1. Introduction
This manual provides essential information for the safe and efficient operation of your Xiuganpo Dual-mode Brushless Motor Controller. This controller is designed for electric bikes, scooters, and tricycles, offering smooth motor starts, comfortable driving, and reduced tire noise. It supports both sine wave and Hall-less motors.
2. Safety Information
- Always disconnect power before installation or maintenance.
- Ensure all connections are secure and correctly wired to prevent damage to the controller or motor.
- Avoid exposing the controller to water or extreme temperatures.
- Do not attempt to open or modify the controller casing, as this may void the warranty and pose safety risks.
- Consult a qualified technician if you are unsure about any installation or troubleshooting steps.
3. Product Overview
The Xiuganpo Dual-mode Brushless Motor Controller is a robust unit housed in a metal casing, designed for durability and efficient heat dissipation. It features multiple wiring harnesses for various functions, ensuring comprehensive control over your electric vehicle's motor.
Figure 3.1: Overview of the Brushless Motor Controller with its wiring harnesses.
Figure 3.2: Dimensions of the Brushless Motor Controller (approximately 17.7cm x 8.4cm x 4.1cm).
The controller supports a voltage range of 48V, 60V, or 64V and handles power outputs between 1000W and 1500W, with a current limit of 26A-30A. Its dual-mode capability allows it to operate with or without Hall sensors.
4. Setup and Installation
Proper installation is crucial for the controller's performance and safety. Refer to the wiring diagram below and ensure all connections are made correctly.
Figure 4.1: Detailed view of the controller's wiring harnesses for connection.
4.1 Wiring Connections
Identify and connect the following wires according to your vehicle's electrical system:
- Power Supply: Connect to the main battery power.
- Lithium-ion Power Supply: Specific connection for lithium-ion batteries.
- Electric Door Lock: For ignition control.
- Motor Phase Line: Connect to the motor's phase wires (typically three wires).
- Hall Line: Connect to the motor's Hall sensor wires (if applicable).
- Accelerate Line: Connect to the throttle or accelerator.
- Dial Three-Speed Lines: For speed mode selection.
- Low Level Brake Lines: For low-level brake signal input.
- High Brake Line: For high-level brake signal input.
- General Instrument Line: For connecting to the vehicle's display or instrument panel.
- Anti-theft Alarm Power Cord: For connecting to an anti-theft alarm system's power.
- Anti-theft Alarm Lines: For anti-theft alarm signal input/output.
- Lines to Reverse: For reverse gear functionality.
- Intelligent Learning Recognition: Special wires for automatic motor parameter learning.
4.2 Physical Mounting
Mount the controller securely in a location that is protected from direct moisture and allows for adequate airflow for cooling. Use the integrated mounting tabs for attachment.
5. Operating Instructions
5.1 Initial Power-On and Learning Function
After completing all wiring, perform the intelligent learning recognition process. This allows the controller to adapt to your specific motor parameters for optimal performance. Refer to your vehicle's specific instructions for initiating this process, typically involving connecting the "Intelligent Learning Recognition" wires and following a sequence of power cycles or throttle inputs.
5.2 Basic Operation
- Power On: Turn the electric door lock to the ON position.
- Speed Control: Use the accelerate line (throttle) to control the motor speed.
- Braking: Activating the low or high-level brake lines will cut power to the motor.
- Three-Speed Modes: If connected, use the dial three-speed lines to switch between different speed settings.
- Reverse: If connected, activate the reverse line for backward movement.
6. Maintenance
- Keep the controller clean and free from dust and debris.
- Regularly check all wiring connections for tightness and signs of wear or corrosion.
- Ensure the controller's mounting area remains clear for proper ventilation.
- Avoid using harsh chemicals or abrasive materials for cleaning.
7. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not starting | Loose power connection, faulty electric door lock, motor or Hall sensor issue, learning function not completed. | Check all power and motor connections. Verify electric door lock functionality. Complete the intelligent learning recognition process. Inspect motor and Hall sensors. |
| Motor runs intermittently | Loose wiring, intermittent throttle signal, overheating. | Check all wiring. Inspect throttle for proper function. Ensure adequate ventilation for the controller. |
| Unusual motor noise | Incorrect motor phase connection, motor damage, controller fault. | Verify motor phase line connections. Consult a technician if noise persists after checking connections. |
If troubleshooting steps do not resolve the issue, contact customer support.
8. Specifications
| Feature | Detail |
|---|---|
| Model | Dual-mode Brushless Motor Controller |
| Material | Metal |
| Voltage | 48V / 60V / 64V |
| Power Range | 1000W - 1500W |
| Current Limit | 26A - 30A |
| Dimensions (approx.) | 17.5 x 8.4 x 4 cm (7 x 3.3 x 1.6 inches) |
| Weight (approx.) | 460g (1.01 lbs) |
| Compatibility | Electric car, tricycle (up to 1500W motor power) |
| Motor Type Support | Sine motor, motor without Hall sensors (dual-mode) |
9. Product Videos
Watch the following videos for a visual overview of the product.
Video 9.1: Short overview of the Brushless Motor Controller, showcasing its appearance and connections.
Video 9.2: Another brief visual presentation of the Brushless Motor Controller.
10. Warranty and Support
For warranty information or technical support, please refer to the product packaging or contact your retailer. Keep your purchase receipt for warranty claims.