Electric Scooter Controller Kit Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your 350W 36V 17A Electric Scooter Controller Kit. This kit is designed for 10-inch electric scooters, including models such as FOSTON, X-Play, and DIGMA. It features speed control, cruise control, self-diagnostic capabilities, low voltage protection, and Bluetooth connectivity with the Tuya Smart App.

Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Product Components

The controller kit typically includes the following components:

• Controller (350W, 36V, 17A)
• Dashboard display with communication line
• Accelerator wire
• Brake wire
• Headlight wire (12V yellow +)
• Motor three-phase line
• XT60 Battery wire
• HY Communication line
• Taillight
• HY Hall Wire
• Test Wire

3. Specifications

4. Safety Information

Strictly Adhere to the Following:

• Reversing the positive and negative terminals is strictly prohibited, as it will immediately burn out the controller.
• Ensure all terminals are fully inserted and securely connected to prevent short circuits or poor contact.
• The controller must operate within the specified voltage range; do not exceed the rated voltage.
• The controller's power rating must match the motor's power rating—do not use an undersized controller for an oversized motor.
• Do not use or store the controller in damp, high-temperature, or flammable/explosive environments.
• Installation should be performed by qualified personnel with electrical expertise. Non-professionals must not disassemble or attempt repairs.

5. Installation and Wiring

Proper wiring is crucial for the safe and correct operation of your scooter. Refer to the diagrams below for connection details.

5.1 Controller Wiring Diagram

5.2 Dashboard Wiring Diagram

5.3 Internal Installation Example

6. Operating Instructions

6.1 Dashboard Functions

• Power On/Off: Press and hold the “on/off” button. A “beep” sounds upon startup. The device automatically powers off after ten minutes of inactivity.
• Lights Control: Press the “on/off” button once to toggle the front and rear lights on or off. The rear lights flash when braking (regardless of whether the lights are on).
• Speed Modes (Gears): Double-press the “on/off” button with a “beep” to switch modes:
  • Mode 1 (ECO): 0-10 km/h
  • Mode 2 (D): 0-20 km/h
  • Mode 3 (S): 0-30 km/h (default, speed display turns pink)
• Speed Unit (km/h / mph): Press the "on/off" button three times with a 'beep' sound to switch between km/h and mph display (default km/h). After switching to mph, the speeds for Gears 1, 2, and 3 are “6mph, 12mph, 18mph” respectively.
• Cruise Control: Press the “on/off” button four times. The buzzer will beep to activate or deactivate cruise control. When cruise control is active, holding the throttle for 10 seconds engages cruise mode. The buzzer will beep, the cruise icon will illuminate, and the mode will exit upon subsequent throttle/brake operation, gear shifting, or light activation (default: enabled).
• Start Mode (Zero-start / Non-zero-start): Press the “on/off” button five times. The buzzer will beep once to toggle between zero-start and non-zero-start modes (default: non-zero-start).
• Reset Total Mileage: Press the “on/off” button nine times. The buzzer will beep once to reset the total mileage.
• Unpair Bluetooth: Simultaneously press and hold the “Brake” and “On/Off” buttons until the display shows “UC” during startup.

6.2 Bluetooth Functionality and App Instructions (Tuya Smart App)

The controller features Bluetooth connectivity and can be controlled via the Tuya Smart app. The Bluetooth name for the device is “MAX”.

1. Download App: Scan the QR code on the specification sheet (or product packaging) to download the “Tuya Smart” app, or search for it in your app store.
2. Permissions (Android): After downloading and installing, Android users must enable all permissions for the Tuya Smart app in (System Settings > Application Settings) to control the vehicle via the app.
3. Pairing: Open the app, tap 'Add Device', enable 'Auto-discovery' in the top-right corner, search for the “MAX” device via Bluetooth, then add and complete.
4. Unlock Motor: Tap "Unlock Motor” (with the scooter powered on). The app interface will display vehicle information and complete Bluetooth pairing. Once paired successfully, vehicle details will be saved for automatic reconnection next time.
5. App Controls: The app allows you to:
   • Switch between zero-start and non-zero-start modes.
   • Enable cruise control.
   • Change gears.
   • Switch between metric and imperial units (in More Settings).
   • View current voltage (in More Settings).
   • Turn on headlights.
   • View real-time location, riding time, current trip distance, and average speed after tapping the central map to start riding.
   • Lock the bike via the app interface's lock button to disable motor rotation. When locked, the display shows “LC”.
   • Clear device data by tapping the upper-right corner of the app interface.
6. Adjust Speed Limits: Speed limits for gears 1, 2, and 3 can be freely disabled via the app's advanced settings. After disabling, gear speeds become: 5-15 km/h, 15-25 km/h, 20-40km/h (speeds adjusted via the app will retain the current settings).

