VOTOL Controller EM150 EM150S EM-150 User Manual

4.1 Software Installation (Windows 7/10 Only)

The controller software supports Windows 7 and Windows 10 operating systems. iOS and XP systems are not supported.

1. USB Driver Installation:
   1. Download and decompress the "USB-to-serial-win 10-20150814" file. For abroad PC systems, ensure no Chinese characters are present in the file name.
   2. Choose the suitable driver for your computer (e.g., 32-bit or 64-bit Windows 7/10).
   3. After installation, connect the USB cable between the controller and your computer. If connection issues arise, right-click "My Computer" on the desktop, then "Device Manager" > "Port (COM & LPT)". Locate the COM port with an exclamation mark, right-click, and select "Update Software".
   4. Browse your computer to find the driver software. Select "Prolific USB-to-Serial Comm Port Version: 3.3.2.102 [2008/9/24]". Click "Next" to install and close the software upon completion.
2. Software Installation (Newer Versions):

   For versions from 2018.7 onwards, only the USB driver needs to be installed. The software can then be opened directly.

   1. Copy the TeeChart5.ocx file to the C drive root directory.
   2. Click "setup Register File Finish Installation" (allow installation if prompted). After installation, run the EM_V3 program.
3. Bluetooth Serial Port Connection (Optional):

   If using a VOLT company Bluetooth series port connection module:

   1. Connect the Bluetooth module and power it on.
   2. Pair with the Bluetooth series port from your device's Bluetooth list.
   3. Input the password "1234" to connect.
4. Troubleshooting Software Installation:

   If the software fails to install, try changing your computer system language to English or Chinese. This issue can occur due to C++ runtime differences in various PC systems, especially those not in English.
5. Software COM Port Not Found:

   If your computer shows COM port information but the software doesn't, it's likely a driver issue. Re-research drivers or install the "FT232 Driver" file.

4.2 Wiring Connection

Proper wiring is crucial for the safe and correct operation of the controller. Refer to the diagrams below for detailed connection instructions. If you are unsure about any connections, please consult with a professional.

4.3 Controller Connection and Self-Learning

1. Power on the controller, but keep the ignition off.
2. If your controller has CAN functionality, click "CAN enable" in the software, then click "Open".
3. Click the "researching" button at the bottom of the software. Choose the correct series port from the device COM list (usually the last one). Click "open series port"; the device should show "connected".
4. Turn on the ignition. Click "connect" controller (it is recommended to click more than twice).
5. The voltage parameter can be freely chosen based on the controller's hardware support.

Controller Self-Learning Work: The controller learns "hall angle shift" data. For other data, refer to the provided guides or consult the manual PDF.

5.1 Battery Voltage Adjustment

The voltage parameter can be freely chosen under the hardware support of the controller. Adjusting the voltage parameter without proper hardware support will damage the controller.

5.2 Controller Under-voltage and Soft Under-voltage Adjustment

Fill in the required under-pressure protection parameters and software under-pressure parameters:

• Under voltage value: The threshold at which the controller enters hardware under-voltage protection. Setting range is based on battery under-voltage value.
• Soft under-voltage: Generally under-voltage + 3V.
• Undervoltage variation: This is the range for under-voltage recovery. For example, if set to 63V for overvoltage and 1V for undervoltage variation, the controller will recover at 64V.

Note: It is not recommended to change under-voltage settings as it can easily damage the battery and reduce its life due to excessive discharge.

5.3 Controller Battery Current and Phase Current Limited Adjustment

Battery Current Adjustment:

Warning: Do not set values outside the specified range, as this will damage the controller.

Phase Current Limited Value: This limits the motor torque output. The biggest value is full power output, and adjustment is generally not suggested.

5.4 Throttle Voltage Adjustment (Max 5.5V)

• Low protection value: Indicates a throttle error.
• Starting voltage: The motor starts running when this value is reached.
• End voltage: The controller considers full voltage reached. It is recommended to set this 0.2V lower than the actual torque voltage.
• High protection value: If the throttle voltage exceeds this, a torque fault will be displayed.

5.5 Start Setting Adjustment (For Tricycle Gear Box Only)

• Start torque: Used for gear combination.
• Combined torque: Force for lifting after gear clearance is combined.
• Upward slope: Upward slope of motor torque.
• Downward slope: Downward slope of motor torque.

