HUDAMZKY KT 36V/48V 500W Ebike Brushless Motor Controller and S866 LCD Display User Manual

1. Product Overview

The HUDAMZKY KT 36V/48V 500W Brushless Motor Controller is designed for electric bike conversion kits, offering reliable power management for your ebike. This controller is specifically engineered to communicate with KT brand displays, ensuring seamless integration and optimal performance.

Figure 1: HUDAMZKY KT 36V/48V 500W Brushless Motor Controller with various connectors.

Key Features:

• KT Communication Protocol: Exclusively compatible with KT brand displays (KT-LCD3, LCD4, LCD5, LCD6, LCD7, LCD8). Verify your display model before purchase.
• Stable Performance: Features 9 stable Moss tubes, capable of withstanding a maximum current of 22A for short durations. Includes thermal overload protection.
• Efficient Heat Dissipation: Constructed with an aluminum alloy shell featuring grooves for effective heat dissipation, protecting internal components.
• Clear Connectors: Each connector is uniquely designed to minimize installation confusion.
• Wide Application: Suitable for 36V/48V 500W electric mountain bikes, road bikes, electric scooters, and similar applications.

2. Specifications

Figure 2: Physical dimensions and key electrical parameters of the controller.

3. Important Compatibility Note

This controller operates using the KT communication protocol. It is only compatible with KT brand displays such as KT-LCD3, LCD4, LCD5, LCD6, LCD7, and LCD8. Using a non-KT brand display may result in malfunction or improper operation. Please verify the brand and model of your existing display before installation.

Figure 3: Visual reminder to check for the 'KT Mark' on your controller for compatibility.

4. Installation and Connection

Careful connection of all components is crucial for proper function. Each connector on the controller is distinct to prevent incorrect connections. Refer to the diagrams and video for guidance.

Figure 4: Diagram illustrating the various labeled connectors on the controller, including Ebrake, Throttle, Battery, PAS, Display, and Motor.

Connection Steps:

1. Power Connection: Connect the red and black power lines from the controller to your ebike battery. Ensure polarity is correct.
2. Motor Phase Lines: Connect the blue, green, and yellow phase lines from the controller to the corresponding motor phase lines. Match colors carefully.
3. Hall Sensor: Connect the Hall sensor wires, ensuring color-to-color matching for proper motor commutation.
4. Display Connection: Connect the S866 LCD display to the designated display connector on the controller.
5. Throttle Connection: Connect the throttle. Pay attention to the red and black lines within the throttle connector, ensuring they are connected correspondingly.
6. E-Brake Levers: Connect the e-brake levers to their respective connectors.
7. PAS Sensor: Connect the Pedal Assist System (PAS) sensor.
8. Lights (Optional): If applicable, connect any ebike lights to the designated light connectors.

Visual Installation Guide:

5. Operating the S866 Display

The S866 LCD display provides essential information and allows for parameter adjustments. Refer to the manual and Video 1 for detailed instructions.

Basic Operations:

• Power On/Off: Long press the power button to turn the display on or off.
• Adjust PAS Parameters: Use the '+' and '-' buttons to adjust the Pedal Assist System (PAS) levels.
• Enter Parameter Setting Mode: Long press the '+' and '-' buttons simultaneously to enter the parameter setting mode (P01-P20).

Parameter Settings (P01-P20):

The display allows adjustment of various parameters to customize your ebike's performance. Use the power button to cycle through parameters and '+' / '-' to adjust values. Long press the power button to exit parameter setting mode.

• P01: Backlight Brightness: Adjust display backlight intensity (1-5, 5 being brightest).
• P02: Change Metric: Switch between metric (km) and imperial (miles) units.
• P03: Battery Voltage Setting: Set the battery voltage (e.g., 36V, 48V). Default is 36V.
• P04: Hibernate Mode Time: Set the time before the display enters hibernate mode (1-60 minutes).
• P05: Total Assist Levels: Define the number of PAS levels (e.g., 3, 5, 9 levels).
• P06: Wheel Size (inch): Set the wheel diameter in inches for accurate speed and distance readings.
• P07: Speed Calculation: Parameter for speed sensor type.
• P08: Speed Limit Range: Set the maximum speed limit.
• P09: Zero Speed Start: Enable/disable zero speed start (motor assists from standstill).
• P10: Driving Mode Selection: Select driving mode (e.g., 0: only assist mode, 1: electric mode, 2: both modes).
• P11: Assist Sensitivity: Adjust the sensitivity of the PAS sensor (1-24).
• P12: Assist Starting Power: Set the initial power of the motor when starting assist (1-5).
• P13: Assist Disc Type: Specify the type of assist disc (e.g., 5 magnets, 8 magnets, 12 magnets).
• P14: Current Limit of Controller: Set the current limit for the controller (range 3-20A, 12A by default).
• P15: Low Voltage Protection Setting of Controller: Adjust the low voltage cut-off for battery protection.
• P16: ODO Distance Reset: Hold '+' for 5 seconds to reset the odometer.
• P17: 0 Cruise Mode: Enable/disable cruise mode.
• P18: Speed Ratio: Adjust speed ratio for fine-tuning speed readings.
• P19: Assist Level: Set assist level 0 enable/disable.
• P20: Protocol Selection: Protocol setting (0: NO 2 PROTOCOL, 1: S5 PROTOCOL, 2: RESERVED, 3: RESERVED).

6. Error Codes

The S866 display may show error codes to indicate issues. Refer to the table below for common error codes and their descriptions:

7. Maintenance

To ensure the longevity and optimal performance of your HUDAMZKY controller and S866 display, follow these maintenance guidelines:

• Keep Clean: Regularly wipe down the controller and display with a soft, dry cloth. Avoid using harsh chemicals or abrasive materials.
• Check Connections: Periodically inspect all electrical connections for tightness and signs of wear or corrosion. Ensure waterproof plugs are securely seated.
• Avoid Water Exposure: While the motor plug is waterproof, the controller itself should be protected from direct water exposure and heavy rain.
• Temperature Management: Ensure the controller is mounted in a location with adequate airflow to prevent overheating. The aluminum casing is designed for heat dissipation.
• Cable Management: Secure all cables to prevent them from snagging, rubbing, or getting damaged during riding.

8. Troubleshooting

If you encounter issues with your ebike system, refer to the error codes section (Section 6) for specific diagnostics. General troubleshooting steps include:

• No Power to Display: Check battery connection, ensure the display cable is securely plugged into the controller, and verify the battery is charged.
• Motor Not Responding: Check all motor phase and Hall sensor connections. Ensure the throttle is correctly connected and not damaged. Verify PAS sensor installation if using pedal assist.
• Incorrect Speed/Distance Readings: Confirm the wheel size (P06) is correctly set in the display parameters.
• PAS Not Assisting: If the display is normal but PAS is not working, adjust the PAS parameters in the display (P11, P12, P13).
• Persistent Errors: If an error code persists after checking connections and parameters, consult the error code table for specific actions. If the issue remains unresolved, contact customer support.

9. Product Application Examples

The HUDAMZKY KT 36V/48V 500W Brushless Motor Controller is versatile and can be integrated into various electric bicycle and scooter setups.

Figure 5: The controller is suitable for various electric vehicles, including e-bicycles, e-scooters, and e-tricycles.

10. Warranty and Support

For warranty information, technical support, or any inquiries regarding your HUDAMZKY product, please refer to the contact details provided with your purchase or visit the official HUDAMZKY website. Ensure you have your product model and purchase date available when contacting support.