RisunMotor 48-72V 80A Sine Wave Ebike Controller and UKC-1 Display User Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your RisunMotor 48-72V 80A Sine Wave Ebike Controller and optional UKC-1 Colorful Display. This programmable controller is designed to offer high efficiency, reduced noise, and lower energy consumption for a smoother and more comfortable electric biking experience.

Overview of the RisunMotor Ebike Controller and UKC-1 Display components.

2. Package Contents

Please verify that all items listed below are included in your package:

• 1 x 24 MOSFET 80A 48V, 60V, 72V Universal Voltage 2600W-4000W Intelligent Programmable Sine Wave Controller
• 1 x USB Data Cable (for PC connection and parameter setting)
• 1 x Bluetooth Module (for smartphone app connection and parameter setting)
• 1 x Light Connection Adapter Cable (O-ring to SM-2A Plug)
• 1 x Hall Sensor Adapter Cable (DJ7061A-2.3-11 to DJ7061Y-2.8-21 Plug)
• 1 x Battery Power Adapter Cable (O-ring to Anderson Plug)
• 1 x 48V, 60V, 72V UKC1 Colorful Display (Optional, includes 5-level PAS, Speed Limit, Speed Display, Voltage Selection, Start Mode, Regenerative Braking Function)

3. Features and Advantages

• Programmable Sine Wave Control: High efficiency, low noise, and reduced energy consumption for a comfortable riding experience.
• Smooth Operation: Motor torque ripple is minimized through FOC (Field-Oriented Control) for smoother performance.
• Universal Voltage: Compatible with 48V, 60V, and 72V systems.
• Flexible Display Options: Can operate with or without the UKC-1 display.
• Easy Parameter Setting: Adjust settings via a mobile phone app (Bluetooth) or computer software (USB data cable).
• Comprehensive Protection: Includes locked-rotor, over-current, overload, over-temperature, speed, over-voltage, and under-voltage protection for system safety and longevity.
• Multi-functional: Features smart motor matching, 5-speed levels for throttle and PAS, speed limit, anti-theft, regenerative braking, electric braking, and keyless start.
• Efficient Heat Dissipation: Designed with a thick heat sink aluminum plate for optimal cooling.
• Durable Casing: Anodized aluminum controller case provides scratch resistance.
• Precise Torque Control: Accurate current ring ensures sufficient torque for starting and climbing.
• Intelligent Diagnostics: System status and fault management with LED indicators for easy troubleshooting.
• Peripheral Interfaces: Supports cruise control, anti-theft, and electronic brake functions.
• CAN BUS: Optional for communication with body instruments and BMS.

4. Specifications

Controller dimensions (275mm x 120mm x 65mm shown in diagram).

5. Setup and Installation

Carefully follow these instructions for proper installation. Incorrect wiring can damage the controller or other components.

Detailed wiring diagram for the RisunMotor Ebike Controller.

1. Battery Connection: Connect the thick red and black wires from the controller to your e-bike battery (positive to red, negative to black). Ensure a secure connection.
2. Motor Phase Wires: Connect the thick yellow, green, and blue wires from the controller to the corresponding phase wires of your motor.
3. Hall Sensor Wires: Connect the thin multi-color Hall sensor connector from the controller to your motor's Hall sensor wires.
4. Throttle: Connect the 3-pin throttle connector.
5. Low Brake: Connect the 2-pin low brake connector.
6. Ignition Key: Connect the 2-pin ignition key connector.
7. Speed Limit: Connect the 2-pin speed limit connector if using this feature.
8. SVS: Connect the 2-pin SVS connector (if applicable to your setup).
9. Intelligent: Connect the 2-pin intelligent connector (if applicable).
10. Light Connection: Connect the 2-pin light connection adapter cable (O-ring to SM-2A Plug) for your e-bike lights.
11. Battery Power Adapter Cable: Use the provided O-ring to Anderson Plug adapter cable for battery connection if needed.
12. Communication Plug: This 2-pin connector is used for communication with the display or programming tools. Ensure it is connected for display operation. If using without a display, a jumper connector may be required (refer to the full manual for details).
13. USB Data Cable: Connect the optional USB data cable to your computer for programming.
14. UKC1 Display Connection: Connect the green connector from the UKC1 display to the corresponding port on the controller.

