1. Introduction
This instruction manual provides essential information for the safe and effective installation, operation, and maintenance of your doinal 72V 5000W Brushless Motor Kit. This kit is designed for electric vehicle conversion projects such as go-karts, motorcycles, and scooters. Please read this manual thoroughly before attempting any installation or operation to ensure proper functionality and safety.
2. Product Overview
The doinal 72V 5000W Brushless Motor Kit includes a high-performance brushless DC motor, a Fardriver controller, and a twist throttle with key. Key features include a V-magnet rotor for stability and efficiency, an external Hall sensor for improved heat dissipation and serviceability, and an all-aluminum body with a heatsink for effective air cooling.
Figure 2.1: Overview of the 72V 5000W Brushless Motor Kit, showing the motor, Fardriver controller, and throttle with key.
2.1 Key Features
- High Efficiency Motor: 72V 5000W brushless DC motor with a rated speed of 6800rpm and peak torque of 35N.m.
- Advanced Controller: 100A Fardriver controller, programmable, sine wave, with APP connectivity for monitoring and tuning parameters.
- V-Magnet Rotor: Upgraded V-magnet rotor with 5 pair magnet poles for enhanced stability and efficiency.
- External Hall Sensor: Hall sensor located near the back cover for better heat dissipation and easier maintenance.
- Robust Construction: All-aluminum body with integrated heatsink for effective air cooling and IP54 waterproof rating.
- Sprocket Compatibility: Designed to fit T8F/35H sprockets.
Figure 2.2: Illustration of the new design V-magnet rotor, highlighting its internal structure for improved performance.
Figure 2.3: Close-up view of the external Hall sensor, positioned for better heat dissipation and accessibility.
Figure 2.4: Image showing the all-aluminum body with integrated heatsink fins, designed for efficient air cooling.
3. Specifications
3.1 Motor Specifications
| Parameter | Value |
|---|---|
| Rated Voltage | 72V DC |
| Rated Wattage | 5000W |
| Peak Power | 10KW |
| Rated Speed | 6800 RPM |
| No Load Speed | 8000 RPM |
| Rated Torque | 8.5 N.m |
| Peak Torque | 35 N.m |
| Rated Current | 60A |
| Peak Current | 80-100A |
| Efficiency | Max 90% |
| Insulation Class | F (155℃) |
| IP Rating | IP54 |
| Magnet Poles | 5 Pair / 10 PCS |
| Temperature Sensor | KTY84-130 |
| Product Dimensions | 4.6"W x 5.4"H (4.6 x 4.6 x 5.4 inches) |
| Weight | 17.64 Pounds |
Figure 3.1: Visual representation of key motor parameters.
Figure 3.2: Detailed diagram showing motor dimensions and upgraded shaft specifications.
3.2 Fardriver Controller Specifications
| Parameter | Value |
|---|---|
| Rated Voltage | 48-72V |
| Current | 100A |
| Protect Phase Current | 300A |
| Adapter Motor | 3-5KW BLDC Motor |
| Net Weight | 1.9KG (4.2lb) |
| IP Rating | IP67 |
Figure 3.3: Fardriver controller with key specifications and dimensions.
4. What's in the Box
The doinal 72V 5000W Brushless Motor Kit package includes the following components:
- 1x 72V 5000W Brushless Motor
- 1x 100A Fardriver Controller (Programmable)
- 1x Electric Throttler with Key
5. Setup and Installation
Proper installation is crucial for the safe and optimal performance of your motor kit. It is recommended that installation be performed by individuals with experience in electric vehicle systems.
5.1 Motor Mounting
The motor features base mounting holes with a screw model of M8. Ensure the mounting surface is robust and capable of supporting the motor's weight and torque. Refer to the dimension diagram for precise installation hole spacing.
Figure 5.1: Motor installation hole spacing (Screw Model: M6) and 8MM² phase wire detail.
Note: If your project has strict requirements for motor size, carefully compare the provided size drawing to avoid installation issues.
5.2 Controller Wiring
The Fardriver controller requires careful wiring. Follow the diagram below for correct connections. Incorrect wiring can damage the components or lead to unsafe operation.
Figure 5.2: Comprehensive wiring diagram for the Fardriver controller, showing connections for throttle, brake, Hall sensor, and other functions.
Key Wiring Connections:
- Battery Connection: Connect the positive pole of the battery to the red port on the controller and the negative pole to the black port. An adapter wire may be needed.
- E-LOCK (Power Lock): Connect the "E Lock" wire to the positive of the controller or the ignition lock. The controller will not power on without this connection.
- Hall Sensor: Connect the Hall sensor wires according to the diagram. Do not remove the screw on the Hall sensor, as this can impair motor function.
- Throttle: Connect the electric throttler.
- Brake: Connect brake wires (low-level BL, high-level BH).
- High/Low Speed: Connect for speed control functionality.
- Reverse: Connect for reverse functionality.
- Anti-Theft: Connect for anti-theft features.
- Bluetooth Serial: If the controller has built-in Bluetooth, this wire is not needed.
