KolorowyGhost
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What is the maximum power it can handle?
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VESC based INNOTRACE M620 Simple motor controller
- Thread starter TPEHAK
- Start date
TPEHAK
🚴♂️ Mega poster
The controller can probably make more than 10kW (100V 100A). At that power the M620 motor stator will probably overheat in a minute or so while the controller will probably be around 50 C so the controller is not the bottleneck here.
You completed the initial version much faster than I anticipated.
Fingers crossed and waiting for the initial test results!
Btw - can the controller have a build in step down with meaningful current to support reasonable lightning without external dc-dc unit?
Fingers crossed and waiting for the initial test results!
Btw - can the controller have a build in step down with meaningful current to support reasonable lightning without external dc-dc unit?
TPEHAK
🚴♂️ Mega poster
Probably can if you go back to design with two boards to have more space. The connectors for lights for this controller are occupied for different purposes though (USB, Bluetooth, CAN).
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TPEHAK
🚴♂️ Mega poster
But the best solution would be just to purchase a module on AliExpress, a connector for the light cables, terminals for the connector, some ring terminals and heat shrink wrap and make a dongle and put it inside the motor.
www.lcsc.com
www.lcsc.com
You still need an external stuff to control the lights or at least a BMS with turning power off function. But if you want to control the lights from Bafang Display you need to figure out how it meant to control the lights (probably from CAN bus) and most likely design a module with an overhead like transistors circuits controlled from MCU to control the light module. And you can implement all bells and whistles like tail light with run mode and stop signal, turn signals and a bunch of other stuff. Of cause we are not going to do this since it is too much work and no-one is going to use it anyway.
PHB-4R | Rectangular Connector Housings | DLL | LCSC
PHB-4R Rectangular Connector Housings by DLL. Features 2mm and 2mm. From $0.0268, in stock. Datasheet available.
PH-RT | Rectangular Connector Contacts | DLL | LCSC
PH-RT Rectangular Connector Contacts by DLL. Features 0.05~0.33 and 22~28. From $0.0062, in stock. Datasheet available.
You still need an external stuff to control the lights or at least a BMS with turning power off function. But if you want to control the lights from Bafang Display you need to figure out how it meant to control the lights (probably from CAN bus) and most likely design a module with an overhead like transistors circuits controlled from MCU to control the light module. And you can implement all bells and whistles like tail light with run mode and stop signal, turn signals and a bunch of other stuff. Of cause we are not going to do this since it is too much work and no-one is going to use it anyway.
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TPEHAK
🚴♂️ Mega poster
The motor controllers have been complete!
Thanks... probably better for now keep it simple and separate thenBut the best solution would be just to purchase a module on AliExpress, a connector for the light cables, terminals for the connector, some ring terminals and heat shrink wrap and make a dongle and put it inside the motor.
PHB-4R | Rectangular Connector Housings | DLL | LCSC
PHB-4R Rectangular Connector Housings by DLL. Features 2mm and 2mm. From $0.0268, in stock. Datasheet available.
PH-RT | Rectangular Connector Contacts | DLL | LCSC
PH-RT Rectangular Connector Contacts by DLL. Features 0.05~0.33 and 22~28. From $0.0062, in stock. Datasheet available.
View attachment 391115
You still need an external stuff to control the lights or at least a BMS with turning power off function. But if you want to control the lights from Bafang Display you need to figure out how it meant to control the lights (probably from CAN bus) and most likely design a module with an overhead like transistors circuits controlled from MCU to control the light module. And you can implement all bells and whistles like tail light with run mode and stop signal, turn signals and a bunch of other stuff. Of cause we are not going to do this since it is too much work and no-one is going to use it anyway.
Fingers crossed on the test.
From my side in the future I may try to play with the software to tune up the controls... and possibly fix the throttle issue but for now need to order the motor and build bike first
TPEHAK
🚴♂️ Mega poster
The Bluetooth dongle and ST-Link V2 programmer leads have arrived!
