VOTOL EM100GTS 72360S Brushless DC Motor Controller Instruction Manual

1. Introduction

The VOTOL EM100GTS 72360S is an intelligent, programmable brushless DC motor controller designed for electric motorcycles and motor scooters. This controller is capable of handling up to 200A maximum release current and 360A phase line current, making it suitable for motors ranging from 2000 watts to 4000 watts. It operates universally across a voltage range of 60V to 84V. This manual provides essential information for the safe and effective installation, operation, and maintenance of your VOTOL EM100GTS controller.

2. Specifications

Default Functions: Hall Plug, Reverse, Low Brake 0V, Throttle (0-5V), High Brake 12V, Ignition, One-line/Hall Meter Wire, Program Port, Three Speed, Sport Model, Parking, Anti-Theft, Regen Charge, Flux Weaken Current.

3. Package Contents

Please verify that all items are present and undamaged upon opening the package:

• VOTOL EM100GTS 72360S Brushless DC Motor Controller
• Wiring Harness
• USB Programming Cable

4. Safety Information

WARNING: Improper installation or use can lead to serious injury or damage to the product and connected components. Always follow these safety guidelines:

• Professional Installation Recommended: Due to the high voltage and complex wiring involved, installation should ideally be performed by a qualified technician.
• Disconnect Power: Always ensure the battery is disconnected before performing any installation, wiring, or maintenance on the controller or motor.
• High Voltage: This controller operates at high voltages. Exercise extreme caution to avoid electric shock.
• Correct Wiring: Double-check all wiring connections against diagrams before applying power. Incorrect wiring can cause permanent damage to the controller, motor, or battery.
• Secure Mounting: Mount the controller securely in a location that is protected from moisture, excessive heat, and physical impact. Ensure adequate airflow for cooling.
• Avoid Water Exposure: The controller is not waterproof. Protect it from rain, splashes, and submersion.

5. Setup

5.1 Physical Installation

Mount the VOTOL EM100GTS controller to a stable surface on your electric vehicle. Ensure the mounting location provides sufficient ventilation for heat dissipation, especially considering the controller's heat sink design. The controller dimensions are 172mm (Length) x 105mm (Width) x 56mm (Height).

5.2 Wiring Connections

Connect the wiring harness to the controller and then to your motor, battery, throttle, brakes, and other accessories. Refer to the specific wiring diagram provided with your vehicle or motor for precise connections. Key connections include:

• Battery Power: Connect the main positive and negative terminals from your 60V-84V battery.
• Motor Phase Wires: Connect the three phase wires (U, V, W) from the controller to the corresponding motor phase wires.
• Hall Sensor Wires: Connect the Hall sensor wires from the motor to the controller's Hall plug.
• Throttle: Connect the throttle input (0-5V).
• Brake Inputs: Connect low brake (0V) and high brake (12V) signals as required.
• Ignition: Connect the ignition switch.
• Other Functions: Connect wires for Reverse, One-line/Hall Meter, Three Speed, Sport Model, Parking, Anti-Theft, Regen Charge, and Flux Weaken Current as per your vehicle's configuration.

5.3 Programming

The VOTOL EM100GTS controller is programmable via a USB cable and dedicated software (LD-EM-V3). This software allows for fine-tuning of various parameters to match your motor and riding preferences. Connect the USB programming cable to the controller's program port and to your computer.

The software interface includes several tabs for configuration:

• Page 1 (Basic Settings): Configure parameters such as Model (EM-100), Battery Voltage (e.g., 72V), Undervoltage, Overvoltage, Busbar Current (A), and Phase Current. You can also set throttle voltage limits and start settings (start torque, rate of rise/decline).

  

• Page 2 (Sport Mode Setup & Three-speed): Adjust Current-Limiting (A) and Flux-Weakening values for Sport mode. Configure three-speed settings (Low, Mid, High percentages) and enable/disable features like Downhill Electric Brake (HDC/HHC) and Speed Limit.

  

• Page 3 (Motor Setting & Output): Set motor-specific parameters like Pole pairs, Reversing speed limit, EBS ratio, and Motor type (e.g., surface-mount). Configure output options such as One-Line/Hall Speedometer, Cruise, and Moving vehicle booster settings.

  

• Display: Monitor real-time data including RPM, Voltage, Current, Controller Temperature, External Temperature, and view any active Fault Codes.

  

• Port Settings: Configure the input/output functions for various pins on the controller.

  

Always save your configuration after making changes and perform a test run in a safe environment.

6. Operating Instructions

Once the controller is correctly installed and programmed, operating your electric vehicle is straightforward:

• Power On: Turn the ignition key or switch to power on the vehicle.
• Throttle Control: Gently apply the throttle to accelerate. The controller will regulate power to the motor based on your throttle input and programmed settings (e.g., three-speed mode, sport mode).
• Braking: Use the vehicle's brake levers. The controller supports both low brake (0V) and high brake (12V) inputs, and can be configured for regenerative braking (Regen Charge) if enabled.
• Speed Modes: If configured, switch between the three-speed modes (Low, Mid, High) or activate Sport Mode for enhanced performance.
• Parking/Anti-Theft: Utilize the parking and anti-theft functions if they have been wired and enabled during programming.

7. Maintenance

Regular maintenance helps ensure the longevity and optimal performance of your VOTOL EM100GTS controller:

• Keep Clean: Periodically clean the exterior of the controller, especially the heat sink fins, to ensure efficient cooling. Use a dry, soft cloth.
• Inspect Connections: Regularly check all wiring connections for tightness and signs of corrosion or damage. Loose connections can lead to overheating or intermittent operation.
• Avoid Moisture: Ensure the controller remains dry. If it gets wet, disconnect power immediately and allow it to dry completely before reconnecting.
• Software Updates: Check the manufacturer's website periodically for any available software updates for the LD-EM-V3 programming tool or controller firmware.
• Environmental Protection: Protect the controller from extreme temperatures and direct sunlight when the vehicle is parked.

8. Troubleshooting

If you encounter issues with your controller, consider the following troubleshooting steps:

• No Power/No Response:
  • Check battery connections and ensure the battery is charged.
  • Verify the ignition switch is functioning correctly.
  • Inspect all main power cables for damage.
• Motor Not Running/Erratic Behavior:
  • Check all motor phase wires and Hall sensor connections.
  • Ensure the throttle is connected correctly and providing a valid signal (0-5V).
  • Connect to the LD-EM-V3 software and check the 'Display' tab for any active 'Fault Code' messages.
  • Review your programming settings (Page 1, 2, 3) to ensure they match your motor and vehicle configuration.
• Overheating:
  • Ensure the controller is mounted in a well-ventilated area and the heat sink is clear of obstructions.
  • Check for excessive load on the motor or incorrect programming parameters (e.g., current limits).
• Brakes Not Working:
  • Verify brake switch connections (Low Brake 0V, High Brake 12V).
  • Check programming settings related to braking.

For persistent issues, consult the detailed fault codes and diagnostic information within the LD-EM-V3 software or contact technical support.

9. User Tips

• Start with Default Settings: When first setting up, it's often best to use conservative or default programming values and gradually adjust them as you become familiar with the controller's behavior and your motor's characteristics.
• Document Your Settings: Before making significant changes to the controller's programming, save your current configuration. This allows you to revert to a known working state if issues arise.
• Test in a Safe Environment: After any programming changes or wiring modifications, always test the vehicle in a controlled and safe environment before full operation.

10. Warranty and Support

For warranty information, technical support, or service inquiries, please contact the seller or manufacturer directly. Keep your purchase receipt and product model number (EM100GTS 72360S) readily available when seeking support.