Ebike Brushless Motor Controller

Important Considerations Before Use

This manual provides essential information for the installation, operation, and maintenance of your Ebike Brushless Motor Controller Model X062-AXD003. Please read it thoroughly before attempting any installation or use.

• Protocol Compatibility: This controller utilizes the KDS communication protocol. Ensure your display meter is compatible with the KDS protocol. Incompatibility may result in error codes on the display.
• Pre-Purchase Verification: It is highly recommended to contact customer service before purchasing. Provide clear photos of your original controller's label and all connectors. This helps verify compatibility and ensures you receive the correct model.
• Order Confirmation: After placing an order, monitor your email for an order confirmation within 12 hours. Promptly respond to this email to confirm your order details. Failure to respond will be interpreted as agreement to the order and acceptance of the no-return policy for incompatible items.

Specifications

Figure 1: Controller Model and Specifications Label (X062-AXD003, 48V, 25A, KDS)

Figure 2: Controller Dimensions (113mm x 63mm x 33mm)

Setup and Installation

Proper installation is crucial for the safe and efficient operation of your ebike. If you are unsure about any steps, please consult a qualified technician.

Figure 3: Ebike Brushless Motor Controller Wiring Diagram

Refer to Figure 3 for the connection points on the controller:

1. Power Input (1): Connect the main power supply from your ebike battery to these red and black wires. Ensure correct polarity (red to positive, black to negative).
2. Brake Levers (2): Connect your ebike's brake lever wires to these white and red wires. These typically cut power to the motor when brakes are applied.
3. Motor Phase Wires (3): Connect the three thick motor phase wires (typically yellow, green, blue) from your ebike motor to this 3-pin connector. Match colors if possible.
4. Display/Throttle (4): Connect your ebike's display unit and/or throttle grip to this multi-pin connector. This connection handles communication for speed, battery level, and throttle input.
5. Pedal Assist Sensor (PAS) (5): Connect the pedal assist sensor (PAS) to this 3-pin connector. This sensor detects pedaling motion to provide motor assistance.
6. Motor Hall Sensor Wires (6): Connect the motor's Hall sensor wires to this multi-pin connector. These sensors provide feedback on motor position for smooth operation.

Connector Modification: If your existing ebike connectors do not match those on the controller, modification may be required. This involves cutting and splicing wires. If you are not proficient in electrical wiring, seek professional assistance. Customer service can provide guidance on connector modification.

Operating Instructions

Once the controller is correctly installed and all connections are secure, you can begin operating your ebike. The controller manages the power delivery to the motor based on your input from the throttle and pedal assist sensor, and communicates with the display unit.

1. Power On: Turn on your ebike's battery and then the display unit. The display should power on and show relevant information.
2. Throttle Control: Gently twist the throttle grip to engage the motor. Start with low throttle input to get accustomed to the power delivery.
3. Pedal Assist: Begin pedaling, and the pedal assist sensor will signal the controller to provide motor assistance. The level of assistance is typically adjustable via your display unit.
4. Braking: Applying the brakes will cut power to the motor, ensuring safe stopping.
5. Display Functions: Use your ebike's display unit to monitor speed, battery level, assist mode, and other relevant parameters. Refer to your display unit's manual for specific functions.

Maintenance

To ensure the longevity and optimal performance of your brushless motor controller, follow these general maintenance guidelines:

• Keep Dry: Protect the controller from water and excessive moisture. While it may have some water resistance, prolonged exposure can cause damage.
• Cleanliness: Periodically clean the exterior of the controller with a dry or slightly damp cloth. Avoid using harsh chemicals or solvents.
• Inspect Connections: Regularly check all electrical connections for tightness and signs of corrosion or wear. Loose connections can lead to intermittent power or damage.
• Avoid Overheating: Ensure the controller has adequate ventilation and is not covered or obstructed, especially during prolonged use or in hot weather. Overheating can reduce performance and lifespan.
• Secure Mounting: Ensure the controller is securely mounted to prevent vibrations and physical damage during riding.

Troubleshooting

If you encounter issues with your ebike's motor system, consider the following troubleshooting steps:

• Display Error Codes: If your display shows error codes, first verify that your display unit is compatible with the KDS protocol. Incompatible protocols are a common cause of errors. Consult your display's manual for specific error code meanings.
• No Power/Intermittent Power:
  • Check battery charge level.
  • Inspect all power connections (Connection 1 in Figure 3) for looseness or damage.
  • Ensure the ebike's main power switch and display are turned on.
• Motor Not Responding to Throttle/PAS:
  • Verify throttle and PAS connections (Connections 4 and 5 in Figure 3).
  • Check motor phase and Hall sensor connections (Connections 3 and 6 in Figure 3).
  • Ensure brake levers are not engaged, as they cut motor power.
• Unusual Motor Noise/Rough Operation:
  • Check motor phase and Hall sensor connections for proper seating and damage.
  • Ensure the motor itself is functioning correctly.
• Controller Overheating: If the controller feels excessively hot, reduce load on the motor, allow it to cool, and ensure it has proper ventilation.

If troubleshooting steps do not resolve the issue, please contact customer service with a detailed description of the problem and any error codes displayed.

User Tips

• Always Verify Model: Before purchasing a replacement controller, always take photos of your existing controller's label and connectors. This is the most reliable way to ensure compatibility and avoid issues.
• Understand Protocols: Be aware that different ebike components (like controllers and displays) use different communication protocols. A mismatch will prevent proper function.
• Professional Installation for Modifications: If your new controller's connectors do not match your ebike's wiring, and modifications are necessary, consider having a professional ebike technician perform the work to prevent damage.

Warranty and Support

For any questions, technical assistance, or support regarding your Ebike Brushless Motor Controller, please contact our customer service. When contacting support, please have your controller model (X062-AXD003) and any relevant photos or details about your ebike setup ready.

As per the important considerations, communication with customer service regarding model verification before purchase is crucial for support related to compatibility issues.