The Bluetooth dongle is compatible with nrf51_vesc ecosystem Makerbase MKS ESC_BT V1.0
The 28AWG leads with connector for ST-Link V2 programmer on the controller side are 7 pins JST GH 1.25
You can crimp that cable leads with this 10 pin 2x5P 2.54mm pitch connector fits ST-Link V2 programmer connector
www.lcsc.com
Here are the terminals for this connector fit 28AWG wires
www.lcsc.com
The Bluetooth dongle is compatible with nrf51_vesc ecosystem Makerbase MKS ESC_BT V1.0
The 28AWG leads with connector for ST-Link V2 programmer on the controller side are 7 pins JST GH 1.25
You can crimp that cable leads with this 10 pin 2x5P 2.54mm pitch connector fits ST-Link V2 programmer connector
TJC8H-2.54-S-10Y | Rectangular Connector Housings | DLL | LCSC
TJC8H-2.54-S-10Y Rectangular Connector Housings by DLL. Features 2.54mm and 2.54mm. From $0.0761, in stock. Datasheet available.
Here are the terminals for this connector fit 28AWG wires
TJC8-2.54-T | Rectangular Connector Contacts | DLL | LCSC
TJC8-2.54-T Rectangular Connector Contacts by DLL. Features 22~28 and Tin. From $0.0084, in stock. Datasheet available.
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TPEHAK
🚴♂️ Mega poster
While we are waiting the controller delivery we can prepare the Bluetooth cable.
You need a 2x2P (4 pin) PHB 2.0 connector and terminals for 26AWG.
2x2P (4 pin) PHB 2.0 connectors can be purchased here
www.lcsc.com
28-24 AWG terminals can be purchased here
www.lcsc.com
Chop the original Bluetooth cable terminals off
Strip the wires and crimp the PHB 2.0 terminals on the Bluetooth cable. You can use this crimper
Attach the wires to the PHB 2.0 connector matching the pins to the Bluetooth module connector pins in the KiCAD schematic
You need a 2x2P (4 pin) PHB 2.0 connector and terminals for 26AWG.
2x2P (4 pin) PHB 2.0 connectors can be purchased here
HC-PHB-2*2Y | Rectangular Connector Housings | HCTL | LCSC
HC-PHB-2*2Y Rectangular Connector Housings by HCTL. Features 2mm and 2mm. From $0.0204, in stock. Datasheet available.
28-24 AWG terminals can be purchased here
HC-PHB-T | Rectangular Connector Contacts | HCTL | LCSC
HC-PHB-T Rectangular Connector Contacts by HCTL. Features 22~28 and Tin. From $0.0062, in stock. Datasheet available.
Chop the original Bluetooth cable terminals off
Strip the wires and crimp the PHB 2.0 terminals on the Bluetooth cable. You can use this crimper
Attach the wires to the PHB 2.0 connector matching the pins to the Bluetooth module connector pins in the KiCAD schematic
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TPEHAK
🚴♂️ Mega poster
The controllers have arrived the US. We are so close guys!
TPEHAK
🚴♂️ Mega poster
You guess what guys, Santa just visited our house!
TPEHAK
🚴♂️ Mega poster
Ermahgerd, it feels like Christmas!
TPEHAK
🚴♂️ Mega poster
What am I gonna do with all those controllers?
JLCPCB nailed it, the quality is pristine!
JLCPCB nailed it, the quality is pristine!
TPEHAK
🚴♂️ Mega poster
The cheap 7 pins JST GH 1.25 cable for firmware flashing fits good and you can use it instead of the more expensive Tag Connect cable to connect an ST Link V2 dongle to flash the firmware.
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TPEHAK
🚴♂️ Mega poster
The controller has been flashed with the firmware file and it is alive! The green LED works, the Bluetooth communication works!
TPEHAK
🚴♂️ Mega poster
The controller has been attached to the motor, and all the cables have been connected. Wish me luck guys because of I am about to plug the battery!
TPEHAK
🚴♂️ Mega poster
The moment of truth is here guys! Guess what, we did it again! It works! Unbelievable! From the first try! How it is even possible! Time to celebrate the success!
