User Manual: 36V 48V 60V 72V 350W 500W 600W 20A-25A Brushless Controller

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your ChongXiao Brushless Controller. This intelligent brushless sine wave controller is designed for electric bikes and e-scooters, offering versatile voltage compatibility and robust performance. Please read this manual thoroughly before installation and use to ensure proper function and safety.

Figure 1: Overview of the ChongXiao Brushless Controller with its wiring harness.

2. Product Features

The ChongXiao Brushless Controller is equipped with a range of features to enhance the performance and functionality of your electric bike or e-scooter:

• Intelligent Brushless Sine Wave Control: Provides smooth and efficient power delivery.
• Wide Voltage Compatibility: Supports 36V, 42V, 48V, 52V, 60V, 72V, and 84V systems.
• Current Range: Operates within a 20A-25A current range.
• Rated Power: Compatible with 350W, 450W, and 500W motors.
• Phase Angle Compatibility: Supports both 60° and 120° phase angles.
• PAS (Pedal Assist) Functionality: Integrates with pedal assist systems.
• Intelligent Recognition (Self-Learning Line): Simplifies motor pairing.
• Brake System Support: Includes low-level and high-level brake signal inputs.
• Reverse Gear: Allows for reverse movement.
• Cruise Control: Enables maintaining a constant speed.
• Speed Controller Handle (Throttle) Support: Connects directly to standard throttles.
• Multiple Data Meter & Hall Meter Support: For display and sensor integration.
• Three-Speed Gear Function: Provides multiple speed modes.
• Electric Door Lock: For system security.
• Anti-Theft Alarm Signal & Power: Integrated alarm capabilities.
• Special for Differential Motor: Compatibility with specific motor types.

Figure 2: Detailed view of the controller's label, showing key specifications.

3. Specifications

Figure 3: Physical dimensions of the controller (147mm x 86mm x 48mm).

4. Setup and Installation

Proper wiring is crucial for the safe and correct operation of the controller. Refer to the wiring diagram below and follow these steps:

Figure 4: Detailed wiring diagram showing all connection points.

1. Connect Motor Lines: Connect the motor phase lines (usually three thick wires) from the controller to the motor, matching colors (e.g., blue to blue, green to green, yellow to yellow).
2. Connect Battery Lines: Connect the main power lines from the controller to the battery. Ensure correct polarity: red wire to battery positive (+), black wire to battery negative (-).
3. Connect Throttle and Electric Door Lock: Connect the throttle (speed controller handle) line to the controller, matching colors. If your throttle does not have an integrated electric door lock, the controller's electric door lock wires can be shorted (connected together) to bypass this function and allow the controller to power on.
4. Connect Hall Wires (if applicable): If your motor has Hall sensors, connect the Hall wires from the motor to the controller. If your motor does not have Hall wires, this connection is not required; the controller can operate in sensorless mode.
5. Intelligent Recognition (Self-Learning):
   • Dock the two self-learning lines (often white wires). The wheel will start to spin forward or reverse.
   • If the wheel spins forward correctly, separate the self-learning lines.
   • If the wheel spins in reverse, separate the self-learning lines, then dock them again. The wheel should now spin forward. Once it spins forward, separate the self-learning lines. This completes the motor phase learning process.
6. Connect Other Functions: Connect other desired functions as needed, such as PAS (Pedal Assist), brake signals (low/high level), cruise control, three-speed gear, multiple data meter, anti-theft alarm, etc. Functions not in use do not need to be wired.

Important Safety Note:

• Always ensure the power is off before making or changing any connections.
• Double-check all connections for correct polarity and secure fit to prevent damage to the controller or other components.
• When performing the self-learning process, ensure the wheel is elevated and can spin freely without obstruction.

5. Operating Instructions

Once the controller is correctly installed and wired, operating your electric bike or e-scooter is straightforward:

• Power On: Ensure the battery is connected and the electric door lock (if used) is engaged to power on the controller.
• Throttle Control: Use the speed controller handle (throttle) to regulate the motor's speed. Gently twist the throttle to accelerate.
• Three-Speed Gear: If connected, use the three-speed gear switch to select between different speed modes (e.g., low, medium, high) for varying riding conditions.
• Cruise Control: If connected and activated, the cruise control function will maintain a constant speed without continuous throttle input. Refer to your specific vehicle's instructions for activating cruise control.
• Braking: Apply the brakes. The controller will cut power to the motor when brake signals are detected.
• Pedal Assist (PAS): If your vehicle has a PAS sensor and it's connected, the motor will provide assistance when you pedal, reducing the need for constant throttle input.

6. Maintenance

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

• Keep Dry: The controller is an electronic device. Avoid exposure to water, excessive moisture, or extreme humidity. While the aluminum casing offers some protection, it is not fully waterproof.
• Clean Regularly: Periodically clean the exterior of the controller with a dry, soft cloth to remove dust and dirt. Do not use liquid cleaners or solvents.
• Inspect Connections: Regularly check all wire connections to ensure they are secure and free from corrosion or damage. Loose connections can lead to intermittent operation or component failure.
• Avoid Overheating: Ensure the controller is mounted in a location with adequate airflow to prevent overheating, especially during prolonged high-power operation. The ribbed aluminum casing is designed for heat dissipation.
• Protect from Physical Damage: Mount the controller securely to prevent vibrations or impacts that could damage internal components.

7. Troubleshooting

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

8. Warranty and Support

As per product specifications, this product does not come with a manufacturer's warranty. For any technical assistance or inquiries regarding the ChongXiao Brushless Controller, please refer to the retailer or point of purchase for support.

For general information and troubleshooting tips, you may also refer to online communities and resources related to electric bike and e-scooter controllers.