1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your new Electric Bike Brushless Controller. Designed for high-power electric vehicles, including two-wheel electric motorcycles and three-wheel electric vehicles, this controller offers stable, efficient, and low-power consumption performance with a long service life. It features a full cast aluminum shell for strong heat dissipation, dustproof, and waterproof capabilities, ensuring high stability.
2. Safety Information
⚠️ Disclaimer: Please be aware of potential fire risks associated with electric vehicle components. Always follow the instruction manual strictly for charging and storage of associated battery packs. Improper installation or use can lead to serious injury or damage.
- Ensure all power is disconnected before attempting any installation or wiring.
- Always wear appropriate safety gear, including gloves and eye protection, when working with electrical components.
- Verify all connections are secure and insulated to prevent short circuits.
- Do not expose the controller to extreme temperatures or direct sunlight for prolonged periods.
- Keep the controller away from flammable materials.
- If you are unsure about any step, consult a qualified technician.
3. Product Overview
The brushless controller is a key component for managing the power delivery to your electric vehicle's motor. This universal controller supports multiple voltage ranges (36V-48V, 48V-60V, 60V-72V) and power outputs (500W/1000W), making it versatile for various applications. Its robust cast aluminum housing ensures durability and efficient heat dissipation.
4. Specifications
| Feature | Specification |
|---|---|
| Type | Brushless Motor Controller |
| Working Voltage | DC10V to DC50V (Universal 36V-48V, 48V-60V, 60V-72V) |
| Control Power | 0.01W to 5000W (Specific models: 500W or 1000W) |
| Current Limiting | 28A (for 500W models), 38A (for 1000W models) |
| Lower Volts | DC42/53V (varies by model) |
| Angle | 120°/60° |
| Material | Cast Aluminum Shell |
| Weight | Approx. 485g |
| Dimensions (L x W x H) | 13cm x 8.5cm x 4cm (5.12in x 3.35in x 1.57in) |
| Origin | Mainland China |
Note: Specific voltage and power ratings may vary slightly depending on the exact model purchased. Refer to the label on your controller for precise details.
5. Installation and Setup
Careful installation is crucial for the proper functioning and safety of your electric vehicle. Follow these steps to connect the brushless controller.
5.1 Wiring Diagram Overview
The controller features a comprehensive wiring harness. Refer to the diagram below and the detailed connection list for proper setup.
5.2 Connection Points
Identify and connect the following wires according to your electric vehicle's system:
- Reverse: Connect to the reverse switch/signal.
- 3-Speed: Connect to the 3-speed gear switch.
- Low Brake: Connect to the low-level brake signal.
- High Gear: Connect to the high-level gear signal.
- Power: Main power input from the battery.
- Throttle: Connect to the throttle input.
- GND: Ground connection.
- PAS Signal: Connect to the Pedal Assist System sensor.
- Learning: Used for motor learning/pairing (refer to specific motor instructions).
- Security Signal: Connect to security system (if applicable).
- TXD: Transmit data line (for display/communication).
- RXD: Receive data line (for display/communication).
- Motor: Connect to the motor phase wires (usually three thick wires).
- Battery: Main battery connection (thick red for positive, thick black for negative).
- Brake: Connect to the brake levers/sensors.
- Display: Connect to the electric bike display unit.
5.3 Initial Power-Up
After all connections are made and secured:
- Double-check all wiring against the diagram.
- Ensure the battery is fully charged.
- Turn on the main power switch of your electric vehicle.
- Observe the display (if connected) for any error codes or abnormal behavior.
- Test the throttle, brakes, and other functions at a low speed in a safe environment.
6. Operating Instructions
Once installed, the brushless controller manages the power to your motor based on your input from the throttle, PAS, and other sensors.
- Throttle Control: Gently twist the throttle to accelerate. Release to decelerate.
- Brake Function: Engaging the brakes will cut power to the motor, ensuring safe stopping.
- 3-Speed Function: Use the 3-speed switch to select different power output levels, affecting acceleration and top speed.
- Reverse Function: If connected, the reverse switch allows for backward movement. Use with caution.
- Display Integration: The controller communicates with compatible displays to show speed, battery level, and other vital information.
7. Maintenance
To ensure the longevity and optimal performance of your brushless controller:
- Regular Inspection: Periodically check all wiring connections for looseness, corrosion, or damage.
- Cleaning: Keep the controller's exterior clean and free from dirt, dust, and moisture. Use a dry cloth for cleaning.
- Heat Management: Ensure the controller's cast aluminum shell has adequate airflow for heat dissipation. Do not cover it or obstruct its fins.
- Avoid Water Immersion: While dustproof and waterproof to a degree, avoid fully immersing the controller in water.
- Storage: When not in use for extended periods, store the electric vehicle and its components in a dry, cool place.
8. Troubleshooting
If you encounter issues with your controller, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not responding | Loose power/motor connections, faulty throttle, low battery. | Check all wiring, test throttle, charge battery. |
| Intermittent power | Loose connections, damaged wiring, overheating. | Inspect connections, ensure proper ventilation for the controller. |
| Controller gets excessively hot | Overload, insufficient cooling, short circuit. | Reduce load, ensure proper airflow, check for short circuits. |
| Display not working | Loose display connection, incompatible display. | Check display wiring, ensure display is compatible with the controller's communication protocol. |
If the problem persists after attempting these solutions, please contact customer support.
9. User Tips
- Voltage Compatibility: This controller is universal for 36V-48V, 48V-60V, and 60V-72V systems. Ensure your battery voltage matches the selected operating range of the controller for optimal performance and to prevent damage.
- Power Matching: While the controller supports 500W and 1000W motors, ensure the controller's power rating matches or exceeds your motor's power requirement. For example, if you have a 600W motor, a 1000W controller model would be suitable.
- Display Connection: The controller has a dedicated 'Display' connection. For specific display models like the S866, verify the wiring pinout and communication protocol (e.g., UART, CAN bus) to ensure compatibility. Consult your display's manual for its wiring requirements.
- Motor Learning Function: Utilize the 'Learning' wire if your motor requires an initial pairing or calibration with the controller. Follow your motor's specific instructions for this process.
10. Frequently Asked Questions (FAQ)
- Q: Is this controller compatible with a 48V 600W motor?
- A: Yes, this controller is designed to be universal across various voltages (36V-72V) and power outputs (500W/1000W). A 48V 600W motor would be compatible with the 48V-60V range and the 1000W version of the controller, ensuring sufficient power handling.
- Q: Does this controller have a connection for an S866 display?
- A: The controller includes a 'Display' connection. While it is generally compatible with many e-bike displays, specific compatibility with an S866 display depends on the S866's wiring and communication protocol. You may need to match the pinout of the controller's display wires to your S866 display's input. Consult the S866 display manual for its wiring specifications.
11. Warranty and Support
This product is manufactured to high standards. For any issues or technical support, please contact the seller or manufacturer directly. Keep your purchase records for warranty claims.
