controller. This controller is specifically designed as a replacement part for DYU D2, D2+, and D3+ electric bicycles. Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Safety Information

• Always disconnect the battery power before performing any installation, maintenance, or repair work on your electric bicycle.
• Electrical work should only be performed by individuals with appropriate knowledge and experience. If unsure, seek professional assistance.
• Ensure all connections are secure and properly insulated to prevent short circuits.
• Do not expose the controller to water or excessive moisture.
• Verify that the voltage and current ratings of the controller match your electric bicycle's specifications.
• Keep children and pets away from the work area.

3. Package Contents

Your package should contain the following item:

• 1 x 36V Brushless Motor Controller (Model: DGHB2.6)

4. Specifications

Refer to the product label for detailed electrical specifications:

Physical Dimensions (Approximate)

• Length: 13 cm
• Width: 8 cm
• Height: 9 cm
• Weight: 0.3 kg

5. Installation and Setup

Important: Ensure the electric bicycle's power is completely off and the battery is disconnected before beginning installation. Incorrect wiring can damage the controller or other components.

1. Locate Existing Controller: Identify the current controller on your DYU D2, D2+, or D3+ electric bicycle. Note its mounting position and how the wires are connected.
2. Disconnect Old Controller: Carefully disconnect all wires from the old controller. Take photos or make notes of each connection point if necessary, especially for color-coded wires.
3. Mount New Controller: Secure the new DGHB2.6 controller in the same location as the old one, using appropriate fasteners. Ensure it is protected from physical damage and moisture.
4. Connect Wiring: The controller features a variety of color-coded connectors. Match these connectors to the corresponding ports on your electric bicycle. Common connections include:
   • Power Wires: Typically thicker red (positive) and black (negative) wires connecting to the battery.
   • Motor Wires: Usually three thicker wires (e.g., yellow, green, blue) connecting to the motor phases.
   • Hall Sensor Wires: A thinner bundle of wires (e.g., red, black, yellow, green, blue) connecting to the motor's Hall sensors.
   • Throttle Wires: Typically three wires (e.g., red, black, green) connecting to the throttle.
   • Brake Lever Wires: Wires connecting to the brake levers, often with a low-level signal.
   • Display/Control Panel Wires: Connections for the e-bike's display or control panel.
   • Other Wires: May include wires for pedal assist sensor (PAS), lights, or other accessories.

   Note: The specific color coding and connector types may vary slightly. Always ensure a direct match with your bicycle's existing wiring. If you are unsure about any connection, consult a qualified e-bike technician.

5. Secure Connections: Double-check all connections to ensure they are firm and properly seated. Use zip ties or other means to tidy up and secure loose wires, preventing them from snagging or interfering with moving parts.
6. Insulate: Ensure any exposed wire connections are properly insulated with electrical tape or heat shrink tubing.

6. Operating Instructions

Once the controller is correctly installed and all connections are secure:

1. Reconnect Battery: Reconnect the electric bicycle's battery.
2. Power On: Turn on the electric bicycle's main power switch (if applicable) and/or the display unit.
3. Test Functionality:
   • Verify that the display (if present) powers on and shows correct information.
   • Gently twist the throttle to ensure the motor responds smoothly.
   • Test the brake levers to confirm that they cut off motor power.
   • If your bike has pedal assist, test its functionality.
4. Initial Ride: Perform a short, controlled test ride in a safe area to confirm all functions are working as expected before regular use.

The controller manages the power delivery to the motor based on your throttle input, pedal assist level, and brake signals. It is designed to provide a smooth and efficient riding experience for your DYU electric bicycle.

7. Maintenance

To ensure the longevity and optimal performance of your controller:

• Keep Clean and Dry: Regularly clean the exterior of the controller with a dry cloth. Avoid using water or harsh chemicals. Ensure it remains dry and protected from rain or splashes.
• Inspect Connections: Periodically check all wire connections for looseness, corrosion, or damage. Secure any loose connections.
• Avoid Overheating: Ensure the controller has adequate ventilation and is not covered, especially during prolonged use, to prevent overheating.
• Protect from Impact: Avoid dropping the controller or subjecting it to strong impacts.

8. Troubleshooting

If you encounter issues with your electric bicycle after installing the new controller, consider the following common troubleshooting steps:

If these steps do not resolve the issue, it is recommended to consult a professional e-bike repair service.

9. User Tips

• When replacing the controller, it's often helpful to label each wire connection as you disconnect the old controller to ensure correct re-connection.
• Always use appropriate tools for electrical work to avoid damaging connectors or wires.
• Consider taking photos of the original wiring setup before disassembly for reference.

10. Warranty and Support

For any questions regarding the installation, operation, or troubleshooting of your 36V Brushless Motor Controller, please contact the seller or manufacturer directly. Keep your purchase records for any warranty claims.

Manufacturer: Shenzhen Counterbalance Technology Co., Ltd.