ChongXiao 36V-60V 500W-1000W Brushless Square Wave Controller with LCD Display User Manual

Product Overview

This intelligent brushless square wave controller and LCD display set is designed for electric bikes and electric scooters. It provides precise control over motor speed and direction, along with real-time operational data via the LCD display. The controller supports a wide range of voltages and power outputs, making it versatile for various applications.

Image: ChongXiao Brushless Square Wave Controller and LCD Display.

Specifications

• Voltage: 36V/48V/52V/58V/60V/64V Universal
• Current: 26A-36A
• Rated Power: 500W-1000W
• Number of Transistors: 12
• Brake Type: High/Low Electrical Level, Linear Brake (Thumb Brake), Regeneration Brake
• Phase Angle: 60°/120° Automatic Identification
• Material: Aluminum
• Item Package Dimensions L x W x H: 9.76 x 9.53 x 5.16 inches
• Package Weight: 0.98 Kilograms

Controller Dimensions

Image: Controller dimensions showing length (176mm), width (88mm), and height (50mm).

Setup and Installation

Follow these steps for proper installation of your brushless controller and LCD display:

1. Connect Phase Lines: Connect the motor phase lines (usually thicker wires) color to color with the corresponding controller phase lines.
2. Connect Battery: Connect the battery lines. The red wire is for battery positive (+), and the black wire is for battery negative (-).
3. Connect LCD Display/Throttle: Connect the controller's LCD line. If not using an LCD, connect the throttle (color to color). If your throttle does not have an electric door lock, the controller's electric door lock wires may need to be shorted.
4. Connect Hall Lines: Connect the motor Hall sensor lines. If your motor does not have Hall lines, this connection is not required.
5. Self-Learning Process: Dock the two intelligent recognition lines (also called self-learning lines). The motor wheel will rotate automatically. If the wheel rotates forward, separate the self-learning lines. If the wheel rotates in reverse, separate the self-learning lines and then dock them again. Once the wheel rotates forward, separate the self-learning lines. This process allows the controller to intelligently identify the battery voltage and adjust the motor's rotation direction.
6. Connect Other Functions: Connect other function wires as needed (e.g., brake light power, low-level brake, reverse gear, head light/rear light, PAS, linear brake, regeneration brake, speed control handle).

Wiring Diagram

Image: Detailed wiring diagram for the brushless controller, illustrating connections for battery, motor, display, and various functions.

Installation Video Guide

Operating Instructions

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

LCD Display Functions

• Power On/Off: Use the designated button on the display or an NFC card (if included) to turn the system on or off.
• Speed Control: Adjust speed using the throttle handle.
• Assist Gear Option: The display typically offers 3 assist gear options (e.g., ECO, STD, SPORT) to control power output.
• Data Display: View current speed, mileage (ODO/TRIP), riding time, and current battery voltage.
• Cruise Assist Mode: Long press the 'Up' key on the display to enter or exit cruise assist mode.

Settings Menu (P-Parameters)

To access the settings menu, long press the Up and Down keys simultaneously. The menu provides a total of 20 parameters (P01-P20) for configuration. Refer to the detailed product manual for specific meanings and adjustment ranges for each parameter.

• P03: Set battery voltage. Ensure this matches your battery's nominal voltage for accurate readings and optimal performance.

Image: LCD display interface showing speed, battery level, and gear settings.

Maintenance

Proper maintenance ensures the longevity and reliable operation of your controller and display.

• Keep Dry: Protect the controller and display from water and excessive moisture. While the unit may have some water resistance, it is not fully waterproof.
• Clean Gently: Use a soft, dry cloth to clean the display and controller housing. Avoid abrasive cleaners or solvents.
• Inspect Connections: Periodically check all wiring connections to ensure they are secure and free from corrosion or damage. Loose connections can lead to intermittent operation or system failure.
• Avoid Extreme Temperatures: Do not expose the unit to prolonged direct sunlight or extreme cold, as this can affect electronic components.

Troubleshooting

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

• No Power/Display Not Turning On:
  • Check battery connections and ensure the battery is charged.
  • Verify the electric door lock connection (if applicable) is properly made or shorted if not used.
  • Ensure the display cable is securely connected to the controller.
• Motor Not Responding/Intermittent Operation:
  • Re-perform the self-learning process to ensure proper motor identification.
  • Check all motor phase wires and Hall sensor wires for secure connections.
  • Inspect throttle connections.
• Error Code E-006: This error code often indicates a motor Hall sensor issue or a problem with the motor's connection to the controller. Ensure all Hall sensor wires are correctly connected and undamaged. If the motor does not have Hall sensors, ensure the controller is configured for sensorless operation (if supported and applicable). If the issue persists, the motor or controller may require professional inspection.
• Incorrect Speed/Mileage Readings: This may require adjusting the wheel size parameter in the display's settings menu (P-parameters). Refer to the full product manual for instructions on accessing and modifying this setting.

For persistent issues not covered here, please contact customer support.

Warranty Information

This product comes with a limited warranty. Please note that the manufacturer's specifications indicate "Warranty Description: No" for this product. For any specific warranty claims or details, please refer to the purchase documentation or contact the seller directly.

Customer Support

If you require further assistance, have questions about installation, operation, or troubleshooting, please contact the seller or manufacturer's customer support. Provide your product model and purchase details for efficient service.

Manufacturer: ChongXiao