Refer to the detailed wiring table for specific wire descriptions and functions:
| Wire Description | Function |
|---|---|
| Black: GND, Orange: Lock, Black&White: Signal FW, Pink&Red: Power +60VC, Brown&Red: Wheel Smooth Signal U | Anti-Theft |
| Brown: BOOST, Blue&Red: Cruise XH | P/Cruise |
| Yellow & White: High Speed, Black: GND, Blue&White: Low Speed | High / Low Speed |
| Black: GND, Green & White: Throttle Signal SV, Red & White: Power + ACC+ | Throttle |
| Brown & White: Reverse RE, Black: GND | Reverse |
| Yellow & Green: Low Level Braking BL, Black: GND | Brake (Low-Level) |
| Red: Hall +, Blue: Hall C, White: Temp, Green: Hall B, Black: GND, Yellow: Hall A | Hall Sensor |
| Purple: Analog Speedometer SPA | Speedometer SPA |
| Light Blue: LIN SPD | Speedometer SPD |
| Grey: High Level Braking BH | Brake (High-Level) |
| Orange: Power Lock KEY | E-Lock |
| White Connector | Bluetooth Serial Port |
6. Operating Instructions
6.1 Initial Power-On
After completing all wiring, turn the key on the electric throttler to power on the system. The controller will emit a single beep upon startup. If the controller beeps continuously or in a pattern, refer to the troubleshooting section.
6.2 Fardriver APP Usage
The Fardriver controller is programmable and can be managed via a dedicated mobile application. This allows for monitoring motor status and tuning parameters.
- Download the APP:
- For Apple mobile devices, search for "Fardrive" in the App Store.
- For Android mobile devices, the app can be downloaded from: http://182.92.233.85:6868/FarDriverSigned.apk
- Bind the Controller: Follow the in-app instructions to bind your controller.
- Set Parameters: Adjust motor parameters as needed within the APP. The motor status will be clearly visible.
Figure 6.1: Screenshot of the Fardriver App interface, displaying motor power, speed, battery capacity, and temperature.
Note: If your controller has "Bluetooth Built-in" labeled, there is no need to connect an external Bluetooth adapter; you can directly use the Fardriver APP.
7. Maintenance
- Regular Inspection: Periodically check all wiring connections for tightness and signs of wear or damage.
- Cleanliness: Keep the motor and controller free from excessive dirt, dust, and moisture. The motor has an IP54 rating and the controller an IP67 rating, but prolonged exposure to harsh conditions should be avoided.
- Heat Management: Ensure adequate airflow around the motor's heatsink fins for optimal cooling.
- Hall Sensor: The external Hall sensor design allows for easier inspection and replacement if necessary. Do not tamper with the Hall sensor screw.
- Operating Temperature: Monitor motor and controller temperatures via the Fardriver APP, especially during extended use.
8. Troubleshooting
This section addresses common issues indicated by controller beeps and provides potential solutions.
8.1 Controller Beep Alarms
The Fardriver controller uses beep patterns to indicate various operational statuses or errors. Understanding these patterns can help diagnose issues.
- Normal Startup: During normal startup, the buzzer will sound once and then stop.
- Continuous Beep: If a continuous beep is heard, check whether both the brake and throttle are engaged simultaneously. This feature verifies the status of the brake and throttle. The buzzer will sound when both are pressed and stop when either is released.
- Self-Learning Mode: If the pattern consists of two short beeps followed by one long beep, repeating cyclically, it indicates the controller is in self-learning mode. Proceed with the self-learning operation steps to complete the process.
- Controller Program Verification Failure: If the pattern consists of one short beep, a brief pause, and then one short beep, repeating cyclically, it indicates a controller program verification failure. In this case, the program must be upgraded again.
- Incompatible Program: If the pattern consists of four short beeps, one long beep, and then five short beeps, repeating cyclically, it indicates that the upgraded program is incompatible with the controller. Check whether the program matches the model number on the controller's label. If not, locate the correct program and perform the upgrade again.
- Specific Faults: If the buzzer sounds between 1 and 15 times, the number of beeps corresponds to a specific fault. Refer to the following table for details.
| Beep Count | Reason |
|---|---|
| 1 | Motor Hall Sensor Fault |
| 2 | Current Protection Restart |
| 3 | Throttle Pedal Fault |
| 4 | Phase Current Overflow |
| 5 | Voltage Fault |
| 6 | Anti-Theft Alarm Signal |
| 7 | Motor Over-Temperature |
| 8 | Controller Over-Temperature |
| 9 | Phase Current Sudden Change |
| 10 | Phase Current Zero Point Fault |
| 11 | Phase Wire Short Circuit |
| 12 | Line Current Zero Point Fault |
| 13 | MOSFET Upper Bridge Fault |
| 14 | MOSFET Lower Bridge Fault |
| 15 | MOE Peak Line Current Protection |
If you encounter an error and are unsure how to resolve it, please contact customer support for assistance.
9. Warranty and Support
For any issues regarding missing parts, defects, or operational problems, please contact the seller directly. Do not attempt to return the package or replace the product without prior communication. The seller will investigate and provide corresponding solutions.
Protection plans are available for purchase separately through Amazon, offering extended coverage for your product. Please refer to Amazon's protection plan details for more information.