VOTOL Electric Scooter Controller Cable Harness User Manual

1. Product Overview

This manual provides detailed instructions for the installation, operation, and maintenance of the VOTOL Electric Scooter Controller Cable Harness. These harnesses are designed for various VOTOL EM series controllers, including EM25, EM30, EM50, EM100, EM150, EM50-4, and EM80, as well as GTS SP 7235, 7255, and 72350 models. The cable harness facilitates the connection between your electric scooter's controller and various components, ensuring proper functionality.

2. Specifications

3. Setup and Installation

Careful installation of the cable harness is crucial for the proper functioning of your electric scooter controller. Refer to the detailed wiring diagram below and the specific harness variant for your controller model.

3.1 General Wiring Diagram

Connection Points Explained:

• Hall Signal Line: Connects to the motor's Hall sensors for position feedback.
• Gray Purple Electric Door Lock Cable: Connects to the scooter's electric door lock system.
• One Key Repair Line: Used for diagnostic or repair functions, often a single button press.
• Pink Green Black Turn Signal: Connects to the turn signal system.
• Three Speed Lines (Black, White, Green, White and Black): These lines control the scooter's speed modes. The black and white lines are effective when the shift gear is clicked.
• Computer Debugging or Bluetooth Debugging Jack: Port for connecting to a computer or Bluetooth module for controller configuration and diagnostics.
• Low Brake or Offset Line: Connects to the low-level brake signal.
• S in Passing Gear: Specific connection for a passing gear function.
• Purple High Brake Wire: Connects to the high-level brake signal.
• Anti-theft Positive and Negative Wire: Power connections for the anti-theft system.
• Anti-theft Cable: Data or signal cable for the anti-theft system.
• Learning Wires: Two specific wires that, when inserted together, initiate the motor phase angle learning process.

3.2 Specific Harness Variants

Ensure you use the correct cable harness variant for your VOTOL controller model:

4. Operating Instructions

Once the cable harness is correctly installed, the controller can be operated according to its specific model's instructions. Key operational aspects related to the harness include:

• Motor Phase Angle Learning: To ensure optimal motor performance, connect the two designated 'learning wires' (as shown in Figure 2) to allow the controller to learn the motor's phase angle. Disconnect them once the learning process is complete.
• Speed Control: The three speed lines enable different speed modes. Ensure the black and white lines are correctly connected and activated via the scooter's shift gear for speed adjustments.
• Debugging and Configuration: Use the computer or Bluetooth debugging jack to connect to the controller for advanced settings, diagnostics, and firmware updates. Refer to your controller's software manual for detailed instructions.
• Braking System: Verify connections for both low brake and purple high brake wires to ensure responsive and safe braking.
• Anti-theft System: Ensure the anti-theft positive/negative wires and the anti-theft cable are properly connected for the system to function.

5. Maintenance

To ensure the longevity and reliable performance of your VOTOL controller cable harness, follow these maintenance guidelines:

• Regular Inspection: Periodically check all connections for signs of wear, corrosion, or looseness. Ensure all connectors are fully seated.
• Cleanliness: Keep the harness and connectors free from dirt, dust, and moisture. Use a dry, soft cloth for cleaning. Avoid using harsh chemicals.
• Cable Routing: Ensure cables are routed away from moving parts, sharp edges, and heat sources to prevent damage. Avoid excessive bending or pinching of wires.
• Environmental Protection: If operating in wet or dusty conditions, ensure all connections are properly sealed or protected to prevent ingress.

6. Troubleshooting

If you encounter issues with your electric scooter's controller or related functions, consider the following troubleshooting steps:

• No Power/Controller Not Responding: Check the electric door lock cable (gray purple) and ensure it has a secure connection. Verify the main power supply to the controller.
• Motor Not Functioning Correctly: Ensure the Hall signal line is properly connected. If the motor is new or has been replaced, perform the motor phase angle learning procedure using the learning wires.
• Incorrect Speed Modes: Inspect the three speed lines (black, white, green, white and black) for proper connection and ensure the shift gear mechanism is functioning.
• Braking Issues: Check the low brake, offset line, and purple high brake wire connections. Ensure they are secure and free from damage.
• Anti-theft System Malfunction: Verify the anti-theft positive/negative wires and the anti-theft cable connections.
• General Connectivity Problems: Use the computer or Bluetooth debugging jack to connect to the controller and check for error codes or diagnostic information.

If problems persist after checking these points, it is recommended to consult a qualified technician or contact customer support.

7. User Tips

• Always ensure all connections are secure and properly insulated before operating the scooter to prevent short circuits or electrical hazards.
• Refer to your specific VOTOL controller manual for detailed programming and advanced settings, as this harness provides the physical connections.
• When debugging, ensure the correct software or app is used for your controller model to avoid compatibility issues.
• Take photos of your existing wiring before disconnecting anything to aid in reassembly.

8. Warranty and Support

This VOTOL Controller Cable Harness is guaranteed to be 100% New and Original. Shenzhen CHY Electronic Technology Co., Ltd. maintains a strict quality management system to ensure the reliability of its products. Every component undergoes rigorous testing, including visual inspection, acetone wipe tests, X-ray tests, ROHS tests, De-cap tests, and electrical tests when necessary.

For any questions, technical support, or further information regarding our products, please contact us:

• Contact: CHY Electronic Technology Co., Ltd.
• WhatsApp: +86 19310036253