5.6 Controller and Motor Temperature Protection Adjustment

• Start: When the temperature reaches this value, the controller enters temperature protection mode and limits motor torque.
• Over temp: Cuts off motor torque output.
• Recovery: When the motor temperature drops below this value, you can re-twist the throttle to restore motor motivation.
• Max: The maximum motor temperature is 150°C.

5.7 Sport Mode (S Gear) Settings

Parameters for sports mode:

• Current-Limiting (A): Boost function. When the controller enters S gear, battery current increases for more powerful climbing.
• Flux-Weakening Value: When the controller enters S gear, the motor will be in flux weakening condition, increasing speed. Setting range depends on motor condition.
• Automatic Logout Enablers:
  • Logout time (S): e.g., 30 seconds after entering S gear, auto-exit S gear sport mode.
  • Recovery time (S): Auto-exit S gear, recover from S gear time. Invalid if S gear is pressed during recovery.
• Downhill Electric Brake Assist (HDC/HHC):
  • HDC Enable: Makes RPM stable for constant speed. If battery voltage is low, ensure max RPM is not lower than before.
  • HDC Lowrst Speed: If your motor is 1000rpm, set this between 1000rpm and 1200rpm (real RPM * 110%~120%).
• Speed Limit Setting:
  • Speed Limited Enable: Activates speed limit function.
  • Speed Ratio (%): Adjustable from 0 to 100 percent. Can be customized via a sport wire to speed limit function.

Warning: Setting flux weakening values out of range can cause motor demagnetization and damage.

5.8 Flux Weakening & Three Speed Setting

Flux Weakening:

• Flux Weakening Compensation Factor: Generally not recommended to change.
• Flux Weakening Value (Blue): Data for motor running noise and shock adjustment. If the motor has shock, set this value lower than 800. It will not reduce speed.
• Flux Weakening Value (Red): Adjustable by motor.
• Mid Flux-Weakening Value: Data for motor start speed.
• Capacitor Protection Value (Yellow): Modification is not recommended.

Three Speed Setting:

The three-gear ratio range is 0-100%.

• Three Speed Modes: Two modes are available: by button and by switch.
• Three Gear Default Gear: Enables for point switch. Changes controller default gear when powered on.
• Soft Start Enable: Opens controller as soft start. Closing it results in hard start. Soft start grade ranges from 1-16 (lower value means softer start).

5.9 Motor Setting

• Motor Pole Pairs: Fill in correctly for accurate motor speed (RPM) acquisition.
• Motor Type (Mid-drive motor): Fill in the correct motor magnet type for motor matching.
• Hall Phase Shift Angle (Degrees) Adjustment: Fill in the range (-180~180) for controller and motor phase adjustment. You can test with -180, -120, -60, 0, 60, 120, 180. To change running direction, add or subtract 120 from your current data.

Note: For Wheel Hub motors, use surface mount. QS can set 120 hall shift for V3 motors.

5.10 Speedometer Output

The controller offers two types of speedometer data output: ONE-LIN speedometer and Hall speedometer. The choice depends on the vehicle's speedometer. The ONE-LIN communication uses a fixed agreement.

5.11 Moving Assist and Cruising Function

• Moving Assist Function: Valid after checking. The speed of the transfer assist is a percentage of the motor base speed (default 10%). Moving assist torque value is 320, corresponding to 9-10N.m (varied by motor characteristics).
• Cruise Function: Valid after checking. To activate, maintain a certain throttle angle for more than 8 seconds. Any operation (brake, turning handle) will exit cruise mode.

5.12 Dual Voltage Adaptive Function

This function allows automatic switching between low and high voltage modes based on the battery voltage.

5.13 Reversing, EBS Setting, Low Brake Selection, Starting Safety Switch Function

• Reversing Speed Limit (%): Adjustable from 0-100%. Do not exceed 30% to avoid accidents.
• EBS Ratio (%): Adjustable from 0-100% for electronic brake force.
• Low Brake Enable: When enabled, the original single-branch power-down function becomes a low-level brake.
• Safety Switch Function: When using, press the safety switch before starting the vehicle.

