1. Introduction
This manual provides detailed instructions for the installation, operation, maintenance, and troubleshooting of the JP 60V Dual Motor Controller. This controller is designed for use with specific electric scooter models including BOYUEDA, LAOTIE, YUME, Duotts D88, ES19, TI30, and ES18P. Please read this manual thoroughly before installation and use to ensure proper function and safety.
Important Note: If your scooter uses a controller from a different brand, compatibility is not guaranteed. Replacing it may lead to unexpected behavior. The manufacturer does not assume liabilities in such situations. Always contact support with your original accessory details if unsure.
2. Safety Information
Always observe the following safety precautions:
- Ensure the scooter is powered off and disconnected from the battery before performing any installation or maintenance.
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Handle electrical components with care to avoid damage or short circuits.
- Verify all connections are secure and correctly wired according to the diagrams provided.
- Do not attempt to modify the controller or its wiring.
- Keep the controller dry and away from moisture.
- If you are unsure about any step, seek professional assistance.
3. Package Contents
The package typically includes:
- JP 60V Dual Motor Controller (Quantity and specific amperage may vary based on order, e.g., 45A or 50A)
- Associated wiring harnesses
- (Optional, depending on variant) LCD Display unit
Please check all components upon receipt. If any items are missing or damaged, contact your seller immediately.
4. Specifications
| Feature | Detail |
|---|---|
| Voltage | 60V DC |
| Amperage Options | 45A, 50A (per controller) |
| Type | Brushless Motor Controller |
| Compatibility | BOYUEDA, LAOTIE, YUME, Duotts D88, ES19, TI30, ES18P Electric Scooters |
| Origin | Mainland China |
| High-concerned chemical | None |
5. Setup and Installation
This section outlines the general installation process for the JP 60V Dual Motor Controller. Due to variations in scooter models, some steps may differ. Always refer to the specific wiring diagram for your controller model (e.g., 60V 45A or 60V 50A).
5.1 General Installation Steps
- **Power Disconnection**: Ensure your electric scooter is completely powered off and the battery is disconnected before starting any work.
- **Access Old Controller**: Locate and carefully remove the existing motor controller(s) from your scooter. Note the existing wiring configuration if possible.
- **Mount New Controller**: Securely mount the new JP 60V Dual Motor Controller(s) in the designated location on your scooter.
- **Wiring**: Follow the specific wiring diagram provided for your controller model. Connect each wire carefully.
- **Double Check Connections**: Before reconnecting the battery, thoroughly inspect all wiring connections to ensure they are correct and secure. Loose connections can cause malfunctions or damage.
- **Reconnect Battery**: Carefully reconnect the scooter battery.
- **Initial Test**: Power on the scooter and perform a low-speed test in a safe environment. Check for proper motor function, brake response, and display readings.
5.2 Wiring Diagrams
Refer to the following diagrams for detailed wiring instructions based on your controller model. These diagrams illustrate the connections for various components such as power, motors, brakes, display, and switches.
Figure 1: JP 60V 50A Controller Wiring Diagram. This diagram shows connections for Motor three line, Power output line, Brake power off, Speed limited wire (one to front controller), Motor hall wire, Signal wire (to front controller), Dual drive wire (to single/dual switch), Power supply (to lights and horn), Power switch (to voltage key or remove), LCD display wire, and Power output line.
Figure 2: JP 60V 45A Controller Wiring Diagram. This diagram details connections for Controller A and Controller B. Controller A includes: Speed Limiting Wire (One to ECO Switch, One to Rear Controller), Brake power off (One to rear controller, One is to brake lever), Hall sensor (To Front Motor), Dual-drive wire (To single/dual switch), Signal wire (To rear controller), Phase wires (to front motor), and Power Cable (to battery outlet). Controller B includes: Brake lights wire (to brake lights), Brake power off (one to front controller), Hall sensor (to rear motor), Controller signal wire (to front controller), Speed Limiting Wire (to front controller), LCD display wire (Color to color), Power supply (to GPS tracker always have electricity), Power switch (to voltage key or remove), Power supply (to lights and horn), Phase wires (to rear motor), and Power cable (to battery outlet).
