BLDC Controller 36V-60V Sine Wave Dual Drive User Manual

I. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of your 36-60V 12-40A Sine Wave Brushless Motor Controller. Please read this manual carefully before use to ensure proper function and safety.

II. Safety Warnings

• Do not operate in damp or humid environments. Exposure to moisture can damage the controller and pose electrical hazards.
• Avoid contact with high temperatures or open flames. Excessive heat can cause damage or malfunction.
• Unauthorized disassembly or modification is strictly prohibited. Tampering with the controller can void the warranty and lead to unsafe operation.

III. Specifications

The BLDC Controller offers robust performance and versatile compatibility:

• Type: Controller
• Nominal Voltage: 36V / 48V / 52V / 60V (Input Voltage: 30V-75V)
• Rate Power: 350W-2000W
• Motor Compatibility: Supports 2 brushless motors (Dual Drive Functionality)
• Max Bus Current (Single drive): 6A-20A
• Max Bus Current (Dual drive): 12A-40A
• Max Phase Current: 12A-55A
• Motor Phase Angle: 120°/60°
• Throttle Voltage: 1.1V-4.2V
• Brake: Low/High Electrical Level
• Dimensions: 260mm (Length) x 60mm (Width) x 35mm (Height)
• Technology: Sine Wave for smooth and efficient operation
• Operation Modes: Three modes of operation

IV. Installation and Setup

Follow these steps to properly install and set up your BLDC controller:

1. Disconnect Power: Always disconnect power from the battery before beginning any installation or wiring.
2. Connect Motor Phase Lines: Connect the motor phase lines (usually three thick wires) to the corresponding phase wires on the controller. Ensure color-to-color matching.
3. Connect Hall Lines: Connect the Hall sensor lines (usually five thinner wires) to the controller. Ensure color-to-color matching. If your motor does not have Hall lines, this step can be skipped.
4. Connect Battery Lines: Connect the battery power lines to the controller. The red wire is for Battery+ and the black wire is for Battery-.
5. Intelligent Recognition (Self-Learning Line) Setup:
   • Turn off the main power.
   • Connect the two intelligent recognition (self-learning) lines together.
   • Turn on the main power. The wheel will start to rotate forward or reverse.
   • If the wheel rotates forward, separate the intelligent recognition lines.
   • If the wheel rotates in reverse, separate the intelligent recognition lines, then connect them together again. The wheel should now rotate forward. Once it rotates forward, separate the intelligent recognition lines.
   • Important: This self-learning step must be completed within 2 minutes after the power is turned on. If the timeout occurs, turn off the power and then turn it back on to restart the process.
6. Connect Throttle: Connect the controller's throttle wires to the throttle. Ensure color-to-color matching.
7. Connect Electric Door Lock: Connect the controller's electric door lock wire to the throttle's electric door lock. If your throttle does not have an electric door lock, short the controller's electric door lock wire. The controller's electric door lock must always be connected or shorted for operation.
8. Note: When using throttle to control speed, the two intelligent recognition lines must be separated.
9. Connect Other Functions: Connect other functional wires as needed (e.g., reverse, cruise, 3-speed, PAS, brake, meters).
10. Secure Mounting: Ensure secure and firm mounting of the controller during installation to prevent damage from vibrations or impacts.

V. Operating Instructions

After successful installation and initial setup:

1. Power On: Turn on the main power switch of your electric vehicle.
2. Test Operation: Carefully test the throttle response, brake functions, and any other connected features (e.g., 3-speed, cruise, reverse).
3. Three Mode Operation: The controller supports three modes of operation. Refer to your vehicle's display or control panel for switching between modes, if applicable.
4. Dual Drive: If configured for dual drive, ensure both motors respond correctly to throttle input.

VI. Maintenance

To ensure the longevity and optimal performance of your BLDC controller:

• Regular Inspection: Periodically check all wiring connections for tightness and signs of wear or corrosion.
• Cleanliness: Keep the controller clean and free from dust, dirt, and debris. Use a dry cloth for cleaning.
• Environmental Protection: Avoid exposing the controller to extreme temperatures, direct sunlight for prolonged periods, or excessive moisture.
• Do not touch exposed wires. Always ensure all connections are properly insulated.

VII. Troubleshooting

Here are some common issues and their solutions:

1. Failure to start:

Check whether wiring connections are loose. Ensure all main power, battery, motor phase, and Hall sensor wires are securely connected.

2. Abnormal heating:

Reduce the load on the motor or improve heat dissipation around the controller. Ensure the controller is mounted in a location with adequate airflow.

3. Loss of control:

Restart the device. If the issue persists, re-perform the intelligent recognition (self-learning) procedure. If the problem continues, contact after-sales service.

VIII. User Tips

• Initial Setup: Take your time during the initial wiring and self-learning process. Double-check all connections before applying power.
• Overload Protection: The controller includes overcurrent protection. Avoid prolonged overload operation to prevent motor damage and ensure controller longevity.
• Energy Efficiency: The sine wave technology and high efficiency design help extend battery range. Optimize your riding style to maximize this benefit.

IX. Warranty and Support

We provide free technical support for this product.

If you have any questions, require assistance with installation, troubleshooting, or have other inquiries, please contact customer service for consultation.

Please refer to the official product page or your purchase documentation for specific warranty terms and contact information.