1. Introduction
This manual provides essential information for the safe and efficient operation of your Mechanivis FarDriver Controller ND72340. Please read this manual thoroughly before installation and use to ensure proper functionality and to prevent damage to the unit or connected components. Retain this manual for future reference.
2. Product Overview
The Mechanivis FarDriver Controller ND72340 is a high-performance BLDC motor controller designed for electric bike applications, supporting 2KW-3KW motors. It operates within a voltage range of 48V-72V DC, with a phase current of 450A and a DC current of 120A. This controller offers robust performance and reliability for various electric vehicle systems.
Figure 2.1: The FarDriver Controller ND72340 shown with its accompanying wiring harness, illustrating the main unit and connection cables.
Key Features:
- High Performance: Designed for 2KW-3KW BLDC motors, providing efficient power delivery.
- Wide Voltage Range: Compatible with 48V-72V DC systems.
- Robust Protection: Includes over-voltage, over-current, and overheating protection for enhanced stability and longevity.
- User-Friendly Interface: Simple design for convenient use, development, and debugging.
- Versatile Application: Suitable for industrial automation, electric vehicles, and similar fields.
3. Specifications
| Parameter | Value |
|---|---|
| Controller Type | DC Motor Controller |
| Model Number | ND72340 |
| Voltage Range | 48V-72V DC |
| DC Current | 120A |
| Phase Current | 450A |
| Compatible Motor Power | 2KW-3KW |
| Item Weight | 2.1 KG (4.63 lbs) |
| Item Length | 179.9 mm |
| Item Width | 117.9 mm |
| Item Height | 59.9 mm |
| Manufacturer Part Number | ND72450 |
Figure 3.1: Dimensional drawing of the controller, showing length, width, and height measurements for installation planning.
4. Setup and Installation
Proper installation is crucial for the safe and reliable operation of the controller. If you are unsure about any step, consult a qualified technician.
4.1 Safety Precautions
- Always disconnect the battery power before performing any installation or maintenance.
- Ensure all connections are secure and properly insulated to prevent short circuits.
- Wear appropriate personal protective equipment (PPE), such as safety glasses and gloves.
- Avoid installing the controller in areas exposed to direct sunlight, excessive heat, moisture, or strong vibrations.
4.2 Mounting the Controller
- Select a suitable mounting location on the vehicle frame that provides adequate ventilation and protection from environmental elements.
- Use appropriate fasteners to securely mount the controller. Refer to Figure 3.1 for mounting dimensions.
- Ensure the controller is mounted in an orientation that allows for easy access to wiring connections and proper heat dissipation.
4.3 Wiring Connections
The controller features various terminals and connectors for power, motor, and signal connections. Refer to the diagram below for typical connection points.
Figure 4.1: Top view of the controller, highlighting the main power (B+, B-) and motor phase (U, V, W) terminals.
- Battery Connection: Connect the positive (+) terminal of the battery to the B+ terminal on the controller (typically red). Connect the negative (-) terminal of the battery to the B- terminal on the controller (typically black). Ensure correct polarity.
- Motor Phase Wires: Connect the three motor phase wires (U, V, W) from your BLDC motor to the corresponding U (yellow), V (green), and W (blue) terminals on the controller.
- Hall Sensor Wires: Connect the motor's Hall sensor wires to the designated Hall sensor connector on the controller's wiring harness.
- Throttle Connection: Connect the throttle signal wire, power, and ground to the appropriate pins on the controller's throttle connector.
- Other Signal Wires: Connect other necessary signal wires such as ignition, brake, speed sensor, and communication lines according to your specific electric bike system's requirements and the controller's wiring diagram (not provided in this general manual, refer to specific product documentation if available).
- Double-check all connections for tightness and correct routing.
5. Operating Instructions
Once the controller is correctly installed and all connections are verified, you can proceed with operation.
- Power On: Turn on the main power switch of your electric bike. The controller should initialize, and any connected display units should power on.
- Self-Learning (if applicable): Some controllers feature a self-learning function to automatically match motor parameters. Consult your specific product documentation for instructions on initiating this process if available.
- Throttle Control: Gently apply the throttle. The motor should respond smoothly. If the motor spins in the wrong direction, refer to the troubleshooting section or consult your specific wiring diagram for phase wire reversal options.
- Brake Function: Test the brake levers. Applying the brakes should cut power to the motor.
- Regular Checks: Periodically check for unusual noises, vibrations, or excessive heat during operation.
6. Maintenance
Regular maintenance helps ensure the longevity and optimal performance of your FarDriver Controller.
- Keep Clean: Periodically clean the exterior of the controller to prevent dust and debris buildup, which can hinder heat dissipation. Use a soft, dry cloth.
- Inspect Connections: Regularly check all wiring connections for tightness and signs of corrosion or damage. Loose connections can lead to intermittent operation or component failure.
- Environmental Protection: Ensure the controller remains protected from water, extreme temperatures, and direct impacts.
- Software Updates: If applicable, check the manufacturer's website for any available firmware updates that may improve performance or address known issues.
7. Troubleshooting
This section provides solutions to common issues you might encounter with your controller. For problems not listed here, contact customer support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor does not run | No power to controller; Loose connections; Faulty throttle; Motor or Hall sensor issue. | Check battery connection and voltage; Verify all wiring connections; Test throttle functionality; Inspect motor and Hall sensors. |
| Motor runs in wrong direction | Incorrect motor phase wire connection; Incorrect Hall sensor connection. | Reverse two of the three motor phase wires (U, V, W); If still incorrect, try reversing two Hall sensor wires. |
| Intermittent power or stuttering | Loose wiring connections; Overheating; Low battery voltage. | Check all connections; Ensure adequate ventilation for the controller; Charge battery fully. |
| Controller gets excessively hot | Overload; Insufficient ventilation; Short circuit. | Reduce load on motor; Ensure controller is in a well-ventilated area; Check for short circuits in wiring. |
8. Warranty and Support
Mechanivis products are manufactured to high-quality standards. For specific warranty terms and conditions, please refer to the warranty card included with your purchase or visit the official Mechanivis website. For technical support, troubleshooting assistance, or spare parts, please contact Mechanivis customer service through their official channels.
Note: Unauthorized modifications or improper installation may void your warranty.