Zerone 36V-48V Brushless Motor Controller and LCD Display Kit User Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of your Zerone 36V-48V Brushless Motor Controller and LCD Display Kit. This kit is designed to provide sensitive and stable speed control for electric scooters, cars, and bikes, featuring a clear LCD display for real-time data monitoring.

Please read this manual carefully before installation and use to ensure proper function and longevity of the product.

2. Product Overview

2.1 Components

• Brushless Motor Controller (36V-48V compatible)
• LCD Display (S866 model) with integrated control buttons
• Connecting cables and waterproof connectors

2.2 Key Features

• Sensitive Control: Provides steady speed and responsive control for braking and direction changes.
• Clear LCD Display: Shows state and data clearly, with backlight for visibility in dim environments. Features quick operation buttons.
• Durable Controller Circuit: Metal shell with good heat dissipation prevents thermal overloading of the inner circuit.
• Wide Application: Suitable for electric bikes, cars, and scooters.
• Rainproof Design: The LCD display is made of quality materials, lightweight, rainproof, sturdy, and durable for all weather conditions.

2.3 Product Visuals

Image 1: Overview of the Zerone Brushless Motor Controller and LCD Display Kit, showing the controller unit, LCD display, and connecting wires.

Image 2: Close-up of the Zerone Brushless Motor Controller, highlighting its multiple wiring harnesses for various connections.

Image 3: The Zerone S866 LCD Display unit, shown with its attached connecting cable.

3. Setup and Installation

3.1 General Installation Guidelines

• Ensure the power is off before beginning any installation.
• Mount the LCD display securely on a 22.5mm handlebar.
• Mount the controller in a protected area, away from direct moisture and physical impact.
• Connect all wires firmly. Loose connections can lead to malfunctions.

3.2 Wiring Connections

The controller features various color-coded wires for different functions. Carefully match each connector to its corresponding component (motor, battery, throttle, brakes, etc.).

Important Note: Some products use waterproof connectors where the lead wire colors may not be visible within the wire harness. Refer to the connector shape and pin configuration for correct matching.

Before connecting the main power, ensure all phase wires are correctly matched to prevent damage.

Image 4: Example of a person installing the controller unit on an electric bicycle, demonstrating the typical placement and wiring process.

3.3 Video Guide: Motor Brushless Controller Overview

4. Operating Instructions

4.1 LCD Display (S866) Functions

The LCD display provides essential information and allows for various settings adjustments.

• Display Information: Speed (AVG, MAX, Current), Power Indicator, Fault Indication, Total Mileage (ODO), Single Trip Mileage (TRIP), Single Boot Time (TIME), Battery Voltage (VOL), Endurance (DST).
• Control Functions: Power switch, Wheel diameter setting, Idle automatic hibernation time setting, Backlight brightness adjustment, Start mode setting, Drive mode setting, Voltage level setting, Controller limit value setting.
• Communication Protocol: UART.

Image 5: Detailed diagram of the LCD-S866 display, showing its apparent size, material, and a comprehensive introduction to its various display functions and control settings.

4.2 Setting Parameters (P-Codes)

Access the settings menu by pressing and holding the appropriate buttons (refer to the display diagram for specific button functions). The following parameters can be adjusted:

• P01: Backlight Brightness: Levels 1 (darkest) to 3 (brightest).
• P02: Mileage Unit: 0 = KM (Kilometers), 1 = MILE (Miles).
• P03: Voltage Level: 24V, 36V, 48V, 60V. Default is 36V.
• P04: Dormancy Time: 0 = No dormancy. Other numbers represent dormancy time in 1-60 minutes.
• P05: Help File Bit: 0, 3 file mode, 1, 5 gear mode.
• P06: Wheel Diameter: Set wheel diameter in inches. Precision: 0.1. This parameter is related to the meter display speed and needs to be entered correctly.
• P07: Speed Gauge Magnetic Steel Number: Range 1-100. This parameter is related to the meter display speed and needs to be entered correctly. For an ordinary hub motor, input the number of magnetic steel. If it is a high-speed motor, calculate the deceleration ratio, and the input data is (number of magnetic steel x deceleration ratio).

Image 6: Continuation of the LCD-S866 operation instructions, detailing the speed display area and various P-code settings for customization.

Image 7: The rainproof LCD display mounted on handlebars, demonstrating its visibility and durability in wet conditions.

5. Maintenance

Regular maintenance ensures optimal performance and extends the lifespan of your controller kit.

• Cleaning: Wipe the LCD display and controller with a soft, damp cloth. Avoid abrasive cleaners or solvents.
• Connection Checks: Periodically inspect all wiring connections to ensure they are secure and free from corrosion or damage.
• Environmental Protection: While the LCD display is rainproof, avoid prolonged exposure to heavy rain or submersion. Keep the controller unit dry.
• Storage: If storing the vehicle for an extended period, ensure the kit is clean and disconnected from the power source.

6. Troubleshooting

If you encounter issues with your Zerone controller kit, refer to the following common problems and solutions:

• No Power/Display Not Turning On:
  • Check battery connections and ensure the battery is charged.
  • Verify all power cables to the controller and display are securely connected.
• Error Code 10 on Display:
  • This error often indicates a communication issue or a sensor problem. Recheck all wiring, especially the Hall sensor connections.
  • Ensure the controller and display are compatible and correctly paired.
• No Speed Detection:
  • Verify that the wheel diameter (P06) and magnetic steel number (P07) settings are correctly configured in the LCD display.
  • Check the speed sensor wiring and ensure it is properly connected to the controller.
• Incompatible Connectors / Missing Jumper:
  • Ensure all connectors match. If a specific jumper or connector (e.g., for a master switch) is missing or unclear, consult the product diagram or contact support.
  • Avoid forcing incompatible connectors, as this can cause damage.
• Motor Not Responding / Irregular Operation:
  • Check motor phase wire connections. Ensure they are correctly matched.
  • Inspect for any visible damage to the controller or motor wiring.

If troubleshooting steps do not resolve the issue, contact Zerone customer support for further assistance.

7. Specifications

8. Warranty Information

For detailed warranty information, please refer to the product packaging or the official Zerone website. Keep your purchase receipt as proof of purchase for any warranty claims.

9. Customer Support

If you have any questions, require technical assistance, or need to report an issue, please contact Zerone customer support through the retailer where you purchased the product or visit the official Zerone website for contact details.