1. Introduction
This manual provides essential information for the safe and effective use of your 48V 22A Brushless Motor Controller, model LSW1234-10-1E. This controller is designed for electric bikes and mountain bikes, offering advanced features for motor management and protection. Please read this manual thoroughly before installation and operation.
2. Safety Information
- Always disconnect the battery before performing any installation, maintenance, or wiring adjustments.
- Ensure all connections are secure and properly insulated to prevent short circuits.
- Do not expose the controller to water or extreme moisture.
- Avoid modifying the controller's internal components. Unauthorized modifications can lead to malfunction and void any potential warranty.
- Verify that the battery voltage matches the controller's rated voltage (48V) to prevent damage.
- Keep children away from electrical components.
3. Product Overview
The LSW1234-10-1E Brushless Motor Controller is a robust component for electric bicycles, featuring several intelligent protection mechanisms and configurable settings to enhance ride safety and performance.
Key Features:
- Invisible Soft/Hard Start: Configurable start mode (default hard start) with memory.
- Invisible Single/Double Hall Booster: Configurable power assist mode (default single Hall Boost) with memory. Requires a 3-wire power assist sensor.
- Under Voltage Protection: Automatically stops output when battery voltage drops below a safe threshold, protecting the battery from over-discharge.
- Power-on Anti-Flying and Running Anti-Flying: Prevents unintended motor activation due to wiring errors or throttle malfunctions, enhancing vehicle safety.
- MOS Tube Short Circuit Protection: Detects and prevents damage to other MOS tubes in case of a serial short-circuit during power-up.
- High Temperature Protection: Reduces or stops motor output if the controller's internal temperature becomes too high.
- Rotation Protection: Limits current when the motor is blocked and cuts off the circuit after 2 seconds to protect both the motor and controller.
4. Specifications
| Feature | Specification |
|---|---|
| Model | LSW1234-10-1E |
| Rated Voltage | DC 48V |
| Maximum Current | 22A |
| Rated Current | 11A |
| Low Voltage Protection | 39V |
| Throttle Adjustment Voltage | 1.2V - 4.4V |
| Item Weight | 517g |
| Dimensions (L*W*H) | 109mm * 63mm * 33mm |
5. Setup and Installation
Proper installation is crucial for the controller's performance and safety. If you are unsure about any steps, consult a qualified technician.
Wiring Connections:
The controller features multiple wire harnesses for various components. While a detailed wiring diagram is not provided, typical connections include:
- Battery Power: Connect to your 48V battery pack. Ensure correct polarity (red for positive, black for negative).
- Motor Phase Wires: Connect to the motor's three phase wires (typically thicker wires, often green, blue, yellow).
- Motor Hall Sensor Wires: Connect to the motor's Hall sensor wires (typically thinner wires, often green, blue, yellow, red, black).
- Throttle: Connect the throttle unit. The throttle adjustment voltage is 1.2V-4.4V.
- Power Assist Sensor (PAS): Connect your 3-wire power assist sensor.
- Brake Levers: Connect brake levers with cut-off switches.
- Display/Meter (if applicable): Connect to your e-bike display unit.
Always double-check all connections before powering on the system.
Configuration Settings:
The controller allows for 'invisible' configuration of certain features:
- Soft/Hard Start Mode:
- Squeeze the brake lever.
- Turn the throttle handle to its maximum position.
- Power up the controller.
- Wait for 3 seconds. The controller will switch to Soft Start mode (default is Hard Start). This setting has memory.
- Repeat the entire procedure to switch back to Hard Start.
- Single/Double Hall Booster Mode:
- Squeeze the brake lever.
- Power up the controller.
- Turn the throttle handle three times (full rotation back and forth). The controller will switch to Dual Hall Boost mode (default is Single Hall Boost). This setting has memory.
- Repeat the entire procedure to switch back to Single Hall Boost.
Note: This feature only works with a 3-wire power assist sensor.
6. Operating Instructions
Once installed and configured, the controller operates automatically based on your throttle input and power assist sensor activity.
- Power On: Turn on your e-bike's battery and display (if applicable). The controller will initialize.
- Throttle Control: Gently twist the throttle to accelerate. The motor will respond according to the selected start mode (soft or hard).
- Pedal Assist: If a power assist sensor is connected and enabled, the motor will provide assistance as you pedal, based on the selected Hall booster mode.
- Braking: Engaging the brake levers will cut off power to the motor, ensuring safe stopping.
- Power Off: Turn off your e-bike's battery and display when not in use.
7. Maintenance
To ensure the longevity and optimal performance of your motor controller, follow these maintenance guidelines:
- Regular Inspection: Periodically check all wiring connections for looseness, corrosion, or damage.
- Cleanliness: Keep the controller clean and free from dust, dirt, and debris. Use a dry, soft cloth for cleaning.
- Environmental Protection: Avoid exposing the controller to extreme temperatures, direct sunlight for prolonged periods, or excessive moisture.
- Cable Management: Ensure cables are neatly routed and secured to prevent chafing or accidental disconnection.
- Heat Dissipation: Ensure the controller is mounted in a location that allows for adequate airflow to prevent overheating.
8. Troubleshooting
If you encounter issues with your controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor does not start | Low battery voltage Loose connections Throttle malfunction Brake lever engaged | Check battery charge; ensure voltage is above 39V. Inspect all wiring connections. Check throttle for proper function. Ensure brake levers are fully released. |
| Motor stops unexpectedly | Overheating controller Motor blocked (Rotation Protection) Battery voltage dropped too low (Under Voltage Protection) | Allow controller to cool down; check mounting for airflow. Check for obstructions in the motor or drivetrain. Recharge battery. |
| Motor runs erratically or with reduced power | Loose motor phase/Hall sensor wires Partial short circuit (MOS Tube Protection) Incorrect Hall booster setting | Check and secure all motor connections. Inspect wiring for damage. Verify the correct Single/Double Hall Booster setting for your PAS. |
| Controller feels hot to touch | Heavy load/prolonged use Insufficient ventilation | Reduce load or allow for cooling periods. Ensure controller is mounted in a well-ventilated area. |
9. User Tips
- Cable Management: Use zip ties or cable wraps to keep all wires tidy and away from moving parts or sharp edges. This prevents wear and tear and improves safety.
- Water Protection: While the controller is designed for outdoor use, consider adding extra protection (e.g., a waterproof enclosure or sealant around cable entries) if you frequently ride in wet conditions.
- Battery Health: Regularly monitor your e-bike battery's health. A declining battery can trigger the controller's under-voltage protection more frequently, indicating it might be time for a replacement or service.
- Test Settings: After changing the soft/hard start or Hall booster settings, perform a brief test ride in a safe, open area to ensure the desired behavior.
10. Warranty & Support
For any technical assistance or warranty inquiries, please contact your retailer or the manufacturer directly. Keep your purchase receipt as proof of purchase.
