1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your ZUIDID E-Bicycle Controller. This versatile controller is designed for electric bicycles and scooters, supporting various voltage and wattage configurations for brushless motors. Please read this manual thoroughly before installation and use to ensure safe and optimal performance.
2. Specifications
| Feature | Description |
|---|---|
| Brand Name | ZUIDID |
| Type | Controller |
| Rated Voltage | 24V / 36V / 48V (Universal) |
| Maximum Current | 26 ± 1A |
| Motor Compatibility | 24V500W, 24V750W, 36V500W, 36V750W, 48V500W, 48V750W brushless motors (with or without Hall sensors) |
| Wave Type | Sine Wave / Square Wave (Three-mode) |
| Material | Aluminum alloy (with groove for heat dissipation) |
| Origin | Mainland China |
3. Setup and Installation
3.1 Safety Precautions
- Always disconnect the battery before making any electrical connections.
- Ensure all connections are secure and properly insulated to prevent short circuits.
- Verify voltage compatibility between the controller, battery, and motor.
- Installation should ideally be performed by a qualified technician.
3.2 Component Identification
Refer to the diagram below to identify the various connectors on your controller:
- Phase Line (3-pin): Connects to the motor's phase wires.
- Hall Line (6-pin): Connects to the motor's Hall sensor wires (if applicable).
- Throttle (3-pin): Connects to the throttle unit.
- PAS (3-pin): Connects to the Pedal Assist System sensor.
- Battery (2-pin): Connects to the battery's power output.
- Display (5-pin): Connects to the display unit.
- Light (2-pin): Connects to the bicycle's light system.
- Self-study (1-pin): Used for motor self-learning function.
- E-brake (2-pin): Connects to the electronic brake levers.
3.3 Wiring Instructions
Follow these steps to connect your controller. For a visual guide, please refer to the video demonstration below.
- Battery Connection: Connect the 2-pin Battery connector from the controller to your e-bike battery. Ensure correct polarity (red to positive, black to negative).
- Motor Phase Lines: Connect the three 3-pin Phase Line connectors from the controller to the corresponding phase wires of your brushless motor.
- Motor Hall Lines (if applicable): If your motor has Hall sensors, connect the 6-pin Hall Line connector from the controller to the motor's Hall sensor wires. If your motor is 'no hall', this connection may not be used.
- Throttle: Connect the 3-pin Throttle connector to your e-bike's throttle unit.
- Display: Connect the 5-pin Display connector to your e-bike's display unit. Note: The display unit must match the No.2 communication protocol for proper functionality.
- PAS Sensor (optional): Connect the 3-pin PAS connector to your Pedal Assist System sensor.
- Lights (optional): Connect the 2-pin Light connector to your e-bike's lights.
- E-Brake (optional): Connect the 2-pin E-brake connectors to your electronic brake levers.
- Self-Study Function: After all other connections are made, connect the 1-pin Self-study wires. This allows the controller to learn the motor's parameters. Once the motor starts spinning correctly, disconnect the self-study wires. If the motor spins in the wrong direction, disconnect, reconnect, and try again.
3.4 Video Demonstration: Wiring and Testing
This video demonstrates the wiring process and initial testing of the controller with a motor and display unit.
4. Operating Instructions
- Power On: Once all connections are secure, turn on the main power switch of your e-bike. The display unit should illuminate.
- Throttle Control: Gently twist the throttle to engage the motor. The speed will increase with further twisting.
- Pedal Assist (PAS): If a PAS sensor is installed, pedaling will activate motor assistance. The level of assistance can typically be adjusted via the display unit.
- Braking: Engaging the electronic brake levers will cut off motor power and activate braking.
- Display Functions: Your display unit will show information such as speed, battery level, and possibly trip distance or power mode. Refer to your display unit's specific manual for detailed operation.
5. Maintenance
- Regular Inspection: Periodically check all electrical connections for tightness and signs of wear or corrosion.
- Cleaning: Keep the controller and its connectors clean and free from dust, dirt, and moisture. Use a dry cloth for cleaning.
- Avoid Water Exposure: While the controller is designed to be robust, avoid submerging it in water or exposing it to heavy rain for prolonged periods.
- Heat Dissipation: Ensure the controller's aluminum alloy casing is not obstructed, allowing for proper heat dissipation.
6. Troubleshooting
- Motor Not Responding:
- Check all power connections, especially the battery and motor phase lines.
- Ensure the display unit is powered on and functioning.
- Verify the throttle connection.
- If the motor has Hall sensors, check the Hall line connection.
- Perform the self-study procedure again.
- Controller Overheating:
- The controller has a built-in thermal overload protection. If the temperature is too high, it will cut off current to protect the system. Allow it to cool down.
- Ensure adequate airflow around the controller for proper heat dissipation.
- Check for excessive load on the motor or incorrect motor parameters.
- Display Not Working:
- Ensure the display is correctly connected to the 5-pin connector.
- Verify that the display unit is compatible and uses the No.2 communication protocol.
- Check the power supply to the display.
- Motor Spins in Wrong Direction:
- Disconnect the 1-pin Self-study wires, then reconnect them to re-initiate the motor learning process.
7. User Tips
- For optimal performance, ensure your battery is fully charged before each ride.
- Always use compatible components (motor, battery, display) with the controller's specifications.
- Regularly check tire pressure and brake functionality for a safe riding experience.
8. Warranty and Support
For any issues or questions not covered in this manual, please contact the seller or manufacturer's customer support. Keep your purchase receipt for warranty purposes.