5.14 Controller Status Display

The software provides a real-time display of the controller's working status, including RPM, Voltage, Current, Fault Code, Hall Fault, Brake status, Motor Hall status, Undervoltage, Overvoltage, Overcurrent, Controller Failure, Out of Control, Overheating, and temperature readings.

5.15 Port Setting Interface

• Hall Speed Setting: For EM30S/50S/100S/150S models, if using a Hall Type Display, select "IO" and "F", "13: Hall". For EM200S models, select "IO" and "F", "13: Hall".
• Three Speed Setting:
  • For EM30S/50S/100S/150S models: Three speed is achieved by switch. PD0-low speed, PD1-high speed, PB3-middle speed.
  • For EM200S models: Three speed is achieved by switch. PA0-low speed, PB2-high speed.
  • For EM30S/50S/100S/150S models: Three speed is achieved by button. PD1-egear button, PB3-sport mode.
  • For EM200S models: Three speed is achieved by button. PA0-empty, PB2-egear button.

5.16 Remote Operation (Software Update and Debugging)

This function should only be used under the guidance of a company engineer.

It is used for software updates, current calibration, and remote operation.

1. Click "opening file" > choose the ".bin" file > Click "download". The file import is successful when it shows 100%.

If the controller cannot communicate, try brushing the bottom program:

1. Close ignition.
2. Open the debugging software, open the serial port (no need to click "connect").
3. Open ignition, open the "CAN.Bin" file.
4. Connect normally.

7.1 Matching a New Brand Controller

For simple testing and adjustment, ensure the connection is correct for phase wire and Hall wire. Set the correct data for motor poles and Hall shift. Hall shift is important and can be tested from -180 to 180. Refer to section 5.9 for guidance.

Note: The most controllers we sell are universal versions, not customized for a specific brand. Therefore, after installation, some auxiliary functions of the original vehicle may not work normally (such as speedometer display). Most functional interfaces need to be modified, not plug and play. Before refitting, carefully check the function line on the original vehicle and the communication signal of the speedometer.

7.2 Parking Function Setting

The parking function can be activated by a button press or a switch. Set the PC14 port in the software. Choose "SW" & "F" and briefly touch your parking wire to any GND wire (or connect a button). The "P" gear should appear on your display, indicating the parking function is active. Alternatively, choose "LA" & "F" and connect your parking wire and GND to a switch. The "P" gear will show when the switch is activated.

7.3 Stop Twist Throttle, Motor Still Running

If the motor continues to run after releasing the throttle, try adjusting the Hall shift data. Experiment with values like -60 to 120, and refer to section 5.9 for guidance.

7.4 How to Set Speed Limit

Choose an unused function wire (e.g., sport wire), assign it to PB3 port in the software, and select "24: speed_limit". Then, in page 2 of the software, set your desired speed limit percentage. If you want a permanent speed limit without a switch, connect the speed limit wire directly to GND.

7.5 Controller Fault or Hall Error

If the controller works fine on the road but the software shows a controller fault when connected to a PC, there is no problem with the controller. However, if the controller cannot run on the road and the software shows a Hall error (with Hall connected), check the plug connection first. If the connection is fine, test the Hall voltage from the motor. The Hall positive and negative should be around 5V, and the three Hall signal wires should have the same voltage. If not, the motor Hall is likely faulty or damaged.

Warning: All controllers are tested before shipping. Hall port damage is usually caused by incorrect wiring of the Hall plug or different color sequences in motor Hall plugs. Incorrect connection of Hall negative and positive will damage it quickly upon power-on.

7.6 Test Controller Hall Error

If a controller Hall fault occurs and all connections (battery, ignition, motor phase wire, motor Hall plug) are correct, you can test the controller Hall voltage:

1. Connect the positive and negative of the battery to the controller.
2. Turn on ignition and power on.
3. Measure the positive and negative poles of the controller Hall. It should be around 5V. If the reading is different (e.g., 0.9V), the Hall port is damaged.

7.7 Reverse Function Not Working

If your reverse function wire is connected correctly and your display shows "R" gear but the motor does not reverse, check your software parameters. Sometimes there are two ports for reverse; remove one to empty, and it should work.