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TPEHAK
🚴♂️ Mega poster
The cadence/torque sensor works! Holy cow! Now we just need to assemble this bad boy, calibrate the rotary encoder, install it on the bicycle and give it a real spin.
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TPEHAK
🚴♂️ Mega poster
Alrighty guys, the motor with the INNOTRACE M620 CAN Simple controller has been assembled and the encoder has been calibrated and it it works.
Here is the motor controller installation process. Make sure you flashed the firmware on the controller before installing it to the motor. The firmware file and firmware installation instructions can be found in the "Readme.txt" file in the "M620 CAN Simple Controller\Firmware" folder in the shared archive of the controller files.
1) 3D print the "Rotary Encoder Bumper 3D Print.step" file located in "M620 CAN Simple Controller\Idividual Parts Footprints, Symbols, 3D CAD\Extra parts" folder in the shared archive of the controller files out of high temperature plastic. I used ABS. Glue this bumper to the encoder area on the PCB on with B-7000 glue.
It is not necessary, but it might save your controller if the motor rotor bearing will fail.
The glue can be purchased here
2) 3D print the "Insulation.step" file located in "M620 CAN Simple Controller\Idividual Parts Footprints, Symbols, 3D CAD\Extra parts" folder in the shared archive of the controller files out of high temperature plastic. I used ABS. You also can cut this part manually out of 0.4-0.5mm thick sheet of high temperature resistant insulating material (you can use fiberglass boards or fish paper for this purpose)
2) Glue the insulation on the bottom of the PCB with double sided adhesive tape.
The tape can be purchased here
3) Cut 2 of 13x34mm rectangular shape thermal pads out of 0.5mm thick thermal pad. Attach those to bottom of the controller in the openings in the insulation and remove the protective layer.
This thermal pad should do it
4) Attach the controller to the motor case with 3 of M3X5mm screws. I also recommend to apply Loctite 243 blue to those screws before installation.
These screws should work
www.mcmaster.com
Loctite 243 can be purchased here
5) Attach the original Bafang M620 controller green, yellow and blue phase leads to the controller following the color indication on the controller PCB with M3x6x6 terminal block screws. Do not overtighten the screws.
M3x6x6 terminal block screws can be purchased here
https://www.aliexpress.us/item/3256807308404688.html?spm=a2g0o.productlist.main.2.1453fnPdfnPd0K&algo_pvid=6043b8b5-2430-4c81-8cd6-4ee721288407&algo_exp_id=6043b8b5-2430-4c81-8cd6-4ee721288407-1&pdp_ext_f={"order"%3A"328"%2C"eval"%3A"1"%2C"fromPage"%3A"search"%7D&pdp_npi=6%40dis%21USD%213.01%212.93%21%21%2120.21%2119.66%21%40210328df17860617113504682e0ea7%2112000041017461189%21sea%21US%214251763666%21X%211%210%21n_tag%3A-29919%3Bd%3A92cc84d5%3Bm03_new_user%3A-29895&curPageLogUid=UcoYNtQOB1xk&utparam-url=scene%3Asearch%7Cquery_from%3A%7Cx_object_id%3A1005007494719440%7C_p_origin_prod%3A
6) Connect the 8 pins connector (display, throttle, brakes) to the receptacle marked "DISP" on the controller PCB. Also connect the 4 pins speed sensor connector (blue, red, green, black bands marked wires on the Bafang M620 CAN harness) to the receptacle marked "SPD" on the controller PCB.
7) Attach the battery leads to the controller following the GND (black lead) and B+ (red lead) indications on the controller PCB with M3x6x6 terminal block screws. Do not overtighten the screws. The image below indicates the proper leads routing.
8) Connect the Bluetooth dongle to the controller receptacle marked "BLE".
The information for the Bluetooth dongle cable and pinout can be found here
endless-sphere.com
9) Place the Bluetooth dongle the way it does not interfere with anything and route the Bluetooth antenna cable outside the motor crossing the motor harness rubber grommet like it is illustrated on the picture below.
