1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your LSW1234-10-1E Brushless Motor Controller. Designed for 48V electric bike systems, this intelligent controller ensures efficient and reliable performance. Please read this manual thoroughly before installation and use to ensure proper function and safety.
2. Safety Information
- Always disconnect power before installing or performing maintenance on the controller.
- Ensure all connections are secure and properly insulated to prevent short circuits.
- Do not attempt to open or modify the controller casing, as this may void the warranty and pose a safety risk.
- Keep the controller away from water, excessive heat, and corrosive substances.
- Professional installation is recommended if you are unfamiliar with electrical systems.
3. Product Overview
The LSW1234-10-1E is an intelligent brushless motor controller designed for electric bicycles. It manages power delivery to the motor, providing smooth and efficient operation. The controller features multiple connectors for various e-bike components such as the motor, battery, throttle, and display.
4. Specifications
| Feature | Specification |
|---|---|
| Product Name | E-bike Intelligent Controller |
| Model | LSW1234-10-1E |
| Rated Voltage | 48V (Supports 24V/36V/48V Power Supply) |
| Maximum Current | 22A |
| Rated Current | 11A |
| Low Voltage Protection | 39V |
| Throttle Adjustment Voltage | 1.2V - 4.4V |
| Rated Working Current | 6~25A |
| Maximum Working Current | 30mA |
| Off-state Leakage Current | <1μA |
| Working Temperature | -20℃ ~ 60℃ |
| Storage Temperature | -30℃ ~ 70℃ |
5. Setup and Installation
Proper wiring is crucial for the safe and correct operation of your e-bike. Refer to the video demonstration and diagrams below for guidance. Always ensure the battery is disconnected before making any connections.
This video demonstrates the various connectors and their typical connections for the LSW1234-10-1E controller. Pay close attention to the color coding and connector types.
5.1 Wiring Connections Overview
The controller features several sets of wires for connecting to different components of your e-bike. The main connections typically include:
- **Motor Phase Wires:** Usually three thick wires (e.g., blue, green, yellow) connecting directly to the motor.
- **Battery Power Wires:** Two thick wires (red for positive, black for negative) connecting to the battery. These often have a T-plug or similar high-current connector.
- **Hall Sensor Wires:** A multi-pin connector (often 5 or 6 pins) for the motor's Hall sensors, providing feedback on motor position.
- **Throttle Connector:** Typically a 3-pin connector for the throttle input.
- **Brake Levers (E-Brake) Connectors:** Usually two separate connectors (often 2-pin) for brake cut-off switches.
- **Display/Meter Connector:** A multi-pin connector (e.g., 5-pin or 6-pin JULET connector) for the e-bike display or control panel.
- **Pedal Assist Sensor (PAS) Connector:** A 3-pin connector for the pedal assist sensor.
- **Speed Sensor Wire:** (If applicable) A single wire or 2-pin connector.
- **Self-Learning Wires:** Two single wires (often green and yellow, or two white wires) that are temporarily connected during initial setup for motor phase matching.
5.2 Step-by-Step Installation
- **Mount the Controller:** Securely mount the controller in a protected area on your e-bike frame, ensuring it is away from direct water exposure and physical damage.
- **Connect Motor Phase Wires:** Connect the three thick motor phase wires from the controller to the corresponding wires on your motor. Match colors (e.g., blue to blue, green to green, yellow to yellow).
- **Connect Hall Sensor Wires:** Connect the multi-pin Hall sensor connector from the controller to the motor's Hall sensor connector. Ensure correct orientation.
- **Connect Battery Power:** Connect the thick red wire from the controller to the positive (+) terminal of your 48V battery, and the thick black wire to the negative (-) terminal. Ensure polarity is correct.
- **Connect Throttle:** Connect the throttle connector to the e-bike's throttle unit.
- **Connect Brake Levers:** Connect the brake lever connectors to your e-brake levers.
- **Connect Display/Meter:** Connect the display/meter connector to your e-bike's display unit. Note the JULET connector shown in the video for the display.
- **Connect PAS Sensor (Optional):** If your e-bike has a pedal assist system, connect the PAS sensor connector.
- **Initial Self-Learning (Motor Phase Matching):**
- With all other connections made (except self-learning wires), power on the e-bike.
