1. Introduction
This manual provides detailed instructions for the installation, operation, programming, and maintenance of your Kunray 72V 5000W Brushless Controller. This high-power controller is designed for electric bikes, motorcycles, and similar applications, offering programmable features and robust performance. Please read this manual thoroughly before use to ensure proper functionality and safety.
2. Specifications
The Kunray KR5V 100A Brushless Controller features the following key specifications:
Key Parameters
| Current | 100A |
| Rated Voltage | 48-72V |
| Net Weight | 1.9KG |
| Protect Phase Current | 300A |
| Adapter Motor | 3-5KW |
| IP Class | IP67 |
These parameters are crucial for compatibility and performance.
Physical Dimensions
| Length (L) | 179.9 cm / 70.82 in |
| Width (W) | 117.9 cm / 46.42 in |
| Height (H) | 59.7 cm / 23.50 in |
Ensure adequate space for installation.
3. Setup and Installation
Careful wiring is essential for the correct and safe operation of your controller. Refer to the diagrams and table below for detailed connection instructions.
3.1 Wiring Diagram Overview
The controller comes with a comprehensive wiring harness. Identify each connector before making any connections.
3.2 Detailed Wiring Connections
This diagram illustrates the connections for various functions including throttle, brakes, anti-theft, hall sensors, and more. Pay close attention to wire colors and their corresponding functions.
3.3 Wiring Function Table
The following table provides a detailed description of each wire's color and its function:
| Pic | Describe | Functions |
|---|---|---|
| Black: GND, Orange: Lock | Anti-Theft | |
| Brown: BOOST, Blue&Red: Cruise XH | P/Cruise | |
| Yellow & White: High Speed, Black: GND, Blue & White: Low Speed | High / Low Speed | |
| Black: GND, Green & White: Throttle Signal SV, Red & White: Power + ACC+ | THROTTLE | |
| Brown & White: Reverse RE, Black: GND | REVERSE | |
| Yellow & Green: Low Level Braking BL, Black: GND | BRAKE (low-level) | |
| Red: Hall +, White: Temp, Green: Hall B, Black: GND, Yellow: Hall A | HALL | |
| Purple: Analog Speedometer SPA | Speedometer SPA | |
| Light Blue: LIN SPD | Speedometer SPD | |
| Grey: High Level Braking BH | BRAKE (HIGH LEVEL) | |
| Orange: Power Lock KEY | E-Lock | |
| Bluetooth Serial Port | Bluetooth | |
| Brown | One-line display |
NOTE: If the controller has built-in Bluetooth, the external Bluetooth serial connector is not needed.
4. Operation
4.1 Basic Operation
Once properly wired, the controller manages motor functions based on throttle input, brake signals, and other connected accessories. Ensure all connections are secure before powering on the system.
4.2 Bluetooth Connectivity
The controller features built-in Bluetooth support, allowing for parameter modification and system connection via a smartphone application.
- Android App: Download the Fardriver App from: http://182.92.233.85:6868/FarDriverSigned.apk
- Apple App: Search for "fardriver" in the App Store.
Use the app to connect with the system and modify parameters as needed. If matching with a new brand motor, reprogramming may be required.
5. Programming and Configuration
The Fardriver controller is highly programmable, allowing customization of various motor and system parameters. For a complete and detailed guide, please refer to the official Fardriver ND Controller instructions PDF: Fardriver-ND-Controller-instructions.pdf. Key programmable aspects include:
5.1 Basic Parameters
- Position Sensor: Configure for 120° Hall, General encoder, or specific encoder types (4096, 8192, 60° Hall).
- Temperature Sensor: Options include PTC, NTC, KTY84-130, KTY83-122, KTY83-121.
- Phase Shift: Adjust motor angle position. Self-learning method is available if the angle is unclear.
5.2 Self-Learning Process
The controller supports a self-learning function to adapt to your motor. This can be initiated via the upper computer software or by a specific brake-pinching sequence without a computer.
- Computer Method: Click the self-learning button in the software. The controller will emit 2 short and 1 long beep.
