HALLOMOTOR Sine Wave Intelligent EBike Controller & SW900 Display User Manual

1. Einleitung

This manual provides essential information for the installation, operation, and maintenance of your HALLOMOTOR Sine Wave Intelligent EBike Controller and SW900 Display. This system is designed for 48V-72V battery systems, delivering 2000W-4000W of power with a 60A current rating and an 18 MOSFET configuration for smooth and efficient electric bicycle performance. Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Produktüberschreitungview

The HALLOMOTOR EBike Controller and SW900 Display system consists of a high-performance sine wave controller and a digital display unit. The controller manages power delivery to the motor, while the display provides real-time riding data and allows for system configuration.

Abbildung 2.1: The HALLOMOTOR Sine Wave Intelligent EBike Controller (bottom) and the SW900 Display (top). The controller is a black, finned aluminum casing with numerous wires extending from one end. The display is a rectangular black unit with a digital screen and control buttons on the left side, connected by a cable.

Abbildung 2.2: Nahaufnahme view of the HALLOMOTOR EBike Controller, showcasing the extensive wiring harness. Various colored wires with different connectors are visible, including thick power cables, motor phase wires, and smaller signal wires for accessories and sensors. A yellow XT90 connector is also visible.

Abbildung 2.3: Dimensions of the EBike Controller. The image indicates a length of 26.5 cm, a width of 9.5 cm (including mounting bracket), and a height of 5.0 cm. The main body length is approximately 23.5 cm.

Abbildung 2.4: Product label on the side of the Sine Wave Controller. It displays the model number RM607260ASVPR, Rated Voltage: DC60V/72V, Maximum Current: 60±1A, Rated Current: 30A, Speed Set: 1-4.2V, Brake Input: Low-Level, and Low Voltage Protection: DC50/60±1V.

Abbildung 2.5: Detailed wiring diagram for the EBike Controller. Key connections are numbered and labeled: 1. Motor Cable connection (3-Phase), 2. Power Supply Cable XT90, 3. Light, 4. Electric Lock, 5. Self Learning, 6. Display, 7. Reverse, 8. Throttle, 9. Brake, 10. Cruise, 11. Speed Limit, 12. PAS (Pedal Assist System), 13. Alarm, 14. Hall sensor wires.

Abbildung 2.6: The SW900 Display unit. This digital display shows speed, odometer (ODO), trip distance, battery level, power output (WATT), and pedal assist system (PAS) level. It features control buttons on the left for navigation and settings.

3. Spezifikationen

Anzeigeeinheit: SW900 Digital Display

• Functions: Speed, Odometer (ODO), Trip Distance, Battery Level, Power Output (WATT), PAS Level.
• Compatibility: Designed to work seamlessly with the HALLOMOTOR Sine Wave Controller.

4. Einrichtung und Installation

Proper installation is crucial for the safe and efficient operation of your e-bike system. If you are unsure about any steps, it is recommended to seek assistance from a qualified e-bike technician.

4.1 Sicherheitsvorkehrungen

• Vor jeglichen Installations- oder Wartungsarbeiten muss die Batterie immer abgeklemmt werden.
• Stellen Sie sicher, dass alle Verbindungen sicher und ordnungsgemäß isoliert sind, um Kurzschlüsse zu vermeiden.
• Stellen Sie sicher, dass die Batterie voltage entspricht der angegebenen Lautstärke des Controllerstage-Bereich (48V-72V).
• Tragen Sie geeignete Schutzausrüstung, einschließlich Augenschutz.

4.2 Mounting the Controller and Display

• Regler: Mount the controller in a location that is protected from direct water exposure and physical impact, allowing for adequate airflow for cooling. Use the integrated mounting bracket and appropriate fasteners.
• Anzeige: Mount the SW900 display securely on your handlebar in a position that is easily visible and accessible while riding.

4.3 Wiring Connections (Refer to Figure 2.5)

1. Motor Cable (3-Phase): Connect the three thick motor phase wires (typically green, blue, yellow) from the controller to the corresponding motor phase wires. Ensure correct color matching.
2. Hall-Sensor-Kabel: Connect the smaller Hall sensor wires from the controller to the motor's Hall sensor connector. These are crucial for smooth motor operation.
3. Power Supply Cable (XT90): Connect the main power cable (XT90 connector) from the controller to your e-bike battery. Ensure polarity is correct (red to positive, black to negative).
4. Elektrisches Schloss: Connect the electric lock wires (if applicable) to your ignition switch or power button.
5. Anzeige: Connect the SW900 display cable to the designated display port on the controller.
6. Drosseln: Connect the throttle cable to the controller's throttle input.
7. PAS (Pedal Assist System): Connect the PAS sensor cable to the controller's PAS input.
8. Bremse: Connect the brake lever cut-off switches (if equipped) to the controller's brake input. This provides a low-level brake signal to cut motor power when braking.
9. Light/Alarm/Reverse/Cruise/Speed Limit: Connect any optional accessories such as lights, alarm systems, reverse function, cruise control, or speed limit switches to their respective ports on the controller as needed.
10. Selbstlernende Kabel: These two wires are typically used for initial motor pairing. Connect them briefly, allow the motor to spin, then disconnect. Refer to specific self-learning instructions if provided with your motor.