7. Motor Self-Learning Methods

If your motor does not rotate or reverses unexpectedly, follow these steps for motor self-learning. Note that due to variations in motors, the no-load maximum speed may not always reach the control settings.

1. Rack the motor (ensure it's off the ground).
2. Grab the brake handle (brake set to maximum).
3. Turn on the motor.
4. Adjust the speed control handle from zero to maximum, 3 times in a row. The meter will display Fx or -x (x=0-5) after operation.
5. Release the brake handle and speed control handle. The motor will automatically rotate for a few seconds and then stop. If it does not rotate, immediately shut down the machine and re-operate.
6. Adjust the speed control handle to the maximum to see if the motor rotation direction is correct. If it is correct, release the speed control handle to let the motor skid to a stop (do not brake) to complete the study and then turn off the power. If not correct, proceed to the next step.
7. When the motor rotation direction is not correct, release the speed control handle and wait for the motor to stop. Grab the brake (brake adjusted to the maximum), adjust the speed control handle from zero to the maximum 1 time, and then release the brake and the speed control handle. At this time, the meter will change from F to - or from - to F.
8. Adjust the speed control handle to the maximum to see whether the motor rotation direction is correct. If it is correct, release the speed control handle and let the motor coast to a stop (do not brake) to complete the study and then turn off the power. If it is not correct, then repeat step 7.

8. Troubleshooting

8.1 Fault Warning Codes

The dashboard display may show error codes to indicate specific issues:

• E2: Throttle Failure
• E3: Brake Failure
• E4: MOS Failure, Overcurrent Protection
• E5: Hall Sensor Failure
• E6: Stall Protection (Locked rotor protection)
• E7: Undervoltage Protection
• E8: Overvoltage Protection
• E9: Communication Failure

8.2 Motor Running Issues

If your scooter's motor is not running well, consider the following:

1. Motor Noise, Not Smooth, or Speed Below 15 km/h:

   This often indicates an issue with the Hall line connections. Test the 6 different Hall line connection methods shown in Figure 8.1 (A.hall line section) one by one and choose the one that results in the smoothest operation.
2. Motor Runs Smoothly but in Reverse:

   This indicates an issue with the Phase line connections. Change the wire connection of the Phase line as shown in Figure 8.1 (B. phase line section) until the motor runs correctly.

8.3 Battery Level Display

The battery icon on the dashboard indicates the charge level:

• Five-bar: 40.5V–42.0V
• Four-bar: 38.5V–40.4V
• Three-bar: 36.5V–38.4V
• Two-bar: 35.5V-36.4V
• One-bar: 33.5V-35.4V

A low voltage alarm triggers when battery voltage drops below 33.5V, causing the battery icon to flash one bar. Undervoltage protection activates when battery voltage falls below 31V, stopping the motor, displaying an E7 error, and turning off the battery level indicator.

9. Maintenance

To ensure the longevity and optimal performance of your scooter controller kit:

• Keep the controller and all connections clean and free from dust and moisture.
• Regularly check all wiring connections for tightness and signs of wear or damage.
• Avoid exposing the controller to extreme temperatures or direct sunlight for prolonged periods.
• Do not attempt to open or modify the controller, as this may void any applicable warranties and could lead to malfunction or injury.

10. User Tips

• For optimal performance, ensure your scooter's motor is compatible with a 350W, 36V controller.
• Always perform the motor self-learning procedure after initial installation or if you experience unusual motor behavior.
• Familiarize yourself with the Tuya Smart App features to customize your riding experience, including speed limits and start modes.
• Regularly check the battery voltage via the app or dashboard to avoid undervoltage protection activation during rides.

11. Warranty and Support

This product is covered by a standard manufacturer's warranty against defects in materials and workmanship. For specific warranty terms and conditions, please refer to the documentation provided at the time of purchase or contact the seller directly. Technical support may be available through the seller or manufacturer for assistance with installation, troubleshooting, and general inquiries.

For further assistance, you may refer to the user manual PDF available at: User Manual (PDF)