- Connect the two self-learning wires (often green and yellow, or two white wires) together. The motor should start spinning slowly.
- If the motor spins in the correct direction, disconnect the self-learning wires. The self-learning process is complete.
- If the motor spins in the wrong direction, disconnect the self-learning wires, then reconnect them. The motor should now spin in the opposite direction. Once correct, disconnect the self-learning wires.
- Never leave the self-learning wires connected during normal operation.
- **Secure All Connections:** Double-check all connections for tightness and proper insulation. Use zip ties or cable wraps to manage wires neatly and prevent them from snagging.
6. Operating Instructions
Once the controller is correctly installed and all connections are secure, your e-bike system is ready for operation. The controller works in conjunction with your e-bike's display, throttle, and PAS sensor to provide power to the motor.
- **Power On:** Turn on your e-bike's battery and then the display unit.
- **Throttle Control:** Use the throttle to control the motor's speed. The throttle adjustment voltage range is 1.2V-4.4V.
- **Pedal Assist (PAS):** If equipped, the PAS sensor will detect your pedaling and provide motor assistance based on the selected assist level on your display.
- **Brake Cut-off:** The brake levers with cut-off switches will immediately cut power to the motor when activated, enhancing safety.
7. Maintenance
- **Regular Inspection:** Periodically check all wiring connections for looseness or damage.
- **Cleaning:** Keep the controller clean and free from dust and debris. Use a dry cloth for cleaning. Do not use water or cleaning solvents directly on the controller.
- **Avoid Overheating:** Ensure the controller has adequate ventilation and is not covered, especially during prolonged use, to prevent overheating.
- **Storage:** If storing the e-bike for an extended period, ensure the controller is kept in a dry, temperature-controlled environment within the specified storage temperature range (-30℃ ~ 70℃).
8. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not spinning | Loose connections, low battery, faulty throttle, incorrect motor phase/Hall sensor wiring. | Check all wiring, ensure battery is charged, test throttle, perform self-learning process. |
| Motor spinning in wrong direction | Incorrect motor phase/Hall sensor wiring. | Perform the self-learning process as described in Section 5.2. |
| Intermittent power/cuts out | Loose connections, overheating, low voltage protection activated. | Check all connections, ensure proper ventilation, charge battery. |
| Display not working | Loose display connection, faulty display unit. | Check display wiring, ensure it's securely connected to the controller. |
9. User Tips
- **Wire Management:** Use cable ties to neatly organize and secure all wires. This prevents damage from rubbing or snagging and makes troubleshooting easier.
- **Water Protection:** While the controller is designed for outdoor use, avoid submerging it in water or exposing it to heavy rain for extended periods. Consider additional waterproofing for connectors if riding in very wet conditions.
- **Compatibility:** Ensure your motor, battery, and display are compatible with a 48V system and the controller's current ratings (Max 22A, Rated 11A).
- **Initial Test:** After installation, perform a brief test ride in a safe, open area to ensure all functions (throttle, brakes, PAS) are working correctly before full use.
10. Warranty and Support
This product is covered by a standard manufacturer's warranty against defects in materials and workmanship. For warranty claims or technical support, please contact your retailer or the manufacturer directly. Keep your purchase receipt as proof of purchase.
If you have any questions or problems, we will try our best to do for you and solve problems together. If you are not online, please leave a message to us, and we will restore you with the fastest speed.
11. Frequently Asked Questions (FAQ)
Q: What should I do if the motor spins in the wrong direction after installation?
A: This indicates incorrect motor phase or Hall sensor wiring. Please perform the self-learning process detailed in Section 5.2. Connect the two self-learning wires, and if the motor spins incorrectly, disconnect and reconnect them to reverse the direction. Once correct, disconnect them permanently.
Q: Can I use this controller with a 36V battery?
A: Yes, the controller supports 24V/36V/48V power supplies. However, ensure your motor and other components are also compatible with the chosen voltage.
Q: What is the purpose of the "Low Voltage Protection"?
A: The low voltage protection (39V for a 48V system) is a safety feature that cuts power to the motor when the battery voltage drops below a certain threshold. This prevents over-discharge of the battery, which can damage it and shorten its lifespan.