Important: Always ensure the power is off before making or changing any connections. Double-check all connections before powering on the system.

6. Operation

Once installed, the controller and UKC-1 display provide various functions for controlling your e-bike:

UKC-1 Colorful Display Functions:

UKC-1 Display showing speed, battery, assist level, and other data, with 180° rotation feature.

• Speed Display: Shows real-time speed.
• PAS (Pedal Assist System) Levels: Select from 5 levels of pedal assistance.
• Speed Limit: Set and monitor your desired speed limit.
• Voltage Selection: View current battery voltage.
• Start Mode: Configure how the motor starts.
• Regenerative Braking Function: Engages regenerative braking to recover energy.
• Keyless Start: Allows starting the e-bike without a physical key.
• Electric Braking: Provides electronic braking functionality.

Refer to the specific UKC-1 display manual for detailed instructions on navigating menus and adjusting settings directly from the display.

7. Programming and Customization

The RisunMotor controller is programmable, allowing you to fine-tune its performance to your preferences and motor characteristics.

• Mobile App (Bluetooth): Use the provided Bluetooth module to connect your smartphone to the controller. Download the official RisunMotor app to access and modify parameters.
• PC Software (USB Data Cable): Connect the controller to a computer using the USB data cable. Install the RisunMotor PC software to perform advanced parameter adjustments and diagnostics.

For detailed instructions on using the programming software and app, including motor matching procedures, please refer to the "Controller Manual-APP Version" and "Controller Manual-USB Cable" documents available from RisunMotor.

8. Maintenance

To ensure the longevity and optimal performance of your controller and display, follow these maintenance guidelines:

• Keep Dry: Protect the controller and display from water and excessive moisture. Although rated IP65, prolonged exposure to water should be avoided.
• 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.
• Cable Management: Route cables neatly and secure them to prevent chafing or snagging.
• Avoid Extreme Temperatures: Do not expose the components to extreme heat or cold for extended periods.

9. Troubleshooting

Here are solutions to common issues you might encounter:

• Controller without Display: If you intend to use the controller without the UKC-1 display, ensure the communication plug has a jumper connector installed. Refer to the full Controller Connection Diagram (Page 3, point No.5) for details.
• Display Error "30H": This error typically indicates a communication issue. Verify that the communication plug (Page 6, point No.12 in the Controller Connection Diagram) is correctly connected between the controller and the display.
• Bluetooth/USB Connection Failure: If you experience "Connection Failure" when connecting the Bluetooth module or USB cable, first ensure the communication plug (Page 6, point No.12 in the Controller Connection Diagram) is disconnected from the display. Then, reconnect the Bluetooth module or USB cable firmly to ensure a good connection.
• Motor Matching: For optimal efficiency, it is recommended to perform a motor matching procedure with the controller. Detailed steps can be found in the "Controller Manual-APP Version" (Page 5-9) or "Controller Manual-USB Cable" (Page 6-7) documents.

10. User Tips

• Motor Compatibility: Always ensure the controller's wattage and voltage ratings are compatible with your motor's specifications for optimal performance and to prevent damage. This controller is rated for 2600W-4000W.
• Initial Setup: Take the time to properly match your motor with the controller during the initial setup using the programming tools. This step significantly improves efficiency and reduces noise.
• Regular Checks: Periodically inspect all wiring and connections for wear or looseness, especially after riding in rough terrain or wet conditions.

11. Support

For further assistance, technical support, or warranty inquiries, please contact RisunMotor Official Store directly through their official channels. Provide your product model and any relevant details to help them assist you efficiently.