10) Attach the plastic cowl
11) Make sure the motor case gasket is on the motor side case halve. Connect the torque sensor connector to the receptacle on the controller PCB marked "TRQ"
12) Connect the motor stator temperature sensor connector to the receptacle on the controller PCB marked "TEMP"
Proceed here VESC based INNOTRACE M620 Simple motor controller
Here is the motor controller installation process. Make sure you flashed the firmware on the controller before installing it to the motor. The firmware file and firmware installation instructions can be found in the "Readme.txt" file in the "M620 CAN Simple Controller\Firmware" folder in the shared archive of the controller files.
1) 3D print the "Rotary Encoder Bumper 3D Print.step" file located in "M620 CAN Simple Controller\Idividual Parts Footprints, Symbols, 3D CAD\Extra parts" folder in the shared archive of the controller files out of high temperature plastic. I used ABS. Glue this bumper to the encoder area on the PCB on with B-7000 glue.
It is not necessary, but it might save your controller if the motor rotor bearing will fail.
The glue can be purchased here
2) 3D print the "Insulation.step" file located in "M620 CAN Simple Controller\Idividual Parts Footprints, Symbols, 3D CAD\Extra parts" folder in the shared archive of the controller files out of high temperature plastic. I used ABS. You also can cut this part manually out of 0.4-0.5mm thick sheet of high temperature resistant insulating material (you can use fiberglass boards or fish paper for this purpose)
2) Glue the insulation on the bottom of the PCB with double sided adhesive tape.
The tape can be purchased here
3) Cut 2 of 13x34mm rectangular shape thermal pads out of 0.5mm thick thermal pad. Attach those to bottom of the controller in the openings in the insulation and remove the protective layer.
This thermal pad should do it
4) Attach the controller to the motor case with 3 of M3X5mm screws. I also recommend to apply Loctite 243 blue to those screws before installation.
These screws should work
McMaster-Carr
McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.
Loctite 243 can be purchased here
5) Attach the original Bafang M620 controller green, yellow and blue phase leads to the controller following the color indication on the controller PCB with M3x6x6 terminal block screws. Do not overtighten the screws.
M3x6x6 terminal block screws can be purchased here
https://www.aliexpress.us/item/3256807308404688.html?spm=a2g0o.productlist.main.2.1453fnPdfnPd0K&algo_pvid=6043b8b5-2430-4c81-8cd6-4ee721288407&algo_exp_id=6043b8b5-2430-4c81-8cd6-4ee721288407-1&pdp_ext_f={"order"%3A"328"%2C"eval"%3A"1"%2C"fromPage"%3A"search"%7D&pdp_npi=6%40dis%21USD%213.01%212.93%21%21%2120.21%2119.66%21%40210328df17860617113504682e0ea7%2112000041017461189%21sea%21US%214251763666%21X%211%210%21n_tag%3A-29919%3Bd%3A92cc84d5%3Bm03_new_user%3A-29895&curPageLogUid=UcoYNtQOB1xk&utparam-url=scene%3Asearch%7Cquery_from%3A%7Cx_object_id%3A1005007494719440%7C_p_origin_prod%3A
6) Connect the 8 pins connector (display, throttle, brakes) to the receptacle marked "DISP" on the controller PCB. Also connect the 4 pins speed sensor connector (blue, red, green, black bands marked wires on the Bafang M620 CAN harness) to the receptacle marked "SPD" on the controller PCB.
7) Attach the battery leads to the controller following the GND (black lead) and B+ (red lead) indications on the controller PCB with M3x6x6 terminal block screws. Do not overtighten the screws. The image below indicates the proper leads routing.
8) Connect the Bluetooth dongle to the controller receptacle marked "BLE".
The information for the Bluetooth dongle cable and pinout can be found here
VESC based INNOTRACE M620 Simple motor controller
What is the maximum power it can handle?
endless-sphere.com
9) Place the Bluetooth dongle the way it does not interfere with anything and route the Bluetooth antenna cable outside the motor crossing the motor harness rubber grommet like it is illustrated on the picture below.