- Brake Pinching Method (without computer):
- Keep the brake connected, controller off, motor still.
- Turn throttle to end, turn on. Controller will alarm, motor won't turn.
- Enter self-learning (Mose password 8 bits: 11000000).
- Listen for 2 short and 1 long beep to confirm entry into self-learning state.
- Self-Learning Execution: Once in self-learning, lift the wheel, turn the throttle to the end. The motor should spin up. If not, check Hall/motor wire connections (blue and green lines may need swapping). After turning, the speed will adjust, and phase shift will be automatically set.
5.3 Throttle Threshold
Configure idle and full voltage thresholds for the throttle to ensure proper response and safety.
| Type | Idle Voltage | Full Voltage |
|---|---|---|
| Electric Motorcycle Converter | 0.8V-0.9V | 4.1-4.3V |
| Central Control Transfer | 0.8V-0.9V | 4.5-4.95V |
| 12V Accelerator Pedal | 0.0V-0.2V | 4.6-4.8V |
5.4 Current Limiting and Speed Control
- Maximum Phase Current: Limits the motor's output torque.
- Maximum Line Current: Determines maximum output power and speed.
- Speed Control Levels: Default 4 levels: BOOST, High Speed, Medium Speed, Low Speed.
5.5 Functional Input Feet
The controller allows configuration of various functions via dedicated input pins:
- BOOST: Activates a temporary power boost.
- Cruise: Enables cruise control functionality.
- Anti-theft: Connects to anti-theft systems.
- High/Low Speed: Switches between different speed modes.
- E-Lock: For ignition control.
6. Troubleshooting (BEEP ALARM)
The controller uses a series of beeps to indicate various operational states or faults. Refer to the table below for interpreting beep codes.
| Beep Count | Reason |
|---|---|
| 1 | Motor Hall Sensor Fault |
| 2 | Throttle Pedal Fault |
| 3 | Current Protection Restart |
| 4 | Phase Current Overflow |
| 5 | Voltage Fault |
| 6 | Anti-Theft Alarm Signal |
| 7 | Motor Over-Temperature |
| 8 | Controller Over-Temperature |
| 9 | Phase Current Sudden Change |
| 10 | Phase Current Zero Point Fault |
| 11 | Phase Wire Short Circuit |
| 12 | Line Current Zero Point Fault |
| 13 | MOSFET Upper Bridge Fault |
| 14 | MOSFET Lower Bridge Fault |
| 15 | MOE Peak Line Current Protection |
If you encounter an error and are unable to resolve it, please contact technical support.
7. Maintenance
The Kunray Brushless Controller is designed for durability and requires minimal maintenance. However, regular checks can prolong its lifespan and ensure optimal performance:
- Visual Inspection: Periodically check all wiring connections for signs of wear, corrosion, or loose contacts.
- Cleanliness: Keep the controller free from dust, dirt, and moisture. Use a soft, dry cloth for cleaning.
- Heat Management: Ensure the controller has adequate airflow and is not obstructed, especially during high-power operation, to prevent overheating.
- Firmware Updates: Check the Fardriver app or Kunray website for any available firmware updates that might improve performance or address issues.
8. User Tips
While no specific user reviews or Q&A were provided, here are some general tips for optimizing your experience with the Kunray Brushless Controller:
- Start with Default Settings: When first setting up, use the default parameters and gradually adjust them to your preference and motor characteristics.
- Test Safely: Always perform initial tests in a controlled environment, with the drive wheel off the ground, to ensure correct motor direction and throttle response.
- App for Fine-Tuning: Utilize the Fardriver app for precise adjustments to parameters like acceleration sensitivity, speed limits, and energy feedback.
- Monitor Performance: Pay attention to motor temperature and controller behavior, especially during demanding use, to prevent potential issues.
9. Warranty and Support
For warranty information and technical support, please refer to the seller's policies or contact the manufacturer directly. Keep your purchase records for any warranty claims.
For further technical details and advanced programming, consult the comprehensive Fardriver ND Controller instructions PDF: Fardriver-ND-Controller-instructions.pdf.