KT E-Bike Controller Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your KT 36V/48V 15A brushless e-bike controller. Designed for 250W to 350W electric bicycles, this controller offers reliable performance and is available in waterproof (WP) and standard (SM) plug configurations, as well as Sinewave and Squarewave types. Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Safety Information

• Fire Risk: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of your e-bike battery and related components.
• Light/Lamp Current: When connecting a light or lamp to the KT controller, ensure its current draw is approximately 70 mA (less than 100 mA). Exceeding 100 mA can damage the controller. It is recommended not to use front and rear lights simultaneously if their combined current exceeds this limit.
• Professional Installation: If you are unsure about any installation steps, consult a qualified e-bike technician.
• Waterproof Connectors: While the controller is waterproof, ensure all connections are properly sealed and secured to prevent water ingress.

3. Product Overview

The KT-15A controller is a key component for your e-bike's electrical system, managing power delivery to the brushless motor. It is compatible exclusively with KT brand displays that share the same communication protocol.

Figure 3.1: KT E-Bike Controller (250W/350W) with connectors.

The controller features a robust silver casing and is designed for durability. It comes in different plug types (Waterproof 'WP' and Standard 'SM') and waveform types (Sinewave for smoother, quieter operation, or Squarewave).

Figure 3.2: Controller label indicating model, voltage, current, speed set, brake input, and low voltage protection. Also shows a JULET connector, emphasizing the importance of matching connector types for waterproof systems.

4. Installation and Wiring

Carefully follow the wiring diagrams below based on your controller's plug type (WP, SM, or WP+SM) and desired functions. Ensure all connections are secure before powering on the system.

4.1. General Wiring Considerations

• Compatibility: This KT controller is only compatible with KT displays. Ensure your display uses the same communication protocol.
• Waterproof Connectors: If you have a waterproof system, verify that your existing cable brand (e.g., Julet, Higo, YLS) matches the controller's connectors. While many are compatible, slight variations in line sequence can occur.
• Cable Length: The cable lengths are approximately 10-13cm for individual connections.

4.2. Wiring Diagrams

Figure 4.1: Wiring for WP (Waterproof) controller with light function. Connections include Motor (9pin), Power (XT60), Light (2pin Red), PAS (3pin Yellow), and 1T5 (9pin).

Figure 4.2: Wiring for WP+SM (Waterproof + Standard) controller with light function. Connections include Motor (9pin), Throttle (3pin), Ebrake (3pin*2), Power (XT60), PAS (3pin), Light (2pin*2), and Display (5pin).

Figure 4.3: Wiring for SM (Standard) controller with light function. Connections include Motor (9pin), Display (5pin), Light (2pin*2), PAS (3pin), Throttle (3pin), Ebrake (3pin*2), and Power (XT60).

Figure 4.4: Comprehensive overview of wiring for WP+SM, WP, and SM controllers, including a diagram for the 1-to-5 cable (9pin) and individual cable lengths for various connections.

5. Operation

Once correctly installed, the KT controller manages the power flow to your e-bike's motor based on your input from the display, throttle, and PAS (Pedal Assist System).

• Speed Control: The speed is set via the display or throttle, typically within a 1-4.2V range.
• Brake Input: The controller supports low-level brake input, which cuts motor power when brakes are applied.
• Low Voltage Protection: The controller includes a low voltage protection feature, activating at DC30/40±0.5V to prevent battery over-discharge.
• Sinewave vs. Squarewave: Sinewave controllers generally provide a smoother and quieter riding experience compared to Squarewave controllers.

6. Maintenance

To ensure the longevity and optimal performance of your KT e-bike controller, consider the following maintenance tips:

• Keep Dry: Although some versions are waterproof, it's best to keep the controller as dry as possible. Avoid prolonged exposure to heavy rain or submersion.
• Clean Connections: Periodically check and clean all electrical connections to prevent corrosion and ensure good conductivity.
• Secure Mounting: Ensure the controller is securely mounted to prevent vibrations and physical damage.
• Avoid Overheating: Ensure adequate airflow around the controller, especially during extended use, to prevent overheating.

7. Troubleshooting

• Controller Damage from Lights: If your controller is damaged after connecting lights, verify that the light's current draw is less than 100 mA. Using high-current lights can overload and damage the controller.
• Incompatibility Issues: If the controller does not function with your display, ensure both are KT brand and share the same communication protocol. Also, check the appearance and brand of waterproof connectors (e.g., Julet) for proper line sequence compatibility.
• No Power/Intermittent Power: Check all cable connections for looseness or damage. Verify battery voltage is within the operating range (36V/48V) and above the low voltage protection threshold.
• Motor Not Responding: Ensure the motor's 9-pin connector is fully seated and undamaged. Check throttle and PAS connections.

If you encounter persistent issues or are unsure about troubleshooting steps, please contact the seller for assistance.

8. Specifications

Figure 8.1: Dimensions of the KT E-Bike Controller: 80mm (Length) x 50mm (Width) x 30mm (Height).

9. User Tips

• Smooth Riding: If you prioritize a quieter and smoother ride, consider the Sinewave version of the controller.
• Verify Connectors: Before purchasing or installing, always double-check the type and brand of your existing e-bike connectors, especially for waterproof systems, to ensure compatibility with the KT controller.
• Light Usage: Be mindful of the current draw of any lights connected to the controller to avoid damage.

10. Warranty and Support

For any questions, technical support, or warranty claims regarding your KT E-Bike Controller, please contact the seller directly through the platform where you made your purchase. Provide your order details and a clear description of the issue for prompt assistance.