The BAFANG CR C101.C is a controller designed for electric bicycles, serving as a central component for managing various functions and power distribution. This dealer manual provides comprehensive information for understanding, installing, and maintaining the device.
Function Description
The CR C101.C controller integrates several key functions essential for the operation of an electric bicycle. It manages power supply, motor control, sensor input, and communication with other components. Its core function is to regulate the power delivered to the motor based on user input (e.g., pedal assist level, throttle) and sensor data (e.g., torque, speed).
Key functions include:
- Communication Protocol: Utilizes the CAN (Controller Area Network) protocol for robust and efficient communication between various components of the e-bike system.
- Brake Cut-off Function: Incorporates a safety feature that cuts off motor power when the brakes are applied, enhancing rider safety.
- Power Assist Type: Supports both torque and speed-based power assist, allowing for a natural and responsive riding experience.
- Battery Communication Function: Communicates with the battery management system (BMS) to monitor battery status and ensure optimal performance and safety.
- Calculation of Remaining Distance, Output Power, and Calorie: Provides riders with useful data about their ride, including estimated remaining range, current power output, and calories burned.
- Walk Assistance: Offers a walk assist mode (up to 6 km/h), making it easier to maneuver the e-bike when not riding.
- Front and Rear Light Control: Supports the control of front and rear lights (6V3W for front, 6V0.5W/12V1W for rear), enhancing visibility and safety.
- Power Assist Level: Allows riders to select from 0-5 power assist levels, offering flexibility in choosing the desired level of assistance.
- Set Speed Limit, Wheel Diameter, and Wheel Circumference: Enables customization of ride parameters to match local regulations and specific bicycle configurations.
- Error Code Indication: Provides error codes to help diagnose and troubleshoot issues, simplifying maintenance and repair.
Important Technical Specifications
The CR C101.C controller is built to meet specific performance and environmental standards, ensuring reliability and durability.
Electrical Specifications:
- Power Supply: 48V DC
- Rated Input Power: 850W
- Rated Output Power: 650W
- Rated Current: 18A
- Undervoltage Protection: 42V (This protects the battery from over-discharge, extending its lifespan.)
- Shutdown Leakage Current: ≤10uA (Indicates very low power consumption when the system is off, preserving battery charge.)
- Static Operating Current: ≤50mA (Low power consumption during standby, contributing to battery efficiency.)
Environmental Specifications:
- Operating Temperature: -20°C to 60°C (Ensures reliable operation across a wide range of environmental conditions.)
- Storage Temperature: -25°C to 70°C (Allows for safe storage in varying climates.)
- Storage Humidity: 30% to 70% (Maintains component integrity during storage.)
- Protection Rating: IP65 (Indicates protection against dust ingress and low-pressure water jets from any direction, making it suitable for outdoor use.)
Physical Specifications:
- Length: 109 ± 1 mm
- Width: 56 ± 0.5 mm
- Height: 34 ± 0.5 mm
- Weight: 435 ± 10 g (Relatively compact and lightweight, contributing minimally to the overall bike weight.)
Certifications:
- CE / ROHS: Complies with European safety, health, and environmental protection standards, and restricts the use of certain hazardous substances in electrical and electronic equipment.
- Scope: EN 15194 EPAC (European standard for electrically power assisted cycles, ensuring the controller meets specific performance and safety requirements for e-bikes.)
Usage Features
The CR C101.C controller is designed for ease of integration and user-friendliness within an e-bike system. Its various interfaces allow for connection to essential components.
Cabling Connections:
- Battery Connection: Connects to the battery's communication cable (A: female connector from battery BMS; a: male connector from controller) and power cable (B: male connector from battery (negative); b: female connector from controller (negative); C: female connector from battery (positive); c: male connector from controller (positive)). This ensures both power supply and data exchange with the battery.
- Motor Connection: Connects directly to the motor (D: male connector from motor; d: female connector from controller), facilitating power delivery and control.
- EB-BUS Connection: Connects to the EB-BUS cable (E: female connector from EB-BUS cable; e: male connector from controller), which is typically used for connecting the display, throttle, and other peripheral devices.
- Sensor Connection: Connects to the sensor (F: male connector from sensor; f: female connector from controller), which could be a torque sensor, speed sensor, or other input devices.
- Light Connection: Connects to the light cable (G: male connector from light cable; g: female connector from controller), providing power and control for the e-bike's lighting system.
Interface Definitions:
The manual provides detailed pin definitions for each connector, crucial for proper wiring and troubleshooting:
- Battery Power Cable: Red (Power +), Black (Power -).
- Motor Cable (M11.4): Thick yellow (Phase U), Thick green (Phase V), Thick blue (Phase W), White (Motor temperature), Red (5V), Black (GND), Yellow (Hall U), Green (Hall V), Blue (Hall W).
- Battery Communication (3104A1002): Yellow (CAN L), Red (5V), Green (CAN H), Null (Plug).
- Torque Sensor Cable (M6.5): Green (CAN H), Brown (Power assist 1), Black (GND), White (CAN L), Purple (Power assist 2), Orange (5V).
- Front Light Cable: Red (Front light 6V3W/12V6W), Black (GND).
- Rear Light Cable: White (Rear light 6V0.5W/12V1W), Black (GND).
- EB-BUS Cable (G8.5): Blue (Throttle signal), Red (5V), Yellow (CAN L), White (Brake signal), Black (GND), Orange (Key signal), Brown (HMI power), Green (CAN H).
Maintenance Features
The design of the CR C101.C controller incorporates features that aid in maintenance and ensure long-term reliability.
Troubleshooting and Diagnostics:
- Error Code Indication: The controller's ability to provide error codes simplifies the diagnostic process, allowing dealers and technicians to quickly identify and address issues.
- Detailed Interface Definitions: The comprehensive pinout diagrams for all connectors are invaluable for checking connections, testing signals, and isolating faults during repair.
Durability and Protection:
- IP65 Protection Rating: This high level of ingress protection means the controller is well-sealed against dust and water, reducing the likelihood of internal damage from environmental factors and minimizing the need for frequent cleaning or repair due to contamination.
- Robust Operating and Storage Temperatures: The wide temperature ranges ensure the controller can withstand harsh conditions without performance degradation, reducing the need for premature replacement.
Installation and Repair Best Practices:
- Caution for Stable and Lasting Work: The manual explicitly advises powering off the system before plugging or unplugging any connectors or performing repairs. This critical safety measure prevents electrical damage to the controller and other components, contributing to the longevity of the product.
- Modular Design: The use of distinct connectors for each function (battery, motor, lights, sensors, EB-BUS) facilitates easier replacement of individual components if they fail, rather than requiring a full system overhaul.
Overall, the BAFANG CR C101.C controller is a robust and feature-rich component designed to be the intelligent core of an electric bicycle, offering a blend of performance, safety, and ease of maintenance for both dealers and end-users.
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