HUDAMZKY KT 48V/52V 30A Brushless Ebike Controller Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of the HUDAMZKY KT 48V/52V 30A Brushless Ebike Controller. This controller is designed for electric bicycles, motorbikes, and conversion kits, supporting 1000W/1500W hub motors. It is compatible exclusively with KT brand LED and LCD displays.

Figure 1: Product Application Examples. The controller is suitable for various electric vehicle types.

2. Important Safety Information

• Always ensure the power is off before installation or maintenance.
• This controller is only compatible with KT brand displays. Using non-KT displays may cause malfunction. Verify your display model is "KT" before connecting.
• Incorrect wiring can damage the controller or other components. Follow wiring diagrams carefully.
• Ensure all connections are secure and waterproof to prevent short circuits and corrosion.
• Do not attempt to open or modify the controller casing, as this may void the warranty and pose safety risks.
• If the controller overheats, it will automatically cut off current to protect the system. Allow it to cool down before resuming operation.

Figure 2: Verify KT Brand Mark on your controller for compatibility.

3. Product Overview and Features

The HUDAMZKY KT Brushless Controller is a robust component for electric bike conversion kits. It features a durable aluminum alloy casing with grooves for efficient heat dissipation, protecting internal components from thermal overload.

• Brand: KT (KUTENG)
• Mosfets: 12 Mosfets for stable performance.
• Maximum Current: 30±2A (for 30A version).
• Rated Current: 15A.
• Rated Voltage: DC 36V/48V.
• Low Voltage Protection: DC30/40±0.5V.
• Heat Dissipation: Aluminum alloy shell with grooved design.
• Clear Connectors: Each connector is distinct for easy identification during installation.

Figure 3: HUDAMZKY KT Brushless Ebike Controller with wiring.

4. Specifications

Figure 4: Controller Dimensions and Electrical Parameters.

5. Setup and Installation

Before beginning installation, ensure your electric bike's power is completely disconnected. Identify each connector on the controller using the diagrams below. Each connector is uniquely shaped and color-coded to prevent incorrect connections.

5.1 Wiring Diagram Overview

Figure 5: Comprehensive Wiring Diagram.

5.2 Connector Identification

The controller features various connectors for different components of your e-bike system. Refer to the following descriptions and images for proper identification:

• Battery Connector (PP30): Red and black wires for power input.
• Phase Lines: Three thick wires (blue, yellow, green) connecting to the motor's phase wires.
• Hall Sensor Wire: A multi-pin connector (DJ7061-2.8-21) for the motor's Hall sensors.
• PAS (Pedal Assist System) Connector (SM-3A): Typically brown, black, and yellow wires for pedal assist signal.
• Throttle Connector: Red, black, and white wires for throttle input.
• E-Brake Connectors (SM-2Y): Two separate connectors (red/blue and red/black) for electronic brake levers.
• Display Connector (SM-5A): Multi-pin connector for connecting the KT LED or LCD display. Includes RX, TX, Control, 36V/48V, and GND wires.

Figure 6: SM Plug Connection Types.

5.3 Connection Procedure

1. Connect the three thick Phase Lines (blue, yellow, green) from the controller to the corresponding phase wires of your hub motor.
2. Connect the Hall Sensor Wire from the controller to the motor's Hall sensor cable.
3. Connect the Battery Connector to your e-bike battery. Ensure correct polarity (red to positive, black to negative).
4. Connect the Display Connector to your KT brand LED or LCD display.
5. Connect the PAS Connector to your Pedal Assist System sensor.
6. Connect the Throttle Connector to your e-bike throttle.
7. Connect the E-Brake Connectors to your electronic brake levers.
8. Once all connections are made, double-check for security and proper alignment before powering on the system.

Note: The provided video demonstrates the connection process for the PAS system. While the video is a short preview, it visually aids in understanding the physical connection.

6. Operating Instructions

Once the controller is correctly installed and connected to a compatible KT display, you can power on your e-bike system. The display will provide information and allow you to adjust settings.

• Power On/Off: Use the power button on your KT display to turn the system on or off.
• PAS Level Adjustment: Adjust the pedal assist levels via your KT display. If PAS is not working correctly, access the display's parameter settings and adjust them as needed. Refer to your specific KT display manual for detailed instructions on parameter adjustment.
• Throttle Control: The throttle provides direct motor power. Use it carefully, especially when starting.
• Brake Function: The e-brake levers will cut off motor power when activated, ensuring safe stopping.

7. Maintenance

• Regular Inspection: Periodically check all wiring connections for looseness or damage.
• Cleaning: Keep the controller clean and free from dirt, dust, and moisture. Use a dry cloth for cleaning.
• Heat Management: Ensure the controller is mounted in a location with adequate airflow to facilitate heat dissipation. Avoid covering it with insulating materials.
• Water Exposure: While the controller is designed to be robust, avoid direct high-pressure water spray during cleaning.

8. Troubleshooting

• Controller Not Powering On:
  • Check battery connection and charge level.
  • Verify the display is correctly connected and powered.
  • Inspect all main power wires for damage.
• Motor Not Responding:
  • Ensure phase lines and Hall sensor wires are securely connected.
  • Check throttle and PAS connections.
  • Verify that the e-brake levers are not engaged, as they cut motor power.
• PAS Not Assisting:
  • Confirm the PAS sensor is correctly installed and connected.
  • Adjust PAS parameters in your KT display settings. If you do not have the display manual, contact customer support for assistance.
• Overheating:
  • Reduce load on the motor.
  • Ensure the controller has proper ventilation.
  • Check for any short circuits in the motor or wiring.
• Incompatibility Issues:
  • This controller is only compatible with KT brand displays. If you are using a non-KT display, it will not function correctly.

9. Warranty and Support

For warranty information or technical support, please refer to the seller's contact information or the product packaging. Ensure you retain your proof of purchase for any warranty claims. For specific display parameter adjustments, consult your KT display's instruction manual or contact the manufacturer.