1. Introduction
This manual provides essential information for the safe and efficient installation, operation, and maintenance of your Kunray Brushless DC Motor and Speed Controller Kit. This kit is designed for various electric vehicles, including electric bikes, scooters, and go-karts, offering power options from 1000W to 3000W and voltage compatibility from 36V to 72V.
Please read this manual thoroughly before attempting any installation or operation to ensure proper usage and prevent damage or injury.
Kunray Brushless DC Motor Product Showcase
2. Safety Information
⚠️ Disclaimer: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of any connected battery. Always ensure proper insulation and secure connections for all electrical components.
- Always wear appropriate safety gear when working with electrical components.
- Ensure the power supply is disconnected before making any electrical connections or performing maintenance.
- Avoid exposing the motor and controller to water or extreme temperatures.
- Verify all connections are secure and correctly wired according to the diagrams provided.
3. Product Overview
The Kunray Brushless DC Motor Kit typically includes the following components:
Complete Kit Components: Motor, Controller, Foot Pedal, Twist Grip Throttle, 3-Speed Switch, T8F Chain, 54T T8F Chainring, E-Lock Key, Screws & Tools
3.1. Motor
- Type: Brushless High Speed DC Motor
- Material: High Quality Aluminum Motor and High Quality Rotor Magnet (All Copper)
- Cooling: Features a total of 400 cooling holes at the front and rear for quick heat dissipation.
Internal View of Brushless DC Motor with Copper Windings
Motor Cooling Holes (Front and Rear)
3.2. BLDC Controller
The controller manages motor speed and various functions.
3.3. Accessories
- Foot Pedal
- Twist Grip Throttle
- 3-Speed Switch
- T8F Chain
- 54T T8F Chainring
- E-Lock Key
- Wiring Connect Box
- Screws & Tools
4. Specifications
4.1. Motor Specifications
Brushless DC Motor Dimensions (Side View)
| Model | Voltage | Power | Rated Current | Torque (N.m) | Rated Speed (RPM) |
|---|---|---|---|---|---|
| KRMY1020 / KRMY-1029 | 36V | 1000W | 27.7A | 5.7 | 3750 |
| KRMY1020 / KRMY-1029 | 48V | 1000W | 20.8A | 5.1 | 4650 |
| KRMY1020 / KRMY-1029 | 48V | 1500W | 30A | 5.1 | 4100 |
| KRMY1020 / KRMY-1029 | 48V | 1600W | 34A | 5.1 | 4350 |
| KRMY1020 / KRMY-1029 | 48V | 2000W | 42A | 6.9 | 5650 |
| KRMY1020 / KRMY-1029 | 60V | 2000W | 35A | 5.1 | 5400 |
| KRMY1020 / KRMY-1029 | 60V | 2500W | 45A | 5.6 | 5800 |
| KRMY1020 / KRMY-1029 | 72V | 3000W | 45A | 5.4 | 6700 |
48V 2000W Motor Speed Measurement (Digital Tachometer)
72V 3000W Motor Speed Measurement (Digital Tachometer)
36V 1000W Motor Speed Measurement (Digital Tachometer)
4.2. Controller Specifications
BLDC Controller Dimensions
BLDC Controller Dimensions (Side View)
| Parameter | Value |
|---|---|
| Voltage | 48V-72V |
| Protect Voltage | 42V |
| Power | 2000W, 3000W |
| Current | 45A |
| Mosfet | 24 Mosfet |
| Phase Degree | 120 |
5. Setup and Installation
Follow these general steps for installing your motor kit. Specific vehicle configurations may vary.
5.1. Motor Mounting
Securely mount the motor to your vehicle's frame using appropriate hardware. Ensure the T8F sprocket aligns correctly with your chain system.
Motor with T8F Sprocket and Mounting Hardware
5.2. Controller Wiring
Connect the controller to the motor, battery, throttle, brakes, and other accessories according to the wiring diagrams below. Pay close attention to wire colors and connector types.
5.2.1. 1000W Controller Wiring Diagram
1000W Controller Wiring Diagram Overview
Detailed 1000W Controller Wiring Connections
5.2.2. 2000W/3000W Controller Wiring Diagram
2000W/3000W Controller Wiring Diagram
Detailed 2000W/3000W Controller Wiring Connections
BLDC Controller Label and Wiring Details (72V 3000W)
Key Connections:
- Motor Phase Wires: Connect the three thick wires from the motor to the corresponding phase wires on the controller (usually Blue, Green, Yellow).
- Battery +/-: Connect the main battery positive and negative terminals to the controller.
- E-Lock: Connect the E-lock for power on/off functionality.
- Throttle: Connect the throttle unit (twist grip or foot pedal).
- Brakes: Connect high-level and low-level brake signals.
- Hall Sensor: Connect the Hall sensor wires from the motor to the controller.
- 3-Speed (L M H): Connect the 3-speed switch for speed selection.
- Reverse: Connect the reverse switch.
- Anti-Theft: Connect anti-theft system if applicable.
- Cruise: Connect cruise control function if desired.
- Hard Boot: For initial setup or specific functions.
6. Operating Instructions
Once all components are correctly installed and connected:
- Power On: Turn the E-lock key to the 'ON' position.
- Self-Study Function: The controller may have a self-study function to automatically recognize motor parameters. Refer to the controller's specific instructions for activation.
- Speed Control: Use the twist grip throttle or foot pedal to control the motor speed.
- 3-Speed Switch: Select desired speed mode (Low, Medium, High) using the 3-speed switch.
- Reverse Function: Activate the reverse switch for backward movement. Note that the reverse function may limit speed for safety.
- Braking: Apply brakes. The controller supports both high-level and low-level brake signals.
- Cruise Control: If connected, activate the cruise function to maintain a constant speed.
- Anti-Theft: If an anti-theft system is connected, refer to its specific instructions for operation.
7. Maintenance
- Regular Inspection: Periodically check all electrical connections for tightness and signs of wear or corrosion.
- Cleaning: Keep the motor and controller clean and free from dust, dirt, and moisture. Use a dry cloth for cleaning.
- Cooling: Ensure the motor's cooling holes are not obstructed to maintain optimal operating temperature.
- Lubrication: Lubricate the chain and sprocket as needed to ensure smooth operation and prevent wear.
- Battery Care: Follow the manufacturer's guidelines for battery charging and storage to prolong its lifespan and prevent hazards.
8. Troubleshooting
- Motor Not Running:
- Check E-lock connection and ensure it's 'ON'.
- Verify battery connection and charge level.
- Inspect all wiring connections for looseness or damage.
- Ensure throttle is correctly connected and functioning. - Motor Runs Slowly or Intermittently:
- Check battery voltage; a low battery can cause reduced performance.
- Inspect motor phase wires and Hall sensor wires for proper connection.
- Ensure the 3-speed switch is not set to a low-speed mode unintentionally. - Motor Direction Issue:
- If the motor runs in the wrong direction, check the motor phase wire connections or use the controller's self-study function if available. - Reverse Speed Limited:
- The reverse function is often designed with a speed limit for safety. This is normal operation.
9. User Tips
- Battery Compatibility: Ensure your battery voltage matches the motor and controller's rated voltage (e.g., 36V, 48V, 60V, 72V).
- Wiring Clarity: Take photos of your wiring before disconnecting anything for easier reassembly or troubleshooting.
- Controller Functions: Familiarize yourself with all controller functions like 'Self-Study' and 'Hard Start' for optimal performance and customization.
10. Warranty and Support
For warranty claims, technical support, or replacement parts, please contact Kunray Official Store directly through your purchase platform. Provide your order number and a detailed description of the issue for prompt assistance.