1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your Bafang G060/G062 Fat Motor Controller Set. This controller is specifically designed for BAFANG 48V 1000W FAT motors. Please read this manual thoroughly before installation and use to ensure proper function and safety.
2. Package Contents
Verify that all items listed below are included in your package:
- 1 x 36V/48V 30A Controller
- 1 x Thumb Throttle
- 1 x Pair of Brake Levers
- 1 x 1T4 EBUS Cable
- 1 x Pedal Assist Sensor (PAS)
- 1 x Display (optional, depending on selected variant)
3. Specifications
The Bafang G060/G062 Controller is designed for brushless motors with the following specifications:
| Feature | Specification |
|---|---|
| Model | KT36/48VPRCL-SC20TP |
| Rated Voltage | DC36V/48V |
| Rated Current | 15A |
| Maximum Current | 30 ± 2A |
| Speed Set | 1-4.2V |
| Brake Input | Low-Level |
| Low Voltage Protection | DC30/40 ± 0.5V |
| Dimensions (L x W x H) | 171mm x 83mm x 41mm |
| Motor Compatibility | BAFANG 48V 1000W FAT Motor (G060/G062 series) |
4. Safety Instructions
- Always ensure the battery is disconnected before performing any installation, maintenance, or wiring adjustments.
- Improper wiring can cause damage to the controller, motor, or battery, and may pose a fire hazard.
- Ensure all connections are secure and waterproof where necessary.
- This controller is designed for specific Bafang 48V 1000W FAT motors. Using it with incompatible motors or accessories may lead to malfunction or damage.
- If you are unsure about any part of the installation, consult a qualified e-bike technician.
5. Setup and Installation
Follow these steps carefully to install your Bafang controller set. Refer to the wiring diagrams for visual guidance.
5.1 Wiring Connections
- Main Motor Connection: Connect the main motor cable (often a red circular connector) from your Bafang motor to the corresponding port on the controller.
- Power (Battery) Connection: Connect your 48V battery to the controller's power input (typically an XT60 connector, labeled 'Power'). Ensure correct polarity.
- EB BUS Mainline: Connect the 1T4 EBUS cable to the EB BUS mainline port on the controller. This cable will then branch out to other accessories.
- Pedal Assist Sensor (PAS): Connect the PAS sensor to its designated port on the 1T4 EBUS cable.
- Thumb Throttle: Connect the thumb throttle to its designated port on the 1T4 EBUS cable.
- Brake Levers: Connect the brake levers (which typically include motor cut-off sensors) to their designated ports on the 1T4 EBUS cable.
- Display (Optional): If using a display, connect it to the appropriate port on the 1T4 EBUS cable. If you are using your own KT display, ensure compatibility.
- Speed Limit Light: Connect the speed limit light cable if your setup includes this feature.
- Reverse Gear / Electric Door Lock: Connect these optional features to their respective ports on the controller if applicable to your e-bike setup.
Important Note:
- This controller is only compatible with BAFANG 48V 1000W FAT motors (G060/G062 series). Accessories from other brands may not be compatible.
- Ensure your Bafang FAT motor plug is compatible with the controller's connectors before attempting connection.
6. Operating Instructions
Once the controller and all components are correctly installed and connected, you can begin operating your e-bike.
6.1 Power On/Off
- To power on the system, turn on your e-bike battery and then press the power button on your display unit (if installed).
- To power off, press and hold the power button on your display, or turn off the e-bike battery.
6.2 Using the Display (Optional)
If your set includes a display (e.g., LCD3, TF01H, TF02H, TF02S), it provides information and control over your e-bike's functions.
- Information Displayed: Speed, battery level, assist level, trip distance, total distance, and potentially error codes.
- Assist Level Adjustment: Use the '+' and '-' buttons on the display to cycle through different levels of pedal assist.
- Walk Mode: Some displays offer a walk mode (usually by holding the '-' button) for easy maneuvering of the bike when not riding.
- Lights: Some displays can control integrated e-bike lights.
6.3 Throttle Operation
The thumb throttle provides on-demand power. Gently press the throttle to engage the motor. The amount of power delivered is proportional to how far the throttle is pressed.
6.4 Pedal Assist System (PAS)
The PAS system provides motor assistance as you pedal. The level of assistance depends on the selected assist level on your display.
6.5 Brake Levers
The brake levers are equipped with sensors that cut off motor power when activated, ensuring safe braking.
7. Maintenance
Regular maintenance helps ensure the longevity and optimal performance of your Bafang controller set.
- Keep Connections Clean and Dry: Periodically check all electrical connections for corrosion or damage. Ensure they are clean and dry.
- Secure Wiring: Ensure all cables are properly routed and secured to prevent snagging or damage during riding.
- Controller Housing: Keep the controller housing clean and free from excessive dirt or debris. Avoid exposing it to extreme moisture or direct water jets.
- Battery Care: Follow your battery manufacturer's instructions for charging and storage. A well-maintained battery is crucial for system performance.
- General Inspection: Regularly inspect all components for signs of wear, loose connections, or physical damage.
8. Troubleshooting
If you encounter issues with your Bafang controller set, refer to the following common troubleshooting steps:
| Problem | Possible Cause | Solution |
|---|---|---|
| No power to display/motor | Battery off or low charge; loose power connection; faulty display. | Ensure battery is on and charged. Check all power connections. Test with a known good display if possible. |
| Motor not assisting/working | PAS sensor issue; throttle issue; brake cut-off engaged; motor connection loose; incompatible motor. | Check PAS sensor alignment. Ensure throttle is connected. Verify brake levers are not stuck. Check motor cable connection. Confirm motor compatibility. |
| Inconsistent power delivery | Loose connections; faulty throttle/PAS; controller overheating. | Inspect all connections. Allow controller to cool if it feels hot. |
| Display shows error code | Specific component malfunction. | Refer to your display's specific manual for error code meanings and solutions. Common errors relate to motor, throttle, or brake sensors. |
9. User Tips
- Cable Management: Use zip ties or cable wraps to neatly organize and secure all wiring. This prevents damage and ensures a clean look.
- Water Protection: While components are generally splash-proof, avoid submerging the controller or exposing it to heavy rain for extended periods. Consider additional waterproofing for connectors in very wet environments.
- Regular Checks: Before each ride, quickly check that all connections are snug and no cables are frayed.
10. Warranty and Support
For warranty information or technical support, please contact the seller or manufacturer directly. Keep your purchase receipt as proof of purchase.
