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Commissioning a BLDC Motor Controller: Key Steps and Best Practices*

BLDC (Brushless DC) motors are increasingly used in systems requiring efficiency, reliability, and compactness. Their proper operation closely depends on a rigorous commissioning of the controller. Here are the essential steps to ensure safety, performance, and durability.

1. Check Polarity and DC Protections

Before any connection, it is imperative to secure the power line:

  • Check the polarity: the + and – of the battery pack or power supply must be clearly identified. A polarity reversal can instantly destroy the controller.

  • Install a fuse as close as possible to the positive pole (+) to protect the DC line in case of a short circuit.

  • Provide a disconnect switch or a main switch to quickly isolate the system in case of emergency.

  • Check ground continuity and voltage compatibility between the pack and the controller (e.g., 24 V, 48 V, 72 V, etc.).

2. Connect Phases and Sensors

The BLDC motor generally has three phases (U, V, W) and position sensors (Hall or encoder).

  • Phase connection: connect the motor cables to the controller terminals according to the manufacturer's pinout. Incorrect phase order can reverse the rotation direction or cause jerking.

  • Sensor connection: connect the Hall sensor wires or the encoder connector according to the diagram.

  • Check the sensor power supply (often 5 V or 12 V) provided by the controller.

  • If necessary, reverse two phases or adjust the rotation direction parameter during testing.

3. Configure the Controller

Once the wiring is done, proceed to the software configuration of the controller:

  • Pack voltage: enter the nominal value of the battery or power supply.

  • Current limits: set the continuous (nominal) current and the peak current (acceleration, start-up).

  • Temperature limits: enter the motor and controller protection thresholds to avoid overheating.

  • Sensor type: select “Hall”, “encoder” or “sensorless” depending on the equipment used.

  • Rotation direction: choose the desired direction or adjust if the no-load test reveals a reversal.

  • Acceleration and deceleration ramps: adjust the response dynamics to avoid jerking or overcurrents.

4. No-Load Test

Before applying load to the motor, perform a test without mechanical constraint:

  • Start with a gradual speed increase.

  • Monitor the telemetry: current consumption, speed, voltage, and temperature.

  • Ensure the absence of faults (overvoltage, overcurrent, faulty sensors).

  • Check that the motor runs smoothly and without excessive vibrations.

This test confirms the coherence of the wiring and parameters before applying a real torque.

5. Light Load Test

Once the no-load operation is validated, gradually introduce a light mechanical load:

  • Check the heating of the motor and controller after a few minutes.

  • Be attentive to any abnormal noise (whistling, clicking, vibration).

  • Evaluate the delivered torque and speed stability.

  • Ensure that consumption remains within nominal limits and that no error messages appear.

These observations ensure that the system is ready for full load operation.

Conclusion

Commissioning a BLDC controller is not just a simple connection. It is a methodical procedure, combining electrical checks, precise settings, and progressive testing.

By following these steps — safety, wiring, configuration, no-load test, and then load test — optimal operation, increased equipment longevity, and reliable motor-controller system operation are ensured.


*: The technical information presented in this article is provided for guidance only. It does not replace the official manuals of the manufacturers. Before any installation, handling, or use, please consult the product documentation and follow the safety instructions. Torque.works cannot be held responsible for inappropriate use or incorrect interpretation of the information provided.