After all connections are made, double-check them for security and correctness before connecting the battery.

5. Bedienungsanleitung

The SW900 display provides an intuitive interface for controlling and monitoring your e-bike.

5.1 Ein-/Ausschalten

• To power on the system, press and hold the power button on the SW900 display for a few seconds.
• Zum Ausschalten halten Sie die Einschalttaste erneut gedrückt, bis sich das Display ausschaltet.

5.2 Anzeigefunktionen

The SW900 display shows various parameters:

• Geschwindigkeit: Current riding speed (Km/h or Mph).
• ODO: Total odometer reading (total distance traveled).
• AUSFLUG: Trip distance for the current ride.
• Batteriestand: Grafische Darstellung des verbleibenden Akkuladestands.
• WATT: Real-time power output from the motor.
• PAS-Stufe: Current Pedal Assist System level (e.g., 0-5).

5.3 Adjusting PAS Level

Use the '+' and '-' buttons on the display to increase or decrease the pedal assist level. Level 0 typically means no assist, while higher numbers provide more motor assistance.

5.4 Einstellungsmenü

The SW900 display usually has a settings menu accessible by pressing a combination of buttons (e.g., power and '+' simultaneously). This menu allows for configuration of parameters such as wheel size, speed unit (Km/h/Mph), battery voltage, and more. Refer to the specific SW900 display manual for detailed instructions on navigating and adjusting settings.

6. Wartung

Regular maintenance helps ensure the longevity and reliable performance of your e-bike controller and display.

• Sauber halten: Periodically wipe down the controller and display with a soft, damp Tuch. Vermeiden Sie die Verwendung aggressiver Chemikalien oder scheuernder Materialien.
• Verbindungen prüfen: Regularly inspect all wiring connections for tightness and signs of corrosion or damage. Ensure all connectors are fully seated.
• Vor Wasser schützen: While the controller has an IP65 waterproof rating, avoid submerging it in water or exposing it to high-pressure water jets. Ensure the display is also protected from heavy rain.
• Vermeiden Sie physischen Schaden: Protect the controller and display from impacts or drops.
• Temperatur: Operate and store the components within their specified temperature ranges to prevent damage.

7. Fehlerbehebung

This section addresses common issues you might encounter. For more complex problems, consult a professional e-bike technician.

7.1 Keine Stromversorgung für Display/Motor

• Batterie prüfen: Ensure the battery is charged and properly connected to the controller.
• Hauptstromanschluss: Verify the XT90 power cable connection is secure.
• Elektrisches Schloss: If an electric lock is used, ensure it is in the "ON" position.
• Anzeigekabel: Check the connection between the display and the controller.

7.2 Motor reagiert nicht

• Throttle/PAS: Ensure the throttle is connected and functioning, and the PAS sensor is correctly installed and aligned.
• Bremshebel: Check if the brake cut-off switches are engaged. Disconnect them temporarily to test if they are causing the issue.
• Motor Phase/Hall Wires: Verify all motor phase and Hall sensor wires are securely connected and correctly matched.
• Self-Learning: If the motor is new or has been disconnected, perform the self-learning procedure (briefly connect the self-learning wires, allow motor to spin, then disconnect).

7.3 Incorrect Speed/Distance Readings

• Radgrößeneinstellung: Access the SW900 display settings menu and ensure the correct wheel size is configured.
• Geschwindigkeitsmesser: Check if the speed sensor (if external) is properly installed and functioning.

7.4 Display Error Codes

The SW900 display may show error codes. Refer to the specific SW900 display manual for a list of error codes and their corresponding troubleshooting steps.

8. Garantie und Support

For warranty information and technical support, please contact your original seller or HALLOMOTOR directly. Keep your purchase receipt as proof of purchase. Specific warranty terms and conditions may vary.

Wenn Sie sich an den Support wenden, halten Sie bitte folgende Informationen bereit:

• Product Model: HALLOMOTOR 60A Controller + SW900 Display
• Kaufdatum
• Beschreibung des Problems
• Any relevant error codes from the display