1. Introduction
This manual provides essential information for the installation, operation, maintenance, and troubleshooting of the DKYS DK72350 Intelligent Debugging Programming Controller. This brushless DC controller is designed for electric motorcycles, offering advanced control and programming capabilities.
Video 1: Overview of the DKYS DK72350 Brushless DC Controller, showcasing its design, heat sink, and internal components.
2. Specifications
| Feature | Detail |
|---|---|
| Brand | DKYS |
| Model Number | DKYS DK72350 |
| Type | Brushless DC Controller |
| Voltage | 72V |
| Line Current | 120A |
| Phase Current | 350A |
| Adapt Motor Power | 1000-3000W |
| Max Speed (Theoretical) | 115 km/h |
| Origin | Mainland China (Jiangsu, China) |
| High-concerned chemical | None |
Package Dimensions & Weight:
- Length: 24 cm
- Width: 18 cm
- Height: 13 cm
- Weight: 4.8 kg
3. Setup Instructions
Proper installation is crucial for the safe and efficient operation of your DKYS DK72350 controller. Please follow these guidelines carefully.
3.1 Unpacking and Inspection
- Carefully remove the controller and all accessories from the packaging.
- Inspect the controller for any visible damage. Do not proceed with installation if damage is found.
- Verify that all components listed in the package contents are present.
Figure 1: DKYS DK72350 controller and included wiring harness.
3.2 Mounting the Controller
- Choose a secure location on your electric motorcycle that is protected from direct water exposure and excessive vibration.
- Ensure adequate airflow around the controller's heat sink for optimal cooling.
- Use appropriate fasteners to securely mount the controller.
Figure 2: The controller's heat sink, designed for efficient thermal management.
3.3 Wiring Connections
The controller comes with a wiring harness for connecting to the motor, battery, throttle, and other components. Refer to the labels on the wiring harness and the controller for correct connections.
- Motor Phase Wires: Connect the three thick wires from the controller to the corresponding motor phase wires (U, V, W).
- Hall Sensor Wires: Connect the smaller Hall sensor wires from the motor to the designated connector on the harness.
- Battery Power: Connect the main positive and negative battery cables to the controller's power terminals. Ensure correct polarity.
- Ignition/Key Switch: Connect the ignition wire to the vehicle's key switch.
- Throttle: Connect the throttle signal, power, and ground wires.
- Brake Levers: Connect the brake signal wires.
- Other Signals: Connect any additional signals such as speed sensor, reverse, cruise control, etc., as per your vehicle's requirements and the controller's capabilities.
Figure 3: The comprehensive wiring harness with clearly labeled connectors for various functions.
3.4 Initial Power-Up and Programming
After all connections are made, perform a preliminary check before applying full power.
- Double-check all wiring connections for security and correct polarity.
- The controller is an "Intelligent Debugging Programming Controller," meaning it requires software configuration. Connect the provided USB programming cable to the controller and a computer.
- Install the necessary software (not provided in this manual, typically available from the manufacturer or seller) on your computer.
- Follow the software instructions to configure motor parameters, throttle response, braking, and other settings.
- Start with conservative settings during initial testing.
Figure 4: Close-up of the USB programming cable integrated into the wiring harness for controller configuration.
4. Operating Instructions
Once the controller is correctly installed and programmed, operating your electric motorcycle will involve the following general steps:
- Power On: Turn the key switch to the ON position. The controller will perform a self-check.
- Throttle Control: Gently apply the throttle to initiate motor rotation. The response will depend on your programmed settings.
- Braking: Use the brake levers to slow down or stop. The controller may offer regenerative braking if configured.
- Monitoring: If your system includes a display, monitor battery voltage, speed, and other relevant parameters during operation.
- Safety: Always operate your electric motorcycle safely and in accordance with local regulations.
5. Maintenance
Regular maintenance helps ensure the longevity and reliable performance of your controller.
- Keep Clean: Periodically clean the exterior of the controller, especially the heat sink fins, to prevent dust and debris buildup that can hinder cooling. Use a soft, dry cloth.
- Inspect Connections: Regularly check all wiring connections for tightness and signs of corrosion or wear. Loose connections can lead to poor performance or damage.
- Environmental Protection: Ensure the controller remains protected from excessive moisture, extreme temperatures, and corrosive substances.
- Software Updates: Check with the manufacturer for any available firmware updates for the controller, which may improve performance or add features.
6. Troubleshooting
If you encounter issues with your controller, consider the following common troubleshooting steps:
- No Power:
- Check battery connections and ensure the battery is charged.
- Verify the ignition/key switch is functioning correctly.
- Inspect the main power fuse (if applicable) for continuity.
- Motor Not Responding to Throttle:
- Check throttle connections.
- Ensure the throttle is correctly calibrated in the programming software.
- Verify motor phase and Hall sensor connections.
- Erratic Motor Behavior:
- Re-check all motor wiring (phase and Hall sensors).
- Review controller programming settings for any incorrect parameters.
- Ensure no interference from other electronic devices.
- Overheating:
- Ensure the controller is mounted in a location with good airflow.
- Clean any debris from the heat sink fins.
- Check for excessive load on the motor or incorrect programming that might cause high current draw.
- Persistent Issues: If problems persist after basic troubleshooting, contact technical support.
7. User Tips
- Start with Default Settings: When first programming, it's often best to start with the manufacturer's recommended default settings or conservative values and adjust gradually.
- Backup Configurations: Always save a backup of your controller's configuration settings after successful programming.
- Professional Installation: If you are unfamiliar with electric vehicle wiring or controller programming, consider seeking professional assistance for installation and initial setup.
- Regular Checks: Periodically check the physical mounting and wiring connections to ensure they remain secure, especially after riding on rough terrain.
8. Warranty and Support
8.1 Warranty Information
The DKYS DK72350 controller comes with a 3-month warranty from the date of purchase. This warranty covers manufacturing defects and malfunctions under normal use. It does not cover damage caused by improper installation, misuse, accidents, unauthorized modifications, or natural disasters.
8.2 Technical Support
For technical assistance, programming guidance, or warranty claims, please contact the seller directly:
- WHATSAPP: +86 17352870921
- Email: w17770950324@gmail.com
When contacting support, please provide your product model (DKYS DK72350), purchase date, and a detailed description of the issue.
