Bafang ultra max G510 M620 tear down

[Sinhu]

Hello !
My name is Stig i’m from Norway and i pedal a fatbike with a ultra max motor.

Last week i found a full suspension fatbike in bad shape with a motor that had a fried controller. While i wait for the Phaserunner from Grid i have startet a full tear down of the bike.


Starting with the motor:


Taking every think apart i was supprised how well buildt it is.

And the motor in parts look like this.View attachment 3DA8D74F32E4B.jpeg"]4[/ATTACH]ment]

There you have it a Bafang G510 in parts.

Tomorrow I will be back with a complete review of every connection from motor and controller, coresponded with color code and plasment in each connection.

 

[john61ct]

nice

is that compatible with the supercharging Exess controller?

 

[Sinhu]

Hi !

Connectors



Starting with the EB-bus cable:


Its basicly the same just with another connector, if you purces a 1t4 eb-bus from bafang you can eadely modefy with the JST connector

 

[Sinhu]

nice

is that compatible with the supercharging Exess controller?

The excess controller is made from scrath by av german company and they requere you send the motor to them for installing it.

 

[Sinhu]

The EB-bus cable has 8 pins


The colored used in Bafang cabels ar usaly the same

Side by side with the other connector used by Bafang



Nr. 1 blue - throttle
Nr. 2 white - breaksensor
Nr. 3 orange - PL swith to display
Nr. 4 brown - P+ positiv 48v
Nr. 5 black - gnd negativ
Nr. 6 yellow - TxD transmiting line from controller
Nr. 7 green - RxD reciving line to controller
Nr. 8 red - 5v +

 

[Sinhu]

Compairing the cables with the controller board

 

[Sinhu]

Breaksensor, two types in the breakleaver that only uses to of three pins, breaking the conection signals the controller to cut power.


Number two uses all three lines.



Nr.2 white - breaksensor
Nr.8 black - gnd-
Nr.5 red - 5v+

 

[Sinhu]

Throttle has the same type 3 pin connector as breaksensor just reversed.

The signal lines are
Nr.1 throttle - blue
Nr. 5 5v + red
Nr. 8 gnd - black

 

[Sinhu]

The last connector is the display



Nr.3 pl - orange
Nr.4 P+ - brown
Nr.6 TxD - yellow
Nr.7 RxD - green
Nr.8 5v - red

This is all signal lines going thru the eb-bus cable

 

[john61ct]

av german company and they requere you send the motor to them for installing it.

Yes I would think this sort of find would be the perfect opportunity

 

[Sinhu]

I would love having a exsess controller fitted, but if anything happen or it do not work properly it is 2500km to the store.

The only option i found is phaserunner, it seems to be as flexible as i want. And if i find a replasment later the phaserunner work on anything so thats a keeper

 

[Sinhu]

Next connectors from the motor and controller


Controller with flip side

In the red cirkle is one headlights and the other rearlight gives 5v 500ma +and gnd on the controll bord




Seen from the flip side the conector coresponds with:

Gear sensor. Gnd 4,3v
Gnd Spd 4,3v

 

[Sinhu]

Every connection from G510

 

[john61ct]

Yes Phaserunner looks powerful enough, didn't realize the motor tops out lower than 90A right?

 

[Sinhu]

The challange is heat, but tou can run 90v and 90amp that 8000w in terory.

But i’m aiming at a every day bike, and will run it on 48v pack but are planing to get a 72v pack. So with 40amp i will get up to 3000w, most querius about the toruqe

 

[Sinhu]

A problem i used a bit of time looking at is the hallsensor, in version V1.5 they ise a IC Hall



With the controller removed i have to install new ones. And the placement has been troubuling me.

To my surprise Bafang use the old rotor design with slots for the hallsensors

Planing to use Honeywell ss41

With about 12 space from the stator to the housing it should be plenty of room.

I found a Bafang G330 M400 for sale at a very reasonable price, as i knew it has «normal» hall sensors and a step down but identic to the G510 stator and rotor.

I have to do some more research, but i hobe that i can use the M400 hallsensor circuit board on the G510

Feed back from tech:
« You can use the SS41 sensors, as you can see from the PCB, there are some filter capacitors to help smooth the signals from the sensors. Any 6V or higher ceramic cap should be fine.

You can also see there is a temp sensor.

I'd install a 10K NTC temp sensor with B3900 or B3600, and secure it to the motor winding directly.

Note that you should place the halls in a 120° timing configuration.»

The Phaserunner has arrived, jippi

Was lucky to find a burned G510 with a hall board and installed that on the Stator.

 

[mwesleyroper]

Please continue. You have answered many of my questions without having to ask them.

 

[mwesleyroper]

Stig,

I'm also trying to mate a Phaserunner to a G510 and run it sensored. I have the same hall board as you displayed here. Should the halls be rearranged to a 120 degree pattern and rewired to the hall board? Is this your plan?
Regards,

Mike

 

[qwerkus]

Are you sure you can't program the Phaserunner to use digital hall input already present on your board ? It's a 300 bucks piece of hardware with very powerful functionalities. Sounds silly to revert back to ss41 halls...

 

[mwesleyroper]

I have tried to find information about using the digital hall sensor in conjunction
with an aftermarket controller for months without success.

 

[Sinhu]

Hi !

Well on the first generations of the G510 motor, they used the normal Hall sensor asembly. And for a while they produced the motor with the new sensor (magnet on the rotor) but still had the hallsensors mounted in the stator but unconected.

And the nice thing is that if you remove the stator, can be a bit tricky but by heating the housing it much easyer.

There are slot on the stator for the hallsensors, so no worrys about the placement.
And room for it as well.

My project has been at standstill for a while, but planing to starting to test the PR in sensored mode soon

 

[brake034]

Yesterday I agreed with Stig that I will take over his Grin setup for my M620 motor project.
So I will be further posting on my progress as soon as it arrives here in Thailand.

 

[Jatan]

Could you tell the Stack length, Gauge of Wire and how many wires are used in one strand, in G510.

 

[Sinhu]

Hi !

Not sure if i understand what info you want ?

Do you mean the EB-bus cable too the controller or the wirirng inside the mortor ?