10) Attach the plastic cowl
11) Make sure the motor case gasket is on the motor side case halve. Connect the torque sensor connector to the receptacle on the controller PCB marked "TRQ"
12) Connect the motor stator temperature sensor connector to the receptacle on the controller PCB marked "TEMP"
Proceed here VESC based INNOTRACE M620 Simple motor controller
Last edited:
TPEHAK
🚴♂️ Mega poster
13) Connect the motor phase leads matching the colors.
14) Close the motor case making sure you do not jam the wires or anything else. Make sure the Bluetooth antenna cable goes between the rubber grommet and the gasket
15) Finish the motor assembly tightening the motor case screws.
16) Now you can install the motor on your bicycle and calibrate the rotary encoder with VESC Tool application. Make sure the bicycle chain in not on the motor chainring during the rotary encoder calibration.
Important note: if you want to do motor parameters detection make sure the display is set to Eco support mode (if the display will be set in any higher support mode some motor parameters will be detected wrong and the walk assist mode will not work properly causing the motor acceleration. If the display will be set in no support mode or walk assist mode the motor detection will not work at all). For rotary encoder calibration the display can be set to any support mode (no support mode and walk mode will not allow you to calibrate the rotary encoder).
14) Close the motor case making sure you do not jam the wires or anything else. Make sure the Bluetooth antenna cable goes between the rubber grommet and the gasket
15) Finish the motor assembly tightening the motor case screws.
16) Now you can install the motor on your bicycle and calibrate the rotary encoder with VESC Tool application. Make sure the bicycle chain in not on the motor chainring during the rotary encoder calibration.
Important note: if you want to do motor parameters detection make sure the display is set to Eco support mode (if the display will be set in any higher support mode some motor parameters will be detected wrong and the walk assist mode will not work properly causing the motor acceleration. If the display will be set in no support mode or walk assist mode the motor detection will not work at all). For rotary encoder calibration the display can be set to any support mode (no support mode and walk mode will not allow you to calibrate the rotary encoder).
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TPEHAK
🚴♂️ Mega poster
Swapping the good old INNOTRACE Shrimp on the new INNOTRACE M620 CAN Simple
The Bluetooth antenna can freely hang between the motor and the frame
The Bluetooth antenna can freely hang between the motor and the frame
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TPEHAK
🚴♂️ Mega poster
Just took it for a spin and it works beautifully!
The motor max temperature I saw was 85C after long uphill at full power. The controller temperature at the same time was not higher than 40C.
The power settings are 80A 14S 52V battery, 150A motor current, 280A absolute maximum current, 4100W maximum wattage.
So I highly recommend you this motor controller and you better pair it with 80-100A 16-20S battery to squeeze maximum out of it.
I will post updated files later but there are no changes to the PCB and PCB assembly files so you can use the existing files to purchase or make the controller.
The motor max temperature I saw was 85C after long uphill at full power. The controller temperature at the same time was not higher than 40C.
The power settings are 80A 14S 52V battery, 150A motor current, 280A absolute maximum current, 4100W maximum wattage.
So I highly recommend you this motor controller and you better pair it with 80-100A 16-20S battery to squeeze maximum out of it.
I will post updated files later but there are no changes to the PCB and PCB assembly files so you can use the existing files to purchase or make the controller.
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TPEHAK
🚴♂️ Mega poster
The instructions for such person about how to buy controllers are posted here
VESC based INNOTRACE M620 Simple motor controller
The archive with the current versions of the motor controller files (KiCAD version 10.0.5), Gerber files, BOM file, components placement file, CAD files and firmware files can be downloaded here (updated on 2026-07-24)...
endless-sphere.com
That person needs to find parts replacements in case of some pars are out of stock though using the JLCPCB interface and inspect the pars positions and orientation (even the pars were placed and positioned properly when I ordered the controllers) and fix it if necessary using the JLCPCB interface. There is a lot of YouTube videos about how to do this so that person can also watch those videos. If that person is not sure about something that person can post questions here.
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