Figure 3: JP 52V 25A Controller Wiring Diagram. This diagram shows connections for Power Cable (to battery outlet), Speed Limited Wire (one to ECO switch, one to rear controller), Brake Power Off (one to brake level, one to rear controller), Signal Wire (to rear controller, color to color), Dual-drive Wire (to single/dual switch), and Phase Wires (to front motor).
6. Operating Instructions
Once the controller is correctly installed and tested, the operation of your electric scooter should function as designed. The controller manages power delivery to the motors based on your throttle input and other scooter controls.
- **Power On/Off**: Use the scooter's main power switch or key to turn the system on or off.
- **Throttle Control**: The controller translates your throttle input into motor speed. Apply throttle smoothly.
- **Braking**: The controller integrates with the scooter's braking system, often including regenerative braking or motor cut-off functions when brakes are applied.
- **Display (if applicable)**: If your setup includes an LCD display, it will show information such as speed, battery level, and mode settings, which are managed by the controller.
- **Speed Limiting/ECO Mode**: If your scooter has a speed limiting or ECO mode switch, the controller will adjust power output accordingly.
- **Dual/Single Drive**: If your scooter has a dual/single drive switch, the controller will activate or deactivate one of the motors as selected.
7. Maintenance
The JP 60V Dual Motor Controller is designed for durability and requires minimal maintenance. However, regular checks can prolong its lifespan and ensure safe operation:
- **Keep Clean**: Periodically clean the exterior of the controller to prevent dust and debris buildup, which can affect heat dissipation.
- **Check Connections**: Annually or bi-annually, inspect all wiring connections to ensure they remain tight and free from corrosion.
- **Avoid Moisture**: Protect the controller from water exposure. While some scooters may have water resistance, direct exposure to heavy rain or submersion can damage the electronics.
- **Temperature Management**: Ensure the controller has adequate airflow to prevent overheating, especially during prolonged high-power usage.
8. Troubleshooting
If you encounter issues with your scooter after installing the JP 60V Dual Motor Controller, consider the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Scooter does not power on. | Loose battery connection, faulty power switch, controller not receiving power. | Check battery connections. Verify power switch functionality. Ensure controller power cable is securely connected. |
| Motor not responding to throttle. | Loose throttle connection, faulty throttle, motor hall sensor issue, signal wire disconnected. | Inspect throttle wiring. Check motor hall sensor connections. Ensure signal wires are correctly connected as per diagram. |
| Inconsistent speed or jerky acceleration. | Loose phase wire connections, damaged motor wires, incorrect controller settings (if adjustable). | Verify all phase wire connections are tight. Inspect motor wires for damage. Consult scooter's specific manual for controller settings if applicable. |
| Brakes not cutting off motor power. | Brake power off wire disconnected or faulty brake lever switch. | Check brake power off wire connection to the controller. Test brake lever switch. |
| Display not working (if applicable). | Loose display wire, faulty display unit. | Ensure LCD display wire is securely connected (color to color). |
If troubleshooting steps do not resolve the issue, contact your seller or a qualified technician for further assistance.
9. User Tips
- **Compatibility Check**: Before purchasing, always confirm the voltage and amperage of your original controller to ensure you select the correct replacement.
- **Professional Installation**: If you are not experienced with electrical wiring, consider having the controller installed by a professional to avoid damage to the scooter or the new controller.
- **Wire Management**: After installation, ensure all wires are neatly routed and secured to prevent them from being pinched or damaged during scooter operation.
10. Warranty and Support
For warranty information and technical support, please refer to the terms provided by your original seller or contact them directly. Keep your purchase receipt as proof of purchase.
If you have any questions after receiving the package, please contact the seller first for prompt assistance.
